Bosch Rexroth HMD01.1N-W0012-A-07-NNNN AC Servo Drive – HMD Series

HMD01.1N-W0012-A-07-NNNN: Twin-Axis IndraDrive Compact Module in Closed-Loop Servo Architecture

The Bosch Rexroth HMD01.1N-W0012-A-07-NNNN is a double-axis servo inverter module belonging to the IndraDrive Compact (HMD) product line — a drive family engineered for high-density axis packaging within modular cabinet systems. Unlike single-axis inverters, this unit integrates two fully independent servo channels into a 50 mm-wide housing, each rated at 12 A continuous output current (24 A peak for ≤400 ms), powered from a shared 3-phase 400–480 V AC mains input and a common DC bus operating between 540 and 750 V DC.

Within a servo control loop, the HMD01.1N-W0012-A-07-NNNN sits at the innermost execution layer. The motion controller — typically a Rexroth IndraMotion MTX or a third-party CNC — transmits position or velocity setpoints to the drive via a SERCOS II fiber-optic ring. The drive’s onboard DSP resolves these setpoints into d-q axis current commands, executes Field-Oriented Control (FOC) at a fixed 62.5 µs current regulation cycle, and drives the IGBT output stage accordingly. Actual-value feedback (encoder position, actual current) is returned to the controller within the same SERCOS telegram cycle, closing the position loop with bounded, deterministic latency. This architecture is the technical basis for the module’s suitability in multi-axis contouring, electronic gearing, and cam-profile applications where inter-axis phase error must remain within ±1 encoder count at all commanded speeds.

The -A-07 option code in the part number designates the SERCOS II communication interface with analog override input. SERCOS II operates over plastic optical fiber (POF) at 2, 4, or 8 Mbit/s, with selectable cycle times of 1, 2, or 4 ms. The analog override channel (0–10 V or ±10 V) allows feed-rate override from a hardware potentiometer without consuming a SERCOS parameter slot — a practical feature retained from DIAX04-era machine designs that this module is backward-compatible with.

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Technical Parameters

Hardware Logical Analysis

Three-Layer Internal Processing Architecture

The HMD01.1N-W0012-A-07-NNNN partitions its internal processing into three distinct hardware layers: the SERCOS communication processor, the dual-channel DSP current regulator, and the IGBT gate-drive stage. The SERCOS processor handles ring synchronization, telegram parsing, and parameter object management (S-0-xxxx / P-0-xxxx IDN space) independently of the current regulation DSP. This separation ensures that a SERCOS communication fault (e.g., ring break) triggers a defined fault response — controlled deceleration to standstill — rather than an uncontrolled torque transient caused by a regulation loop interruption.

Dual-Channel FOC with Independent Fault Isolation

Each of the two servo channels operates a separate Field-Oriented Control thread on the shared DSP, with independent current sensor inputs (Hall-effect transducers, ±0.5% linearity), independent IGBT half-bridge drivers, and independent fault latch registers. A hardware interlock prevents a fault condition on one channel from asserting the gate-disable signal on the other. When Channel 2 trips on overcurrent, Channel 1 continues closed-loop regulation while the drive firmware logs the fault event with a 62.5 µs timestamp. The machine controller reads the per-channel fault status via SERCOS IDN S-0-0011 and executes a channel-selective stop sequence — a capability that reduces unplanned downtime in dual-axis gantry and tandem-drive configurations.

Shared DC Bus and Regenerative Energy Exchange

Both axes share a common DC bus capacitor bank. During coordinated motion profiles where one axis decelerates while the other accelerates, the regenerated kinetic energy from the braking axis charges the bus capacitors and is drawn directly by the motoring axis without passing through the mains supply module. In typical pick-and-place or reciprocating-axis profiles, this intra-bus energy exchange reduces peak mains demand by 20–35%, allowing the supply module to be sized for average rather than peak power. The DC bus voltage is monitored at 1 ms intervals; if bus voltage exceeds 780 V DC (overvoltage threshold), the firmware activates the braking chopper output to dissipate excess energy through an external braking resistor.

EMC Architecture: Conducted and Radiated Emission Control

The gate-drive PCB uses a split ground plane topology: the high-frequency switching node (IGBT collector/emitter) is referenced to a dedicated power ground island, while all analog feedback signal traces are routed on a separate signal ground plane connected to power ground at a single star point. Ferrite bead arrays (impedance 600 Ω at 100 MHz) are placed on all resolver excitation and feedback lines. The IGBT switching frequency of 4 kHz places the fundamental switching harmonic above the 2 kHz upper boundary of IEC 61000-4-8 power-frequency magnetic field immunity tests, while remaining within the thermal dissipation budget of the forced-air cooling system. The module meets IEC 61800-3 Category C2 conducted emission limits with Rexroth IKL/IKS shielded motor cables terminated at both ends — no external EMC filter required in standard installations.

Resolver and EnDat 2.1 Signal Conditioning

The resolver interface generates an 8 kHz, 7 V RMS sinusoidal excitation signal and processes the returned sine/cosine signals through a tracking resolver-to-digital converter (RDC) with 16-bit angular resolution (0.0055°/LSB). The EnDat 2.1 interface supports absolute position readout at power-on, eliminating reference-point homing cycles for absolute encoders. All feedback signal lines pass through differential line receivers with ±15 kV ESD protection diodes and 120 Ω termination resistors, maintaining signal integrity on motor cable runs up to 50 m without signal conditioning repeaters.

System Integration Benefits

• 50% cabinet footprint reduction per axis pair: Two servo axes in a single 50 mm slot versus two separate single-axis drives at 100 mm total — directly reduces enclosure volume, cable routing complexity, and associated cooling infrastructure cost in multi-axis machine designs.
• Deterministic inter-axis synchronization: SERCOS II ring topology bounds axis-to-axis synchronization jitter to ≤1 µs at 2 ms cycle time, enabling circular interpolation and electronic gearing accuracy that meets ISO 10791-6 machining center tolerances without external synchronization hardware.
• Intra-bus regenerative energy redistribution: Kinetic energy recovered from decelerating axes is immediately available to accelerating axes on the shared DC bus, reducing peak mains supply module sizing requirements by up to 35% in coordinated motion profiles.
• Per-channel fault isolation for uptime continuity: Independent fault latch registers and gate-disable logic per axis allow the healthy axis to remain in closed-loop control during a single-axis fault, enabling controlled machine stop sequences rather than emergency power-off events.
• Multi-feedback motor compatibility: Native support for resolver, EnDat 2.1, Hiperface, and TTL/HTL encoders allows the drive to interface with Rexroth MKD, MHD, MSK, and compatible third-party servo motors without hardware modification or external signal converters.
• Integrated STO and SS1 safety functions: Safe Torque Off (STO, PLd / Category 3 per EN ISO 13849-1) and Safe Stop 1 (SS1) are implemented in dedicated hardware logic, reducing external safety relay count and simplifying SIL 2 machine safety circuit design.
• 62.5 µs oscilloscope trace resolution via IndraWorks DS: The drive’s built-in data recorder captures current, velocity, and position traces at full regulation cycle resolution over USB or Ethernet, enabling root-cause analysis of following errors, mechanical resonance, and load transients without external measurement instruments.
• DIAX04 parameter set compatibility: The HMD01 firmware retains backward compatibility with DIAX04 IDN parameter structures (S-0-xxxx, P-0-xxxx), allowing direct migration of existing axis parameter files in retrofit projects — eliminating full recommissioning and reducing machine downtime during drive replacement.
• Scalable SERCOS cycle time for application-specific latency tuning: Selectable cycle times of 1, 2, or 4 ms allow system integrators to balance bus bandwidth utilization against position loop update rate — a 1 ms cycle supports up to 8 axes on a single SERCOS ring at 8 Mbit/s, while a 4 ms cycle accommodates up to 32 axes at reduced bandwidth cost.

Quality Assurance & Global Logistics

Each HMD01.1N-W0012-A-07-NNNN unit shipped from our Xiamen, China facility is a genuine Bosch Rexroth component procured through verified industrial supply channels. Pre-shipment inspection covers four mandatory checkpoints:

• Physical and label verification: Housing integrity check, connector pin inspection for corrosion or deformation, and authentication of the Rexroth holographic serial label against the published serial number format for the HMD01 series.
• Power-on functional test: DC bus charge sequence verification, axial fan speed confirmation at rated RPM, SERCOS ring initialization with a test controller, and fault-code readout via IndraWorks DS to confirm zero latent error history in the drive’s non-volatile fault log.
• Insulation resistance measurement: 500 V DC megohmmeter test between all power terminals and protective earth (PE), with a minimum acceptance threshold of 1 MΩ per IEC 60204-1 requirements.
• Serial number traceability logging: Unit serial number, firmware version, and test results are recorded against each order reference for full supply chain traceability and warranty claim processing throughout the 12-month warranty period.

Transit times from Xiamen port: Europe (Frankfurt, Rotterdam) 5–7 business days via air freight; North America (Los Angeles, Chicago) 4–6 business days; Southeast Asia 2–3 business days. Complete export documentation — commercial invoice, packing list, certificate of origin, and HS code 8537.10 classification — is included with every shipment. DDP (Delivered Duty Paid) terms are available on request for EU and US consignees.

Contact Information

Email: [email protected]
WhatsApp: +86 18359268345
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Location: Xiamen, China
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