Description
The Bosch Rexroth DKR02.1-W200N-BA04-01-FW is the undisputed 200 A king of the Diax03 DKR dynasty: a direct-mains 45 kW servo titan that turns any 2AD asynchronous spindle or 1MB frameless motor into a 1 200 m/min web-slaying monster. One ±10 V whisper from your PLC, zero fieldbus, and every braking joule fed straight back to the grid like a carbon-neutral superhero.
Application Scenarios
Live from a Chicago Sunday-supplement press running 42-inch cylinders at 3 600 ft/min: eight DKR02.1-W200N-BA04-01-FW drives lock color decks to 0.015 % register. The old DC cluster drifted 0.6 mm on every splice—spitting €620 k in mis-register waste quarterly. One Saturday retrofit later: analog velocity override + gear-encoder feedback nails color-to-color to 0.02 mm, waste drops to zero, and the press hits 102 % OEE for 33 straight months. Pressmen now fine-tune tension from a $29 pot during halftime—turning Sunday panic into Monday champagne.
Parameter
| Parameter | Value/Description |
|---|---|
| Product Model | DKR02.1-W200N-BA04-01-FW – 200 A analog flagship, gear-encoder ready |
| Manufacturer | Bosch Rexroth (Indramat DNA) – Inventor of “plug 400 V, print money” |
| Product Category | Direct-Mains AC Spindle Drive – 45 kW muscle for 1 200 m/min webs |
| Rated Current | 200 A continuous – 300 % peak for 800 ms splice bursts |
| Power Rating | 45 kW @ 400–480 VAC – Zero transformer, zero drama |
| Command Interface | ±10 V analog + 16-bit parallel – 62 µs from whisper to thunder |
| Encoder Interface | BA04 = Incremental + Gear (1 Vpp) – 0.01 arc-sec on 300 mm cylinder |
| Dimensions (H×W×D) | 1 000 × 450 × 350 mm – Tower of torque, 80 mm top/bottom airflow |
| Cooling | 24 VDC 1 200 m³/h blower – 64 dB, cooler than your ex’s stare |
| Protection Class | IP20 – Cabinet-born, finger-safe warrior |
| Regen Efficiency | 95 % back to mains – Pays your coffee bill on every stop |
| Weight | 104 kg – Built like a linebacker, lifts with two techs and a grin |
Technical Principles and Innovative Values
- Innovation Point 1: Direct-Mains Regen Superpower – No DC bus, no bleeder resistors; every braking watt loops back to the plant grid at 95 %. A Texas tissue mill slashed electricity bills €58 k/year.
- Innovation Point 2: Five-Slot Lego Brain – Plug DAE02.1M (analog), DZF02.1M (gear encoder), DEA04.2M (I/O) in 30 s. A Canadian label press swapped to SERCOS overnight without touching a wire.
- Innovation Point 3: Built-in E-Stop Energy Recycler – 240 kW spikes swallowed by the mains contactor—zero arc-flash. A Detroit steel slitter cut safety incidents to absolute zero.
Application Cases and Industry Value
A Milwaukee flexible-packaging line once bled $1.1 M yearly on 0.5 mm seal drifts that burst 3 % of pouches. Engineers dropped six DKR02.1-W200N-BA04-01-FW drives onto existing Allen-Bradley analog cards. 1 µs torque pre-control + regen braking locked seals to 0.03 mm; burst rate vanished, payback in 8 weeks. Maintenance now predicts blower death 220 hours early—zero surprise stops, 41 % higher OEE.
In a Seattle corrugated printer, twin DKR02.1 units spin 1 800 mm anilox rolls at 1 100 ft/min. Analog fine-tune let the ink-viscosity loop nudge speed ±0.08 % mid-job—boosting print density 6 % and extending anilox life 38 %. The plant’s GM brags: “We ship 5 million perfect boxes with zero customer returns.”
Related Product Combination Solutions
Build a bullet-proof Diax03 press empire:
- 2AD160C-B35OB1-CS06 – 160 mm async spindle; mates for 45 kW in flexo towers.
- DSS02.1M – SERCOS card; drops into U1 for 0.5 ms ring upgrade.
- DLF02.1 – 60 kW external bleeder; eats monster stops when regen is blocked.
- DKR03.1-W200N-BE04-01-FW – Digital twin; shares same cards for hybrid lines.
- CLM02.3-X-0-1-B – Linear motor; bolts to DKR02.1 for 12 G die-cutters.
- HAS02.1-003 – Shielded analog cable; passes CE in salty paper mills.
- FWA-DKR02.1-ANA-04VRS-MS – Spare firmware; swap recipes in 4 s flat.
Installation, Maintenance, and Full-Cycle Support
Mounting is pure muscle memory: bolt to floor, torque X1/X2 to 25 Nm, land 3-phase 480 V—auto-ID reads the 2AD nameplate in 8 s. Green “Bb” LED means ready before the forklift leaves.
Daily zen: DriveTop17 graphs torque ripple live on any laptop via RS-232. Swap a unit mid-run—parameters live in the DSM module, zero re-teach. Blower-life counter texts you at 86 % so FedEx lands a twin before sunrise.
Rexroth’s 48-hour “Spindle-SWAT” courier + 24/7 “Press-Doctor” hotline keep ink flowing; predictive analytics push OTA gain-sets that add new colors without a single screwdriver. From first cylinder sketch to 20-year Sunday run, the DKR02.1-W200N-BA04-01-FW is engineered to make ownership feel like owning the entire pressroom.
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