ctrlX AUTOMATION

ctrlX DRIVE cabinet-free: When the control cabinet becomes obsolete

Cabinet-free servo drive technology boasts a number of crucial benefits – simple installation, drastically reduced space requirements, minimum cabling and high flexibility. The ctrlX DRIVE cabinet-free IP65/IP67 system virtually eliminates the control cabinet, thus creating space for modular, lean production systems. Andreas Knops explains the system’s distinguishing features.

ctrlX DRIVE cabinet-free is the latest generation of cabinet-free servo drive technology from Bosch Rexroth. What is different about it?

This solution is the successor to the existing IndraDrive Mi cabinet-free drive system. We develop the entire drive technology portfolio based on the compact and open ctrlX DRIVE technology. Over 20 years of experience in cabinet-free drive technology have gone into ctrlX DRIVE cabinet-free, taking it to a new level.

Key new developments include the expansion of the power increments, the cooling concept and new topology options. We offer the inverters as a single-axis variant in six increments from 6 A to 54 A and as a double-axis variant in five increments from 6 A to 30 A maximum current. With a maximum current of up to 54 A, users are now able to choose whether to realize their machine with a control cabinet, without a control cabinet or with a combination of both variants.

This allows the greatest possible flexibility for both existing and completely new application scenarios.

For which applications is this drive system intended?

ctrlX DRIVE cabinet-free is particularly suitable for machines in which saving space and minimizing cabling are key requirements. It also helps to reduce the machine footprint.

In addition, the drive system supports the realization of modular machine concepts, which pays dividends in both production and later use. In concrete terms, this means that the production of the machine can be modularized more easily and that end users will be able to subsequently expand the machines with additional modules according to their needs.

What specific savings will be achieved?

We calculate the savings made on a case-by-case basis together with our customers. They can be quantified over the entire life cycle based on the machine design, the operating mode and the operating time.

Because the solution almost completely eliminates the control cabinet, the space and cabling required is reduced by up to 90%. This results in a more compact design and provides the option of mounting the device directly, for example on the machine frame. This not only saves time and costs, but also makes assembly, project planning and operation easier.

In addition, the solution enables significant energy savings of up to 70 percent. The decentralized design eliminates energy consumption for control cabinet air-conditioning, which lowers operating costs. In addition, the ctrlX DRIVE cabinet-free version uses silicon carbide semiconductors (SiC technology), which significantly reduce energy losses and thus increase overall energy efficiency. By using SiC semiconductors, power losses can be reduced by up to 60 percent compared to IGBT technology.

Operating the inverters on a common DC link for the purpose of energy exchange also helps increase overall efficiency. Depending on the operating mode of the machine, we also utilize various options – e.g. energy recovery, passive or active energy storage, peak load reduction – to reduce the energy requirement specifically for the respective application.

Why is ctrlX DRIVE cabinet-free designed according to protection class IP65/IP67?

The IP65/IP67 protection rating ensures that the system works reliably even in harsh or extreme conditions – for example, where protection against water jets is required.

Due to its openness, the drive system can be seamlessly integrated into a wide variety of automation architectures. With all its features and benefits, ctrlX DRIVE speeds up cabinet-free development and commissioning processes – and supports consistently flexible, cost-efficient and energy-saving production.

To learn more, please visit www.boschrexroth.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Bosch Rexroth’s ctrlX DRIVE cabinet-free shows: the future of servo drive technology is cabinet-free

Steffen Winkler
Game Changer
ctrlX AUTOMATION

  • ctrlX DRIVE cabinet-free reduces space and cabling by up to 90 percent
  • Modular, flexible, and energy-efficient IP65 system
  • Bosch Rexroth is a pioneer in cabinet-free drive technology

Modularity, simple installation, and drastically reduced space requirements as well as minimum cabling – these are the key benefits of cabinet-free drive technology. Based on 20 years of development experience in this field, Bosch Rexroth now also offers a cabinet-free solution in protection class IP65 with the ctrlX DRIVE cabinet-free. Bosch Rexroth sees these solutions as the future of servo drive technology, as they ideally meet the increasing requirements for efficiency and adaptability in modern production environments.

Modular, flexible and energy-efficient system: the new ctrlX DRIVE cabinet-free.

“Today, more than ever, mechanical engineering is about saving space, reducing costs, and enabling rapid adaptation to new challenges,” says Steffen Winkler, Senior Vice President Sales Business Unit Automation & Electrification Solutions at Bosch Rexroth.

Bosch Rexroth is a pioneer in cabinet-free drive technology. The company presented its first solutions some 20 years ago and has been implementing numerous projects worldwide ever since. With the new ctrlX DRIVE cabinet-free, Bosch Rexroth presents the next stage of development for this technology, which meets the requirements of modern machine designs.

The servo drive of the future is flexible and saves space and energy

Control cabinets take up space and are expensive to install and service. The ctrlX DRIVE cabinet-free IP65 system almost completely eliminates the control cabinet and reduces the space and cabling requirements by up to 90 percent. This not only saves time and costs, but also makes assembly, project planning, and operation easier.

Furthermore, the cabinet-free solution enables energy savings of up to 70 percent. The decentralized design eliminates energy consumption for control cabinet air-conditioning, which lowers operating costs. In addition, the ctrlX DRIVE cabinet-free uses silicon carbide semiconductors (SiC technology), which significantly reduce energy losses and thus increase overall energy efficiency.

ctrlX DRIVE cabinet-free offers maximum flexibility in application. Mechanical engineers can choose from an extensive product portfolio that includes single and dual-axis inverters with currents from 6 to 54 A. The drives are freely scalable – up to 100 drives can be operated in a line with a total length of up to 200 m. With multi-Ethernet interfaces, freely selectable motors, and modular expansion options, the system offers solutions for a wide range of industries and applications.

The machine can be adapted and expanded easily thanks to the system’s modular design. As a result, machines can be flexibly configured to meet new requirements without having to completely change existing structures.

“Cabinet-free drive technology already pays off during the machine development process. It speeds up time-to-market and project realization. And in practical applications, users benefit from greater flexibility and potential savings, for example in terms of energy. With ctrlX DRIVE cabinet-free, we are driving forward the development of innovative, future-oriented machines,” says Winkler.

To learn more, please visit www.boschrexroth.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Trends in automation: security, AI and sustainability are drivers of the future
Portrait view of Steffen Winkler, Game Changer ctrlX AUTOMATION

Steffen Winkler
Game Changer
ctrlX AUTOMATION

  • Cyber Resilience Act promotes broader security measures
  • More and more AI-assisted applications are being integrated into automation systems
  • Sustainable manufacturing becomes a strategic goal
  • The future lies in ecosystems and collaborative innovations

Economic uncertainties, growing regulatory pressure, and a shortage of skilled workers are holding back the industry’s competitiveness and ability to innovate. Automation is a powerful lever to meet these challenges. Bosch Rexroth sees four key trends shaping automation in 2025: increased security measures through the Cyber Resilience Act (CRA), artificial intelligence as an efficiency booster, more sustainability as a response to stricter environmental requirements, and open ecosystems for more innovation.

Increased security measures, artificial intelligence and more sustainability. These are the automation trends from Bosch Rexroth’s perspective for the year 2025. (Image source: Bosch Rexroth AG, created with the help of AI)

“Automation remains the key to making the industry future-proof and competitive. It enables efficiency gains, new business models, and added value. We are seeing more and more companies relying on automation platforms with ecosystems, as they offer the greatest possible scope for action. This trend will also continue to increase in 2025,” explains Steffen Winkler, Senior Vice President Sales Business Unit Automation & Electrification Solutions at Bosch Rexroth.

Even greater focus on security with the Cyber Resilience Act

The Cyber Resilience Act (CRA), which came into force at the end of 2024, presents manufacturers and operators of industrial automation systems with new security requirements. The European regulation aims to improve security standards for digital products, thus increasing their resilience to cyber attacks. Products should be securely designed and updatable throughout their entire life cycle.

“IT security is more essential than ever for successful digitization strategies and products. The CRA provides clear requirements – this is an important step toward creating a high level of security across the board and strengthening user confidence in digital solutions. We therefore need to make automation solutions fit for these challenges, as we have already done with our operating system ctrlX OS. It is designed to be secure from the ground up and is therefore ideally prepared for the requirements of the CRA,” says Winkler.

For companies in the automation industry, the CRA means an even more intensive focus on security and product integrity. Adherence to the new directives requires a rethink that starts in product development.

AI is a driver of innovation in automation

Artificial intelligence is set to become even more important in 2025 – including in the automation industry. More and more AI-assisted applications are being integrated into automation systems. AI-assisted apps are already available in the partner network ctrlX World.

Artificial intelligence is increasingly embedded in software. AI-assisted software modules, such as neural networks for image processing solutions, are changing the possibilities for automation. AI also provides new operational insights in practice by analyzing data flows in automation devices. And it changes the way we work, for example, in software development. Tools, such as coding co-pilots, speed up programming and enable code to be written faster.

This enables significant efficiency gains both in the development of automation technologies and in their application.

Sustainability as a strategic goal

Sustainability and energy efficiency will continue to challenge industry and therefore also the automation sector. Industry plays a crucial role in achieving the global climate targets. Sustainable manufacturing requires zero emissions, resource efficiency, and cost-effectiveness.

More and more energy-saving functions are therefore being incorporated into automation components. Tools to simulate energy and performance also make an important contribution to optimizing manufacturing processes. There is further potential in the professional reprocessing of automation components: remanufacturing reduces the carbon footprint of used components by more than 50 percent compared to new products and conserves precious resources.

Open ecosystems for collaborative innovations

“The German automation industry is a global leader. To maintain and expand this leading position, it is essential to strengthen Germany as a business location and to boost the industry’s competitiveness even more,” says Winkler, adding: “Simply being at the technological forefront is not enough to remain successful in global competition in the long term.”

The key lies in open platforms and collaborative ecosystems that create real benefits for users. Such ecosystems combine the strengths of different players and thus enable the development of new, innovative approaches. This creates a culture of collaboration in which partners from different areas work together on solutions that go far beyond the capabilities of individual companies. In addition, open cooperation strengthens users’ trust in digital technologies by providing them with more flexible, interoperable, and future-proof solutions.

Bosch Rexroth constantly drives forward openness and co-creation in the automation world with its operating system ctrlX OS and the automation system ctrlX AUTOMATION.

As one of the world’s leading suppliers of drive and control technologies, Bosch Rexroth ensures efficient, powerful and safe movement in machines and systems of any size. The company bundles global application experience in the market segments of Mobile and Industrial Applications as well as Factory Automation. With its intelligent components, customized system solutions, engineering and services, Bosch Rexroth is creating the necessary environment for fully connected applications. Bosch Rexroth offers its customers hydraulics, electric drive and control technology, gear technology and linear motion and assembly technology, including software and interfaces to the Internet of Things. With locations in over 80 countries, around 33,800 associates generated sales revenue of 7.6 billion euros in 2023.

To learn more, please visit www.boschrexroth.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Cybersecurity – not a freestyle, but a duty

The factory of the future is characterized by the increasing networking of control technology, IT and IoT. The various systems must be seamlessly interconnected to ensure end-to-end digital processes. At the same time, however, this increases the risk of cyber attacks, as attackers have more and more entry points. In the connected world, attacks can cause more damage than ever before. It is therefore essential that security is consistently implemented at all levels. ctrlX AUTOMATION shows how this works while maintaining radical openness in automation.

More and more devices and machines are being networked and communicate via the Internet of Things (IoT). This creates numerous opportunities, but also risks. The more components are connected, the larger the attack surface. Cyber attacks can paralyze production and lead to financial losses and image damage.

Many systems in factories are outdated and were developed without considering cyber security. This makes them more vulnerable to attacks and difficult or impossible to update. It is therefore necessary to develop more resilient solutions. This must include IT systems as well as control technology and the IoT. This means: radical openness at all levels meets security at all levels.

But secure: from the control system to the apps

With ctrlX AUTOMATION, Bosch Rexroth has launched an end-to-end, open automation solution that has been designed from the ground up to be completely secure. The high security standards apply to all components in the automation toolkit and to every component by which the system grows. The hardware and software products are Secure by Design. This means that security requirements are already taken into account in the development phase. The automation solution, which was developed with a focus on conformity with IEC 62443-4-2, is based on the Linux Ubuntu Core operating system, which is considered to be extremely secure.

The ctrlX CORE controller is an example of the high level of security in the ctrlX AUTOMATION portfolio. The associated IoT software has fully integrated IT security standards according to IEC 62443-4-2 for access control and remote maintenance. In addition, the controller offers various security features such as Secure Boot, a security chip in accordance with TPM 2.0, and a minimal network footprint when delivered. With the optional firewall and VPN client, the controller can be upgraded to a full-fledged network appliance, which ensures the highest possible availability and security of the connected network components.

Since ctrlX AUTOMATION is not a self-contained system, but rather a place where different players pool their domain knowledge, the security strategy also includes the partner network ctrlX World. For example, each of the partner apps offered is validated by Bosch Rexroth. This rules out the possibility of third-party software introducing malicious code. This and the sandboxing principle further increase the security of the other apps installed on the system.

ctrlX developR design with a view to the future

The holistic and fundamental implementation of security standards and mechanisms in all facets of ctrlX AUTOMATION creates a resilient overall system that can also demonstrate these capabilities. In order to maintain this level, permanent further development is required – also in view of ever new types of attacks and ways of attack.

That is why ctrlX developR always keep their fingers on the pulse and look to the future. The latest security requirements are already taken into account in the planning and development phase. At Bosch Rexroth, “Two steps ahead” also applies when it comes to security.

If you have any questions or require further information regarding ctrlX AUTOMATION, please contact us: sales@cmafh.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

Bosch Rexroth breaks new ground with the planar system ctrlX FLOW6D

Greater freedom and precision in the area of contactless high-performance transport and positioning

  • 6D planar system added to the ctrlX AUTOMATION portfolio
  • Movers move in six degrees of freedom, even where space is very limited
  • Control system ctrlX CORE with apps for planar systems

Planar systems offer enormous potential for a variety of industry segments. With ctrlX FLOW6D, Bosch Rexroth has raised contactless high-performance transport and positioning to a new level. Free-floating transport platforms, so-called movers, are moved on a horizontal, vertical or overhead working surface. Each mover acts in six degrees of freedom at high speed and with great precision – without any friction or pollution. Integration into the automation toolkit ctrlX AUTOMATION results in an overall solution with a compact control system and apps to increase the range of functions.

A planar system serves as a contactless levitation system for the efficient and safe transport, positioning and handling of loads. On a working surface which can be adapted in a modular fashion, a number of differently shaped and sized movers can be controlled in six dimensions. Strong, specially arranged permanent magnets make this possible. Given their modularity and easily adaptable nature, planar systems can be used in numerous industrial sectors, for example in the semiconductor industry, the food sector, the pharmaceuticals industry or in assembly systems.

The ctrlX FLOW6D planar system allows contactless high-performance transport and positioning in six dimensions.

New planar system takes off

ctrlX FLOW6D offers new room for maneuver and innovative concepts for production systems. Bosch Rexroth has given the system numerous properties to make it stand out from other well-known technologies. Much larger movement ranges, for example a floating height of 20 mm, a 10° tilting angle and endless rotation in any location set new standards. The six degrees of freedom of each mover can be combined with each other as required. For example, rotation and tilting are possible during travel. Vertical or overhead system operation is also possible.

The movers are connected: Power and data are available to users on the floating platform. A mover can be converted into an active agent by adding actuators, sensors and handling components.

This and other properties allow entirely new system concepts and workflows. For example, movers can be operated in a process chamber, transport and process tasks can be combined seamlessly and transport systems can be standardized. The additional degrees of freedom mean that fewer peripheral devices are needed. As a result, the system becomes more compact and cheaper.

“ctrlX FLOW6D forms the backbone of a flexible and efficient production facility. As an open system, it can interact seamlessly with various other systems. Software-controlled production allows it to be adapted to changing products or processes quickly,” explained Steffen Winkler, Vice President Sales, Business Unit Automation & Electrification Solutions at Bosch Rexroth.

By incorporating ctrlX FLOW6D into its automation world, Bosch Rexroth has created an integrated, agile system. “ctrlX AUTOMATION provides the software platform for design, simulation, engineering, operation and service. With ctrlX CORE, we offer a compact, high-performance control system which allows users to make optimum use of the new planar system technology. New functions can easily be added as apps available from the ctrlX Store. As a result, full use of the potential of levitation can be made,” said Steffen Winkler.

To learn more, please visit www.boschrexroth.com

CMA/Flodyne/Hydradyne is an authorized Bosch Rexroth distributor in Illinois, Wisconsin, Iowa and Northern Indiana.

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.

The Smartphone of Automation

Let’s be honest: Over many years, automation has for the most part ignored the developments in the consumer area – and thereby missed countless opportunities for user-friendly approaches. With ctrlX AUTOMATION we have asked ourselves the provocative question: What would automation look like if it were reinvented by Google, Apple or another digital company? We did not have to search long for an answer: It would follow the example of a smartphone, with the highest level of functional integration possible and a flexible app technology thanks to which users can easily individualize their devices. With ctrlX AUTOMATION, we have gotten very close to this idea. At the heart of this solution is the new generation of control systems, ctrlX CORE.

YOUR OWN SOFTWARE TRANSFERRED TO INDUSTRY CONTROL SYSTEM

The new generation of control systems decouples the hardware from the software. This fundamental difference to other control systems creates numerous advantages. Rexroth makes it much easier for all users to update the control system or to transfer the programmed contents to another control.

Standard control systems from large manufacturers are proprietary. This often prevents small manufacturers from implementing their expert knowledge for special applications. Developing their own electronics is usually not an option for them, so they often use an IPC-system in addition to the actual control system. Problems associated with this, such as the integration effort for continuous high-speed data communication or the uncertain long-term availability of PC-based technology, must be accepted.

Now, these machine manufacturers can directly transfer their specialist knowledge to ctrlX CORE as their dedicated industry control system, thereby securing the long-term availability of their solutions. ctrlX CORE combines an open architecture with industrial-grade capabilities and a serviceability of at least 25 years. Developers also face significantly reduced engineering efforts: In addition to their own functions, they have the option of simply installing additional apps from Rexroth instead of programming them themselves, such as data gateways for MES and IT connections, VPN client, firewall or OPC UA. End-to-end data communication is automatically supplied by ctrlX CORE.

ONE COMPACT CONTROL SYSTEM FOR ALL PLATFORMS

The decoupling of hardware and software comes with further consequences. ctrlX CORE puts an end to the separation of the individual automation architectures. The control system is integrated in the drive and requires no additional space, resulting in particularly compact automation solutions with no performance limitations. As an embedded control system, the ctrlX CORE can simply be extended with I/O and performance modules such as 5G or additional storage. As a plug-in card for the IPC, ctrlX CORE combines a real-time capable control solution and edge computing in one platform.

In a compact space, the ARM architecture’s processor holds enough reserve capacity for all potential applications, optimally distributed to the four cores of the 64-bit multicore CPU. With 1 GB of RAM, ctrlX CORE offers enough room for individual functions. The 4 GB of permanent memory and the additional external microSD card offer enough storage space for future application extensions, thus reducing the variance of the hardware customers and user need. The high-performance 1 Gigabit Ethernet interfaces are optimized for the fast communication of large quantities of data in highly connected systems, equipping users perfectly for the factory of the future.

Thanks to the modern and open software architecture, operators can make use of their own software and apps. This is because the container technology of Linux, the world’s most stable and secure real-time operating system, for the first time in automation opens up all possibilities of integrating functions with separate apps. The ctrlX Data Layer, which can be described as the central nervous system, grants central authorized access to all real time and non-real time data from the installed apps, enabling eight million potential accesses per second. ctrlX Data Layer does not need to be configured, as the apps automatically recognize the hardware and can use the data available in the system.

For the field communication of ctrlX CORE, we rely on the EtherCAT ecosystem as a standard. This opens up the entire range of EtherCAT peripheral devices to designers, who can simply integrate them into their own control architecture. It also reduces the effort for writing interfaces and allows for the combination of components best suited for the application in question. In addition, the control system supports further customary real-time Ethernet protocols as well as more than 30 IT and IoT standards and protocols.

UP TO 50 PERCENT LESS ENGINEERING EFFORT

The engineering apps reduce engineering efforts by up to 50 percent. The control system supplies a web server for simple browser-based engineering. With ctrlX WORKS, the user programs every single function in the PLC app (according to IEC 61131), G-Code, C/C++, Python, Blockly or other languages at the click of a mouse. The digital nameplates of the connected devices are recognized automatically and integrated in ctrlX WORKS. The integrated web server simplifies the visualization on browser-based end devices such as web-panels or consumer tablets and supports wireless diagnostic solutions with smart devices via WiFi and Bluetooth. In addition, the control system includes a simulation environment in which functions can be tested virtually and then applied to the control system.

COMPACT, OPEN, POWERFUL

ctrlX CORE decouples the hardware from the software and offers users the most modern software architecture in the world of automation. This openness gives machine manufacturers and end users an unprecedented level of freedom by allowing them to implement their own expertise into an industry-grade control system and to transfer pre-written functions as apps. What’s more, Bosch Rexroth consequently mirrors the user-friendliness of consumer electronics, making automation as easy as handling a smart phone – even without Google or Apple.