TWO STEPS

AHEAD
 5

A NEW WORLD
OF AUTOMATION
The production world is changing and along with it More agile systems are needed to keep pace
the challenges it faces. Rigid, complex automation with the global speed of innovation. This is
systems are no longer a right fit in a world where precisely where Bosch Rexroth’s vision of the
markets are characterized by ever shorter product “Factory of the Future” was born: only the walls,
life cycles and increasingly tougher competition. the floor and the ceiling of the factory remain in
place — everything else is flexible. The Factory
of the Future dynamically reacts to demands
The answer to the new challenges and always provides the ideal solution.
that industry is facing:
This vision marks the beginning of a new world
ctrlX AUTOMATION. of automation with a user-focused automation
platform. Our developers left no stone unturned
in their quest to discover the ultimate solution:
a flexible, scalable automation platform designed
with maximum openness at all levels and interfaces.
NO GOOD
REASONS.
JUST PERFECT
SOLUTIONS.
10 arguments for ctrlX AUTOMATION
A 360°
SOLUTION.
FOR STRAIGHT-
FORWARD
DECISIONS.
 9

1
A COMPLETE
AUTOMATION SOLUTION
Systematic flexibility:
ctrlX AUTOMATION provides all the elements required for any ▶ Maximum scalability
­complete automation solution. The system is extremely scalable and expandability
and meets the requirements for nearly every application. ▶ Perfectly coordinated
system functionality
▶ Virtually any common
The system functionality is perfectly coordinated and can be
interface and
expanded via apps and third-party hardware and s ­ oftware, ­programming
thanks to the complete openness of the system. ­l anguage supported

Offering the best possible networking capability, the automation

system can also be connected with virtually any relevant
automation interface and protocol, providing complete flexibility
of development environment and programming language.

ctrlX IOT ctrlX PLC ctrlX WORKS ctrlX MOTION ctrlX SAFETY
Built-in security IEC and non-IEC Runtime and engineering Motion, Robotics and CNC SafeLogic and SafeMotion

ctrlX DRIVE ctrlX I/O ctrlX CORE ctrlX IPC ctrlX HMI
Drives and motors EtherCAT and CPU and power Box and panel Hardware and software
Gigabit Ethernet
10 | ctrlX AUTOMATION

2
LESS IS MORE CPU AND I/O DRIVES

More compact machines and systems, less

­hardware, faster installation, and significantly
fewer software installations — all of this is
possible thanks to ctrlX AUTOMATION. That’s
because the developers focused on reducing
components, ­complexity, and footprint
whenever possible for all components and
functionality. Right down to the smallest detail.
The space required is reduced significantly
ctrlX AUTOMATION
reduces:
since the installation size of all automation
▶ Space requirements components is up to 50 % smaller on average. HARDWARE BOM
▶ Installation times Many individual components that were ­INSTALLATION POSITIONS
▶ Control cabinet sizes previously required could be eliminated thanks
▶ Service and spare
to the dramatic reduction in component
parts requirements
▶ Logistics work
diversity and functional integration. This
▶ Transaction costs simplifies order and delivery logistics as well
as procurement of replacement parts. The
INSTA
INSTALL
systematic use of web technology reduces the
number of required software installations and
enables maximum flexibility in the hardware
INSTALL
used for engineering, diagnostics, and service.

MOTORS SOFTWARE
­INSTALLATIONS
LIKE SCIENCE
FICTION.
JUST WITH LESS
SPACE.
NON-STOP
PERFORMANCE.
REAL-TIME
CONTROL.
 13

3
CONSISTENT
­PERFORMANCE
ctrlX CORE is the powerful heart that beats inside ctrlX
AUTOMATION. A high-performance 64-bit multicore CPU
forms the basis for all automation topologies — regardless ctrlX CORE provides
▶ Maximum ­performance
of whether PC-based, as an embedded controller or
▶ Universal use in all
integrated in the drive. It therefore transcends the typical ­devices and topologies
boundaries between device platforms. The p ­ erformance of ▶ Long-term avail­
a ctrlX CORE CPU is more than adequate for practically all ability, thanks to full
­automation tasks and, for example, enables s ­ ynchronization ­upgrade compatibility
▶ Service support over
of more than 200 servo drives. Future CPU upgrades are
the long-term with
guaranteed to require no software adaptations. guaranteed availability

ctrlX ctrlX ctrlX

CORE CORE CORE

ctrlX DRIVE ctrlX CORE ctrlX IPC

14 | ctrlX AUTOMATION

4
CONNECTIVITY AT ITS BEST
Flexible automation solutions demand connectivity. And
as the system boasting the best possible connectivity,
ctrlX AUTOMATION focuses uncompromisingly on standardized
as well as sector and manufacturer-neutral interfaces. In
addition to EtherCAT, the system also supports PROFINET
and IO-Link. More than 30 interfaces to IT systems such as
ctrlX I/O provides: OPC UA and MQTT ensure seamless communication within
▶ Maximum freedom of the entire Factory of the Future.
design in automation
▶ The most ctrlX I/O provides a virtually unlimited portfolio of
connectible system
powerful interfaces. Analog and digital I/Os or encoder
▶ Long-term
availability thanks to interfaces are used to connect additional components or
systematic openness for system enhancements and communication with external
infrastructures. They enable direct control of small and
stepper motors.
15
16 | ctrlX AUTOMATION

5
RUNTIME APPS ENGINEERING APPS

PLC MOTION ROBOTICS CNC PLC HMI DRIVE I/O

OPC WEB USER DEVICE

SAFETY SAFETY VIRTUAL ...
UA HMI APP ADMIN

UNIFORM IOT VPN- IOT

...

­ARCHITECTURE
GATEWAY FIREWALL INSIGHTS

ctrlX Data Layer

Fully ­adaptable ctrlX AUTOMATION uses Linux, the most stable

LINUX REAL-TIME
systems: and reliable real-time operating system in
▶ User-developed
the world. The ctrlX Data Layer is the central
software can be run HIGH-PERFORMANCE
without limitation
element of the architecture. It enables simple and
MULTICORE CPU
▶ Custom apps and central access to all available system data and
open-source software parameters in real time, including authorization
ctrlX
can be created management. With 8 million potential accesses CORE
and integrated
per second, maximum performance is assured.
▶ Functionality can be
added at any time,
In addition, the system architecture allows RUNTIME APPS

even during run time developers to effortlessly implement additional

▶ Apps exchange system functions at any time, such as apps
data in real time and open-source software. The automation
and non-real time
platform is therefore available to a vast global
▶ Security is
assured, thanks to
community of programmers who create new
configurable user functions in the programming languages of
administration their choice. This accelerates the development
of innovations and process improvements.

EDGE DEVICE,
ctrlX I/O ctrlX HMI CLOUD, VIRTUAL

ctrlX CORE ctrlX IPC ctrlX DRIVE

TODAY’S
TECHNOLOGY.
READY FOR
FUTURE
STANDARDS.
ONE OPEN
SYSTEM.
OPEN-END
OPPORTUNITIES.
 19

6
THE MOST OPEN
AUTOMATION SYSTEM
ON THE MARKET
As a universal automation system, ctrlX AUTOMATION speaks many
languages. The system software can be selected, configured, and
programmed across all popular programming languages by means Ultimate technological
advantage:
of the flexible and modular software and engineering solution, ctrlX
▶ Free choice of
WORKS. Developers are therefore free in their choice of the development ­programming language
environment and can simultaneously use different programming ▶ Key industry standards can
languages in their p­ rojects. The constantly growing demands with be used immediately
respect to Industry 4.0 / Internet of Things (IoT) applications can ▶ System ­functionality
can be expanded
therefore be fulfilled with minimum effort, backed by the integrated
▶ Structured and secure access to
OPC UA server with its unrivaled range of functions and MQTT data with the ctrlX Data Layer
protocol support. ctrlX CORE uses EtherCAT as the standard for a ▶ Savings in terms of line
real-time Ethernet master. The ctrlX DRIVE servo drives support the control systems because
most common real-time Ethernet protocols as a slave connection. data is available centrally
20 | ctrlX AUTOMATION
 21

7
UNIVERSAL IOT
INTEGRATION
Integration of the automation world and the Internet Device management:
of Things in the Factory of the Future is an a
­ bsolute ▶ Cloud-based device management
via the ctrlX Device Portal
prerequisite for improving competitiveness in the
▶ Security updates and bug fi ­ xing,
digital age. ctrlX AUTOMATION offers better connectivity new function upgrades
than any other system and can be i­ntegrated into all ▶ Backup and recovery of
IT, edge, and cloud systems. automation projects Reliable connectivity:
▶ Automated
­software updates
Security updates, backups, and upgrades of new software
▶ Simple backup
features are performed centrally, simultaneously, and ­ IoT integration:
and restore
efficiently by means of the ctrlX Device Portal. Future ▶ IoT Connector for IT systems via OPC
▶ Effective ­protection
UA Client and Server, MQTT
­standards such as 5G and OPC UA over TSN are already ­ against ­c yber
▶ Expansion via customer-specific
prepared. A security solution certified according to attacks
IoT apps
IEC 62443 ensures the secure exchange of data. A VPN ▶ Ready for new standards: 5G,
expansion or firewall installation can also be implemented OPC UA over TSN …
optionally via app.

Security:
▶ Security by default
▶ Security by design
▶ Certified IT security according
to IEC 62443
▶ Secure production mode
CODE LOW.
LEVEL UP.
 23

8
THE REVOLUTION IN ENGINEERING
With its future-oriented software architecture, The modular ctrlX WORKS software solution
Future-oriented
ctrlX AUTOMATION offers a previously unrivaled increases engineering efficiency in this regard development:
degree of freedom and efficiency, allowing by 30 to 50 %. Web-based system configuration ▶ Faster engineering times
­developers to overcome the challenges of therefore allows fast and simple start-up without ▶ Rapid ­implementation
contemporary software development quickly the need to install software. A completely of innovations
▶ Shorter commissioning
and creatively. In addition to classic PLC and virtual development environment is available
times
motion functions, they can flexibly design for engineering without the use of hardware. ▶ Expertise and s­ ecurity
additional functions in numerous programming Furthermore, the online services of the ctrlX of investment
languages and combine them with one another. Device Portal and the ctrlX Developer Community
are linked with the GitHub software platform
that offers forums and how-to videos.

All options at a glance

STRAIGHTFORWARD FREE CHOICE OF STRAIGHTFORWARD

START-UP ­PROGRAMMING LANGUAGE ­INDIVIDUALIZATION
Web-based access to program IEC61131, PLCopen, ▶ Custom software/IP
code in just a few minutes G-Code, C/C#, Python, ▶ Third-party providers
without software installation Java, Node-RED, Blockly … ▶ Open source

UNLIMITED FUNCTIONALITY VIRTUAL CONTROL ONLINE SERVICES

Unrestricted ­expandability Unrestricted virtual ▶ ctrlX Device Portal
through apps ­availability of control and ▶ ctrlX Developer Community
software environment ▶ GitHub
24 | ctrlX AUTOMATION

9
LONG-TERM AVAILABILITY
AND DIGITAL SERVICES
ctrlX AUTOMATION sets the market standard for the longest
product availability. Bosch Rexroth ensures additional
availability of all components for at least ten years after
the end of active production and therefore secures service
capability for the long term. This period can even be extended
to a total of 25 years, thanks to an optional add-on service.

All service activities for ctrlX AUTOMATION can be initiated directly

ctrlX AUTOMATION via the ctrlX Service App. The ctrlX Device Portal manages all
Service: connected IoT devices via the cloud and also enables s­ ecurity
▶ 24/7 global
updates, parameter backups, secure remote access, etc.
service, spare
parts, and repairs
▶ Product availability Bosch Rexroth supports machine manufacturers and end users ­
up to 25 years beyond worldwide with a 24/7 service hotline, rapid availability of spare
active production parts at any location, as well as repairs. Application specialists
▶ ctrlX Service App
provide advice and support during engineering, commissioning,
enables direct
service activities
and maintenance.
▶ ctrlX Device Portal
allows cloud-based
device management
LIVES LONG
AND PROSPERS.
THANKS TO
LIGHT-SPEED
SERVICE.
INVEST IN
CHANGE.
IT’S THE ONLY
CONSTANT.
 27

10
THE MOST FUTURE-PROOF
­AUTOMATION SYSTEM
In every sector, the decision in favor of an automation system Developed with vision:
and its provider is pivotal in terms of sustained competitiveness. ▶ Uncompromisingly
open, no pro­prietary
Foundational prerequisites are: maximum future-proofing, protection
systems or interfaces
of investment, and a wholly reliable automation partner. ▶ Free choice of
­programming
Bosch Rexroth embraces this responsibility with ctrlX AUTOMATION. language
Future standards, trends, and expansion options have therefore ▶ Software compatible
with any hardware
always been at the forefront and continue to play a vital role in its
▶ Extremely long-
development activities. Thanks to the uncompromisingly open and term a­ vailability of
platform-neutral system architecture at all levels, even now ctrlX all components
AUTOMATION offers the possibility to use future standards such ▶ Ready for future
as 5G, OPC UA over TSN, or programming languages yet under standards such as
5G, TSN, AI etc.
development as soon as they are ready for market. In the future, it
will therefore also be possible for machine manufacturers and users
to implement new types of automation concepts, whether intelligent
AI systems, central server-based solutions or distributed systems.
This ensures full protection of investment and creates trust.
 29

ctrlX AUTOMATION: always the right solution

30 | ctrlX AUTOMATION

ctrlX WORKS
The software and engineering toolbox

ctrlX WORKS is the central nervous system of Highlights

the platform and reduces the engineering time
for new concepts by 30 to 50 %. In addition to More productivity
classic PLC languages in compliance with to ▶ Free choice of programming language
IEC 61131, PLCopen, and G-Code, developers ▶ Limitless functionality that can
can implement functions without restriction in be implemented with ease
the form of apps or open source software. ▶ Virtual testing without hardware
Individual functions can be simply installed, ▶ Simple integration of custom
removed, and tested virtually without affecting and third-party software
existing apps. The central ctrlX Data Layer
guarantees continual access to all real-time Less engineering
and non-real time data of the installed apps. ▶ Web-based engineering
It makes no difference whether the apps are ▶ Pre-programmed functions and
installed as runtime apps on a ctrlX CORE or intuitive programming tools
are executed as engineering apps and services ▶ Developer communities and services
on a PC, smart device, or the cloud.

ctrlX WORKS already includes an extensive

portfolio of high-performance apps for typical
tasks in the area of factory automation. In
addition, users can develop their own
programs in any programming language or
integrate third-party apps.
 31

At a glance:
▶ Engineering is up
to 50 % faster
▶ Rapid ­adaptation
to changes in
the market

DEVELOPER COMMUNITY MANAGEMENT

SERVICES
Order & Benutzer-
SPS-
PLC Motion-­
Motion IoT-­
IoT Andere
Other Device Equipment Shopfloor
Shopfloor User Dritt-
Third- ­party
Mgmt. Mgmt. Stock erwei- anbieter
Lösungen
­solutions Lösungen
solutions Lösungen
solutions Lösungen
solutions mgmt. mgmt. Mgmt
mgmt. extension providers
mgmt. terung

ENGINEERING ADDITIONAL PROGRAMMING SIMULATION

ENGINEERING
Andere
Other
PLC
SPS Virtual
IEC 61131
I/O HMI
HMI Drive
Drive Safety
Safety G-CODE C/C++ PYTHON Blockly Dritt-
third- ­party control
providers
anbieter

ctrlX PLC ctrlX MOTION ctrlX IOT ctrlX HMI COM OTHERS
RUNTIME
PLC Motion
APPS C/C++ IoT Web- Ether
IoT User Web
User ­ Firewall
Firewall EtherCAT OPC UA
OPC UA PYTHON
PYTHON
Tech.
Tech. Robotics Sync. CNC Hyd. Tech. extension
Gateway
Gateway ­eextension
xtension HMI CAT

IoT User User

Insights
Insights VPN TSN 5G
­eextension
xtension ­eextension
xtension
CORE
RUNTIME
ctrlX Data Layer, user management, Linux
32 | ctrlX AUTOMATION

ctrlX PLC
The future-oriented PLC software

ctrlX PLC offers a high-performance PLC control

solution and combines the advantages of classic
PLC automation with the communication and
functional requirements of the Internet of
Things — a perfect combination for the ­
Factory of the Future.

Modular principle for targeted application

The flexible ctrlX PLC guarantees cost-efficient

solutions, even for applications with distributed
architectures. Ready-made function blocks and
automatic code generation increase effectiveness
and efficiency in engineering. In order to define
motion sequences and target positions in
drives, the corresponding function modules
simply need to be called up and combined. The
programming process is streamlined by using
wizards and the enhanced Generic Application
Template with automatic PLC code generation.
The open infrastructure enables protected
integration of in-house expertise.
 33

Open for networking Highlights

The ctrlX Data Layer provides all process and More productivity At a glance:
▶ Highest ­performance,
machine data centrally, replacing PLC line ▶ Openness and standards e ­ liminate
smallest ­hardware
control systems. At the field level, ctrlX PLC hardware dependencies
variance
provides a master function for numerous ▶ Future orientation by design ▶ Reduced ­logistics
fieldbuses such as EtherCAT, PROFINET, and ▶ New degree of freedom with costs
EtherNet/IP. The data and information collected the ctrlX Data Layer ▶ Less time needed
for training and
is forwarded on the basis of established ▶ Increased efficiency thanks t­ o ­unrestricted
engineering
standards such as OPC UA and MQTT. This choice of programming language
▶ The ctrlX Data Layer
means that ctrlX PLC can be i­ntegrated in the provides all process
most diverse automation environments. Fewer components and machine data
▶ Ultra-compact control platform centrally, making
PLC line control
with optimum performance
systems redundant
and minimum variance
▶ Ultimate functionality and flexibility
▶ Savings on logistics, hardware,
and assembly costs

Less engineering
▶ Development of expertise through
­integration of custom applications
▶ Free choice of programming language
34 | ctrlX AUTOMATION

ctrlX IOT
The most modern IoT software

Industry 4.0, the industrial Internet of Things

(IIoT) or the Factory of the Future: The greatest
productivity potential for industrial users lies
in networking. That’s why ctrlX IOT is always
included as part of ctrlX AUTOMATION. Thanks
to full integration of IoT solutions in the
hardware, users have boundless possibilities
and can start implementation immediately.

Ready to run in less than five minutes

Guided configuration dialogs are used to

configure quickly and i­ntuitively — without the
need for p­ rogramming. End-users, too, can
configure or change data connections quickly
at the click of a mouse. With more than 30
direct connection options and communication
standards, ctrlX IOT offers optimum flexibility
for connecting d ­ ifferent devices and seamless
integration into existing or even future systems.
Non-reactive updates ensure an optimum level
of machine availability during the p ­ roduction
process, even when loading updates. A firewall
and VPN access provide continuous control
in order to protect machine availability.
IT security standards compliant with IEC
62443 provide enhanced protection against
 35

viruses and trojans. At the same time, the Highlights

solution enables encrypted transmission At a glance:
of data and secure remote services. More productivity ▶ Increased system
▶ Maximum production capacity and long- efficiency, thanks to
term availability, thanks to non-reactive faster exchange of
data with the IoT
Transparency unleashes updates during the production process
▶ Full ­integration
optimum potential ▶ Local storage of machine of automation
data for maintenance components
Whether online or offline: Machine ▶ Fully integrated IT security standards for ▶ Cost savings via
data can be transparently displayed access control and remote maintenance reduced ­engineering
effort for data
retrospectively for up to six months with ▶ Seamless integration in the Bosch Nexeed
connectivity
IoT Insights. This ranges from production industrial application system
KPIs to notifications for the shift
manager to a fault history for service. Fewer components
▶ IPC and VPN router hardware is
By integrating ctrl X IOT in Bosch's reduced to one control platform
Nexeed i­ndustrial application system, a ▶ Cost savings and lower risk of
universal solution is created ranging from failure thanks to hardware reduction
sensors to cloud applications. Among and IT security standards
other features, Nexeed therefore enables ▶ Machine is “Bosch IoT ready”
central monitoring from the individual
machines to entire global plant networks. Less engineering
▶ Integration of data into existing IT
production systems is easy and
doesn't require programming
▶ Simplest handling for machine
­manufacturers and end-users
36 | ctrlX AUTOMATION

ctrlX MOTION
The motion, robotics, and CNC software

ctrlX MOTION sets new standards for ctrlX MOTION connects the previously
­openness and scalability. Users can perform separate worlds of automation and IT with the
the most varied automation tasks with this ctrlX Data Layer. Users can create functions
software: from simple handling tasks to as apps in any programming language, even
complex robot applications to highly dynamic if graphics-based, and combine them freely.
machines, such as those used in the packaging This allows an unprecedented degree of
and print industry. In this environment, they freedom, flexibility, and efficiency.
control multi-axis applications with strict
requirements with respect to coordinated Guided dialogs for visualization and
movements and synchronicity. ­engineering tasks optimize the project
­workflow during de­velopment and increase
ctrlX MOTION forms the perfect basis for productivity through simple integration
the intelligent automation of p ­ roduction of innovative functions. Web-based
machines. It implements both fast I/O signal engineering supports fast commissioning
processing and highly dynamic motion and shortens time-to-market.
control tasks—with more than 100 axes per
control system. ctrlX MOTION is e ­ xecutable
on all ctrlX AUTOMATION hardware, adapts
flexibly to the respective r­ equirements
and can be expanded at any time.
 37

Highlights

More productivity
▶ Shortest PLC and motion cycle times At a glance:
▶ A control system c­ oordinates ▶ Control system
more than 100 axes for universal and
▶ Ultimate precision, thanks to axis modern ­machine
automation
­synchronization at microsecond speed
▶ Cross-platform
and at a nanometer level of precision performance
and openness
Fewer components ▶ Time-to-market is
▶ All applications on one platform at least 30 % faster
▶ Complete and open
(synchronized motion, coordinated
automation system
motion and hydraulic motion)
▶ Maximum scalability ensures the best
possible solution in terms of space
requirements and functionality

Less engineering
Single Axis Motion CNC
▶ The engineering time is reduced by
up to 50 % thanks to wizard-based
development of application software
and ultimate ease of programming
▶ Can be used for all applications
Synchronized Motion Hydraulic Motion
38 | ctrlX AUTOMATION

ctrlX CORE
The ultra-compact control platform

Nowadays mechanical engineering means

software development. The high-performance
and communication-ready ctrlX CORE
forms the basis for this. It breaks down the
boundaries between the IPC, embedded
system, and drive-based platforms. The 64-bit
multicore CPUs distribute the applications
optimally to the different processor cores.
They offer significantly higher computing
power than previous control platforms in
the same space. ctrlX CORE offers scalable
control for systems requiring anything from
single-axis movements to highly complex
multiple axis movements. It implements
different technology functions with complex
arithmetic operations in parallel with a
high control quality and communicates
with higher-level systems. Process data
can be processed comprehensively by the
control system when ctrlX I/O is activated.
Optional I/O modules for additional
functions and communication protocols in
the same form factor simplify scaling.
 39

Quality down to the tiniest screw Highlights

ctrlX CORE is expressly designed More productivity

for demanding environments and ▶ Unlimited performance, thanks to
withstands vibrations and impact in a 64-bit multicore processors
wide temperature window with high EMC ▶ Optimum distribution of
resistance. The hardware is designed for ­applications to the CPU cores
maximum maintenance-free operation
and long-term availability based on a Fewer components
fanless and design free of wear parts. ▶ Flexible expandability of
­performance and I/O functions
▶ Robust hardware design
At the heart of open communication
Less engineering
Thanks to its open and flexible architecture, ▶ One control system for all platforms
ctrlX CORE is ready to meet whatever the
Factory of the Future may bring. In addition to At a glance:
EtherCAT, the hardware supports many other ▶ Multicore tech­
nology for optimum
common automation protocols. For example,
performance
the gigabit Ethernet interface is ideal for use ▶ The system that
in networked environments, supporting the offers the best
data-intensive exchange of information with possible ­connectivity
higher-level IT systems, HMI devices and on the market
▶ Open and flexible
cloud-based applications. The control system
architecture for
supports more than 30 IT and IoT standards, new freedom in
including OPC UA as server and client as ­developing functions
well as the widely used MQTT protocol.
40 | ctrlX AUTOMATION

ctrlX I/O
The powerful ctrlX CORE enhancement

With ctrlX I/O, Bosch Rexroth provides the Durable and diagnostic-friendly
ideal add-on for holistic automation solutions.
This add-on connects the EtherCAT ecosystem ctrlX I/O is designed for use in industrial
to the machine control level. environments and fulfills the strictest
requirements in terms of vibrations,
­temperature rating, and protection class.
Intuitive use at a new level Clever d
­ iagnostic concepts, on-board sensor
systems, or smart module diagnostics via
The compact I/O portfolio allows simple NFC increase machine up-time and expedite
installation and cabling as well as rapid diagnostics in the event of errors.
exchange of individual modules or
expansions. Configuration is not required
because automatic recognition integrates
each module independently. Additional
communication standards and interfaces
can be integrated via the I/O Performance
Line for enabling future-oriented concepts.
Based on EtherCAT, ctrlX I/O supports
real-time capable data processing. Simple
configuration and commissioning shorten
engineering times by up to 30 %.
 41

Highlights

More productivity
▶ Clever diagnostic concept at module and At a glance:
channel level reduces standstill times ▶ Expandable for
▶ Robust design in IP20 protection holistic ­automation
solutions
class for maintenance- and fault-free
▶ Intuitive and
operation in the control cabinet ergonomic
▶ Simple installation
Fewer components and rapid exchange
▶ Up to 20 I/O points on 12 of modules
▶ Engineering times
mm installation width
are reduced by
▶ Flexible expandability with ­ up to 30 %
performance ­functions ▶ Strictest ­mechanical
requirements
Less engineering ▶ Real-time-enabled
data processing
▶ Tool-free assembly thanks to ergonomic
mechanical design and PUSH-IN technology
▶ Supports the IO-Link standard for
integrating intelligent sensors
42 | ctrlX AUTOMATION

ctrlX IPC
The PC-based automation solution

Sophisticated process control systems often

require high performance reserves, which
ctrlX IPC provides flexibly and scalably.
Thanks to low power loss, the hardware
design needs neither a cooling concept nor
fans, thus facilitating a long and fault-free
operating time. The modular ctrlX CORE
control platform can be integrated in the open
ctrlX IPC portfolio via the PCIe interface.
This means that the system can be expanded
by standard components or open source
software. Numerous wired and wireless
interfaces are available for communication.
ctrlX IPC forms the ideal interface between
field level and cloud and ensures reliable and
secure transmission of large quantities of data.
 43

Security intelligence Highlights

for large volumes of data
More productivity
The integrated hardware and software security ▶ Scalable performance from entry-
infrastructure safeguards the application and level to high-end applications
machine availability at the same time. The ▶ The latest hardware with s­ ecurity-
hardware robustly withstands impact and by-design integrated TPM chip
At a glance:
vibrations and offers high EMC stability. It is ▶ High long-term availability, thanks to ▶ Scalable IPC
therefore ideal for use in practically any ­maintenance-free hardware without ­portfolio from
application and environment. The use of batteries and fans ­entry-level ­solution to
high-performance and robust SSD memories high-end application
▶ Maximum
from upwards of 64 GB allows future-proof Fewer components
­fl exibility across all
machine designs and offers reliable protection ▶ Integration of the ctrlX CORE ­performance ranges
against data loss in the RAID system. All IPCs industrial control platform
are delivered with standard data backup ▶ Space-saving design with
and recovery software. low installation depth

Trusted platform modules (TPM 2.0) use Less engineering

encryption software to protect the computer ▶ Maximum flexibility and modularity
from bootup until the application is running ▶ Flexible topologies
(security by design). This chip also stores ▶ High performance and openness
certificates and serves as a hardware key for with Windows 10 IoT or Linux
further protection mechanisms. Windows 10 ▶ ctrlX IPC components are designed
IoT Enterprise LTSC (Long-Term Servicing ­strategically for one-person installation
Channel) as the operating system is a key
component of ctrlX IPC; it was developed
specially by Microsoft for networking intelligent
devices on the most varied platforms. Linux
can likewise be used as the operating system.
44 | ctrlX AUTOMATION

ctrlX HMI
The perfect user experience combination

The right information at the right time: ease The web-based software solution ctrlX HMI
of use is an increasingly important factor when adapts every representation automatically to
deciding to purchase a machine. ctrlX HMI different display sizes and prepares important
offers machine builders optimum freedom information clearly at all times. Third-party
when it comes to implementing the user provider tools can be used additionally, which
experience with intuitive user guidance. communicate via standard interfaces such
as OPC UA. ctrlX HMI covers all applications
reliably — from the simplest process controls
Innovative and mobile HMI solution to demanding and dynamic simulations.

The portfolio includes small operating panels,

tablets, panel PCs, or large stationary displays
with a screen diagonal of up to 24". Anti-glare
and chemically hardened front glass make display
and operating panels ideal for use in harsh
everyday production environments. The 16:9
screen size supports multi-touch operation
with ten fingers.
 45

Highlights

More productivity
▶ Scalable portfolio from small operating
panels to 24" displays

Fewer components
▶ Web-based HMI with integrated web server

Less engineering
▶ Integrated web-based HMI e ­ ngineering
and simple integration of t­ hird-
party provider HMI tools
▶ Integration of 10" smart devices
for the mobile HMI solution

At a glance:
▶ Perfectly harmonized
hardware and software
for intuitive visualization
▶ Robust hardware
▶ Long life cycle
46 | ctrlX AUTOMATION

ctrlX DRIVE
The most compact drive system

Bosch Rexroth has developed the most Space requirements are halved
compact modular drive system in the world
for its customers with ctrlX DRIVE. Apart The powerful ctrlX CORE control hardware
from space-saving dimensions and maximum can be integrated in the drive housing without
scalability, ctrlX DRIVE boasts advantages needing additional space. Overall, users save
such as virtually unlimited combination up to 50 % in the control cabinet. Further space
options for users, sophisticated engineering savings are possible in combination with
tools, and high energy efficiency. the modern MS2N motors, since they offer
a power density that is up to 30 % higher.

Flexible supplier concept

Complete performance package
The new drive generation offers both simple
­single-axis applications and complex multi-axis All components in the ctrlX DRIVE system
machine systems. The scalable drive portfolio can be combined freely with one another.
includes converters, single and dual-axis Users can expand the drives with additional
inverters, DC/DC converters, and power and hardware and software functions with the
regenerative supply units. ctrlX DRIVE ctrlX DRIVEplus option. Add-on boards for
therefore offers tailored solutions with peak additional encoders, I/O expansions, and the
currents of 6 A to 375 A. Sufficient power is integrated ctrlX CORE control system offer
always available even for extensive machine previously unattainable degrees of freedom.
designs with output of up to 260 kW.
 47

Secure and energy-efficient

With a reaction time of around 4 ms, ctrlX DRIVE

offers one of the fastest SafeMotion solutions
on the market. The energy management
functions enable energy to be exchanged in
the link connection and central network
access components. The patented Smart
Energy Mode reduces peak power of the
drives by up to 70 %. The converters can be
used at the same time as supply units and
inverters. In addition, classic power and
regenerative supply units are also available.
The continuous DC bus o ­ ptimizes the power
requirement and reduces power loss.
 48 | ctrlX AUTOMATION

At a glance:
▶ Most consistent drive
system on the market
▶ Space savings of up to 50 %
▶ From cost-efficient
entry-­level solution to
­high-end solution with
integrated motion control
 49

Robust design Highlights

ctrlX DRIVE has a robust EMC design. More productivity

The new power connector with integrated ▶ Peak currents of 6 A to 375 A
grounding concept allows even better ▶ Converters, power and regenerative supply
interference resistance. The integrated units with peak power of up to 260 kW
DC bus connection eliminates accessory ▶ Flexible power supplier concept – space
sets and is designed for high current- saving, flexible, and energy-efficient
carrying capacity (up to 375 A).
Fewer components
▶ Up to 50 % less space is required
in the control cabinet
▶ Perfect for 300 mm control cabinets
owing to modular multi-axis concept
▶ Integrating ctrlX CORE totally eliminates the
space required for the control system fully

Less engineering
▶ Intelligent functions such as multi-­
Ethernet, multi-encoders, and integrated
web servers allow for simple diagnostics
▶ Less wiring and faster engineering
▶ Single-cable technology
50 | ctrlX AUTOMATION

The high-performance servo motors

Bosch Rexroth servo motors are the perfect available for environments with explosive
team player in the ctrlX DRIVE portfolio. gases and dust. The rotary and linear direct
Boasting compact dimensions, they combine drives in the MS2N motors dispense with
optimum dynamics with maximum precision mechanical transmission components
of position, speed, and torque values. like coupling and gears. The innovative
single-cable technology with cable length
of up to 75 m reduces cabling by 50 %.
Motors for every requirement

The broad model portfolio includes the

right solutions to meet all requirements.
An ATEX-compliant series is therefore
 51

Engineering for experts Highlights

Developers have access to the digital twin More productivity

of the motor, which is stored in a design tool ▶ High torque density for greater power
and in the ctrlX DRIVE controller. Planning ▶ 7 frame sizes with maximum
and design of even complex drive systems torque of up to 692 Nm
can therefore be virtualized quickly and ▶ Maximum dynamics of the servo axes due
reliably. A new torque model transforms to low motor inertia and high overload
each motor into a data source for intelligent capacity
machines or Industry 4.0 applications.
Fewer components
▶ Robust single-cable connection with
a cable length of up to 75 m
▶ MS2N with integrated SafeMotion encoder –
no further safety components are required
▶ Motor as torque sensor makes external
sensors redundant

Less engineering
▶ Plug-and-play expanded encoder data
memory for faster commissioning
▶ Digital twin of the thermal motor model
ctrlX SAFETY
The most comprehensive SafeMotion
and SafeLogic solution

Safety first: standardized safety is an absolute

prerequisite for machine manufacturers and users.
ctrlX SAFETY simplifies implementation of
standardized safety while ensuring maximum
productivity during usage.

Certified safety as standard

The new ctrlX DRIVE drive generation is

systematically fitted with expandable safety
functions. SafeMotion implements safety functions
precisely where motion occurs and responds within
4 ms. Of particular interest for modular concepts
is that manufacturers can use SafeMotion to
implement a purely drive-based safety solution in
their assemblies, which operates i­ndependently
of the higher-level control system.

SafeLogic safety control is an o ­ ptional and compact

expansion of the s ­ tandard control system. Graphic
­programming simplifies e ­ ngineering and reduces
the familiarization time.
 53

SafeMotion and SafeLogic Highlights

as a package solution
More productivity
SafeMotion and SafeLogic together communicate ▶ Fastest safety solution on the market
via Bosch Rexroth’s own safety bus at a with reaction times of 4 ms
speed that is 10 to 15 times faster than via ▶ Optimum integration into machine concepts
classic fieldbuses. Safety equipment can
therefore be designed more compactly, Fewer components
thanks to the fast reaction times. ▶ Less hardware thanks to
software-based scaling
ctrlX SAFETY covers the full range from ▶ Space savings due to faster
entry-level solutions to highly complex reaction times by the system
applications with different packages. Once
At a glance:
they have been created, safety solutions can Less engineering ▶ Fast and adapt-
be integrated into different machine designs ▶ Simplified creation of application able, can be used
without any major adaptations. ctrlX SAFETY programs through graphic programming individually or as
also simplifies engineering in the process via of the safety logic and dialog-based an overall system
▶ The reaction time of
dialog-based acceptance tests. Intelligent support for the acceptance test
the safety solutions
software modules simplify parameterization enables a more
in this context. The unrestricted choice of compact design
bus systems ensures perfect communication ▶ Maximum safety
between components. in production
54 | ctrlX AUTOMATION
 55

ctrlX Configurator
The intuitive tool for a systemic
automation solution

The ctrlX Configurator supports the complete

ctrlX AUTOMATION portfolio and enables
individual configuration of automation
solutions — simply, quickly, and reliably. Users
create the desired system topologies graphically
without product knowledge. Support or
availability can be queried directly from the
configuration tool. Round the clock — worldwide.

▶ Graphic configuration of components

and complete automation solutions
▶ Intuitive handling via modern operating
concept with dynamic 3D product view
▶ Individual problem-solving without
product expertise using m ­ anufacturer-
independent product library
▶ Faster configuration via solution templates
and 24/7 availability of the online platform
▶ System-wide consistency of the
solution configuration via automatic
verification of product relationships
▶ Support for processing in project teams
and for support and availability queries
56 | ctrlX AUTOMATION
 57

Bosch Rexroth Corporation

5150 Prairie Stone Parkway
Hoffman Estates, IL 60192
www.ctrlx-automation.com
www.boschrexroth-us.com/automation

R999001900 (2019-11)
© Bosch Rexroth Corporation February 2020
Subject to change without notice.

This information is only provided to describe the products. No statements

concerning a certain condition or suitability for a certain application
can be derived from our information.
The information given does not release the user from the obligation of own judgment and
verification. It must be remembered that our products are subject to a natural
process of wear and aging.
The data provided is based on average or maximum values and may vary.