January 2020

TECHNOLOGY n 18 www.drivesncontrols.com January 2020 BOSCH REXROTH has unveiled a major new automation platform which, it claims, will be “the most open on the market” and will cut engineering effort by 30–50%, reducing time-to-market “significantly” for new machines. The ctrlX platform, which has taken three years to develop, spans everything from PLCs, motion controllers, industrial PCs, software, I/O and HMIs, to multi-axis servodrives, inverters and safety systems. It uses EtherCat as its main communications technology, rather than the Sercos system that has been the backbone of Rexroth’s systems for many years. But the company will continue to use Sercos in its drives and as an option for slave controls. “We have renewed the portfolio from the ground up,” says Rexroth’s director of market and product management for PLC and IoT systems, Hans Michael Krause. A driving principle, he adds, has been to remove any limitations in power or performance for customers. Rexroth says that ctrlX breaks down the traditional boundaries between machine control systems, IT and the Internet of Things. The scalable platform – which is based on a real-time Linux operating system, open standards, apps and Web-based engineering – can be used to create centralised or decentralised automation topologies. Software functions can be combined in many ways using ready-made, customised and customisable apps. These apps can be created in languages such as C++, Python or Blockly. This, the company says, will give machine-builders new freedoms. They can decide whether to program in IEC 61131, PLCopen, G-Code or in conventional high-level or Internet languages. They will no longer be dependent on PLC specialists and proprietary systems. Configuration and commissioning of the automation components is Web-based, eliminating the need to install Bosch Rexroth chooses EtherCat for ‘the most open automation platform’ Building blocks: Bosch Rexroth’s new ctrlX platform offers users high levels of flexibility when choosing hardware, software, programming languages and apps. software. A digital twin virtual environment is available, enabling programming without needing access to hardware. The new platform supports more than 30 connection options and communications standards for maximum networking flexibility and low-cost end-to-end connections from the field level up to the cloud. The platform is based on a new generation of multi-core processors which can be integrated into embedded PCs and industrial PCs, or into drives. The key components of the user- centred platform include: n Drives including flexible, modular multi-axis systems that are up to half the size of the previous generation. They include single- and dual-axis servodrives, and regenerative supplies with peak ratings of up to 260kW. 40 axes can fit in a 1m-wide rack. n PLCs , which can be drive-based, embedded, running on an IPC, on a server or in the cloud. A free choice of programming languages helps to reduce engineering time. n Motion controls with an “open and secure” software architecture using apps to integrate specific functions, which can be synchronised “in microseconds” and offer “nanometre precision” n Open , modular controls with distributed intelligence that can be embedded, or based in PCs or drives. They use ARM multi-core processors and offer flexible extendability with compact, fine- increment I/O functions n Web-based HMIs which show information on high-performance displays. The scalable hardware ranges from small panels to 21” multitouch displays. n I/Os to connect control systems with the machine automation and communication levels. They provide up to 20 I/O points in 12mm installation widths and support IO- Link for integrating intelligent sensors n Integrated IoT support which helps to obtain information more quickly and to use it to improve OEE. The need for IPC and VPN router hardware is reduced, and IoT can be used to view all of the controllers on a site. n Industrial PCs with scalable performance, sizes and options. The PCs use Windows 10 IoT or Linux operating systems and incorporate high-performance graphics cards for demanding visualisation and simulation applications. n Safety components with reaction times of 4ms, said to be the fastest on the market. Applications are created easily using graphical programming of the safety logic and dialogue-based support for acceptance tests. n A hardware-independent, Web-based graphical configurator which allows users to choose and configure automation systems quickly and easily, using the optimum combination of components. Topologies can be created without in-depth knowledge. Rexroth has designed the ctrlX platform to support future communications standards such as TSN (Time-Sensitive Networking) and 5G. At the recent SPS showin Germany, it was demonstrating the use of 5G in partnership with the communications specialist, Qualcomm. Another aspect of the new platform is its use of digital service assistants that can run on smartphones. For example, if a drive develops a fault it can show a QR code on its display which can be scanned using a phone, which will then show a diagnosis. The ctrlX platform is due to start reaching the market in April 2020. Bosch Rexroth has committed itself to making the system available until 2045, at least. www.boschrexroth.com “We have renewed the portfolio from the ground up. A driving principle has been to remove any limitations in power or performance for customers.”