Bosch Rexroth HDS02.2-W040N-HT20-01-FW AC Servo Drive – HDS Series

HDS02.2-W040N-HT20-01-FW: 40 A Digital Servo Amplifier in the DIAX04 Closed-Loop Motion Architecture

The Bosch Rexroth HDS02.2-W040N-HT20-01-FW is a 40 A continuous-rated digital AC servo drive belonging to the HDS (High Dynamic Servo) second-generation product line within the DIAX04 modular drive platform. Its role in a control loop is unambiguous: it acts as the torque-generating execution layer between the motion controller and the servo motor, translating position or velocity setpoints — delivered via SERCOS fiber-optic ring or ±10 V analog interface — into precisely regulated three-phase PWM output at the motor terminals. The drive closes three nested control loops entirely in the digital domain: a current (torque) loop executing at ≤ 62.5 µs, a velocity loop at 250 µs, and an optional position loop at 1 ms. This architecture eliminates the analog drift and gain-temperature dependency inherent in earlier hybrid drive designs, providing repeatable dynamic stiffness across the full operating envelope.

The W040N designation encodes the 40 A nominal output current and the N-frame power stage. The HT20 suffix identifies the thermal management class: an extended heatsink assembly rated to sustain full 40 A continuous output at 45 °C ambient without derating, a specification relevant to enclosed cabinet installations in foundry, press-shop, and food-processing environments where ambient temperatures routinely exceed 40 °C. The FW firmware variant enables field parameterization via Rexroth IndraWorks DS software through the X2 serial diagnostic port, allowing axis re-tuning, feedback type switching, and safety function configuration without hardware replacement.

In multi-axis systems, the HDS02.2 operates as a slave node on the shared DC bus supplied by a Rexroth HVR or HVE regenerative power supply module. This topology allows kinetic energy recovered during motor deceleration to be redistributed across the bus to accelerating axes, reducing peak demand on the AC supply and lowering heat dissipation in the drive cabinet by up to 30 % compared to individual drive-per-axis architectures with resistive braking.

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Technical Parameters

Hardware Logical Analysis

The HDS02.2-W040N-HT20-01-FW is built around a three-phase IGBT inverter bridge with gate drivers isolated from the control logic by optocouplers rated at 2.5 kV isolation voltage. This galvanic barrier prevents high-frequency switching transients on the motor cable — which can reach dV/dt values of 5–10 kV/µs on 480 V bus systems — from coupling back into the DSP-based control board. The control board itself is a multi-layer PCB with dedicated ground planes for analog feedback signal processing and digital logic, physically separated to suppress common-impedance coupling between the resolver demodulation circuit and the SERCOS ASIC.

EMC compliance is achieved through a combination of hardware and layout measures: a common-mode choke on the DC bus input attenuates conducted emissions above 150 kHz; the motor output terminals are routed through an internal dV/dt filter stage that limits voltage rise time to ≤ 500 V/µs at the motor terminals, protecting winding insulation on cable runs up to 50 m without an external output filter. The SERCOS fiber-optic interface provides complete galvanic isolation between the drive and the motion controller, eliminating ground-loop-induced noise that is a persistent failure mode in analog ±10 V command wiring in environments with large welding or press equipment.

The HT20 heatsink assembly uses extruded aluminum with a fin pitch optimized for the internal fan’s airflow velocity. Thermal resistance from junction to heatsink (Rth j-h) for the IGBT modules is specified at ≤ 0.12 K/W per phase leg, allowing the drive to sustain 80 A peak current for 400 ms without triggering the I²t thermal protection model — a requirement for injection molding clamp axes that demand high-force short-duration clamping cycles. The firmware’s thermal model integrates motor and drive temperature data from NTC sensors to compute a real-time derating curve, issuing a warning diagnostic (E8025) before a hard fault shutdown, giving the machine controller time to execute a controlled stop.

The feedback card supports simultaneous connection of a primary motor encoder (EnDat 2.1 or Hiperface) and a secondary load-side encoder for dual-loop position control, enabling full-closed-loop operation that compensates for ballscrew backlash and thermal expansion in precision machining applications. The resolver interface uses a 10 kHz excitation frequency with synchronous demodulation, achieving 14-bit resolution (16,384 counts/rev) equivalent — adequate for velocity control down to 0.1 rpm without encoder interpolation artifacts.

System Integration Benefits

• Deterministic SERCOS Cycle: The fiber-optic SERCOS ring delivers position setpoints and actual-value telegrams with ±1 µs jitter, enabling synchronization of up to 254 axes on a single ring — a prerequisite for electronic gearing and cam profiling in multi-axis packaging and printing machinery.
• Shared DC Bus Energy Recovery: Regenerative energy from decelerating axes is returned to the common DC bus and consumed by accelerating axes in the same cabinet, reducing peak AC demand and eliminating the need for braking resistors in most duty cycles, lowering cabinet thermal load and component count.
• Plug-and-Play Motor Database: The FW firmware contains a pre-loaded motor parameter database covering Rexroth MHD, MKD, MKE, and MSK families. Selecting the motor type from the database auto-populates current limits, encoder type, thermal model constants, and commutation offset — reducing commissioning time from hours to minutes.
• Integrated Oscilloscope Function: IndraWorks DS provides a 4-channel software oscilloscope with 1 ms sampling, accessible via the X2 port without interrupting production. Engineers can capture current, velocity, and position actual values simultaneously to diagnose resonance, following error, or thermal derating events without external instrumentation.
• Diagnostic Transparency: The drive maintains a non-volatile fault history log of the last 32 events with timestamps, operating hours, and parameter snapshots at fault time. This data is retrievable via SERCOS service channel or X2 serial port, enabling root-cause analysis without on-site presence.
• Safe Torque Off (STO) Hardware Path: The STO function disables IGBT gate signals at the hardware level, independent of firmware state. This allows the machine to enter a safe state without a full drive power cycle, reducing restart time after an E-stop from 30–60 s (full boot) to under 2 s (STO reset), improving OEE on high-throughput lines.
• Scalable Multi-Axis Architecture: The DIAX04 platform supports mixed-axis configurations — HDS02.2 (40 A), HDS03.2 (70 A), and HDS04.2 (100 A) — on the same DC bus and SERCOS ring, allowing machine builders to right-size each axis without changing the control architecture or power supply module.
• Field Firmware Upgrade Path: The FW variant supports in-field firmware updates via IndraWorks DS without drive removal or factory return. This allows adoption of Rexroth firmware patches addressing known issues (e.g., SERCOS phase transition timing, encoder interpolation corrections) without machine downtime beyond a single controlled restart.

Quality Assurance & Global Logistics

Every HDS02.2-W040N-HT20-01-FW unit offered through siemensplc.com is sourced from verified industrial channels — OEM overstock, authorized distributor surplus, or decommissioned machinery with documented service history. Incoming inspection covers: visual examination of PCB, IGBT modules, and capacitor banks for physical damage; firmware version verification against Rexroth release notes; DC bus capacitor ESR measurement to confirm capacitance within 10 % of nameplate value; and continuity check of all I/O and feedback connectors. Units with ESR deviation exceeding 15 % or any evidence of thermal stress on the IGBT substrate are quarantined and not offered for sale.

Original Bosch Rexroth serial number plates, firmware stickers, and CE/UL markings are intact and traceable to Rexroth’s production records. Each unit is packed in an anti-static shielding bag, placed in a custom foam-lined export carton with a humidity indicator card, and sealed with tamper-evident tape. Export documentation — commercial invoice, packing list, and certificate of origin — is prepared in compliance with Chinese customs regulations and the destination country’s import requirements.

Shipment is dispatched from our warehouse in Xiamen, China via DHL Express, FedEx International Priority, or UPS Worldwide Expedited, with full tracking provided at time of dispatch. Transit times to major industrial hubs: Germany 3–5 days, USA 4–6 days, Southeast Asia 2–3 days, Middle East 4–7 days. For urgent plant-down situations, same-day dispatch is available for orders confirmed before 14:00 CST. All shipments are covered by cargo insurance. A 12-month warranty is provided from the invoice date, covering manufacturing defects and premature component failure under normal operating conditions.

Contact Information

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