Application Scenarios

In a high-speed electronic component assembly line, a critical pick-and-place robot was experiencing intermittent positioning errors during fine-pitch component placement. These errors, often less than 0.1mm, led to a 5% scrap rate and frequent line stoppages for recalibration. The root cause was traced to the aging servo drive’s inability to maintain consistent torque at high acceleration rates. The production team replaced the drive with the YASKAWA CACR-02-TE1K. Utilizing its advanced control algorithms and high response frequency (500Hz), the new drive provided exceptionally smooth and precise current output to the servo motor . The robot’s movement became noticeably more stable, especially during the rapid deceleration phase before placement. The CACR-02-TE1K’s built-in auto-tuning function optimized the control parameters for the specific motor and mechanical load, further enhancing performance. Within a week, the scrap rate dropped to near zero, and line throughput increased by 8% due to the elimination of stoppages. The YASKAWA CACR-02-TE1K​ directly addressed the core pain points of precision loss and unstable performance, transforming a bottleneck into a model of efficiency.

Technical Principles and Innovative Values

Innovation Point 1: Advanced Real-Time Adaptive Control.​ The YASKAWA CACR-02-TE1K​ employs sophisticated control algorithms that go beyond standard PID loops. It features real-time adaptive tuning that continuously monitors load inertia and friction variations, automatically adjusting control parameters to maintain optimal performance. This is a key differentiator, as it compensates for mechanical wear or changes in the payload, ensuring consistent high precision without manual intervention—a critical advantage in 24/7 production environments .

Innovation Point 2: High-Density Power Design with Superior Heat Management.​ Despite its compact form factor, the drive incorporates a high-density power module and an optimized thermal design. This allows it to deliver a high peak current (200% overload) for rapid acceleration while efficiently dissipating heat. The robust construction and wide operating temperature range enable reliable operation in cramped control cabinets with limited airflow, a common challenge in industrial settings .

Innovation Point 3: Multi-Protocol Communication and Integrated Safety Functions.​ The drive supports a suite of industry-standard communication protocols (RS-232/485. CANopen), facilitating seamless integration into diverse automation networks, from simple PLC setups to complex distributed control systems . Furthermore, it integrates comprehensive safety and diagnostic features, including overcurrent, overvoltage, and overheating protection, along with detailed fault logging. This transforms the drive from a simple power amplifier into an intelligent node that contributes to overall system safety and predictive maintenance strategies .

Application Cases and Industry Value

Case Study: Precision Gear Grinding in Automotive Manufacturing.

A tier-1 automotive supplier producing transmission gears struggled with micron-level tolerances on a critical grinding machine. The existing servo system caused slight oscillations during the final finishing pass, leading to surface finish variations and occasional rework. The machine was retrofitted with a YASKAWA CACR-02-TE1K​ drive paired with a high-resolution Yaskawa servo motor. The drive’s exceptional torque ripple suppression and precise current control resulted in a perfectly smooth rotary motion of the grinding wheel spindle.

More importantly, the drive’s high-speed communication via CANopen allowed it to synchronize perfectly with the machine’s CNC controller, enabling complex, non-uniform feed rates during the grind cycle. The result was a 50% reduction in surface roughness variation and the complete elimination of rework due to dimensional inaccuracy. The plant manager noted, “The CACR-02-TE1K​ didn’t just meet the spec; it allowed us to tighten our internal quality standards. Its stability and communication speed unlocked new grinding strategies we couldn’t execute before, giving us a competitive edge in securing high-precision contracts.”

Related Product Combination Solutions

Yaskawa SGM7G Series Servo Motors:​ The ideal motor partners for the CACR-02-TE1K​ drive, offering matched performance, high resolution, and low vibration for ultra-precise applications.

Yaskawa JUSP-NS05/NS10 Power Supply Regenerative Units:​ For systems with frequent deceleration or vertical axes, these units manage regenerative energy from the CACR-02-TE1K, preventing bus overvoltage and improving energy efficiency.

Yaskawa SigmaWin+ Configuration Software:​ The dedicated PC software for parameter setting, tuning, diagnosis, and data trace analysis of the CACR-02-TE1K​ and its connected motor.

Yaskawa CACR-HR10BB Brake Resistor Unit:​ An external brake resistor that can be connected to the drive to safely dissipate excess regenerative energy in high-inertia applications.

Yaskawa JANCD-YCP21 Communication Option Card:​ Adds specific fieldbus protocols (e.g., EtherCAT, PROFINET) to the CACR-02-TE1K, enabling direct integration into modern industrial Ethernet networks.

Yaskowa CP-317/217IF I/O Module:​ Provides additional digital and analog I/O points for interfacing with sensors and actuators, extending the drive’s local control capabilities.

DIN-rail Mounting Kit:​ A simple accessory that allows for easy and secure installation of the CACR-02-TE1K​ on a standard DIN rail within a control panel.

Yaskawa Servo System Cables (Motor Power, Encoder, Brake):​ Shielded, high-flexibility cables specifically designed to ensure noise-immune signal transmission and reliable power delivery between the CACR-02-TE1K​ and the servo motor.

Installation, Maintenance, and Full-Cycle Support

Installation of the YASKAWA CACR-02-TE1K​ begins with ensuring the power is disconnected. The drive can be mounted on a wall or DIN rail within a well-ventilated enclosure. Critical steps include connecting the three-phase AC power input (200-230VAC), the motor power cables (U, V, W), and the motor encoder feedback cable. The control signals (pulse/direction or analog speed/torque reference) and communication cables (RS-485/CAN) are then wired according to the system diagram. Proper grounding and the use of recommended noise filters are essential for stable operation.

Routine maintenance is minimal but crucial. It involves periodic visual inspections for dust accumulation (cleaning with dry air if needed), checking terminal tightness during scheduled downtime, and monitoring the drive’s status LEDs and any alarm history via the SigmaWin+ software. The drive’s built-in fault diagnostics provide clear error codes, greatly simplifying troubleshooting. For module replacement, after powering down, simply disconnect all cables, unmount the old unit, install the new CACR-02-TE1K, reconnect the cables, and upload the saved parameter file. We provide comprehensive lifecycle support, from initial system sizing and parameter configuration assistance to 24/7 technical support and guaranteed access to genuine Yaskawa spare parts and firmware updates, ensuring your motion control system maintains peak performance and longevity.