Bosch Rexroth has announced a major expansion of its ctrlX AUTOMATION platform, introducing new functional safety capabilities, an economical servo drive range, security enhancements for its operating system, and preconfigured automation solution sets. The update reflects the industry’s continued shift toward flexible, software-centric industrial automation while maintaining the hardware reliability required for demanding manufacturing applications.

The announcement is relevant to machine builders, system integrators, and industrial users looking to simplify engineering, improve system security, and adapt automation equipment to different production requirements.

New Safety PLC Capabilities for Flexible Machine Design

A key development is the expanded ctrlX SAFETY portfolio, which covers functional safety from drive-integrated functions to software-based safety control.

Bosch Rexroth states that its ctrlX DRIVE platform provides 31 SafeMotion functions, including Safe Torque Off (STO), Safe Stop, Safely Limited Speed, and Safe Maximum Speed. The portfolio also includes compact SAFEX-C.12 and SAFEX-C.15 safety controllers for standalone applications and integration into existing systems, as well as the SAFEX-M.25 controller for modular machine concepts.

Another important feature is the Safety PLC app, which enables safety functions to run on ctrlX OS without requiring separate safety control hardware for supported configurations. This approach can help machine designers reduce cabinet space and increase flexibility when developing modular equipment.

However, safety-related applications still require appropriate risk assessment, validated configurations, and compliance with applicable functional safety requirements. Engineers must confirm that the selected hardware and software architecture is suitable for the intended machine.

ctrlX DRIVE Economy Line Expands Servo Options

Bosch Rexroth is also expanding its ctrlX DRIVE portfolio with an Economy Line designed for applications that need essential servo drive functions without more advanced specialized features.

The company says the new range uses the same firmware and engineering environment as the existing ctrlX DRIVE system, allowing existing projects to be reused without adaptation. This compatibility may simplify engineering for machine builders developing multiple machine variants or cost-sensitive automation solutions.

Servo drives remain important in packaging machinery, material handling, assembly systems, and other applications requiring accurate motion control. Selecting the right drive still depends on motor compatibility, torque and speed requirements, motion profiles, communications, and the operating environment.

ctrlX OS 4.6 Strengthens Security and Engineering

The new ctrlX OS 4.6 long-term support release is based on Ubuntu Core 24 and introduces several software improvements.

New capabilities include single sign-on integration, enhanced OPC UA security features, and Git-based version management for app data directly on the device. Engineers can manage development branches, merge changes, revert to previous versions, and connect to external Git repositories.

These functions can improve traceability and make it easier to manage software and configuration changes throughout a machine’s lifecycle. The update also expands networking, device management, and monitoring capabilities. Bosch Rexroth reports that the ctrlX OS Store now contains 120 applications for different automation tasks.

Preconfigured Solutions for Faster Deployment

The expanded solution sets combine compatible hardware and software for specific applications. One example targets mobile robots and manual forklifts, integrating control, I/O modules, and laser-based localization software. Additional solution sets address energy, building, agriculture, and robotics applications.

For industrial buyers, preconfigured combinations may reduce integration effort, although each application still requires verification of communications, performance, safety, and environmental requirements.

Overall, the latest ctrlX AUTOMATION update demonstrates how industrial automation is evolving through the integration of safety technology, motion control, secure software, and modular engineering tools. For manufacturers planning new machines or modernizing existing equipment, these developments highlight the importance of evaluating both hardware capabilities and software lifecycle management when selecting an automation platform.