ctrlX FLOW

Everything in the flow: Intralogistics solutions for the smart factory

Automating and optimizing intralogistics processes is a key factor for the success of the Factory of the Future. With the ctrlX FLOW product family, Bosch Rexroth offers easy-to-integrate solutions for optimum and highly efficient material and goods flows.

ctrlX FLOWHS

ctrlX FLOW6D

ctrlX FLOWHS: Linear motion system for more high-speed

Speed and dynamics are driving modern factories. And intralogistics too. The aim is to ensure short throughput times by optimizing material flows. Automated motion solutions are the key here: ctrlX FLOW^HS, as a linear motion system, brings flexibility and high speed to manufacturing – with maximum precision and reduced space requirements. The space-saving high-speed system can be configured flexibly for various topologies and thus applications. It is also 100 percent integrated into the automation toolkit ctrlX AUTOMATION and benefits from the openness and safety and the entire ecosystem.

Linear Motion system: Fast. Flexible. Compact.

ctrlX FLOW^HSis well ahead of other motion systems. These benefits make all the difference:

Maximum openness: 100 percent integrated into the automation toolkit ctrlX AUTOMATION
Quick movement and acceleration – with high accuracy and precision
Compact system with a product gap of just 40 mm
Modular segments and movers

Integrated safety features
Great interoperability with external systems – communication with EtherCAT
Low power consumption and high efficiency
Easy-to-use software and support, e.g. for configurations and modifications

Freie und gleichzeitige Bewegung in allen sechs Freiheitsgraden, beispielsweise simultanes Drehen, Fahren und Neigen
Erweiterte Bewegungsbereiche: Schwebehöhe bis 20mm, unbegrenzte Drehung, 10° Neigung in alle Raumrichtungen
Beliebige Orientierung der Arbeitsebene: horizontal, vertikal, überkopf
Sicheres und sanftes Landen und Parken der Mover bei Stromausfall
Drahtlose Bereitstellung von Leistung und Datenkommunikation auf dem Mover
Geringer Leistungsverbrauch, unabhängig von der Nutzlast
Keine Erwärmung der Kachel-Oberfläche
Einfache Handhabung der Mover, kein Verletzungsrisiko
Innovative Maschinenkonzepte mit neuen Arbeitsabläufen
Maschinen mit weniger Platzbedarf und geringer Komplexität
Vereinheitlichung von Transport- und Handhabungssystemen
Einsparung von Peripheriegeräten und Installationsausrüstung
Hohe Sauberkeit, durch abriebfreie Bewegung der Mover
Betrieb der Mover in einer geschlossenen Prozesskammer möglich
Steigerung der Wandlungsfähigkeit, Skalierbarkeit und Flexibilität
Echtzeit-Synchronisation mit Peripheriegeräten möglich
Kommunikation mit Linien- und Maschinensteuerungen

Ready for the future

The high-speed linear motion system ctrlX FLOW^HS is an integral part of ctrlX AUTOMATION. It gives users unrestricted access to a wide range of functions. These include interfaces for seamless integration into other systems, communication and safety standards thanks to ctrlX IOT and the use of powerful ctrlX SAFETY functions. In addition, the motion, CNC and robotics software ctrlX MOTION allows precision synchronization of robotic units and other movement axes.

ctrlX FLOW^HS is based entirely on the control platform ctrlX CORE which uses the advanced and open operating system ctrlX OS. Thanks to the integrated app technology, the solution can easily be expanded and will remain future-proof.

Easy to configure and expand

As a modular linear motion system, ctrlX FLOW^HS offers great flexibility and adaptability. The segment design is conceived for modular configuration and demanding requirements. A wide range of segments and movers for every type of application is available. Thanks to plug & play, segments and movers can easily be combined to form a track. As a result, application-specific topologies, lengths and routes can be created quickly, simply by connecting straights, curves and switches.

Cabinet-free installation is another plus point. After all, the entire electronics is integrated into the segments. Users thus get a modular and space-saving solution with numerous options for expansions and easy maintenance later on.

High speed with less space required

The high-speed system for transport and positioning really lives up to its name. It offers impressive acceleration of up to 10G and achieves speeds of up to 5 m/s. The U-shaped design not only ensures optimal routing but also minimizes friction effects. As a result, the maximum speed can be maintained, even in curves.

The motion system also scores highly with above-average power in terms of payload. This can be scaled to up to 2.5 kg and doubled to 5 kg in a group.

The ctrlX FLOW^HS technology saves space and energy. With smaller movers and a product spacing reduced by 20 percent to just 40 mm, the system can be used efficiently even in confined production environments and can be integrated into production lines in a space-saving manner. This makes it possible to build more compact products, manufacture more efficiently and ultimately reduce the amount of space required.

ctrlX FLOW6D: Planar system with 6 degrees of freedom

Workpiece carrier of the contactless planar system ctrlX FLOW6D

With ctrlX FLOW^6D, contactless high-performance transport and positioning reaches a new level. The planar system from Bosch Rexroth offers greater freedom of movement and maximum precision. The free-floating transport platforms, so-called movers, are moved on a horizontal, vertical or overhead working surface. Each mover acts in six degrees of freedom (6DOF) at high speed and with great precision – without any friction or pollution. Integration into ctrlX AUTOMATION results in an overall solution with a compact control system and apps to increase the range of functions. The result is an integrated, agile system which makes full use of the potential offered by industrial levitation.

Planar system: Floating. Flexible. Simple.

ctrlX FLOW6D stands out from other solutions. These benefits make all the difference:

Free, simultaneous movement in all six degrees of freedom, for example rotation, travel and tilting
Extended movement ranges: Floating height up to 20 mm, unlimited rotation, 10° tilt in all spatial directions
Any orientation of the working level: Horizontal, vertical, overhead
Safe, gentle landing and parking of the movers in the event of a power cut
Wireless provision of power and data communication on the mover
Low power consumption, regardless of the load capacity
No warming of the tile surface
Movers are easy to handle, no risk of injuries

Innovative machine concepts with new working procedures
Machines take up less space and are less complex
Transport and handling systems are standardized
Peripheral devices and installation equipment are no longer needed
High level of cleanliness thanks to abrasion-free movement of the movers
Movers can operate in a closed process chamber
Increased versatility, scalability and flexibility
Real-time synchronization with peripheral devices possible
Communication with line and machine control systems

Free, simultaneous movement in all six degrees of freedom, for example rotation, travel and tilting
Extended movement ranges: Floating height up to 20 mm, unlimited rotation, 10° tilt in all spatial directions
Any orientation of the working level: Horizontal, vertical, overhead
Safe, gentle landing and parking of the movers in the event of a power cut
Wireless provision of power and data communication on the mover
Low power consumption, regardless of the load capacity
No warming of the tile surface
Movers are easy to handle, no risk of injuries
Innovative machine concepts with new working procedures
Machines take up less space and are less complex
Transport and handling systems are standardized
Peripheral devices and installation equipment are no longer needed
High level of cleanliness thanks to abrasion-free movement of the movers
Movers can operate in a closed process chamber
Increased versatility, scalability and flexibility
Real-time synchronization with peripheral devices possible
Communication with line and machine control systems

Three workpiece carriers of the contactless planar system ctrlX FLOW6D, which enables movements in 6 degrees of freedom such as simultaneous rotation, travel and tilt

Floating transport system: ctrlX FLOW6D

Planar systems offer enormous potential for a variety of industry segments. Given their modular, easily adaptable structure, they can be used in numerous industrial sectors, for example in the semiconductor industry, the food sector, the pharmaceuticals industry or in assembly systems.

As a contactless system, ctrlX FLOW^6D allows the efficient, safe and coordinated transport, positioning and handling of loads. The planar system from Bosch Rexroth thus forms the backbone of a flexible and efficient production facility. As an open system, it can interact seamlessly with various other systems.

On a working surface which can be adapted in a modular fashion, a number of differently shaped and sized movers can be controlled in six dimensions. Strong, specially arranged permanent magnets make this possible. The system also sets new standards with its large movement ranges, for example a floating height of up to 20 mm, a 10° tilting angle and endless rotations in any location. The six degrees of freedom of each mover can be combined with each other as required.

Workpiece carrier of the contactless planar system ctrlX FLOW6D, on which glass bottles are placed

A power supply and data communication are available to users on the floating platform. Movers are connected and can also be converted into active agents. This can be achieved by equipping them with actuators, sensors and handling components.

With its numerous properties, the ctrlX FLOW^6D planar system opens up new scope for action and innovative concepts for production systems. The open transport systems allow entirely new system concepts and workflows. For example, movers can be operated in a process chamber, transport and process tasks can be combined seamlessly and transport systems can be standardized. The additional degrees of freedom mean that fewer peripheral devices are needed. As a result, the system becomes more compact, less complex and cheaper.

Eight workpiece carriers of the contactless planar system ctrlX FLOW6D, which enables movements in 6 degrees of freedom such as simultaneous rotation, travel and tilt

Planar system for flexible automation

The floating and contactless ctrlX FLOW^6D system can be integrated perfectly into the Bosch Rexroth automation world. The automation system ctrlX AUTOMATION provides the basis for design, simulation, engineering, operation and service. The heart of the solution, the compact, high-performance control system ctrlX CORE, allows users to make optimum use of the new planar system technology. Full use of the potential of levitation can be made with the help of expansions: New functions can easily be added with the help of apps available from the ctrlX OS Store.

ctrlX FLOW6D – FAQ

You have more questions about the planar system and permanent magnetic levitation?

Have a look at the frequently asked questions about ctrlX FLOW6D!

Frequently Asked Questions

Opened copy of the ctrlX AUTOMATION magazine 2023/2024

ctrlX AUTOMATION Magazine 2023/2024 –
Now available!

„Openness is everything“ – this is the motto of the ctrlX AUTOMATION magazine 2023/2024. This year, it´s all about openness and co-creation, which enables a completely new world of automation. Furthermore, there will be innovations of the product portfolio, exciting case studies and expert opinions on digitalization and connectivity.