Siemens 6AU1445-2AD00-0AA0

Breakdown of Model Code Definition

Official Status: Officially discontinued on Oct 1, 2023. Only second-hand or stock spare parts available. Direct replacement model: 6AU1445-2AD00-0AA1

1. Core Positioning

Integrated multi-axis motion controller under SIMOTION D drive series, embedded with SINAMICS S120 CU320-2 drive core. It delivers a three-in-one solution: PLC logic + motion control + servo drive control, specially designed for high-end multi-axis synchronous applications with High Performance grade.

III. Key Hardware Performance Specifications

1. Axis Control Capacity

Max total controllable axes: 64 axes (with external extended servos)

Built-in drive channels: 6 servo axes / 6 vector axes / 12 V/F axes

Minimum interpolation cycle: 0.25 ms

PROFINET real-time cycle: 0.25 ms (supports Isochronous Real-Time IRT)

Minimum PROFIBUS cycle: 1 ms

Memory: 190 MB operating RAM + 68 MB program storage disk + 20 MB Java application memory

2. Local I/O Terminals (24 VDC)

12 dedicated digital inputs (DI)

16 bidirectional DI/DO (configurable as input or output)

3. Full Interface List
4. 6 × DRIVE-CLiQ ports: Direct connection to S120 servo motors, encoders and terminal modules
5. 2 × PROFIBUS DP: Master/slave adaptive
6. 3 × PROFINET (RT/IRT real-time Ethernet)
7. 2 × Standard TCP/IP Ethernet: Program download, HMI upper communication
8. 2 × USB 2.0: Commissioning, memory card read/write
9. 1 × Expansion option slot: Supports technology boards, memory cards and communication expansion cards
10. Built-in dual cooling fans + backup battery module (standard accessory, retains process parameters upon power loss)
11. Electrical & Environmental Specifications

Power supply: 24 VDC (wide voltage range: 20.4 ~ 28.8 V)

Typical power consumption: 46 W; No-load current approx. 1.9 A; Peak current 5 A

Operating temperature: 0 ~ +55 °C; Storage: -25 ~ +55 °C; Transportation: -40 ~ +70 °C

Altitude: Full power up to 2000 m; Derate 7 °C per additional 1000 m between 2000 ~ 4000 m

Humidity: 5% ~ 95% RH, non-condensing

Dimensions: 380(H) × 50(W) × 270(D) mm; Net weight approx. 3.2 kg

Certifications: CE, UL, cUL, KC; Manufactured in Germany

1. Core Functional Features
2. High-precision multi-axis synchronization: Electronic gear, electronic cam, flying shear, closed-loop tension control, multi-axis interpolation, master-follower tracking
3. Three-in-one control architecture: Integrated SIMOTION motion logic + PLC logic + S120 servo drive control
4. Supported technology packages: Cam, positioning, synchronization, tension, hydraulic, robot kinematic conversion
5. Real-time bus: PROFINET IRT isochronous synchronization with multi-axis synchronization error ＜ 1 μs
6. Power-fail data retention: Built-in lithium battery preserves programs, zero offsets and process parameters
7. Compatible commissioning software: SCOUT / SCOUT TIA (integrated into TIA Portal)
8. Typical Application Industries & Equipment

Machine Tools: 5-axis machining centers, turn-mill centers, laser cutters, press brakes

Automated Production Lines: Packaging & printing, lithium battery winding/slitting, photovoltaic silicon wafer equipment

Automotive: Welding lines, stamping synchronization, coordinated assembly robots

Special Equipment: High-speed flying shears, film tension control, multi-station synchronous conveying lines

1. Replacement & Upgrade Solutions
2. Direct Compatible Replacement (No program modification required for identical specs)

6AU1445-2AD00-0AA1: Minor hardware iteration with fully compatible interfaces, axis capacity and programs; Top choice as spare part for discontinued units

2. Higher-Performance Upgrade Models

D455-2 (6AU1455-2AD00-0AA0): Supports up to 128 axes with enhanced computing performance

D435-2: Cost-saving alternative for medium-low axis count (≤32 axes)

D425-2: For simple small-scale lines with ≤16 axes

VII. Standard Packing List

1. D445-2 DP/PN control unit main body
2. Pre-installed dual fan + backup battery module
3. I/O terminal blocks, DRIVE-CLiQ connectors, bus terminals
4. DIN rail fasteners, mounting screws
5. English hardware manual, safety certification documents

VIII. Troubleshooting & Maintenance Guidelines

1. Battery Alarm: Built-in lithium battery service life 3~5 years. Low voltage alarm triggers at end of service life; matching battery module replacement required
2. Fan Fault: Dual fan redundancy. Single fan failure only triggers alarm without machine stop; timely replacement is required to avoid temperature-induced power derating
3. DRIVE-CLiQ Communication Fault: Prioritize inspection of cable shielding, connector locks and matching bus terminating resistors
4. Sourcing Tips for Discontinued Spares: Original new units are no longer supplied; only refurbished/second-hand dismantled parts available. Verify V4.x/V5.x firmware compatibility before procurement

Full Application Fields of Siemens 6AU1445-2AD00-0AA0 (SIMOTION D445-2 DP/PN)

This model is a 64-axis high-performance integrated drive motion controller, optimized for scenarios requiring high-precision multi-axis synchronization, electronic cams, flying shears, tension control and multi-axis interpolation. It is suitable for medium & large complex multi-axis machinery, covering eight mainstream industries with typical equipment and control requirements listed below:

1. Machine Tool Processing Industry (Core Application Field)

Typical Equipment

5-axis linkage machining centers, turn-mill machines, gantry milling machines, laser/plasma cutting machines, press brakes, grinders, woodworking 5-axis engraving & milling machines, stone CNC carving machines, high-speed mold milling machines

Control Requirements

Multi-axis linear/circular interpolation, RT/IRT isochronous synchronization

Spindle + feed axis electronic gear synchronization, follow-up cutting

High-speed dynamic positioning with short interpolation cycle of 0.25 ms

Integrated drive control paired with SINAMICS S120 servos

1. Packaging & Printing Industry (Largest Application Scenario)

Typical Equipment

High-speed flexographic printers, gravure printing presses, slitting & rewinding machines, self-adhesive label machines, blown film bag-making lines, vertical/horizontal food packaging machines, sanitary napkin & diaper production lines, flying shear cutting equipment, hot stamping & die-cutting machines

Control Requirements

Multi-color register synchronization (electronic cams eliminate register deviation)

Closed-loop constant tension control for webs, roll diameter calculation, taper tension

Flying shear, follow shear, intermittent synchronous cutting

Multi-axis linkage of unwinding/traction/rewinding, supporting full-line synchronization for up to 64 axes

III. Lithium Battery & Photovoltaic New Energy Industry

Typical Equipment

Lithium electrode slitting machines, winding machines, stacking machines, coating machines, calendering equipment; PV silicon wafer cutting machines, film stretching lines, solar cell stringers, PV glass coating production lines

Control Requirements

High-speed constant tension for electrodes, jitter-free web transport

Multi-station cam synchronization, precise electrode positioning

Real-time multi-axis synchronization for long production lines with ultra-small synchronization error

Continuous high-cycle production with fast start-stop dynamic response

1. Automotive Manufacturing Industry

Typical Equipment

Automated stamping lines, welding robot conveying lines, automotive body roll forming equipment, special auto component assembly machines, tire building machines, extrusion lines for sealing strips, precision machining equipment for engine parts

Control Requirements

Synchronization between presses and manipulators for fast pick-and-place

Coordinated multi-robot linkage, master-follower tracking

Profile extrusion traction, fixed-length cutting

Stable 24-hour continuous heavy-load operation

1. Textile, Film & Rubber & Plastic Industry

Typical Equipment

Spinning & drawing production lines, cast film equipment, BOPET/BOPP film stretching lines, plastic extruders, fixed-length pipe cutting machines, rubber vulcanization molding equipment, spunlace/spunbond nonwoven equipment

Control Requirements

Multi-section speed synchronization for multi-layer film stretching

Low-fluctuation tension control for wide webs

Servo linkage of extrusion traction and metering pumps

Distributed multi-axis bus control for long-distance lines

1. Metallurgy & Sheet Metal Processing

Typical Equipment

Trial thin strip continuous casting mills, aluminum/stainless steel slitting & leveling lines, longitudinal & transverse shear units, color coating production lines, metal foil unwinding & winding equipment

Control Requirements

Speed synchronization of main & auxiliary mill rolls, closed-loop sheet thickness compensation, constant tension unwinding/winding, fixed-length cutting via flying shear

VII. Robotics & Automated Assembly Lines

Typical Equipment

Multi-axis gantry manipulators, gantry handling robots, 3C electronic assembly lines, lithium battery module assembly lines, pharmaceutical filling & packaging equipment, synchronous conveying lines for logistics sorting

Control Requirements

Coordinated multi-manipulator operation, synchronization between conveying lines and tooling fixtures, intermittent electronic cam motion, high-precision positioning locking

VIII. Special Complete Equipment

1. Deep Glass Processing: Tempered glass, insulated glass production lines, glass cutting machines
2. Paper Industry: High-speed paper machines, rewinding & slitting, coating equipment
3. Military & Aerospace: 5-axis blade machining, composite material laying equipment
4. Cable Equipment: Wire & cable extrusion, high-speed cabling machines

Selection Matching Logic (Why Choose D445-2 6AU1445-2AD00-0AA0)

1. Axis Range: 16 ~ 64 axes, ideal for machinery with multiple servo linkages. Preferred choice when D435 (max 32 axes) lacks performance and D455 (128 axes) incurs excessive cost
2. Mandatory Process Requirements: Applications requiring flying shear, electronic cam, web tension control and multi-axis IRT isochronous synchronization
3. Communication Demand: Dual bus support for both PROFIBUS DP (legacy equipment connection) and PROFINET IRT (high-speed real-time servo & vision inspection)
4. Integrated Architecture: Embedded SINAMICS S120 CU320-2 drive core unifies PLC logic, motion control and servo drive, saving cabinet space

Unsuitable Application Scenarios

Simple machinery with ≤8 axes (Select D410-2)

Low-cost standalone machines with max 32 axes (Select D435-2)

Extra-large full lines with over 100 axes (Upgrade to D455-2 6AU1455 series)

Complete Practical Application Cases of Siemens 6AU1445-2AD00-0AA0 (SIMOTION D445-2 DP/PN) in Packaging & Printing Industry

This unit is optimized for shaftless transmission with 16~64 axes, multi-color registration, web tension control, flying/follow shear and full-line synchronization, applicable to medium & large high-speed printing, laminating, bag-making and slitting machinery. Below are real engineering cases categorized into four segments: printing equipment, post-web processing, food & daily chemical packaging and special paper products, including axis count, core processes and application advantages.

1. Shaftless Gravure Printing Presses (Benchmark Industry Case)

Case 1: 8-color High-speed Film Gravure Press (Food Packaging Film / Daily Chemical Flexible Packaging)

Equipment Manufacturers: High-end electronic shaft gravure lines from domestic brands Songde & Shanzhang

Hardware Configuration: 1 × 6AU1445-2AD00-0AA0 + SINAMICS S120 servos, total 42 axes

All unwinding, traction, 8 printing units, oven traction, rewinding, front & back surface inspection, flying shear die-cutting driven by independent servos

Core Process Requirements

1. Shaftless registration via electronic cams, dynamic compensation for web elongation, registration accuracy ≤ ±0.05 mm
2. Full-line 0.25 ms IRT isochronous synchronization, maximum line speed 180 m/min
3. Closed-loop taper tension, real-time roll diameter calculation, synchronous emergency stop for web breakage
4. Support for automatic roll splicing, pre-registration, one-click batch parameter recall

Reason for D445 Adoption: Single controller handles 42 axes, with PROFIBUS connecting legacy oven temperature control and PROFINET linking vision registration inspection. Dual DP/PN bus compatible with new & old equipment

Application Outcome: Compared with mechanical long-shaft machines, plate change & setup time reduced by 60%, reject rate cut by 70%

Case 2: 6-color Paper Gravure Press (Cigarette Packaging, Wallpaper, Gift Wrapping Paper)

Axis Count: 36 axes, including printing rollers, cooling traction, transverse flying shear, paper stacking conveying

Specialized Processes: Fixed-length cutting via follow shear, zoned multi-section tension control, multi-color water-based ink synchronization; suitable for thick paper & coated paper with large tension fluctuation

1. Flexographic Printing Presses (Label, Courier Bag, Paper Cup Printing)

Case 3: Wide Web Satellite Flexo Press (Food Labels, Self-adhesive Stickers)

Configuration: D445-2 (6AU1445-2AD00-0AA0) as main controller, 28 servo axes

Process Highlights: Siemens Print Standard technology package with built-in electronic gear registration and servo fine-tuning of printing pressure; switchable intermittent/continuous printing for fast small-batch label changeovers

Auxiliary Peripherals: PROFINET connected vision inspection system real-time corrects phase offset of each printing unit without manual roller adjustment

Case 4: Stack-Type Flexo Press (Courier Bag, Plastic Film Printing)

Line speed 120 m/min, 22 synchronized axes, integrated unwinding-printing-gluing-laminating control covering both printing and laminating web processes

III. Web Laminating, Slitting & Rewinding Equipment (Largest Sub-segment Application)

Case 5: High-speed Dry/Wet Laminator (Aluminum-plastic Film, Food Composite Film)

Axis Count: 32 axes, servos for Unwind A, Unwind B, metering coating roller, laminating traction, rewinding, edge guiding, thickness compensation

Core Control: Multi-layer film speed synchronization, electronic gear tracking between coating roller and substrate, stable tension across high & low speeds; multi-section synchronization for long lines eliminates misalignment from film stretching

Case 6: Fully Automatic Slitting & Rewinding Machine (BOPP Film, Label Paper, Nonwoven Fabric)

Typical Configuration: Single D445 controls 40 axes including unwinding, main traction, multi-blade slitting, Rewind A/B, flying shear for roll change, edge guiding and static elimination linkage

Process Challenges: Switch between narrow & wide materials, taper tension for large/small rolls, deviation-free high-speed slitting; flying shear enables non-stop roll change, boosting production efficiency by 40%

Case 7: High-speed Paper Rewinding & Slitting Machine (Household Paper, Kraft Paper)

Designed for heavy-load servos of high basis weight paper rolls, synchronized multi-blade cutting and constant-tension rewinding; PROFIBUS linked to steam oven temperature control system

1. Integrated Bag-forming / Molding / Die-cutting Packaging Equipment

Case 8: Fully Automatic High-speed Three-side Seal Bag-making Machine (Snack Bags, Mask Bags)

Axis Count: 26 fully servo axes covering unwinding, printing positioning, heat sealing, traction, flying shear, punching and finished product conveying

Core Value of D445: Intermittent feeding via electronic cams with precise phase locking between heat-sealing stations and cutting; stable high-speed operation at 300 bags per minute, one-click parameter switching for long/short bags

Case 9: Web-fed Hot Stamping & Die-cutting Machine (Color Boxes, Gift Packaging)

Process: Main shaft web transport, synchronized hot stamping & die-cutting rollers via electronic cams, flying shear separates finished products to fixed length; 20-axis synchronous control with hot stamping registration accuracy ±0.04 mm

Case 10: Nonwoven Production Line for Sanitary Napkins & Diapers (Integrated Hygiene Packaging)

Large full line with up to 60 axes controlled by D445 as main unit; synchronized unwinding, lamination, cutting and folding of multi-layer nonwovens; multi-section closed-loop tension prevents stretch deformation of soft nonwoven fabrics

1. Special Printing & Post-processing Complete Equipment

Case 11: High-speed Rotary Label Printing Machine (Self-adhesive Labels, Anti-counterfeit Stickers)

Shaftless transmission integrating 4~8 color printing, film laminating, hot stamping and die-cutting, 38 servo axes with IRT isochronous synchronization; supports fast plate change for short-run orders

Case 12: Integrated Blown Film & Printing Production Line

Front-end servo linkage of extrusion metering pumps, synchronized printing, traction and rewinding at the rear. The entire line adopts one D445 for unified motion logic, eliminating communication complexity of multiple coordinated controllers

1. Overseas Benchmark Retrofit Case (D445 Shaftless Retrofit for Legacy Printing Presses)

Retrofit Project of Multi-color Magazine Printing Press at Ovid Bell Press, USA

Original machine adopted mechanical long-shaft transmission with slow setup and large registration error. Replaced with SIMOTION D445 (6AU1445-2AD00-0AA0) + S120 shaftless solution, all printing rollers driven by independent servos.

Retrofit Benefits: Equipment installation cycle shortened by 25%, printing throughput increased by 20%, registration rejects drastically reduced. Dual DP/PN bus retains original oven and cooling systems without full machine replacement, delivering controllable retrofit cost

VII. Why Packaging & Printing Machinery Prioritizes 6AU1445-2AD00-0AA0

1. Matched Axis Control Range: For medium complete machinery with 16~64 axes, offering larger axis capacity than D435 (max 32 axes) and lower cost than D455 (128 axes)
2. Dual Bus Compatibility for Retrofits: PROFIBUS DP connects legacy temperature controllers, edge guides and tension meters; PROFINET IRT links high-speed synchronous servos and vision inspection
3. Mature Industry Technology Packages: Built-in standard libraries for Print, FlyingSaw and Winder web tension, drastically shortening equipment development cycles
4. Integrated Architecture: Embedded S120 drive core unifies PLC and motion logic to simplify cabinet wiring
5. Abundant Stock Spares: Though OEM discontinued, sufficient second-hand & inventory spare parts available, making it the preferred controller for maintenance & retrofit of old printing presses

Unsuitable Printing Scenarios

Small single-color label machines with ≤8 axes (Select D410-2)

Extra-large full lines with over 100 axes (Upgrade to D455-2 6AU1455 series)

Translation Notes

1. Industry standard automation terms adopt internationally recognized Siemens official English terminology (IRT, DRIVE-CLiQ, EOL, Flying Saw, Master-Follower, etc.)
2. Domestic equipment manufacturers (Songde, Shanzhang) retain official Pinyin brand names without translation
3. Process jargon in printing & new energy fields follows global machinery industry customary expressions
4. Units (m/min, mm, ms, °C, kg) remain consistent with original text
5. Model codes, bus names and hardware designations are fully reserved without modification