REXRTOH DDS02.1/03.1 Digital AC Servo Drive

REXRTOH DIAX02 DDS02.1/03.1 Driver Controller: Professional Project Planning and Deep Technical Analysis

In the fields of modern industrial automation, machine tools, textiles, printing, packaging, and robotics, high-performance and high reliability servo drive systems are the core source of power. The DIAX02 series DDS02.1 and DDS03.1 drive controllers launched by INDRAMAT (now under Bosch Rexroth) represent the mature application of its modular digital AC servo drive technology. This article will be based on the official project planning manual, and provide a detailed application guide for engineering and technical personnel by thoroughly analyzing the system architecture, safety specifications, technical characteristics, installation planning, and electrical integration points of this series of controllers.

System Overview and Modular Architecture

The DDS (Digital Drive System) drive controller adopts a highly modular design, aiming to flexibly combine multiple AC servos and spindle drives through a single power supply unit to form a compact drive unit. The system core consists of the driver controller basic unit, software modules, plug-in modules, and firmware, achieving hardware and functional configurability.

Basic Unit: As the core carrier of the driver controller, it provides power interfaces, control logic, and basic cooling architecture. The slots (U1-U5) are initially empty, and corresponding modules need to be assembled according to functional requirements.

Software module: located in slot U5, embedded firmware and driver parameters. It is not only the carrier of functional implementation, but also ensures the portability of parameters during device replacement. The type code on it (such as DSM02.1-FW) identifies the firmware version and feature set.

Plugin module: inserted into the U1-U4 slots of the base unit, greatly expanding the interface and functionality of the controller. Mainly includes:

SERCOS interface (DSS01.1/01.3): Supports digital communication with compatible control systems through fiber optics.

Analog Interface (DAA01.1): Provides an analog command interface with traditional control systems and integrates incremental or absolute encoder simulation functions.

Single axis positioning module (DLC01.1/02.1): Upgrades the drive controller to an independent programmable single axis positioning unit, supporting up to 3000 program blocks.

Input/output interface (DEA04.1/05.1/06.1, etc.): Provides a channel for exchanging digital signals with PLC.

Other specialized interfaces, such as Interbus-S slave interface (DBS02.1/02.2), high-resolution position interface (DEF01.1), gear encoder interface (DZF01.1/02.1), etc., meet specific application requirements.

Firmware: defines all functional characteristics of the driver controller. Firmware is ordered independently to ensure version consistency and traceability. The firmware configuration clearly displays the firmware versions of each module in the entire controller through the nameplate identification on the front panel.

Safety Guidelines: Core Guidelines for Ensuring Personnel and Equipment Safety

The manual extensively emphasizes the importance of safe operation, as any negligence can lead to property damage, personal injury, and even fatal danger.

Electrical Safety

High voltage risk: Exposed parts with operating voltage exceeding 50V are extremely dangerous. Before operation, the power must be disconnected and wait for at least 5 minutes (due to internal capacitor discharge), while ensuring that the device is not accidentally restarted. All units and motors must be reliably grounded at the grounding point.

High discharge current: Leakage current may exceed 3.5mA. All units must be permanently connected to the protective grounding of the power supply system to prevent the casing from being charged.

Protection against low voltage: Signal voltage (5-30V) circuits belong to safety isolation circuits (protection against low voltage), but still require standardized operation.

Preventing dangerous activities:

Incorrect speed commands, software malfunctions, hardware problems, wiring errors, encoder malfunctions, etc. can all cause unpredictable dangerous movements.

We cannot rely solely on the built-in monitoring function of the driver to ensure the safety of operators. Superior monitoring devices or measures must be installed on the equipment side, such as guardrails, cover plates, light curtains, etc., and comprehensive hazard and error analysis must be conducted.

The emergency stop switch must be installed in a location that is easily accessible to the operator, and its function must be verified before starting.

Before entering the danger zone, it is necessary to confirm that the drive has completely stopped.

Installation and handling protection: It is necessary to prevent risks of compression, shearing, cutting, and collision. Use appropriate tools and equipment, wear necessary personal protective equipment (such as goggles, safety shoes, gloves), and ensure a clean work area.

Technical data and selection considerations

Power section:

DC bus voltage: nominal 300V (± 15%).

Current capability: The numbers in the controller model (such as DDS02.1-W050-...) represent peak current, while the sustained current depends on the selected motor and the "overload factor". The manual provides a detailed correspondence table between peak current and continuous current, which is a key basis for motor/controller matching and selection.