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.

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.

ctrlX AUTOMATION

ctrlX CORE and Node RED: OT and IT ready

Exploring the ctrlX Core: Revolutionizing Automation and Control

In the ever-evolving landscape of automation and control technology, the ctrlX CORE has emerged as a game-changer. Developed by Bosch Rexroth, the ctrlX CORE represents a significant leap forward in how we design and implement automation systems. This blog post delves into what makes the ctrlX CORE stand out and how it’s reshaping the future of industrial control.

What is the ctrlX CORE?

At its core, the ctrlX CORE is a highly flexible, scalable, and modular control platform designed to meet the diverse needs of modern industrial automation. It integrates a range of functionalities into a single, compact unit, enabling unprecedented levels of efficiency and adaptability in automation systems.

Key Features and Benefits

  1. Modular Design: The ctrlX CORE’S modular architecture allows users to tailor their automation solutions with various modules and components. This flexibility ensures that the system can be customized to specific application requirements, making it suitable for a wide range of industries and use cases.
  2. Open Architecture: Embracing an open architecture, the ctrlX CORE supports a broad spectrum of standards and protocols. This openness facilitates seamless integration with existing systems and third-party devices, providing users with greater freedom and interoperability.
  3. High Performance: Equipped with advanced processing capabilities, the ctrlX CORE delivers exceptional performance in terms of speed, responsiveness, and data handling. This high-performance backbone is crucial for real-time control and complex automation tasks.
  4. Scalability: One of the standout features of the ctrlX CORE is its scalability. Whether you need a small, simple controller or a more robust system with extensive I/O capabilities, the ctrlX CORE can scale to meet your needs. This scalability helps future-proof investments and allows for easy upgrades as requirements evolve.
  5. Intuitive User Interface: The ctrlX CORE offers an intuitive user interface that simplifies programming, configuration, and monitoring. With tools designed to streamline workflows and reduce complexity, users can quickly set up and manage their automation systems.
  6. Edge Computing Capabilities: Leveraging edge computing, the ctrlX CORE processes data locally, reducing latency and improving response times. This capability is particularly beneficial for applications requiring real-time analytics and decision-making.

Applications Across Industries

The versatility of the ctrlX CORE makes it applicable across a variety of industries:

  • Manufacturing: In manufacturing, the ctrlX CORE can drive complex production lines, coordinate multiple machines, and ensure high precision and efficiency.
  • Logistics: For logistics and warehousing, it can manage automated guided vehicles (AGVs), conveyor systems, and sorting equipment, optimizing operations and reducing downtime.
  • Energy: In the energy sector, it supports the automation of renewable energy systems, power distribution, and monitoring of critical infrastructure.
  • Automotive: The CtrlX Core is also used in the automotive industry for controlling assembly lines, testing equipment, and other automation processes.

Looking Ahead

As industrial automation continues to advance, the ctrlX CORE stands out as a pivotal innovation. Its combination of modularity, performance, and flexibility makes it a valuable tool for businesses looking to enhance their automation capabilities and stay competitive in a rapidly changing market.

Bosch Rexroth’s ctrlX CORE is more than just a control platform; it’s a step towards a more connected, intelligent, and adaptable future in industrial automation. For businesses seeking to leverage the latest in automation technology, the ctrlX CORE represents a powerful and forward-thinking solution.

Here is a showcase for Node RED, one of the most popular apps for the ctrlX.

Unleashing Creativity and Efficiency with Node-RED

In the rapidly evolving world of technology, staying ahead often means finding new and efficient ways to integrate and automate processes. Enter Node-RED, a powerful tool that’s been making waves in the tech community for its versatility and ease of use. If you haven’t heard of it yet, it’s time to get acquainted.

What is Node-RED?

Node-RED is an open-source flow-based development tool designed for wiring together hardware devices, APIs, and online services. Developed by IBM, Node-RED provides a browser-based flow editor that makes it incredibly easy to create and manage workflows with minimal coding. Think of it as a visual programming environment where you can drag and drop nodes (blocks of code) to build applications or automate tasks.

Why Node-RED?

**1. Ease of Use: Node-RED’s drag-and-drop interface simplifies the process of designing and deploying workflows. You don’t need to be a coding expert to get started; the visual nature of the tool allows you to create complex systems by simply connecting different nodes.

**2. Flexibility: Whether you’re working with IoT devices, APIs, or just need to automate a task, Node-RED has a vast library of pre-built nodes and integrations. This flexibility allows you to connect to almost any service or device with minimal configuration.

**3. Rapid Prototyping: Node-RED is ideal for prototyping and experimentation. Its visual interface allows you to quickly iterate on your design, test different workflows, and see results in real-time.

**4. Community and Ecosystem: Being open-source, Node-RED has a vibrant community that contributes to its ecosystem. There are countless nodes available for various purposes, from integrating with social media platforms to controlling home automation systems.

How Node-RED Works

Node-RED uses a flow-based programming model where you build your application by connecting different nodes in a flow. Each node represents a specific function or task, such as sending an HTTP request, processing data, or interacting with a database.

  1. Nodes: These are the building blocks of your application. Each node performs a specific function, such as a sensor reading, data transformation, or sending a notification.
  2. Flows: Flows are the connections between nodes. They define the path that data takes through your application, specifying how data should be processed and transferred between nodes.
  3. Debugging and Monitoring: Node-RED provides built-in tools for debugging and monitoring your flows. You can see real-time logs, inspect data as it moves through your nodes, and quickly identify issues.

Programming Flow

Practical Applications

**1. IoT and Home Automation: Node-RED is a popular choice for IoT applications and smart home automation. You can easily connect sensors, actuators, and other devices to create custom automation rules and control systems.

**2. API Integration: If you need to integrate multiple APIs or services, Node-RED’s flexible nodes make it straightforward to connect and manage data from various sources. This can be particularly useful for aggregating data or creating custom dashboards.

**3. Data Processing: Node-RED’s ability to process and transform data makes it a powerful tool for data pipelines. You can fetch data from different sources, perform transformations, and output the results to your desired destination.

**4. Rapid Prototyping: Whether you’re building a new application or testing an idea, Node-RED’s ease of use and rapid prototyping capabilities allow you to quickly validate concepts and iterate on your designs.

Sample Node Red Dashboard Visualization Credit: Richard Hopkins

Conclusion

Node-RED is transforming how we approach building and integrating applications. Its visual, flow-based programming model simplifies complex tasks and opens up possibilities for both technical and non-technical users. Whether you’re looking to automate your home, integrate APIs, or prototype new ideas, Node-RED offers a powerful and user-friendly platform to bring your projects to life.

So why not give Node-RED a try? Dive into its capabilities and see how it can streamline your workflow and spark your creativity in the world of technology.

Contributor:

John Raysa, Application Engineer – CMAFH
johnraysa@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.

Why automation needs digital twins

Karsten Kreusch. Game Changer
ctrlX WORKS

Whether in relation to components, machinery or complete production processes, these days digital twins play an important role in product lifecycles. As digital replicas of products or processes, they depict their properties, status and behavior and hence connect the real world with a virtual one. As such, they ensure reliable processes throughout the development stage, commissioning and operations and can be used for optimization purposes and to improve quality and increase efficiency. The potential that digital twins possess can also be leveraged for ctrlX AUTOMATION.

Digital twins usually depict various different aspects, e.g. they often combine simulation models with data. Firstly, they can be used to provide a virtual mock-up of products, machinery or plants for simulation purposes. Secondly, they can be used to clearly visualize real-life procedures and processes and hence better understand them as well as test and optimize them virtually and automatically – without having to intervene in reality.

Digital twins can not only improve development and production processes thanks to prognoses but can also improve understanding, contribute to transparency and enhance the performance of the real-life operations of systems or plants. Digital twins make product development simpler, more reliable and more efficient. In addition to the optimization of product features by means of simulation processes, the interplay between hardware and software can, for example, also be tested virtually early on and any errors can be identified and rectified prior to commissioning with zero risks involved. Engineering or production processes can therefore be made more efficient – benefiting not only component and machine manufacturers but end users too.

The so-called asset administration shell (AAS) is becoming the standard for the implementation of digital twins in Industry 4.0 systems and has been standardized in IEC63278. Accordingly, each I4.0 component is represented by an AAS, which forms an information shell for an asset or a hierarchy of assets. It describes all contained sub-models, which depict aspects such as sensor data or positioning mode, as well as available functions. In production, the AAS is used to ensure interoperability and IT security in manufacturing and IT systems by means of a set of standardized interfaces, such as OPC UA, TSN, DetNet, REST, JSON and XML, etc. Bosch Rexroth also aligns itself with this industry standard for the implementation of digital twins, thus continuing the pursuit of its strategy of openness.

Replicating and testing Bosch Rexroth products virtually

ctrlX AUTOMATION provides users with various different ways of using digital twins. Firstly, all sorts of different virtual replicas of Bosch Rexroth’s automation products can be created. Secondly, corresponding partner apps from the ctrlX World can be used for various digital twin applications.

One or more virtual controls can be created on a PC with the software and engineering toolbox ctrlX WORKS and operated via a web-based interface. ctrlX COREvirtual is the virtual version of the real-life control and is based on identical software. The virtual replica can be used to conduct tests and carry out commissioning without any control hardware – with full functionality. The simulation model is, for example, used to test PLC and motion programs. It is also used for communications tests between a control and the I/O level of a system.

Digital twins can also be used to virtually commission, parameterize and optimize products from Bosch Rexroth’s drive and motor range, including as part of considerations concerning mechatronic systems or complete machines. This also applies for the most compact drive system on the market, ctrlX DRIVE. Drive models are available to users for different application scenarios and various simulation systems available on the market, for example for MATLAB/Simulink, Modelica-based systems and ISG Virtuos.

Scalable simulation solutions for different use cases

In addition to the digital twins of ctrlX AUTOMATION products, the openness and expandability of the system offer a wealth of further possibilities. As such, IoT functionalities can, for example, be implemented for acquiring data and thus for generating digital twins of complete production processes. Users can use Bosch Rexroth’s IoT apps or those of partners from the ctrlX World for this. They can even develop their own apps with the Software Development Kit.

Bosch Rexroth offers scalable simulation solutions to suit any requirements through which simulations can be carried out for peripherals, kinematics, dynamics and physics in various topologies. The solutions thus enable an extremely broad range of applications, from kinematic simulation with 3D geometries right through to the connection of high-level simulation systems.

Digital twins are much more than visual reproductions of reality and accompany products as digital shadows all the way through to operations and service. Digital twins are, for example, ideal in mechanical and plant engineering for the real-time monitoring and predictive maintenance of machinery and plants. Digital information can be seamlessly orchestrated in real time.

The possible applications are therefore practically endless. Bosch Rexroth customers therefore have numerous options for easily optimizing processes, improving the quality of their products and achieving safety through transparency – right from the development stage all the way through to ongoing operations.

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.