Bosch Rexroth CLC-D02.2 Positioning Control Card – DIAX04 Series

Bosch Rexroth CLC-D02.2 — Closed-Loop Positioning Control Card for DIAX04 Digital AC Servo Drives

The Bosch Rexroth CLC-D02.2 is a plug-in positioning control card designed exclusively for the DIAX04 digital AC servo drive platform. It assumes full responsibility for closed-loop position regulation within the drive, executing interpolation, homing sequences, and following-error supervision at the card level — independent of the host controller’s scan cycle. In high-throughput manufacturing environments where axis repeatability is measured in micrometers and cycle times in milliseconds, offloading position-loop computation to the drive card is not a convenience; it is an architectural necessity.

The DIAX04 platform spans four drive variants — HDD, HDS, HMS, and HMD — covering power classes from compact single-axis configurations to multi-axis coordinated systems. The CLC-D02.2 slots into the control card bay of these drives and communicates with the drive’s internal DSP via the proprietary DIAX04 backplane bus, operating at a fixed interpolation cycle that is decoupled from the fieldbus update rate. This decoupling is the fundamental reason the card can sustain sub-millisecond position-loop closure even when the upstream SERCOS or analog interface card is handling communication overhead.

Real-time Stock & RFQ: [email protected] | WhatsApp: +86 18359268345

Technical Parameters

Hardware Logical Analysis

The CLC-D02.2 implements a three-tier cascade control architecture: an outer position loop, an intermediate velocity loop, and an inner current (torque) loop. Each tier runs at a progressively shorter sample period — position at the interpolation cycle, velocity at a sub-multiple of that, and current at the PWM switching frequency of the drive’s IGBT stage. This cascade structure ensures that disturbances entering at the mechanical load are attenuated before they propagate upward to the position reference, a property that is mathematically equivalent to increasing the bandwidth of the outer loop without sacrificing stability margins.

The card’s DSP maintains a position accumulator that integrates encoder feedback pulses in real time. When the host PLC issues a target position via the SERCOS or analog interface card, the CLC-D02.2 generates a trapezoidal or S-curve velocity profile internally, then tracks that profile against the encoder accumulator. The following error — the instantaneous difference between commanded and actual position — is continuously compared against a user-parameterized threshold stored in the drive’s non-volatile parameter memory. If the threshold is exceeded, the card asserts a fault signal on the drive’s status bus within one interpolation cycle, preventing mechanical overload before the host PLC’s watchdog timer would even detect the anomaly.

From an EMC standpoint, the CLC-D02.2 PCB routes high-frequency DSP clock signals on inner copper layers, with ground planes on adjacent layers acting as Faraday shields. The backplane connector pins carrying analog feedback signals are physically separated from digital bus lines, and the card’s power supply section uses local decoupling capacitors at each IC supply pin to suppress conducted emissions. These layout decisions are consistent with IEC 61800-3 Category C2 drive system requirements, which mandate that the drive system not cause interference to other equipment sharing the same low-voltage distribution network.

The card’s non-volatile parameter storage uses an EEPROM that retains axis parameters — position loop gain (Kp), velocity feedforward coefficient, homing offset, and software travel limits — across power cycles without requiring a battery. This is architecturally significant in applications where the drive may be powered down frequently, such as energy-saving standby modes in machine tools, because the axis does not require re-parameterization after each restart.

System Integration Benefits

• Reduced PLC computational load: Position loop execution on the CLC-D02.2 removes the most time-critical motion task from the host PLC scan cycle, freeing PLC resources for process logic, HMI communication, and safety monitoring without increasing the PLC’s cycle time.
• Deterministic axis response independent of fieldbus jitter: Because the position loop closes on the card’s own DSP clock rather than on the fieldbus update event, axis response time is bounded by the card’s interpolation period, not by network latency or PLC scheduling variance.
• Plug-in installation with zero external wiring: The card interfaces exclusively through the DIAX04 backplane connector. There are no ribbon cables, no external signal conditioners, and no additional terminal blocks required, reducing installation time and eliminating a class of wiring-related failure modes.
• On-drive fault detection with sub-cycle response: Following-error faults are detected and signaled within one interpolation cycle — typically faster than any PLC-based monitoring scheme — protecting mechanical components such as ballscrews, gearboxes, and couplings from overload damage.
• Parameter persistence across power cycles: EEPROM-based parameter storage eliminates the need for battery-backed RAM and ensures that axis tuning parameters survive power interruptions without data loss or re-commissioning effort.
• Compatibility with multiple homing strategies: Support for limit-switch, encoder zero-pulse, torque-based, and absolute-encoder homing methods allows the same card to be deployed across machine designs with different mechanical reference configurations, reducing spare-part SKU proliferation.
• Diagnostic transparency via drive status bus: The card exposes position error magnitude, homing status, and motion state as readable parameters on the drive’s status interface, enabling the host PLC or SCADA system to log axis health data without requiring additional instrumentation.
• Scalable to multi-axis architectures: In systems where multiple DIAX04 drives share a common SERCOS ring or analog bus, each CLC-D02.2 operates autonomously, so adding axes does not increase the position-loop latency of existing axes — a property that linear scaling of PLC-based position control cannot guarantee.

Quality Assurance & Global Logistics

Every CLC-D02.2 unit dispatched from our Xiamen, China facility is sourced through verified Bosch Rexroth authorized distribution channels or directly from decommissioned OEM equipment with documented service histories. Before shipment, each card passes through a structured inspection protocol: visual examination of the PCB surface, connector pins, and component solder joints under magnification; part number and revision label verification against Rexroth’s official documentation database; and, where test fixtures are available, functional verification in a live DIAX04 drive environment with encoder feedback connected and position loop closed.

Units are packed in anti-static (ESD) shielding bags, placed in foam-lined rigid cartons, and outer-packed in double-wall corrugated export cartons rated for international air and sea freight handling. Shipments from Xiamen reach major industrial hubs in Southeast Asia within 3–5 business days by air express, Europe within 5–8 business days, and North America within 5–7 business days. All export documentation — commercial invoice, packing list, certificate of origin, and where required, ECCN classification — is prepared in-house to avoid customs clearance delays.

A 12-month warranty covers manufacturing defects and functional failures under normal operating conditions. Warranty claims are processed with a target response time of 48 business hours from receipt of the returned unit. Replacement or repair options are offered based on stock availability and fault diagnosis results.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
Web: siemensplc.com
Location: Xiamen, China
© 2026 siemensplc.com. All rights reserved.

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