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Bosch Rexroth ctrlX: Why Open Automation Changes the Game for Machine Builders

March 20267 min readBy the FERSMEK Engineering Team

ctrlX CORE and ctrlX OS combine drive control, motion, PLC, and IIoT in a single Linux-based runtime — here's what that means for commissioning time, TCO, and future-proofing your machines.

Traditional machine architectures carry integration overhead that compounds with every project: a separate PLC for logic, a dedicated drive engineering tool for servo axes, a gateway PC for IIoT connectivity, and bespoke code tying them together. Every interface is a commissioning risk and a long-term maintenance liability. Bosch Rexroth's ctrlX platform is FERSMEK's recommended choice for new machine builds and major retrofits where this overhead is no longer acceptable.

What Is ctrlX?

ctrlX is Bosch Rexroth's open automation ecosystem, built around four core components:

ctrlX CORE
The controller hardware — a compact industrial computer running ctrlX OS. Available in standalone form or embedded inside a ctrlX DRIVE.
ctrlX DRIVE
The servo drive family that succeeds IndraDrive. Runs the same ctrlX OS and connects to the same engineering environment — no separate firmware tool.
ctrlX OS
A hardened Linux operating system with a Docker-based app runtime. Manages scheduling, real-time PLC execution, and app isolation simultaneously.
ctrlX WORKS
The unified engineering environment for programming PLC logic (IEC 61131-3), configuring drive axes, managing apps, and deploying OTA updates — one tool for the whole machine.

Key Benefits

1
One runtime, multiple disciplines
PLC (IEC 61131-3), motion, robotics kinematics, and SCADA logic run in a single ctrlX CORE — no data exchange protocol between controller and drive, no cross-device synchronisation overhead.
2
App-based architecture
Add OPC-UA publisher, Node-RED, Modbus TCP, or MQTT broker as downloadable apps from the Rexroth app store. No separate gateway hardware. Each app runs isolated in its own container.
3
Open Linux OS
Run Python, Node.js, or custom C++ code natively alongside PLC logic on the same hardware. AI inference at the edge, computer vision preprocessing, or custom data pipelines — all without a separate IPC.
4
Shorter commissioning
ctrlX WORKS replaces the separate TIA Portal / IndraWorks / SCADA tool combination. One install, one project file, one update mechanism. Our engineers report 25–35% faster commissioning on comparable machine builds.
5
Scalable performance
The same ctrlX OS runs on a single-axis servo drive and on a 64-core CNC controller. Programming paradigm, update mechanism, and IIoT connectivity stack are identical across the range.
6
Cybersecurity by design
Signed app packages prevent unauthorised software installation. Role-based access control is built into ctrlX OS. A VPN app is available from the app store for secure remote access — no third-party VPN server required.

ctrlX vs Traditional Drive + PLC Setup

AspectTraditional (separate PLC + IndraDrive)ctrlX Platform
Engineering toolsSeparate PLC IDE + IndraWorks DrivectrlX WORKS (unified)
IIoT connectivityExternal gateway PC requiredBuilt-in (OPC-UA, MQTT, Node-RED apps)
Custom logicRequires separate IPC for Python/Node.jsPython/Node.js run natively on ctrlX CORE
Motion axesSeparate servo drive firmware + toolctrlX DRIVE, same OS and toolchain
Software updatesPer-device firmware flashingApp-store OTA updates from ctrlX WORKS
CybersecurityVaries; often relies on network perimeterSigned apps, RBAC, built-in VPN app

Where FERSMEK Uses ctrlX

Current FERSMEK applications of the ctrlX platform:

→Calender nip-control upgrades — ctrlX DRIVE replaces legacy Rexroth IndraDrive + separate Siemens PLC, collapsing two cabinets into one with tighter synchronisation
→Web-tension winding machines — ctrlX CORE runs sectional drive coordination logic (dancer position, taper tension) alongside the OPC-UA server, eliminating the gateway PC
→Multi-axis press force control — ctrlX OS runs the Rexroth proportional valve control loop and a Python-based force-profile analytics process side by side, with data exported directly to InfluxDB via MQTT app
→Retrofit projects — where an obsolete IndraDrive + external PLC cabinet needs replacing without rewiring the entire machine floor

Is ctrlX Right for Your Machine?

ctrlX is the right choice for new machine builds where IIoT connectivity, open custom logic, or multi-discipline control (motion + PLC + process) are requirements. It is also the right choice for major retrofits where the existing cabinet is being replaced entirely and the engineering effort to migrate is already budgeted.

Existing IndraDrive installations do not need immediate replacement. IndraDrive CS/ML hardware has a long service life and Rexroth continues to support it. The migration decision should be driven by a specific project need — not by the platform being new. If your current Rexroth system is stable, well-documented, and meeting performance requirements, a like-for-like replacement is the lower-risk path.

Where ctrlX becomes compelling is when the machine also needs edge analytics, flexible IIoT reporting, or integration with IT systems — requirements that previously demanded a separate IPC and custom integration code. ctrlX makes that capability inherent to the drive platform rather than bolted on.

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Evaluating Bosch Rexroth ctrlX for Your Next Machine?

FERSMEK is a certified Bosch Rexroth specialist with hands-on ctrlX CORE and ctrlX DRIVE experience in nip control, web tension, and press force control applications. Talk to our engineers about what ctrlX can do for your specific machine architecture.

Talk to Our Rexroth Engineers