Description
Key Technical Specifications
- Product Model: HDS02.1-W040N-HS76-01-FW
- Manufacturer: Rexroth / Indramat
- System Platform: DIAX04 Servo Drive System
- Rated Continuous Current: 40 A
- Peak Current Capacity: up to 100 A for short-duration acceleration
- DC Bus Supply Voltage: DC 300–600 V (via HVR/HVE power supply module)
- Control Interface: SERCOS optical fiber communication
- Feedback Support: High-resolution encoder / Indramat motor feedback (DDS/Hiperface depending on FW)
- PWM Switching Frequency: ≥8 kHz
- Internal Current Control Cycle: ~125 μs closed-loop regulation
- Supported Motor Types: MSK/MKD/1MB synchronous, MHD/MKF asynchronous servo motors
- Cooling Method: Air-cooled, forced ventilation integrated
- Protection Class: IP20 (drive rack installation)
- Operating Temperature: 0…45°C (rated), derating up to 55°C
- Certifications: CE, UL, cURus, EN 61800-3 EMC compliance
- MTBF: >200,000 hours based on Rexroth reliability data
- Firmware Type: FW-specific parameterized version, field flashable when required
Technical Architecture & Functional Positioning
The HDS02.1-W040N-HS76-01-FW occupies an essential position within the DIAX04 drive rack as the axis-specific servo control module. It forms the control layer of the servo axis, regulating motor torque, current, and velocity using a tightly coupled current control loop. The module interfaces with the system’s shared DC bus supplied by HVR/HVE units, enabling multi-axis energy sharing and efficient regenerative braking.
Architecturally, the module combines high-speed digital current controllers, an integrated gate driver stage, isolated power electronics, and a fiber-optic SERCOS communication interface. The SERCOS interface provides deterministic communication with cycle times as low as 1 ms, making it suitable for machining centers, robotics, and synchronized multi-axis motion systems. The embedded diagnostic processor continuously monitors IGBT temperature, DC bus voltage, current ripple, and feedback consistency. Any anomaly triggers controlled shutdown algorithms to prevent damage.
Key design concepts include galvanic isolation between logic and power stages, high-bandwidth current regulation for accuracy at low speeds, and modular rack-based construction. This modularity enables system integrators to scale axis count simply by adding new HDS modules into the same drive rack without redesigning the power stage. The engineering benefit is reduced commissioning complexity and consistent behavior across multi-axis systems.
In real installations, the HDS servo module addresses critical challenges such as maintaining torque stability under rapid load changes, suppressing electrical noise from long encoder or motor cables, and ensuring reliable operation under high thermal loads. Its robust IGBT architecture supports heavy-duty industrial cycles such as high-acceleration CNC tool movements or frequent reversing in material handling lines.
Typical Application Scenarios
- Applied in CNC machine tools for high-precision spindle and axis servo control, ensuring stable torque during high-acceleration movements.
- Used in industrial robotics for synchronized multi-axis motion with SERCOS timing control.
- Deployed in metal forming machines requiring fast torque response and high overload capacity.
- Functions as an OEM-compatible replacement in DIAX04 retrofit projects for legacy Indramat automation systems.
- Suitable for automated assembly lines where continuous 24/7 operation demands high MTBF and stable thermal behavior.
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