Bosch Rexroth DKC04.3-LK-ITB01 AC Servo Drive Controller – IndraDrive Cs Series

Bosch Rexroth DKC04.3-LK-ITB01 — Single-Axis IndraDrive Cs Servo Controller in Closed-Loop Motion Architecture

The DKC04.3-LK-ITB01 is a single-axis AC servo drive controller from Bosch Rexroth’s IndraDrive Cs (DKC) platform, engineered for deterministic closed-loop motion control in machine tool, packaging, and general-purpose industrial automation. The unit operates within the DIAX04 / IndraDrive ecosystem, accepting torque, velocity, and position commands via SERCOS fiber-optic ring or analog ±10 V interface, depending on firmware configuration. Its role in a control loop is to translate high-level motion commands from a CNC or PLC into precisely regulated PWM output to the connected servo motor, maintaining position accuracy within encoder resolution limits while enforcing configurable current and velocity limits in hardware.

The ITB01 firmware designation identifies this unit as a SERCOS I/II-compatible variant with integrated position controller and velocity feed-forward. Unlike generic variable-frequency drives, the DKC04.3-LK-ITB01 executes its own position control loop at the drive level, offloading interpolation burden from the master controller and enabling distributed motion architectures with deterministic cycle times as low as 1 ms on SERCOS ring topologies. This architecture is particularly relevant in multi-axis gantry and synchronized packaging lines where inter-axis phase error must remain below ±0.1°.

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Technical Parameters

Hardware Logical Analysis

The DKC04.3-LK-ITB01 implements a three-tier control hierarchy within a single hardware module. At the innermost loop, a dedicated DSP executes the current (torque) control algorithm at a fixed 62.5 µs interrupt cycle, independent of the SERCOS communication frame. This decoupling ensures that current regulation remains stable even during transient communication latency events on the fiber ring. The velocity controller operates at 250 µs, and the position controller at the SERCOS cycle period (1–4 ms), forming a cascaded structure that isolates disturbance rejection at each bandwidth level.

The power stage uses IGBT modules rated for the DC bus voltage with a gate-drive circuit incorporating desaturation detection. On a short-circuit event at the motor terminals, the gate driver blanks all IGBT signals within 2 µs, preventing shoot-through and protecting the DC bus capacitor bank. The DC bus capacitors are film-type with low ESR, selected to handle regenerative energy pulses from deceleration without exceeding the bus overvoltage threshold of 800 V DC.

EMC performance is achieved through a multi-layer approach: the control board uses a ground-plane layer between signal and power traces, the SERCOS fiber interface provides galvanic isolation between the drive and the controller, and the motor cable shield is terminated at the drive chassis via a 360° EMC clamp. This design suppresses common-mode noise injection into the motor cable, which is the primary EMC failure mode in servo drive installations operating near variable-speed pump drives or welding equipment.

The ITB01 firmware stores axis parameters in non-volatile EEPROM with a checksum verification routine executed at power-on. If parameter corruption is detected, the drive enters a safe-state fault mode and outputs a diagnostic code on the seven-segment display, preventing uncontrolled axis motion during commissioning or after a power interruption.

System Integration Benefits

• Distributed position control: The drive executes its own position loop, reducing master controller cycle load and enabling tighter synchronization across multi-axis SERCOS rings without increasing PLC scan time.
• Deterministic SERCOS timing: Hard real-time communication at 1 ms cycle guarantees inter-axis synchronization jitter below 1 µs, critical for electronic gearing and cam profiling applications.
• Transparent diagnostics: IDN S-0-0095 (diagnostic message) and S-0-0011 (class 1 diagnostics) are natively supported, allowing the master controller to read fault codes without interrupting the motion task.
• Velocity feed-forward: Integrated velocity feed-forward reduces following error during constant-velocity traversal, improving surface finish in CNC milling without requiring manual gain tuning at the controller level.
• Regenerative energy handling: The drive returns braking energy to the shared DC bus, reducing heat dissipation in multi-axis cabinets and lowering the required braking resistor capacity.
• Motor thermal model: An internal I²t motor thermal model tracks winding temperature estimation in real time, triggering a controlled deceleration before a thermal fault occurs — protecting motor insulation without requiring an external thermistor in all configurations.
• Parameter set switching: Up to four parameter sets can be stored and switched via a digital input or SERCOS IDN command, enabling rapid changeover between product formats on packaging lines without re-commissioning.
• Safe torque off (STO) readiness: The hardware architecture supports STO-equivalent safe state via the enable input circuit, compatible with EN 954-1 Category 3 safety relay modules for machine guarding integration.

Quality Assurance & Global Logistics

Every DKC04.3-LK-ITB01 unit shipped from our Xiamen, China facility is sourced directly from Bosch Rexroth’s authorized distribution network or verified OEM surplus channels. Incoming units undergo a structured acceptance procedure: visual inspection of housing, connector, and label integrity; serial number verification against Bosch Rexroth’s production database where accessible; and a functional power-on test confirming DC bus charge, display operation, and SERCOS ring initialization.

Units are packed in anti-static ESD bags, placed in custom-cut EPE foam inserts, and shipped in double-wall corrugated cartons rated for international air freight handling. Export documentation includes a commercial invoice, packing list, and certificate of origin. HS Code 8504.40 applies for customs classification in most jurisdictions. DHL Express, FedEx International Priority, and UPS Worldwide Express are the standard carriers, with typical transit times of 3–5 business days to Europe and North America. For time-critical MRO requirements, same-day dispatch is available for orders confirmed before 14:00 CST.

A 12-month warranty covers manufacturing defects and functional failure under normal operating conditions. Warranty claims are processed with a return merchandise authorization (RMA) number issued within 24 hours of fault report submission. Replacement units are dispatched before the defective unit is returned for accounts with established credit terms.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
Web: siemensplc.com
Location: Xiamen, China
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