Bosch Rexroth has announced an expansion of its ctrlX AUTOMATION platform, introducing new solutions for functional safety, drive technology, industrial operating system security, and engineering workflows. The update is designed to help machine builders and industrial manufacturers implement automation systems with greater flexibility while reducing the effort required to develop and deploy application-specific solutions.

The announcement reflects a broader trend in industrial automation: control platforms are increasingly combining established hardware with software-based functions, modular engineering tools, and integrated connectivity.

New Functional Safety Options for Industrial Machines

Bosch Rexroth has expanded its ctrlX SAFETY portfolio to cover functional safety applications ranging from drive-level safety functions to software-based safety control. The ctrlX DRIVE platform supports functions such as Safe Torque Off (STO), Safe Stop, Safely Limited Speed, and Safe Maximum Speed.

The company also offers dedicated safety controllers, including the SAFEX-C.12 and SAFEX-C.15 for standalone or integrated applications, and the SAFEX-M.25 for modular machine concepts. In addition, a Safety PLC app enables safety functions to run directly on the ctrlX OS operating system without requiring separate safety-control hardware for supported configurations.

For machine manufacturers, these options can provide additional flexibility when designing control cabinets and coordinating safety functions with standard automation. However, system designers must still verify hardware compatibility, safety integrity requirements, application constraints, and the applicable machinery safety standards before implementation.

More Flexible Industrial Drive Technology

The ctrlX DRIVE portfolio is also expanding with an Economy Line of servo drives focused on essential drive functions. The range is intended for applications that do not require every advanced feature available in higher-end drive configurations.

Bosch Rexroth states that the new drives share firmware and engineering compatibility with the existing ctrlX DRIVE system, allowing supported projects to be reused without adaptation. This can be relevant to machine builders seeking to balance motion-control requirements with equipment costs.

Servo drives are widely used in packaging machines, assembly systems, material handling equipment, and other applications requiring accurate speed, position, or torque control. Selecting the appropriate drive still requires evaluation of motor characteristics, load profiles, communication interfaces, braking requirements, and dynamic performance.

ctrlX OS 4.6 Strengthens Security and Engineering

Another major update is ctrlX OS 4.6, a long-term support release based on Ubuntu Core 24. New capabilities include single sign-on, enhanced OPC UA security features, and version management for application data using Git directly on the device.

These improvements address practical requirements in connected industrial environments. Single sign-on can help integrate device access into broader identity-management systems, while version control can make software and configuration changes easier to track, compare, and roll back when necessary.

For automation engineers, these capabilities may support more structured engineering workflows and improve traceability across machine projects. They do not eliminate the need for network segmentation, access-control policies, secure backups, patch management, and carefully controlled commissioning procedures.

Ready-Made Solution Sets for Faster Integration

Bosch Rexroth is also expanding its preconfigured solution sets, which combine compatible hardware and software for specific applications. One example targets mobile robots and manual forklifts by bringing together control technology, I/O modules, and laser-based localization software.

For system integrators, coordinated hardware and software packages can simplify component selection and shorten initial integration work. Nevertheless, each solution must be validated against the actual machine design, communication architecture, environmental conditions, and performance requirements.

The latest ctrlX AUTOMATION expansion highlights the growing importance of modular control, integrated safety, secure industrial software, and application-oriented engineering. For manufacturers planning new equipment or upgrading existing machinery, these developments offer additional options to evaluate when building flexible and maintainable automation systems.