Four benefits: Automation ecosystem adds new features, applications, partners, integration

Courtesy: Bosch Rexroth AG

Learning Objectives

Understand new features and applications for an app-based automation platform and how it benefits IT/OT convergence.
New automation and control apps in the automation platform app store and application bundles offer custom solutions for specific challenges.
Control Engineering Rexroth facility tour exclusive shows automation platform integration with automation hardware with on-site photos and motion control video clip.

Automation software ecosystem insights

New features and application areas for the Bosch Rexroth ctrlX OS automation platform helps IT/OT convergence.
Increased application variety and number in the Rexroth ctrlX app store broadens automation ecosystem usefulness while integration with automation hardware continues.
Application bundles in the ctrlX app store provide custom solutions for specific challenges.

New automation ecosystem features, applications, partners and capabilities for operational technology and information technology (IT/OT) convergence were among highlights at the Bosch Rexroth “ctrlX Automation Media Day 2024.” Control Engineering covered the live and online event and received an exclusive in-person tour of the technology demonstration room and other on-site areas (see photos, video clip) at Rexroth’s Hoffman Estates, Illinois, headquarters. The automation ecosystem expansion is helping in four major areas:

The Linux-based operating system, Rexroth ctrlX OS, works with more and different types of automation, providing new features and application areas.
The extended ecosystem of Bosch Rexroth ctrlX has more than 100 partner companies, with increased focus on IT/OT convergence.
Developers are adding a variety of ctrlX apps, more than 80 (more than half from third parties) as of November 2024 with many more under development and in approval stages, extending applications. More than 2,500 customers use ctrlX; five original equipment manufacturers (OEMs) use the operating system, including Congatec for its multicore hypervisor, Dell on servers, Nokia for 5G cloud services and Wago for building automation. New offerings include a new ctrlX OS, ctrlX Works engineering toolbox software, ctrlX PLC, ctrlX Motion, ctrlX World, ctrlX I/O, ctrlX Safety, ctrlX Drive products and ctrlX motors. Engineering savings can total 30%, Rexroth said.
System integration with Rexroth hardware and software was demonstrated in an exclusive Control Engineering tour after the formal media presentation.

Mike Mueller, product manager, factory automation, automation and electrification, Bosch Rexroth Corp., began the media presentation, explaining how the ctrlX Automation platform helps meet present and future industry needs, with cybersecurity and less engineering with low or no-code configuration, data and analytics to help processes and uptime, along with easier integration and future-proof openness.

New features and application areas for the ctrlX OS automation platform

Dave Boeldt, product manager, Bosch Rexroth, discussed 12 new ctrlX platform partners: TXOne Networks (cybersecurity); Fanuc, Kuka (engineering); Ixon (IoT); Lucid Vision Labs, Pepperl+Fuchs, SMC (devices); HD Vision Systems, 36Zero Vision (sensing and vision); ServiceNow (factory IT); Stogl Robotics (Services); and Intel (technology).

The operating system ctrlX OS, developed by Bosch Rexroth, and the associated ecosystem are growing in size, importance and capabilities, the company said in prepared statements. With competitors developing application and offering compatibility, the ecosystem offers extensive integration options for users and for OEM partners. The long-term support (LTS) release 2.6 brings important updates for long-term stability, the company said.

The Linux-based operating system ctrlX OS was originally developed by Bosch Rexroth exclusively for the control platform ctrlX Core and is available as a separate solution for the industrial environment. As a result, it has become a key automation component with its own ecosystem, which offers OEMs extensive integration possibilities and new business opportunities. The ctrlX OS OEMs use the operating system with its digital services and apps in their hardware and software portfolios, implementing advanced automation solutions.

Users benefit from a wide range of seamlessly integrated solutions for automation and can install and use an ever-increasing range of ctrlX apps on their ctrlX OS devices including programmable logic controllers (PLCs), motion control, internet of things (IoT), industrial communication, engineering and sensing and machine vision applications. These can be extended with customer-specific apps. Users benefit from web-based engineering, device management and the large developer community.

“Our goal with ctrlX OS is to create a true alternative to proprietary platforms and establish an open, worldwide leading automation ecosystem. Together with our previous partners Wago, Nokia, Dell Technologies and Congatec, we are now taking the next step. ctrlX OS will be established even more strongly than before as a universal, vendor-neutral operating system for a wide range of industrial applications,” said Steffen Winkler, senior vice president sales business unit automation and electrification solutions at Bosch Rexroth.

The LTS release means that maintenance is provided over several years in the form of service packs containing optimizations and security updates. Users benefit from long-term stability, security and continuous support when using the solutions. LTS release 2.6 expands the flexibility of ctrlX OS by improving the allocation of processor cores and optimized backup and restore capabilities. With this latest release, the software and engineering toolbox ctrlX Works is modular, which enables optimal adaptation and uploads the required modules as needed.

The ctrlX OS automation platform benefits IT/OT convergence

Joaquin Ocampo, drive product manager, Bosch Rexroth, added that more products are in development offering ctrlX integration. New compact 240V and 480V drives will be available next year, offering lower power and smaller footprint along with ctrlX OS compatibility.

Company information cited seamless convergence of IT and OT in factories is critical for innovation, efficiency and flexibility in manufacturing processes, and Bosch Rexroth and ecosystem ctrlX offerings makes IT-OT interactions simple. New partnerships add value. The partner network solution portfolio includes apps for robot integration, AI solutions and tools for energy management.

The Linux-based operating system ctrlX OS and compatible world of automation is growing with new features and application areas with the growing ecosystem around ctrlX OS providing a central platform for innovation and long-term support (LTS release 2.6) with advanced features. Courtesy: Bosch Rexroth AG

“One special focus in the ctrlX World is on solutions for IT and OT convergence. We want to make it easy for users to connect different systems and technologies, paving the way for the smart factory of the future,” Winkler said. “The basis for openness is the operating system ctrlX OS and its associated ecosystem, of which ctrlX World is a key component. Thanks to the associated variety, users can implement all automation tasks quickly and easily with one single platform and suitable apps, and optimize them for the long-term.”

Intelligent and robust Pepperl+Fuchs sensors and systems designed for interoperability allow for the comprehensive automation of manufacturing processes and provide valuable additional data for IoT solutions. The IO-Link masters from Pepperl+Fuchs connect the sensors and actuators to higher-level software systems such as enterprise resource planning (ERP) or manufacturing execution systems (MES) for more efficient communication between the production and office levels. Pepperl+Fuchs RFID systems are another driver for the factory of the future. They enable non-contact identification and traceability and more transparent manufacturing and logistics processes. All common frequencies from the industrial environment are supported. Protocols such as EtherCAT, IO-Link, OPC UA and REST API allow easy integration into ctrlX OS-based devices.

Bosch Rexroth’s ctrlX is shifting toward IT/OT convergence capabilities, part of the partner world of the ctrlX OS Ecosystem, initiated by Bosch Rexroth. Recent additions to Bosch Rexroth’s partner network ctrlX World include Pepperl+Fuchs, ServiceNow and SMC. Courtesy: Mark T. Hoske, Control Engineering

ServiceNow adds automation and optimization of digital workflows to ctrlX World. ServiceNow’s cloud-based platform enables organizations to streamline processes and improve operations. It integrates seamlessly into ctrlX OS devices by using well-known standards such as REST API, webhooks and ETL functions. This gives users the ability to optimize operations, increase productivity and drive digital transformation on one platform.

SMC is the first pneumatics provider in the partner world. The seamless integration of pneumatic and electric automation solutions into ctrlX OS devices, such as the control system ctrlX Core, opens up a new range of possibility for users. The connection of the valve manifold with SMC EX260 and the SMC JXC controller directly through EtherCAT to ctrlX OS devices enables simple control of the air flow in and on the machine. Electrical drive functions can be mapped and integrated in a compact format. The ctrlX OS enables seamless integration into the overall machine concept.

“Different perspectives, experiences and technologies are the basis for faster innovation. Users benefit from the latest technological developments and have access to modern hardware, sensors, controls and cloud-based platforms. They can implement advanced solutions more quickly – for example, through simple IT/OT integration, from the actuator and sensor to the control function, and the integrated service platform,” Winkler said.

Increased application variety broadens automation ecosystem usefulness

Find and purchase all applications and services required for automation in one place, the Bosch Rexroth ctrlX OS Store. The digital marketplace, with more than 80 apps in 16 categories, is growing steadily. Last year’s media update event reported 90 Rexroth ctrlX developers and more than 75 apps. The wide offer ranges from IoT and communication solutions to innovative vision and engineering apps, all of which are validated according to Bosch Rexroth guidelines. About half of the apps come from third-party providers, which underscores the co-creation approach more popular in automation.

Winkler said, “Automation tasks are becoming increasingly diverse and complex in industry. They require a variety of specialized applications. Companies need a single platform that enables them to meet these diverse requirements without having to coordinate multiple providers and systems. The trend toward co-creation is therefore crucial because it allows different supplier to combine their expertise and jointly develop solutions that meet the market’s rapidly changing requirements. The ctrlX OS Store offers this integrated solution and provides an ever-greater variety of applications as a digital marketplace.”

The ctrlX OS Store has engineering apps to simplify development projects, motion solutions, security applications to protect systems, HMI solutions for human-machine interaction, vision apps for integrating vision systems, IoT applications and others.

Bosch Rexroth describes the ctrlX OS store as a one-stop shop for automation with a widening variety of apps. It has more than 80 apps in 16 main categories. New engineering and vision apps ease automation development and solution packages for industrial automation. Courtesy: Bosch Rexroth AG

New automation and control apps in the ctrlX app store

One of the new apps is Model Connect from Bosch Rexroth offers an alternative to classic PLC programming. It combines ctrlX OS devices with model-based software development systems that improve the efficiency and quality of software and simplify its maintenance. The first version supports MATLAB and Simulink from MathWorks. This makes it easier to develop, validate and simulate complex systems such as machines or special process and control technology using models. The control code for ctrlX OS can be generated directly from this by pushing a button and loading onto ctrlX OS-based devices and then executing using the Model Connect app.

The ctrlX Motion app from Bosch Rexroth now has an interface extension (API). This allows users to extend the app with their own motion expertise. Up to 128 drives are supported and numerous new PLCopen functions are available.

The new AI-based LumiScan suite from HD Vision Systems facilitates seamless integration of vision systems into ctrlX OS-based devices, including the industrial control system ctrlX Core. It enables the training of essential models on ctrlX industrial PCs (IPCs) or PCs. This user-friendly solution benefits quality inspection and pick-and-place applications in robotics, simplifying the commissioning and implementation of vision systems. It can be used without specialized expertise, making vision applications accessible to a wider audience.

ctrlX Works Engineering is now modular and simply uploads the required engineering tools as needed – ctrlX Drive, ctrlX I/O and ctrlX PLC Engineering – enabling optimum adaptation to specific requirements. The next phase involves incorporating additional engineering tools from ctrlX OS OEMs, like Wago and other ctrlX World partners. This integration will allow users to easily update required software, enhancing the overall user experience and system management capabilities.

An increasing amount of Rexroth automation equipment is compatible with the Rexroth crtlX OS, Rexroth apps and third-party apps. Automation inside the clear cabinets, constructed for learning and demonstration in the Rexroth Hoffman Estates, Illinois, headquarters, isn’t powered up unless the room is vacant. Courtesy: Mark T. Hoske, Control Engineering

App bundles: custom solutions for specific challenges

Bosch Rexroth created solution packages to meet customer requirements. Remote access, monitoring and connectivity are among the most sought-after applications, the company said.

For remote access, the solutions provide seamless monitoring, control and troubleshooting for ctrlX OS-based devices and networks, regardless of location. Customers can choose among options from ctrlX World partners, such as the VPN client from IXON and the solution from MB connect line, and supplement these with an additional firewall app.

For monitoring, users receive real-time and non-real-time visibility of device data to detect errors early, optimize performance and reduce downtime. Apps that provide comprehensive insights into system states, such as the IoT Dashboard, InfluxDB and Node-RED can be used for this purpose.

For connectivity, robust and cyber-resistant options are available to ensure reliable integration into company networks and AI applications. Suitable apps include OPC UA Server/Client, the MQTT Broker Eclipse Mosquitto, Modbus TCP and the Bosch DeviceBridge app.

Bosch Rexroth, supplier of drive and control technologies, including hydraulics, electric drive and control technology, gear technology and linear motion and assembly technology, software and interfaces to the internet of things. It’s part of the Bosch Group divided into four sectors: Mobility, industrial technology, consumer goods, and energy and building technology.

The Rexroth Hoffman Estates, Illinois, headquarters has a dynameter for motor-drive testing. Courtesy: Mark T. Hoske, Control Engineering

Tour exclusive: Integration with automation hardware: On-site photos, video

The site tour included on-screen and trade-show-type displays of Rexroth products including variable frequency drives, high power universal power converter, DC/DC converters, induction motors, kit motors, servo motors, drive supplies, drive converters, drive inverters, safety control, machine control, IoT control, edge control, building control, open control, I/O devices, drive safety, control in drive, Rexroth Cabinet-free Technology, industrial PCs, web panels and human-machine interfaces (HMIs).

Also displayed were demonstrations of ctrlX apps and integration with devices and safety, programming and configuration options, ctrlX networking options (EtherCAT, EtherNet/IP, Profinet, OPC UA Server, Modbus TCP, MQTT, IO-Link and BACnet); other integration options (manufacturing execution software, Rest API, OPC UA over TSN and JSON; cybersecurity explanations; as well as more on motion control and factory of the future.

Outside of the demo room, the Control Engineering facility tour included a high-voltage demo area used for instruction and testing, along with dynameter for motor-drive testing (photos). A new customer training and demo area with robots, conveyers and other motion controls and safety sensors is under development for OEMs, end-users and system integrators, not yet available for photos.