Bosch Rexroth 06088016 (6088016)

Full name of the material: 0 608 801 6 (Tightening System - Spindle / IO Module)

Series: 0608 Tightening Technology

Positioning: Servo tightening spindle / controller IO interface module for automotive automated tightening lines, a core component of the KE300/400 system.

I. Basic Parameters (Official Summary)

Material Number: 0608 801 6 (Abbreviated as 6088016)

Product Type: Tightening spindle drive module / IO communication interface card

Compatible Systems: Bosch Rexroth KE300/KE400 tightening controllers, tightening guns (such as 0608830xxx series)

Electrical Specifications:

Operating Voltage: 24 V DC ±10%

Power Consumption: ≤ 15 W

Communication Interface: PROFIBUS-DP / CANopen (optional)

Inputs / Outputs: 8DI / 8DO (24 V DC, 0.5 A)

Mechanical Parameters:

Dimensions (L × W × H): 120 × 80 × 35 mm

Installation: Standard DIN rail (35 mm)

Protection Class: IP20

Weight: ≈ 0.8 kg

Environmental Conditions:

Operating Temperature: 0 … +50 °C

Storage temperature: -20 … +70 °C

Relative humidity: 5...95% (no condensation)

II. Function and Application

Signal interface: Connect the tightening spindle (torque/angle sensor) to the controller to collect and output torque, angle, and speed signals.

Bus communication: As a slave station, it is connected to PROFIBUS/CANopen to transmit tightening data, status, and fault codes to the PLC or upper computer.

IO control: Provides 8 digital inputs (start, stop, reset, mode selection) and 8 digital outputs (ready, tightening OK, fault, alarm).

Typical applications: Automobile assembly, engine/transmission tightening stations, and as a component of robot tightening guns.

III. Installation and Wiring (Simplified Version)

1. Installation

Fix on the DIN rail of the control cabinet, install vertically, and leave at least 50 mm of heat dissipation space at the top and bottom.

Avoid strong electromagnetic interference (keep away from frequency converters and contactors).

2. Terminal Block (Typical)

Table

Terminal Signal Description

L+ 24 V DC Positive power supply

M 0 V Negative power supply

DI1~DI8 Digital input 24 V high level effective

DO1~DO8 Digital output 24 V / 0.5 A, relay or transistor

A+ / A- PROFIBUS Differential communication

CAN_H / CAN_L CANopen Differential communication

S1/S2 Spindle sensor Torque/angle signal

Wiring tips:

Use 1.5 mm² twisted pair for power supply and keep it away from power lines.

Use shielded twisted pair for communication lines and ground at one end.

Ground both ends of the sensor line's shield.

IV. Debugging and Usage

Address setting: Set the PROFIBUS address (1~126) or CANopen node number by rotating the DIP switch.

Parameter configuration:

Configure with Bosch Rexroth Tightening Suite software (USB connection): torque range, angle range, tightening strategy (torque control / angle control / yield point), IO mapping, communication parameters.

Typical torque range: 0.1–500 N・m (depending on the spindle model).

Operation process:

Power on → Self-check → Ready (DO1=ON).

DI1=ON → Start tightening → Real-time upload of torque/angle → Completed (DO2=ON) or fault (DO3=ON).

Status and faults:

Indicator lights: PWR (power), RUN (operation), ERR (fault).

Common faults: E01 (overcurrent), E02 (overvoltage), E03 (communication interruption), E04 (sensor abnormality).

V. Maintenance and Precautions

Regular inspection: Clean the heat dissipation ports and check the tightness of the terminal blocks monthly.

Lubrication: The module itself is maintenance-free; the tightening spindle should be lubricated regularly as per the manual.

Prohibitions: Do not plug or unplug communication/ sensor lines while powered; do not operate in environments with excessive temperature or humidity.

Replacement: The spare part number must be exactly the same (06088016), no additional adaptation is required.