With the 'ctrlX Automation' automation platform, Bosch Rexroth aims to remove the traditional boundaries between machine control systems, IT and the Internet of Things. The scalable platform enables the flexible design of both centralized and decentralized topologies. With a Linux real-time operating system based on the Linux distribution Ubuntu, open standards, app technology for programming, web-based engineering and comprehensive IoT connectivity, ctrlX Automation promises to reduce engineering costs by 30 to 50% in the future.

The starting signal for the development of the new platform was given over two years ago when the question was intensively examined: What does the future of control technology in the factory environment look like? According to Steffen Winkler, Sales Manager of the Automation & Electrification Solutions business unit, the starting point was the realization that machines today are still like most cars: "Developed yesterday, hardly upgradeable for tomorrow and rarely allow simple and secure data access. What's more, engineering effort is a major cost driver and hardware upgrades always require complex software conversions. At the same time, software developers are in short supply!"

In search of the right answer, the company in Lohr a. Main broke new ground in several respects: "Instead of asking customers what they think future automation technology should look like, as was often the case in the past, we determined what customers want ourselves - before they do it themselves!" says Dr. Heiner Lang, member of the divisional board and responsible for Development & Factory Automation at Bosch Rexroth. The Rexroth board member is well aware that this entails a certain entrepreneurial risk, but is nevertheless convinced that "it is the only right way to go." Another novelty: "We asked ourselves what automation technology would look like if it were not developed by an automation engineer, but by companies such as Apple, Google or Microsoft," says Steffen Winkler and also provides the reason for this: "Mechanical engineering today is software development and the users of tomorrow are the digital natives who no longer learn G-code or IEC 61131 in their studies. This needs to be taken into account!"

The result is ctrlX - a completely open automation platform that integrates the latest software technologies for engineering as well as all PLC and motion tasks and combines almost any software function using ready-made or self-created and customizable apps. These apps - each of which runs in its own 'sandbox' - can be created in a variety of programming languages such as C++, scripting languages such as Python or new graphical languages such as Blockly. In other words, classic programming according to IEC 61131, PLCopen or G-code is still possible, but is no longer mandatory. However, the controller runtime is still based on Codesys.

Data layer allows 8 million data accesses per second

A so-called data layer, which guarantees 100% hardware independence of the software without any loss of performance and should enable up to 8 million data accesses per second, is the central architectural element for communication between any apps. It therefore forms the central 'nervous system' for the exchange of all real-time and non-real-time data - even across multiple controllers. The transparency of the data layer, which can be accessed with authorization, is also the key to the use of future technologies such as artificial intelligence.

Configuration and commissioning of the automation components is completely web-based and requires no software installation. The system environment is also completely virtual, so that programming can also be carried out without hardware. Last but not least, the development environment supports GitHub, an established developer community with more than ten million registered users worldwide. This gives machine manufacturers access to almost unlimited programming capacities and functions that have already been written can also work better together internally in protected areas.

According to Winkler, the entire system is 'Secure by Design' and meets IT security standards in accordance with IEC 62443: "The configurable user administration prevents unauthorized access to data and functionalities. The system software also offers increased protection against viruses and Trojans. An integrated firewall enables the encrypted transmission of data via VPN and secure remote services." Via the Bosch Rexroth Device Portal, users can manage all intelligent components digitally from a distance and install security updates and new functions without having to be on site.

The hardware basis of ctrlX Automation

In terms of hardware, ctrlX Automation is based on a new generation of multi-core processors - specifically a 64-bit ARM CPU with four cores. This provides sufficient computing power for almost all automation tasks and can be integrated into embedded PCs (ctrlX Core), industrial PCs (ctrlX IPC) or directly into drives (ctrlX Drive). Heiner Lang comments: "Future CPU upgrades do not require any software adaptations. The software runs independently of the hardware in all topologies. Serviceability is guaranteed for all components for at least 20 years, including the CPUs currently in use."

In addition to the control hardware, the new automation system includes expandable I/O modules (ctrlX I/O), a new generation of extremely compact servo drives (ctrlX Drive), a wide range of operating devices (ctrlX HMI) and IPCs (ctrlX IPC) for PC-based automation or edge solutions. The integrated safety technology (ctrlX Safety) combines safe logic and motion.

Ethercat as a system bus

Rexroth has opted for Ethercat as its automation bus - another first. However, this decision should not be seen as a complete departure from Sercos - the previously favored system bus. Sercos will continue to be supported, at least on the slave side; on the master side, however, "the market has decided in favor of Ethercat," says Winkler. In addition, the hardware supports common protocols via ctrlX I/O for end-to-end networking from the field level to the cloud - for example OPC UA, MQTT, Profinet, CAN and IO-Link. The system is also already prepared for TSN and 5G - two communication standards that, alongside Ethercat, are essential for Rexroth in the factory of tomorrow.

The official launch of ctrlX Automation will take place at the SPS trade fair in Nuremberg (November 26-28). The drive-integrated version of the platform and a new motor portfolio, with which Rexroth is primarily addressing robotics and handling applications, will initially be available for the market launch. Over the next three years, the other ctrlX modules will then be successively launched on the market in several "waves" - then also with an extended industry focus.