REXRTOH HNC100-3X Electro hydraulic Motion Control

Rexroth HNC100-3X: A high-performance motion control core designed specifically for electro-hydraulic drive

In industrial applications that require high power density, extreme load capacity, and excellent reliability, hydraulic transmission technology has always held an irreplaceable position. However, integrating traditional hydraulic systems with modern precision motion control and high-level automation has always been a complex technological challenge. Bosch Rexroth, with decades of deep experience in the hydraulic field, has launched the HNC100-3X series programmable motion controller, designed specifically for electro-hydraulic drives. It successfully combines the power advantages of hydraulic with the precision and flexibility of intelligent control, becoming a key bridge connecting hydraulic drives and digital factories.

Introduction: Challenges and Opportunities Faced by Hydraulic Drive Automation

Hydraulic systems are widely used in key fields such as injection molding machines, presses, steel rolling equipment, and heavy engineering machinery due to their unparalleled power density, robustness, and impact resistance. However, traditional hydraulic control often relies on decentralized valves and simple relay logic. When implementing complex, multi axis synchronous, and high dynamic precision motion control, it often faces problems such as system complexity, difficult debugging, low energy efficiency, and insufficient repeatability.

The birth of the Rexroth HNC100-3X was precisely to solve these problems. It is not a simple universal controller, but a motion control solution deeply optimized for hydraulic physical characteristics. It draws on the unique experience gained by Rexroth in thousands of practical application projects, integrating hydraulic drive technology, closed-loop control technology, and modern automation software engineering, aiming to provide machine manufacturers with an advanced control platform that is easier to implement, performs better, and has a lower total cost of ownership.

System positioning and core design philosophy: openness, scalability, and ease of use

HNC100-3X is positioned as an "all-around player" in the field of hydraulic drive control, and its core design concept revolves around three key points:

1. Excellent openness:

The controller supports mainstream fieldbus (such as PROFIBUS DP) and industrial Ethernet (such as PROFINET, EtherNet/IP), making it easy to integrate into any existing automation architecture, whether as a distributed slave or an independent multi axis controller. Its free program programmability and open access to all control parameters allow users to implement any complex motion sequence, effectively protecting the core application knowledge of device manufacturers.

2. Fine scalability of hardware and software:

This is one of the most attractive features of HNC100-3X. Rexroth adheres to and optimizes its mature bundled I/O strategy, providing users with a continuous and scalable path from hardware to software:

On the hardware level, the product line covers everything from ultra compact single axis integrated modules (with a depth of 108mm and a width of only 34mm) to modular construction kits that can control up to 4 electro-hydraulic axes. Users can accurately select based on the number of axes and the required number of analog/digital I/O points (such as voltage/current input/output, SSI/incremental encoder interfaces) to avoid resource waste.

At the software level, the controller firmware integrates comprehensive control, process, and monitoring functions, and all functional modules are already "on board". Users only need to activate the corresponding license according to their actual application needs to use it. This' on-demand activation 'mode achieves precise matching of functionality and cost.

3. Usability throughout:

From engineering design, parameter debugging to fault diagnosis, usability permeates every aspect. The specialized engineering software WIN-PED 7 provides an intuitive graphical interface and step-by-step guidance, significantly reducing the programming threshold. The integrated real-time diagnostic tool WinView can record all PLC and process variables in up to 16 channels, providing powerful data support for analyzing intermittent faults and optimizing machine performance.

Deep analysis of hardware architecture: Born for harsh industrial environments

The hardware design of HNC100-3X fully considers the reliability requirements of industrial applications.

1. Mechanical and electrical characteristics:

All models are installed using 35mm top cap rails (EN 60715), with a compact and sturdy structure. Its working voltage is 18-30 VDC, suitable for industrial standard DC power supply. The controller complies with the CE mark (following the EMC directive 2004/109/EC) and meets strict standards such as EN 60068-2 in terms of vibration resistance, impact resistance, and heat resistance, ensuring stable operation in harsh industrial environments.

2. Scalable I/O resources (taking multi axis modules as an example):

As the number of control axes increases, the resources provided by the controller increase linearly, which is a clear manifestation of its bundled I/O strategy:

Control axis number, analog input (U/I), analog output (U), digital I/O (configurable), SSI/incremental encoder

1 axis 4 (2U+2I) 2 11 points (up to 20 output points) 1

2 axes, 8 (4U+4I), 4 22 points (up to 20 output points), 1 per axis

3-axis 12 (6U+6I) 5 33 points (up to 20 output points) 1 per axis

4-axis 16 (8U+8I) 6 44 points (up to 20 output points) 1 per axis

This configuration ensures that each axis has sufficient sensor signal interfaces and valve drive outputs, without the need for additional expansion modules, simplifying the system structure.

3. Rich communication interfaces:

Standard configuration: RS232, used for basic services and parameter settings.

Optional: PROFIBUS DP/V0, PROFINET RT, EtherNet/IP. The multi axis version also comes standard with a TCP/IP service interface for advanced diagnostics and network communication.

Software and Function: Intelligent Core for Deep Optimization of Hydraulic Control

The power of HNC100-3X is largely due to its software feature set specifically designed for hydraulic optimization.

1. High performance control core:

The controller supports variable scanning cycles, with a single axis scanning time of up to 0.5ms, providing a solid performance foundation for high dynamic response hydraulic servo systems. Its control algorithm has been specially tuned to effectively handle the inherent nonlinearity, hysteresis, and time-varying parameters of hydraulic systems.

2. Rich hydraulic dedicated control functions:

Multi mode control: integrates extended position controller, pressure/force controller, and speed controller, and can seamlessly switch during motion. For example, a typical "position pressure" alternating control can be used in press fit processes to smoothly switch to pressure control after reaching the position.

Hydraulic valve adjustment function: The built-in tool simplifies the zero position and gain calibration of proportional valves or servo valves.

Advanced process functions: including slope function, curve function, virtual cam, multi axis synchronization (2-4 axis synchronization), complex mathematical operations, and contour sequence generation.

3. Comprehensive security and monitoring functions:

To ensure the safety and reliability of the system, the controller integrates multiple monitoring systems: control error monitoring, analog signal cable breakage monitoring, encoder breakage monitoring, travel range limit monitoring, and synchronization error monitoring. These features can prevent device damage and significantly reduce troubleshooting time.

4. Engineering software WIN-PED 7:

This is the core tool for configuring HNC100-3X. It provides an integrated project environment that includes:

Project View: Centralize management of all hardware configurations, parameters, and programs.

Editor: Supports NC language programming that complies with DIN 66025 standards (similar to machine tool G-code), making motion sequence programming particularly familiar to engineers with machine tool backgrounds. For example, switching from position to pressure control only requires a few lines of instructions.

Bus Manager: Intuitively configure network communication.

WinView diagnostic tool: real-time data tracking and recording, is a powerful tool for performance optimization and fault analysis.

Typical Applications and Value Manifestations

The flexibility of HNC100-3X makes it stand out in many industries that require hydraulic power:

Plastic machinery: injection molding machines, blow molding machines, rubber injection presses, achieving precise position and pressure control.

Metal Forming: Compressors, bending machines, stamping machines, hydraulic forming systems, complete high-speed and high-precision synchronous actions.

Rolling and steel: rolling mill, drawing system, swing crystallizer control.

Special equipment: packaging machines, lifting equipment, assembly machines, test benches, etc.

For machine manufacturers, their value lies in:

Shortening time to market: Mature function libraries and easy-to-use tools simplify engineering debugging.

Improving machine performance: Optimized control algorithms enhance motion accuracy, production pace, and energy efficiency.

Reduce total cost of ownership: Reliable hardware and powerful diagnostic capabilities reduce downtime and maintenance costs.

Protecting intellectual property: Protecting applications with passwords to prevent the leakage of core process knowledge.

Technical Support and Ecology

Rexroth provides a comprehensive support system, including hydraulic drive selection, customized training, application development support, and on-site debugging services. Users can also obtain the latest software, firmware, documentation, and tools through their official website, and receive direct technical support through a dedicated email.

Conclusion: A key step towards intelligent hydraulic drive

The Rexroth HNC100-3X series motion controller represents the advanced level of electro-hydraulic drive control technology. It successfully connects the powerful hydraulic power with the precision, flexibility, and intelligence of modern digital control. Through its open system architecture, precise scalability, core algorithms for hydraulic optimization, and user-friendly engineering environment, HNC100-3X not only solves the complex challenges in current hydraulic automation, but also lays a solid foundation for the digitization, networking, and intelligence of hydraulic drive units in future smart factories.

For engineers and manufacturers committed to enhancing equipment competitiveness and developing a new generation of high-performance hydraulic drive equipment, a deep understanding and application of HNC100-3X is undoubtedly a strategic choice to master core control technology and achieve product differentiation advantages. It is not just a controller, but also a future oriented motion control platform that carries decades of hydraulic experience from Rexroth.