Material
Other, Global universal model
Condition
Other, Global universal model
Task
Other, Global universal model
Mathematical Model
Other, Global universal model
Signal
Other, Global universal model
Customized
Non-Customized
Structure
Other, Global universal model
Operating Temperature
0℃~40℃
Relative Humidity
5%-95% (non-condensing)
Dimensions
100mm×150mm×60mm
REXROTH VDP40.2BIN-G4-PS-NN is a low-voltage servo drive in the VDP series. As a control unit for 400W-class low-voltage precision motion control, it is mainly adapted to DC 24V/48V power supply scenarios. It is widely used in low-voltage precision motion control fields such as industrial robot end effectors, small CNC machine tools, electronic equipment assembly lines, medical equipment (e.g., diagnostic instruments, rehabilitation devices), warehouse logistics AGVs, and semiconductor packaging equipment. It undertakes core tasks including high-precision position control, high-dynamic speed adjustment, and stable torque output of servo motors.
Its core advantage lies in its low-voltage optimized design, combined with a high-efficiency power conversion module and a precise closed-loop control algorithm. While achieving low power consumption and high reliability, it ensures precision motion control performance. It can be perfectly matched with Rexroth's corresponding models of low-voltage servo motors to form an integrated "drive-motor" low-voltage control solution, providing solid support for high-precision motion control in low-voltage scenarios. It is a preferred control device in the field of low-voltage industrial automation.
I. Technical Parameters
1. Power and Power Supply Parameters
Rated output power: 400W, adapted to DC low-voltage permanent magnet synchronous servo motors (preferentially matched with Rexroth VEM series low-voltage servo motors).
Rated output current: 10A (continuous), 30A (peak, duration 2s), which can meet the instantaneous overload requirements of low-voltage scenarios.
Input power supply: DC 24V~48V (wide-voltage adaptation, supporting voltage fluctuation of ±15%), compatible with commonly used industrial low-voltage DC power modules.
Power supply efficiency: ≥92% (under rated load); standby power consumption: ≤5W, effectively reducing the energy consumption of low-voltage systems.
Equipped with power reverse connection protection function to prevent equipment damage caused by incorrect wiring.
2. Control Performance Parameters
Control modes: Supports three basic modes (position control, speed control, torque control) and smooth switching between modes without disturbance.
Position control accuracy: Depends on encoder resolution; compatible with incremental encoders (supporting up to 1024 lines) and absolute encoders (supporting up to 17-bit single-turn). The positioning accuracy is ≤±0.001mm when used with precision ball screw transmission.
Speed control range: 0~3000rpm; speed fluctuation at rated speed: ≤±0.1rpm; no crawling phenomenon during low-speed operation (0.5rpm).
Torque control accuracy: ≤±5% of rated torque, supporting torque feedforward compensation.
Dynamic response time: ≤1ms (speed step response); position loop bandwidth: ≥500Hz, enabling quick following of command and load changes.
3. Feedback and Communication Parameters
Standard interfaces: Incremental encoder interface (TTL signal), absolute encoder interface (SSI interface); supports 1Vpp sine wave encoder signal acquisition, and is compatible with small linear scales to achieve full closed-loop control.
Communication interfaces: Standard with two industrial communication interfaces (CANopen, RS485), compatible with Modbus-RTU protocol, and can be connected to low-voltage automation control systems.
Communication rate: Up to 1Mbps for CANopen, up to 115200bps for RS485; command response delay: ≤100μs.
Supports optional IO-Link interface to realize fast communication with low-voltage sensors and actuators.
Equipped with 8-channel digital input and 4-channel digital output interfaces (opto-isolated), supporting custom function configuration.
4. Structural and Environmental Parameters
Adopts a compact modular design; overall dimensions (width×height×depth): 100mm×150mm×60mm; weight: ≤0.8kg; supports rail-mounted installation (standard 35mm DIN rail), saving installation space.
Cooling method: Natural cooling (under rated load); internal cooling fan automatically starts for auxiliary cooling during overload.
Temperature range: Operating temperature 0℃~40℃ (natural cooling), 0℃~50℃ (forced cooling); storage temperature -20℃~60℃.
Relative humidity: 5%~95% (non-condensing).
Protection class: IP20 (panel-mounted).
Vibration resistance class: 2g (10Hz~150Hz), adapting to the vibration environment of mobile equipment (e.g., AGVs).
5. Safety and Protection Parameters
Equipped with comprehensive protection functions, including overcurrent protection, overvoltage protection, undervoltage protection, overtemperature protection, motor stall protection, encoder fault protection, load short-circuit protection, and power reverse connection protection; fault response time: ≤50μs.
Safety level: Complies with IEC 61508 SIL 2 standard, supporting Safe Torque Off (STO) function.
Equipped with fault self-diagnosis function, which can feed back fault types through communication interfaces or status indicators.
Supports parameter backup and restoration functions, and can realize batch parameter configuration through upper computer software.
II. Functional Features
1. Wide-Voltage Adaptation + Low-Power Design for Low-Voltage Scenarios
Adopts a wide-range DC input design, supporting 24V~48V voltage input, compatible with different low-voltage power supply systems, and no additional voltage conversion module is required.
The power conversion module uses high-efficiency MOSFET devices, with power supply efficiency increased to over 92%, reducing energy consumption by 10%~15% compared with traditional low-voltage drives.
Standby power consumption is ≤5W, which can significantly reduce energy consumption in intermittent operation scenarios (e.g., AGV standby, intermittent operation of medical equipment).
Equipped with power reverse connection protection and overvoltage/undervoltage protection, effectively coping with voltage fluctuations and wiring error risks in low-voltage power supply systems.
2. Multi-Mode Precision Control to Meet Diverse Needs
Integrates three core control modes (position control, speed control, torque control). Position control supports jogging, continuous operation, electronic gear, electronic cam, etc., enabling precision alignment control in electronic equipment assembly.
Speed control supports constant speed and speed ramp adjustment, adapting to speed regulation scenarios such as AGV travel drive and small conveyor lines.
Torque control supports constant torque and torque limitation, adapting to pressure control in medical equipment and precision clamping scenarios in semiconductor packaging.
The three modes can be switched without disturbance through communication commands or digital input signals, meeting the multi-process control needs of equipment.
3. Compact Structure + Flexible Installation for Optimized Integration Solutions
Adopts a highly integrated modular design, with a volume of only 100mm×150mm×60mm and a weight of less than 1kg. Compared with traditional low-voltage drives of the same power, its volume is reduced by more than 30%, and it can be easily installed in small equipment or control cabinets with limited space.
Supports standard 35mm DIN rail installation, no special tools are required during installation, improving integration efficiency.
Wiring adopts plug-in terminal design, simplifying on-site wiring and maintenance operations.
Realizes "plug-and-play" with Rexroth VEM series low-voltage servo motors. The drive can quickly complete configuration through the motor parameter self-tuning function, reducing debugging time by 50%.
4. High Reliability + Intelligent Operation and Maintenance to Reduce Downtime Risks
Uses industrial-grade component selection; key components (e.g., power MOSFETs, capacitors) have undergone strict reliability testing, with a Mean Time Between Failures (MTBF) of ≥50,000 hours.
Equipped with comprehensive fault protection and self-diagnosis functions. When an abnormality is detected, it immediately cuts off the output and feeds back fault information, while recording the operating parameters (current, voltage, speed) at the time of the fault to facilitate quick troubleshooting.
Equipped with LED status indicators and a buzzer alarm device to intuitively feed back equipment operating status and fault types.
Supports remote monitoring of operating status, modification of control parameters, and firmware upgrading through upper computer software, realizing remote operation and maintenance.
III. Working Principle
1. Power Conversion and Command Receiving Stage
After a low-voltage DC power supply (24V/48V) is connected to the drive, ripple is filtered out by the power supply filtering unit, and then the DC bus voltage is stably output through the DC-DC conversion module. The drive receives control commands from upper controllers (e.g., PLCs, motion controllers) through communication interfaces (CANopen/RS485) or digital input interfaces, including control mode commands (position/speed/torque), target parameters (target position/speed/torque), and operation commands (start/stop/emergency stop). After the internal logic unit parses the commands, it calls preset control parameters (e.g., PID parameters, acceleration time).
2. Feedback Signal Acquisition Stage
When the servo motor is running, the high-precision encoder at the end collects the rotor's speed and position signals in real time and transmits them to the drive's signal processing unit through the encoder interface. The signal processing unit decodes and filters the collected signals, converts analog signals into digital signals, calculates the motor's current actual speed, actual position, or actual torque, and transmits them to the control algorithm unit. In the case of full closed-loop control, the load position signals collected by the linear scale are also synchronously transmitted to this unit for position accuracy calibration.
3. Closed-Loop Regulation and Calculation Stage
The control algorithm unit compares the target parameters of the upper command with the actual parameters collected by feedback, and calculates the deviation values (position deviation, speed deviation, torque deviation). It uses a PID + feedforward composite control algorithm to calculate the deviation values, and combines the control parameters optimized for low-voltage scenarios to calculate the voltage and current adjustment signals that need to be output. In the position control mode, it combines the S-curve acceleration and deceleration algorithm to generate a smooth speed curve, avoiding impact during start and stop. When the load changes, the disturbance observer is used to compensate for load disturbances in real time to maintain control accuracy.
4. Power Output and Drive Stage
The adjustment signals are transmitted to the power amplification unit. The power amplification unit uses a high-efficiency MOSFET inverter to invert the stabilized DC bus voltage into three-phase AC with adjustable frequency and amplitude, which is output to the stator windings of the low-voltage permanent magnet synchronous servo motor. Through vector control technology, the magnitude and direction of the motor stator magnetic field are precisely controlled to drive the rotor to rotate synchronously, realizing precise adjustment of motor speed and torque. The output current is automatically adjusted according to the load size, and the output power is reduced under light load to achieve energy-saving operation.
5. Safety Monitoring Stage
The safety monitoring unit monitors key parameters in real time, such as input voltage, output current, bus voltage, module temperature, and encoder signals, and compares them with preset safety thresholds. When it is detected that a parameter exceeds the safe range (e.g., the output current exceeds the 30A peak value, or the module temperature exceeds 85℃), it immediately triggers the protection mechanism to cut off the power output, and at the same time feeds back the fault information through the communication interface and status indicator. If power reverse connection is detected, the reverse connection protection circuit is activated immediately to avoid component damage. After the fault is eliminated, the protection state must be released through manual reset or remote command.
IV. Common Faults and Solutions
Fault 1: The Drive Has No Response After Power-on, and the Indicator Light Does Not Turn On
Possible Causes
Input power voltage is too low or no voltage;
Loose or poor contact of power wiring;
Power reverse connection (triggering reverse connection protection);
Fault of the internal power module of the drive;
Fuse blowout.
Solutions
Use a multimeter to detect the input power voltage, ensure it is within the range of 24V~48V±15%. If there is no voltage, check whether the power module is normal;
Re-plug the power terminal blocks to ensure tight contact, and check whether the wire cross-sectional area meets the requirements (≥2.5mm²);
Check the positive and negative wiring of the power supply. If reversed, re-wire and power on again after waiting for 1~2 minutes;
Disconnect the power supply, open the drive housing (by professionals), check whether the fuse is blown. If blown, replace it with a fuse of the same specification (5A/250V);
If the above operations are ineffective, it indicates a fault in the internal power module, and the drive needs to be returned to the factory for repair.
2. Fault 2: CANopen Communication Interruption, Unable to Receive Upper Command
Possible Causes
Broken communication cable or poor contact;
Unconnected terminating resistor (for terminal nodes);
Incorrect communication address configuration;
Fault of the upper controller's communication module;
Signal distortion caused by electromagnetic interference.
Solutions
Check the continuity of the CANopen cable, use a dedicated tester to detect the integrity of the cable, and replace the damaged cable;
Confirm that the bus terminal node has a 120Ω terminating resistor connected. If not, install it;
Check the CANopen communication address of the drive and the configured address of the upper system to ensure uniqueness and no conflict. Reconfigure the address and restart the equipment;
Connect the drive to a backup CANopen bus for testing. If communication is restored, it indicates a fault in the upper controller, and the upper module needs to be repaired;
Add a shielding layer to the communication cable and ground it at one end (grounding resistance ≤4Ω), and keep it away from low-voltage high-current wires to reduce interference.
3. Fault 3: The Motor Runs Unsteadily After Startup, with Step Loss Phenomenon
Possible Causes
Incomplete motor parameter self-tuning or incorrect parameters;
Encoder signal interference or loose installation;
Unreasonable PID parameter configuration;
Overload due to excessive load exceeding the rated torque;
Excessive power supply voltage fluctuation.
Solutions
Execute the motor parameter self-tuning function to ensure the drive correctly identifies motor parameters such as resistance, inductance, and moment of inertia. If self-tuning fails, manually input the motor nameplate parameters;
Check whether the encoder is firmly installed and the cable shielding is in good condition. Re-fasten the encoder and adjust the routing of the signal cable to avoid parallel routing with the power cable;
Enter the drive parameter interface, optimize the PID parameters (increase the position loop gain, reduce the integral time), and eliminate step loss through the trial-and-error method;
Detect the operating current. If it exceeds the 10A rated current, check whether the load is too heavy, optimize the load or replace the motor with a higher power;
Use a multimeter to detect the power supply voltage. If the fluctuation is too large, install a low-voltage voltage stabilizer or a capacitor filter module.
4. Fault 4: The Drive Reports "Overtemperature Fault" and Cannot Operate Normally
Possible Causes
Excessively high operating environment temperature (exceeding 50℃);
Damaged cooling fan (during forced cooling);
Poor ventilation of the drive (blocked);
Long-term overload operation (current exceeding 10A);
Excessive dust accumulation on internal heat sinks.
Solutions
Detect the operating environment temperature. If it exceeds 50℃, improve the ventilation conditions (add fans, clean the heat dissipation space);
Check whether the internal cooling fan rotates normally. If damaged, replace it with a fan of the same model;
Clean the obstacles around the drive to ensure the heat dissipation channel is unobstructed, and the distance between the drive and other equipment is ≥5cm;
Monitor the operating current to avoid long-term overload. If the load continuously exceeds the rated value, replace the drive with a higher power;
Disconnect the power supply, clean the dust on the internal heat sinks of the drive, and blow clean the heat dissipation channel with compressed air.
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