In the world of hydraulic power unit design, customization often feels like the only path. You select a drive, size an enclosure, source the components, and manage the panel wiring and integration. This “engineered-to-order” (ETO) process provides ultimate flexibility, but it comes at a cost: long lead times, complex quoting, and significant engineering overhead.
But what if your application uses a standard variable displacement or fixed displacement pump? What if you need the proven energy savings of a variable frequency drive (VFD) without the ETO timeline?
This is where smarter engineering prevails. Introducing the Bosch Rexroth CytroCab, a pre-engineered packaging program that puts our industry-leading Sytronix VFD technology into a standardized, ready-to-integrate cabinet. It’s the fastest way to bring intelligent, efficient hydraulic power to your machine.
Standardization: Your Competitive Advantage
The core idea behind the CytroCab is simple: by pre-engineering the most requested drive configurations and options, we can dramatically shorten delivery times and simplify the entire procurement process.
Instead of starting from a blank sheet, you start with a proven, reliable base configuration:
A Bosch Rexroth EFC 5610 Variable Frequency Drive
Industry-leading Sytronix pump control software
A rugged, NEMA 12-rated enclosure
Fused circuit protection (upgradable to fused disconnect)
Thermostatically controlled cooling
This isn’t a limitation; it’s an accelerator. It removes the variables and guesswork from panel design, allowing you to get standard pricing and faster delivery, moving your project forward with confidence and speed.
The Power of Sytronix: More Than Just a Drive
At the heart of every CytroCab is our Sytronix control software, a specialized firmware designed to unlock the full potential of your hydraulic system. When paired with a Bosch Rexroth pump, Sytronix isn’t just spinning a motor; it’s intelligently managing power.
Massive Energy Savings: Sytronix automatically reduces motor speed during low-flow or no-flow periods, slashing energy consumption compared to traditional, fixed-speed power units.
Reduced Noise: Lower average motor speeds mean a quieter machine and a more comfortable, productive work environment.
Longer Component Life: Reduced wear on the motor and pump bearings leads to increased uptime and a lower total cost of ownership.
Intelligent Pump Protection: With features like leakage and thermal detection, Sytronix actively protects your pump, enhancing the reliability of your entire system.
Configured for Your Needs
Starting with the base model, the CytroCab offers a focused set of powerful options to tailor the solution to your specific machine requirements. Need local start/stop controls and status lights? The Local Control Kit (LC) adds them directly to the door. Need to monitor HPU sensors or add advanced supervisory functions? The PU option is designed for it.
For modern, connected machinery, the Ethernet Communication Kit (EC) provides a direct link to your plant-wide network, supporting protocols like Ethernet/IP, Profinet, and EtherCAT.
The Smart Choice for Efficient Hydraulics
The CytroCab is the ideal solution for end-users, machine builders and system integrators who need the benefits of a VFD without the cost and complexity of a full ETO build. It combines the reliability of Rexroth components, the intelligence of Sytronix software, and the speed of a standardized, pre-engineered solution.
Stop re-engineering the wheel. Move your project forward faster with the CytroCab.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Your hydraulic pump is working hard right now. Even when your machine isn’t.
If you’re running fixed displacement pumps, they’re delivering full flow every moment they’re spinning—whether your system needs 100% capacity or 10%. It’s like driving with your foot on the gas and using only the brake to control speed. It works, but it’s incredibly wasteful.
The Energy Waste Problem Nobody Talks About
Here’s what most plant managers don’t realize: a typical fixed displacement hydraulic system wastes 30-40% of its input energy during normal operation. That energy doesn’t just disappear—it becomes heat that your cooling system has to remove, creating a double cost.
Let’s put numbers to it. A 50 HP hydraulic power unit running two shifts (4,000 hours/year) at $0.12/kWh costs roughly $18,000 annually to operate. If 35% of that is waste, you’re literally throwing away over $6,000 per year, per machine.
Multiply that across your facility.
The Smarter Alternative
Variable displacement pumps like the Bosch Rexroth A15VSO Series 12 solve this problem elegantly: they only produce the flow your system actually needs at any given moment.
When your press is holding pressure but not moving? The pump swivels to minimal displacement, maintaining pressure with minimal flow. When you need full power for rapid advance? The pump instantly adjusts to maximum displacement. It happens automatically, hundreds of times per cycle.
The result:
30-40% lower energy consumption in typical industrial applications
Reduced heat generation means smaller coolers and longer oil life
Quieter operation when running at reduced displacement
Extended component life due to lower thermal stress
It’s Not Just About Saving Energy
Yes, the energy savings are compelling. But variable displacement brings other advantages that fixed pumps simply can’t match.
Precise Control: Need to vary press closing speed based on part thickness? Simple with proportional control. Want to sequence multiple actuators smoothly? Load-sensing makes it effortless.
System Flexibility: One variable pump can replace multiple fixed pumps with complex valve circuits, simplifying your hydraulic schematic and reducing potential leak points.
Modern Connectivity: With optional sensors, today’s variable pumps aren’t just hydraulic components—they’re smart devices that report operating status, predict maintenance needs, and integrate with your machine control.
The Question Isn’t “If” But “When”
The technology has matured. The energy savings are proven. The payback periods are measured in months.
The real question for manufacturers isn’t whether variable displacement makes sense—it’s why they’re still paying to run inefficient systems.
If you’re still operating fixed displacement pumps on variable load applications, you’re choosing to waste money every single shift. The A15VSO Series 12 provides a straightforward path to eliminate that waste while improving machine performance.
Curious about the potential savings in your facility? A Bosch Rexroth applications specialist can evaluate your current system and calculate your expected ROI. Most manufacturers are surprised by how quickly these pumps pay for themselves.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
There’s a trend in hydraulics toward custom solutions for every application. Custom manifolds. Custom valve assemblies. Custom pressure settings. It sounds sophisticated until you face real-world consequences:
Production schedules built around hoped-for delivery dates
Emergency repairs waiting on special-order components
Inventory nightmares from supporting dozens of unique part numbers
Engineering time spent specifying variations that add complexity without performance benefit
Sometimes the smartest solution is the one that’s actually available.
When Standard Means Better
Bosch Rexroth’s DBD 6-30 pressure relief valves prove that standardized doesn’t mean compromised. These direct-operated relief valves combine proven performance with the practical advantage of consistent stock availability.
Four sizes. 50 to 330 l/min flow capacity covers most mobile and industrial requirements.
Seven pressure ratings. From 25 to 630 bar—low-pressure mobile equipment through high-force industrial presses.
Multiple configurations. Cartridge, threaded, or subplate mounting. Tool-adjustable or hand-adjustable. Standard or enhanced corrosion protection.
The combinations you actually need? Ready to ship.
Reliability Through Simplicity
DBD valves use direct-operated design where system pressure acts directly against a calibrated spring. When pressure exceeds the setting, the valve opens proportionally.
No pilot stages creating delays. No complex controls introducing failure points. Just mechanical reliability that works the same way every cycle.
This simplicity delivers real advantages:
Predictable response when pressure approaches limits—no pilot delays, just direct mechanical action.
Straightforward service when maintenance is needed—springs and seals, not multi-stage troubleshooting.
Consistent performance across temperature ranges and fluid conditions because mechanical operation doesn’t depend on pilot signal quality.
Built for Tough Conditions
Pressure relief valves often end up in exposed locations where environment challenges longevity. That’s why DBD valves offer corrosion protection levels matched to actual conditions:
Standard protection handles typical indoor industrial environments.
J3 protection (240-hour salt spray resistance) suits outdoor installations, mobile equipment, or humid conditions where condensation occurs regularly.
J5 protection (720-hour salt spray resistance) addresses marine applications, coastal facilities, or chemical processing where standard coatings fail within months.
The protection isn’t cosmetic—it’s functional reliability. Corrosion affects spring characteristics and sealing surfaces. Protected valves maintain calibration where unprotected alternatives degrade.
High Pressure Without Hesitation
Maximum ratings of 630 bar aren’t theoretical—they’re proven operating capability. Steel construction, hardened sealing surfaces, and precision manufacturing ensure DBD valves maintain performance and reliability when actually operating at high pressures.
For systems running 315 bar, 400 bar, or 630 bar, you’re not pushing design limits. You’re working within validated capability backed by decades of field installations.
The Availability Equation
Here’s what changes when critical components are consistently available:
Design confidence – Build schedules around actual delivery, not hoped-for dates.
Simplified inventory – Stock one reliable valve family instead of maintaining emergency supplies of multiple alternatives.
Faster emergency response – When pressure protection fails, replacement arrives in days.
Reduced planning stress – “Is it available?” stops being a question you ask weekly.
Quality That Shows Up Consistently
Rexroth manufacturing standards ensure every DBD valve meets specifications:
Precision machining of sealing surfaces
Controlled spring calibration with verification
Functional pressure testing before shipment
Consistent performance across every unit with the same part number
When you install a DBD valve, it performs like every other valve with that specification—predictable, repeatable, reliable.
When Simple Wins
Sophisticated solutions have their place. But when you need reliable pressure protection that’s available when projects demand it, proven when systems depend on it, and consistent when production requires it—standardized excellence beats custom complexity.
DBD 6-30 pressure relief valves: the smart choice that’s actually in stock.
Want to see how standardized reliability can simplify your next project? Contact Bosch Rexroth to discuss your pressure protection requirements.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
You spoke, we engineered. How direct customer feedback shaped the next evolution of compact, intelligent hydraulics.
When Bosch Rexroth introduced the original CytroPac, it fundamentally challenged what a hydraulic power unit had to look like. It eliminated sprawling, leaky 100-liter oil tanks, silenced shrieking pumps, and integrated the variable-frequency drive right on top of the power unit.
It quickly became the benchmark for machine tools and compact industrial automation. But at Bosch Rexroth, being an industry standard is just the baseline.
Over thousands of operational hours on shop floors worldwide, machine builders and maintenance managers gave us clear feedback on how to make CytroPac even better:
“We love the compact footprint, but we need more modularity to mount our own valves and handle large return flows.”
“Give us industrial-grade connectivity and continuous condition monitoring.”
“Help us cut energy consumption and CO₂ even further.”
“Make setup, maintenance, and visual diagnostics simpler for operators on the floor.”
The result is the CytroPac Series 2X—a power unit perfected by you.
Here is a closer look at what’s new in the 2X evolution and what it means for your machines.
Modularity That Fits Your Circuit, Not Ours
In the past, integrating directional or proportional control into a compact hydraulic circuit often meant mounting an external manifold block nearby, running extra hoses, and wasting valuable floor space.
The CytroPac 2X solves this with pre-engineered, factory-matched Functional Modules:
Standard Return Filter Module (M1): 10 µm filtration with integrated cold-start suppression monitoring to prevent false clogging alarms when oil is cold.
Leakage Oil Module (M2): Dedicated dual-return routing with built-in diffusers for pressure-free return of large volume flows, preventing oil foaming and aeration.
Valve Module (M3): An integrated NG6 (ISO 4401-03-02-05) interface plate mounted directly onto the power unit. You can now bolt standard Rexroth directional valves or multi-station manifolds straight onto the CytroPac.
Filter Module with DBV (M4): Integrated system pressure relief directly combined with the return filter.
Whether you need a standalone pressure supply or a complete, self-contained hydraulic control station, the 2X configures to your exact footprint.
Up to 80% Energy Savings: The Math Behind the Machine
Energy costs and carbon reduction mandates are no longer abstract targets—they directly impact operational margins.
The CytroPac 2X pairs high-efficiency motor options (including an IE5 PMSM servo motor on the 4.0 kW model and an IE4 asynchronous motor on the 2.2 kW model) with Bosch Rexroth’s Sytronix variable-speed pump drive.
Instead of running a fixed-speed motor that constantly dumps unused oil over a relief valve at high pressure, CytroPac 2X dynamically matches pump speed to the exact flow and pressure the cycle demands. In holding-pressure or idle phases, the motor slows down or drops into an intelligent sleep mode, slashing energy consumption by up to 80%.
Big Cooling Power in a Tiny 20-Liter Tank
How do you run 280 bar pressure and up to 38.5 l/min of flow out of a unit with only a 20-liter oil tank?
Traditional hydraulics rely on a massive 60 to 100-liter reservoir simply to let trapped air bubbles escape and allow oil to cool down before being drawn back into the pump. CytroPac eliminates this bulk using two patented innovations:
Degassing-Optimized Tank Flow: CFD-designed internal geometries guide returning fluid along precise paths that de-aerate oil almost instantly.
Heat Pipe Cooling Technology: Heat pipes transfer up to 2 kW of heat away from both the submerged motor/pump assembly and the oil reservoir straight into a heavy-duty aluminum cooling plate.
The result? 80% less hydraulic fluid to buy and dispose of, a 50% smaller machine footprint (1,200 cm² vs. 2,400 cm²), and an enclosure that completely muffles pump noise—operating at conversational sound levels even under full load.
Native Connectivity: Smarter Monitoring, Zero Hassle
Gone are the fragile RJ45 and Push-Pull connections of earlier units. The CytroPac 2X standardizes on rugged M12 Multi-Ethernet connectors, allowing seamless integration into fieldbus networks (Profinet, EtherCAT, Ethernet/IP, and Sercos).
The integrated frequency converter acts as an edge sensor node. In addition to standard digital switches, the 2X offers continuous 0–100% oil level sensing and 0–60°C continuous temperature logging. Connected to CytroConnect Solutions, your maintenance team can predict filter clogging, track thermal performance, and plan component servicing long before unexpected downtime occurs.
And for operators on the floor:
A bright Status LED bar integrated directly into the top hood provides immediate visual status from any viewing angle.
An optional 4.3″ HMI Touch Display right on the housing gives technicians instant readout of operating pressure, oil temperature, motor speed, and active alarms.
Our Commissioning Wizard gets the unit running in minutes via the USB service interface.
Designed for Global Deployment
For machine builders exporting to North America, regulatory certifications can be a costly bottleneck. The CytroPac 2X features optional cULus listing complete with an industrial-grade steel hood, alongside integrated Safe Torque Off (STO SIL 3 / PL e). You can specify one global design, confident that it meets electrical and mechanical safety standards anywhere in the world.
The Bottom Line
The CytroPac 2X proves that component evolution doesn’t happen in a vacuum—it happens when engineers listen to the people running the machines every day.
More modularity for custom control circuits.
More connectivity for Industry 4.0 monitoring.
More energy efficiency to cut your power bills and carbon footprint.
More simplicity for the technicians on your shop floor.
Ready to see how much energy and space you can save on your next machine build? Connect with your local Bosch Rexroth representative or explore the full datasheet at www.boschrexroth.com/cytropac.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
What do a 100-ton excavator, a forestry harvester, and a concrete pump truck have in common? They all rely on a hydraulic pump to do the heavy lifting, and for decades, one name has defined reliability in this space: the A10VSO.
But in a world of smart, connected everything, why does this classic workhorse still dominate? Because it solves the three problems that matter most to machine builders and operators: Power, Flexibility, and Uptime.
The Power Problem
High-power machines need to move heavy loads quickly and precisely. This requires a pump that can deliver high pressure and flow without fail. The A10VSO Series 32 is an optimized medium-pressure powerhouse, providing a nominal pressure of 280 bar for continuous use. This raw power, combined with fast control response times, gives operators the dynamic performance needed for demanding tasks.
The Flexibility Problem
Modern machines needs are unique to their application, which can require different pumps for each build resulting in multitudes of different configurations. This can be diifficult to track and manage. The A10VSO’s brilliant solution is its flexible universal through drive capability. Note only are all the through drives rated to 100% capability the flexibility offered by the universal through drive design allows a customer to streamline their inventory, keeping track of less part numbers and allowing for easy through drive conversions in the field. A single pump can be used as a base to create multiple different pump stacks; this brings flexibility back to the designers, headache free conversions in the field, and ease of mind to purchasers.
The Uptime Problem
Unplanned downtime is the enemy of profitability. A failed pump can bring an entire operation to a standstill. The A10VSO’s legendary reputation is built on its durability. Its robust swashplate design, high-quality bearings, and precision manufacturing mean it’s built for a long service life, even in the harshest conditions. It’s the kind of component you install and forget about—which is the highest praise a pump can receive.
Evolving with the Times
The A10VSO series 32 is a modern pump that respects and improves upon its heritage in many different areas; efficiency, noise and reliability. It’s available with a wide range of controls, from simple pressure compensators to sophisticated electro-proportional (EP) versions that integrate seamlessly with modern electronic control systems. This allows it to serve as the reliable foundation for both traditional and “smart” machine concepts.
The A10VSO is more than just a pump. It’s a problem-solver, an enabler of compact design, and a guarantee of uptime. It’s the trusted, powerful heartbeat inside the machines that build and shape our world.
Looking for a pump that delivers on its promises? Explore the A10VSO Series 32.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
In the fast-paced world of manufacturing, where efficiency and productivity are paramount, safety should never be compromised.
Yet one aspect often overlooked in ensuring shopfloor safety is the incorporation of aluminum framing. It’s the backbone of any facility, but it’s frequently deemed less important compared to the conveyors or assembly processes executed on it. It’s time for manufacturers to change their perspective and start viewing aluminum structural framing as a foundational element to their operations.
Sustainability and adaptability: building a safe foundation
The versatility of aluminum framing in manufacturing cannot be overstated, especially in a landscape where sustainability, adaptability and compliance are essential for maintaining a safe working environment. Aluminum framing systems play a role in helping ensure the safety of workers. Companies can reach out for assistance with machine guarding, ergonomic design and resources to stay in compliance with electrostatic discharge (ESD) regulations. Aluminum framing is foundational in addressing these concerns.
A multi-functional and recyclable resource, aluminum framing is synonymous in meeting sustainability goals. While the most robust aluminum framing on the market tends to outlast most employees, when its purpose as one structure is fulfilled, it’s designed to break down and be reconstructed as something else.
Compliance with regulations, particularly concerning machine guarding, is a top priority for manufacturers looking to enhance safety on their factory floors. With the increasing adoption of robotic applications and high-speed conveyance in industrial settings due to automation, aluminum framing plays a crucial role in meeting industry regulations and protecting workers from potential hazards. Whether it’s a collaborative robot (cobot) or a transfer system with speeds of up to 150 meters per minute, there must be adequate enclosure and guarding to stay within safety standards.
A key consideration is the concept of finger-safe enclosures, which prevent accidental contact with hazardous components, reducing the risk of injury and ensuring a safer working environment for all.
In addition to physical safety measures, aluminum framing also plays a vital role in addressing electrostatic discharge (ESD) concerns, particularly in workstations where sensitive electronic components are handled. Aluminum framing solutions can be instrumental in constructing ESD-safe environments, as well as safeguarding against potential damage to circuit boards and delicate semiconductor processes.
The demand for electronic devices amplifies the need for such measures, making ESD compliance an essential consideration in aluminum framing design. By incorporating ESD-safe aluminum framing solutions, manufacturers can mitigate the risk of damage to equipment and ensure the safety of their workers.
Prioritizing safety through aluminum framing
Aluminum framing is not merely a structural component of a factory floor; it’s a critical element that directly impacts the safety and well-being of workers. Every manufacturer must prioritize safety by rethinking how they approach aluminum framing design and implementation.
By recognizing the importance of aluminum framing in maintaining a safe working environment and prioritizing safety in aluminum framing design and implementation, manufacturers can enhance efficiency, mitigate risks and ensure the long-term success of their operations. It’s time to give aluminum framing the attention it deserves and use it as the powerful tool it is to elevate safety in the manufacturing industry.
Protect Your Production with a Robust Aluminum Structural Framing System
Aluminum framing builds a strong foundation for workplace safety that is not only reliable, but configurable to the adapting needs of production. Learn more about the role of aluminum framing is enhancing the safety of both your factory and people.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
In an AI-driven shift, data center construction is growing at a rapid pace.
In 2025, the data center construction market was estimated at 261 billion and expected to steadily grow at a 12% CAGR through 2033.
To meet the demand, additional data centers need to be built with speed and longevity in the forefront. After all, a data center malfunctioning can be detrimental. That’s why a successful data center needs to be built correctly – before the servers even enter the building.
A Tale of Two Materials: Steel and Aluminum
In the high-stakes world of data centers, where every degree of temperature matters, installation efficiency and overall reliability are paramount.
While steel is often viewed as the preferred material due to its strength and structural integrity, this emphasis on efficiency and reliability give aluminum framing its edge. Compared to steel, aluminum framing is more lightweight for easier handling, boasts a stronger strength-to-weight ratio, and greater thermal conductivity.
When purchased in bulk for a large project like constructing a data center, aluminum framing is often more economical, and quicker for construction workers to handle in installation due to being lighter.
Depending on the application, both steel and aluminum can often work together for the overall build. Steel does greater load-bearing strength and if the weight requirements extend aluminum’s specification, using steel is a solution. But in key data center construction applications like hot aisle containment, cold aisle containment, false floors, and even server racks, aluminum framing is a smart start to a successful data center.
Top Aluminum Framing Applications in Data Center Construction
While aluminum framing can be used in more applications, the strengths of the material shine brightest with the following applications:
Hot Aisle Containment
Cold Aisle Containment
Server Racks
False Floors
Hot Aisle Containment
Temperature management is a critical consideration for data centers. Hot aisle containment systems are paramount to reduce energy consumption and improve overall efficiency by preventing the mixing of hot exhaust air and cold supply air. With its ability to form an air-tight containment seal, thermal-conductivity benefits, and easy installation, aluminum framing is the ideal material structure for these critical enclosures.
With a modular aluminum framing system, it can also adapt and be reconfigured if the data center needs to shift as technology evolves.
Cold Aisle Containment
Cold Aisle Containment encloses the aisle where cold supply air is supplied to equipment, using panels and doors to separate it from hot exhaust air. All the same benefits of aluminum framing from hot aisle containment apply to this application.
Server Racks
Beyond aisle containment and temperature control, aluminum profiles are revolutionizing server rack construction. Steel racks will be heavy, which makes them hard to move and limits their adaptability. Aluminum profiles, however, offers a superior alternative that are not only incredibly strong but also remarkably light, facilitating easier transportation and deployment.
False Floors
Data centers require raised floors, also known as false floors, that are elevated between 1-2 feet and support cable management, as well as a distribution system for cold air to server racks. With its impressive strength-to-weight ratio and easier installation, aluminum framing makes an efficient material for false floors that improve cooling efficiency by supporting underfloor airflow.
Beyond its technical strengths, aluminum framing provides unmatched aesthetics – clean lines, precision surfaces, and modularity create an impressive environment that is not just functional, but visually impressive. In a rapidly changing market, where efficiency, speed, and precision are paramount, a material solution that looks as sleek as it performs speaks volumes about the quality of the entire infrastructure.
Aluminum Profiles for Data Center Infrastructure
The emphasis on efficiency and reliability gives aluminum framing its edge for data center construction. Learn more about how aluminum framing plays a critical role in data center construction.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Whether it’s dirt, clean rooms, high dynamics, or limited installation space: If you are clear about the loads, environment, and service life, you will usually find the right solution in the Rexroth standard portfolio.
Linear guides rarely get the spotlight, but they play a central role in mechanical engineering and factory automation. They guide linear movements precisely and reliably under defined environmental and load conditions – as efficiently, compactly, and with as little maintenance as possible. But which linear guide is suitable for dirt, vacuums, clean rooms, extreme temperatures, high dynamics, or limited installation space?
In this blog post you will learn which selection criteria are crucial for linear guides and which applications you can realize particularly economically with our proven standard solutions. If you have special, individual requirements, our experts with decades of application knowledge will be happy to assist you.
Tip: For an overview of the most important types of linear guides – from linear bushings to profiled rail systems and cam roller guides – please visit our linear guides product page.
Which linear guide for which application?
Rexroth linear guides can be found in virtually every industry – from machine tool manufacturing to medical technology, from the food and packaging industry to wood processing, from semiconductor and electronics manufacturing to battery production. The common denominator: the possibility to implement almost any application quickly and cost-effectively. The advantages of the broad standard portfolio of linear guides are a wide selection of proven, quickly configurable solutions with global availability as well as shorter project lead times and machine designs tailored to specific needs. Below are some examples of industry-specific applications and customized solutions:
1. Linear guides for special environmental conditions
Many environments expose linear guides to dirt and contaminants, such as in woodworking and stone processing. Profiled rail systems with special seals (either integrated or as attachments) and the fully sealed standard linear bushings from Bosch Rexroth have proven to be a cost-effective solution for these applications.
Harsh environmental conditions: Double-lip seals protect the linear guides in woodworking and metalworking from dirt and contamination.
The all-metal ball rail systems for extreme conditions NRTVG (NRII Temperature Vacuum Graded) withstand extreme temperatures from -30 to 200°C. They impress not only in cold rooms or glass manufacturing, but also in vacuum environments – such as those encountered in wafer and electronics production. The same applies to the all-metal standard linear bushings.
A risk of corrosion exists in the case of contact with acids, alkalis, or electrolytes in electroplating or battery production, as well as during steam sterilization in the medical or pharmaceutical environment. Linear guides made of NRII (corrosion-resistant steel) and hard chrome plated and coated versions (e.g. zinc-iron) prevent these damaging effects. For use in dry rooms, the Rexroth standard portfolio also includes linear guides with resistant plastics such as POM as well as special lubricants.
Runner block NRTVG for extreme environments.
Miniature ball rail systems and corrosion-resistant profiled rail systems, among others, meet the requirements of various clean room classes in semiconductor and electronics production.
Tip: Depending on the required clean room class, standard versions are often sufficient.
Linear guides are also indispensable in the food sector, especially in packaging and final inspection. The Rexroth ball rail systems in corrosion-resistant NRII or NRFG design (NRII Food Grade) are particularly well suited to these environments. Process-related guiding tasks without direct food contact (e.g. bottle fillers, film wrapping machines, or bag forming, filling, and sealing machines) also benefit from the easy-to-clean, all-metal linear bushings.
All-metal linear bushings.
2. Linear guides for precision, dynamics, and limited installation spaces
Ever-increasing automation is also pushing the boundaries of accuracy, dynamics, and installation space. When it comes to precision, the roller and ball rail systems RSHP/BSHP lead the way in the Rexroth standard portfolio. Why? A patented entry zone in the runner block ensures optimal smooth running – from workpiece machining, feeding, handling, and assembly to cover plate and laser cutting or 3D printing.
Ball rail system BSHP: Thanks to elastically deformable steel bearing plates (2), the entry zone adapts individually to the current operating load of the runner block (1). The balls (4-7) enter the bearing zone between the runner block and the ball rail (3) smoothly, i.e. without any impulse loads.
Tip: Linear axes and multi-axis systems equipped with BSHP linear guides also achieve maximum precision and dynamics.
Short cycle times require high speeds: The high-speed runner block from the Rexroth standard portfolio reaches a record-breaking 10 m/s. Typical application areas include plastic injection molding, pressing and joining, laser cutting, and handling with long travel ranges. The Rexroth standard linear bushings and standard ball rail systems in small sizes also move quickly at speeds of up to 5 m/s.
Incidentally, the durable cam rollers from Bosch Rexroth are also ideally suited for fast movements up to 10 m/s.
Integrated additional functions save installation space and reduce costs. How? For example, through the temperature control function TCRS, which ensures thermal stability in high-precision workpiece machining, or through linear guides with integrated measuring systems.
Good to know: Both options can be retrofitted.
Roller rail system RSHP with patented temperature control option TCRS for high-precision machine tools.
Do you want to implement demanding applications in the mid-range price-performance segment economically? Then the all-round guide system BSCL (Ball Rail System Compact Line) is the right choice. Why? Fast selection, configuration, and ordering, combined with the familiar Rexroth quality, many cost-reducing features, and rapid delivery (worldwide from stock).
Incidentally, the price-optimized BSCL line will be consistently expanded in the coming years to cover even more requirements and applications at an optimized price.
Cost-effective ball rail system BSCL for various applications.
Practical tip: With all Rexroth linear guides, you can interchange rails and runner blocks across all precision and preload classes, thereby saving resources.
For small workspaces and compact machine designs, the Rexroth portfolio also includes miniature ball rail systems that combine small sizes with high load-bearing capacity and positioning accuracy. These properties are in demand in the areas of packaging, medical technology, measurement and testing, as well as in the textile industry and electronics production.
Suitable linear guides for typical requirements
Requirement
Suitable standard solutions from the Rexroth portfolio (examples)
Dirt and shavings
Sealed linear bushings, profiled rail systems (BSHP, RSHP) with comprehensive sealing variants, wipers, and optional cover strips for easy closing of the mounting holes in the rail
Clean room
Miniature ball rail systems and ball rail systems NRTVG in all-metal design for extreme conditions
Extremely high dynamics
Ball rail systems with high-speed runner blocks
High precision
Precision rail guides RSHP/BSHP, optionally also with temperature control function TCRS
Compact design for limited installation space
Miniature ball rail systems
Price-optimized
Ball rail systems BSCL for the medium performance range
Vacuum / extreme temperatures
Ball rail systems in all-metal design, e.g. NRTVG
Hygiene areas
Ball rail systems NRII or NRFG
With Bosch Rexroth as a broad-based solution partner, you can quickly find the right linear guide for your application. Whether for process automation, increased efficiency, or miniaturization; whether for special environmental conditions or for new requirements in dynamics, precision, or functional integration such as measurement or temperature control. With the Linear Motion Technology Selector, you can easily select, configure, and order any individual linear guide from the extensive standard portfolio that perfectly matches your application. A broad standard portfolio not only simplifies selection and engineering, but also often reduces the effort involved in purchasing, logistics, servicing, and spare parts inventory. Take advantage of Bosch Rexroth’s low-maintenance, best-in-class solutions now to reduce your costs over the entire life cycle – and ultimately benefit from greater competitiveness and sustainability in mechanical and plant engineering.
Linear Motion Technology Selector
With the Linear Motion Technology Selector, you can quickly find the right linear guide for your application – including technical data, CAD models, and suitable accessory components.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
For years, the path to sustainability in industrial hydraulics seemed to involve trade-offs. Gaining energy efficiency often meant complex system designs or accepting limitations. But what if you could achieve massive energy savings while also reducing investment costs, simplifying your machine build, and improving performance?
This is the new reality made possible by the Bosch Rexroth A3V pump platform, a highly efficient, high-speed variable displacement pump designed specifically for modern, speed-controlled industrial applications.
The Speed-to-Torque Revolution
The fundamental principle behind the A3V is a game-changer for machine design. In a speed-variable pump system, the required motor torque is directly related to the pump’s displacement and speed. By designing the A3V to operate reliably at exceptionally high speeds—up to 4000 rpm—we’ve flipped the traditional design equation.
This higher speed allows the pump to achieve the same flow rate with a smaller displacement, which in turn reduces the required motor torque by up to 30%.
What does this mean for you?
Downsize Your Motor: You can now use a smaller, less expensive servo motor.
Reduce Drive Costs: A smaller motor often allows for a smaller, more cost-effective converter.
Eliminate Liquid Cooling: In many cases, the smaller servo motor can be air-cooled, eliminating the cost and complexity of water-cooling circuits.
The result is a direct reduction in both initial investment cost and long-term operating costs.
Efficiency You Can Measure (And Hear)
The A3V platform isn’t just fast; it’s a new benchmark for efficiency in medium-pressure hydraulics. With a total efficiency of up to 93%—five percentage points higher than previous generations—it minimizes energy losses during operation. For cyclic applications like injection molding or presses, this can translate to overall energy savings of up to 80% compared to constant-speed systems.
We also engineered the A3V for quieter operation. Its design significantly reduces pressure pulsation, a primary source of hydraulic noise. This leads to a quieter machine, a more comfortable working environment, and less vibrational stress on the entire system.
Built for the Future of Hydraulic Drives
The A3V platform is purpose-built for the demands of modern electro-hydraulic systems.
Recuperation Ready: In applications like lowering a lifting platform or counter-holding a die cushion, the A3V can act as a motor, driving the servo motor as a generator to feed power back into the grid or intermediate circuit.
Unlimited Start/Stop: Designed for highly cyclic applications, it has no restrictions on start/stop cycles or prolonged pressure holding.
Dynamic and Variable: The combination of variable displacement and variable speed allows the system to achieve any operating state with optimized energy use, from high-flow movements to high-pressure holding with minimal torque.
The Smart Choice for Sustainable Hydraulics
The A3V pump platform proves that sustainability and cost-efficiency can go hand-in-hand. By enabling the downsizing of core drive components while delivering best-in-class performance, it represents the next generation of intelligent, medium-pressure industrial hydraulics.
Ready to rethink your drive train? Contact your CMAFH representative to see how the A3V can power your next machine.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
Hydraulics just got a modern user interface: Easy2Connect App
Bosch Rexroth’s Bluetooth-enabled valve solution brings commissioning, tuning, and diagnostics to your iPhone or iPad through the new Easy2Connect app, now live in the US Apple App Store. What used to require a laptop, a cable, and a pile of guesswork is now a quick pairing and a clear dashboard.
Here’s how it works: add the compact Bluetooth dongle (R901505294, VT-ZBT-1-1X) to your valve, open Easy2Connect, and you’re in. You can see configuration at a glance, adjust dynamics with guided steps, and capture error messages in seconds. Whether you’re bringing a line online or chasing down a stubborn issue, you get actionable data where it matters—right at the machine.
It’s time to pair up your valves and get commissioning down to a science.
If you’re running valves like 4WRAE6-3X, DBETA-7X, DBETE-7X, 3DREA6, or Z3DREA6, (Data Sheets Link) this is a simple upgrade that makes a noticeable difference.
Many users already have the valves on-site; adding the Bluetooth “black box” unlocks the digital layer that speeds commissioning, lifts productivity, and maximizes availability. And because it’s retrofit-friendly, you can standardize the experience across mixed fleets without a major overhaul.
The launch starts with iOS in the US, with Android submission to the Google Play Store coming next. Europe and China will continue to run their regional app versions. If you’ve been waiting for the US release, your wait is over, download Easy2Connect, order the dongle if you don’t already have it, and turn your hydraulics into a connected, intuitive system.
In addition to distribution, we design and fabricate complete engineered systems, including hydraulic power units, electrical control panels, pneumatic panels & aluminum framing. Our advanced components and system solutions are found in a wide variety of industrial applications such as wind energy, solar energy, process control and more.
