Coil Processing Lines

Coil Processing Lines – Continuous automation

When sheet metal passes through the system at high speed, every movement determines the quality, cycle time, and process reliability. At the same time, market requirements are increasing: Machine manufacturers need flexible, quickly convertible systems for smaller batch sizes, greater product diversity, and shorter delivery times. It is also vital for them to implement consistent communication concepts for networked processes and to meet new IT security requirements such as the Cyber Resilience Act (CRA).

This is precisely where the "Coil Processing Lines" solution set from Bosch Rexroth comes in. It offers a ready-to-use, modular solution set for blanking line(s) based on ctrlX AUTOMATION. Powerful control and drive technology combines with modern app technology to significantly shorten development and commissioning times, while at the same time increasing plant availability, safety, and sustainability. Applications such as flying saws or roll feeds can be developed quickly, operated safely, and maintained over the long term.

The image shows sheet metal processing on a coil processing line.

Complete solution for coil processing lines – The advantages:

• Open, modular, and future-proof for blanking line(s)

• Shorter project durations thanks to pre-configured modules

• Increased plant availability and operational safety

• Special functions for roll feed and flying saw applications

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Solution set for coil processing

The image shows the individual components from the ctrlX AUTOMATION toolkit that are used for the Solution Set, such as the ctrlX OS operating system, represented as an app icon, or the hardware products like ctrlX CORE or ctrlX DRIVE.

The "Coil Processing Lines" solution set combines perfectly coordinated components from the automation system ctrlX AUTOMATION. It offers a complete hardware and software architecture, specifically tailored to the needs of conveyor systems in coil processing. The set is based around the control platform ctrlX CORE with ctrlX MOTION, the compact ctrlX DRIVE, powerful motors, and efficient ctrlX I/O modules. Communication with third-party components takes place via EtherCAT or Profinet, for seamless integration into existing systems.

All PLC and motion functions for coil processing lines are available as apps, which significantly reduces development and commissioning times. The web-based engineering and HMI environment allows intuitive operation as well as quick configuration and parameterization.

ctrlX SAFETY and integrated IT security functions ensure functional safety and meet the current requirements of the Cyber Resilience Act. The "Coil Processing Lines" solution set thus considerably simplifies the development, commissioning, and operation of blanking line(s), while offering maximum flexibility, reliability, and future viability.

The image illustrates the topology of the Coil Processing Lines solution set, featuring the ctrlX AUTOMATION hardware products.

Example application for coil processing lines

High-performance automation for coil lines: with the powerful control platform ctrlX CORE, the compact ctrlX DRIVE and robust motors, rapid I/O integration via EtherCAT/Profinet, safety functions via ctrlX SAFETY, as well as modular expansion through apps and partner solutions from ctrlX World.

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ctrlX OS Community

Do you need further assistance? In the ctrlX OS Community you will find blog posts, GitHub applications, and how-to guides on topics such as coil processing lines and many other areas of application for ctrlX AUTOMATION.

Go to ctrlX OS Community!

Hardware and software components of the solution set

The image shows the control system ctrlX CORE. Next to the product is the app icon for ctrlX OS, the Linux-based operating system that runs on the controller.

ctrlX CORE – Centralized control platform

The control system ctrlX CORE is at the heart of the "Coil Processing Lines" solution set. It combines PLC, Motion, and IoT functionality on an open, future-proof platform. Thanks to the operating system ctrlX OS and app technology, the control system can be flexibly adapted to any conveyor belt application. Open interfaces such as EtherCAT and Profinet enable seamless communication – ready for the Cyber Resilience Act and featuring integrated security-by-design architecture.

The pictures shows the drive system ctrlX DRIVE.

ctrlX DRIVE – Dynamic drive for maximum precision

The compact and modular ctrlX DRIVE ensures maximum dynamics and precision in roll feed and flying saw applications. Powerful servo drives and precise motion synchronization enable exact movement profiles – even at high speeds. Combined with ctrlX SAFETY and ctrlX CORE, the drive guarantees maximum process reliability and productivity with minimum engineering work.

ctrlX I/O – Rapid response times for precise processes

The ctrlX I/O modules enable fast inputs and outputs for press or feed control. The flexible I/O architecture communicates with the control system and drive via EtherCAT and Profinet, enabling consistent networking and simple integration of external components – ideal for coil processing applications with high cycle rates and tight timeframes.

The image shows the ctrlX SAFETY C.12 safety control from the ctrlX AUTOMATION portfolio.

ctrlX SAFETY – Functional safety up to SIL 3

ctrlX SAFETY provides all safety-related functions for coil lines – from the drive-integrated safety solution to the complete safety control system up to SIL 3. Communication with ctrlX DRIVE and ctrlX CORE ensures maximum system availability and protection of both people and machines – without any additional programming work.

The image shows the app icon for ctrlX PLC. The term 'PLC' is included in the icon for better clarification of which app it is.

ctrlX PLC – Flexible PLC software

The ctrlX PLC software solution combines classic PLC functionality with open app technology for coil processing lines. It controls precise movements in conveyor systems, such as flying saws or roll feeds. The PLC software can be easily integrated into existing machine concepts – for maximum flexibility and efficiency in engineering. It is also scalable as needed.

The image shows the app icon for ctrlX MOTION. The term Motion is included in the icon for better clarification of which app it is.

ctrlX MOTION – Motion for roll feed and flying saw applications

ctrlX MOTION enables highly precise, synchronized motion sequences in coil lines. The software synchronizes the cutting axis of the flying saw with the moving material line and controls roll feeds within the exact time window. This increases dynamism, repeatability, and stroke rate – a crucial factor for productivity in coil processing lines.

The image shows the ctrlX HMI Portfolio from ctrlX AUTOMATION, e.g., web panels, operator panels, or displays.

ctrlX HMI and WebIQ – Intuitive and quick to use

Browser-based tools such as ctrlX HMI and WebIQ ensure intuitive visualization and operation. From configuration to parameterization to commissioning, the web-based environment accelerates all engineering steps. The result: shorter project durations for coil processing lines and a modern, responsive application.

ctrlX OS – Open operating system

The operating system ctrlX OS with ecosystem provides access to a comprehensive world of apps. The portfolio not only includes apps from Bosch Rexroth, but can also be supplemented with apps from the ctrlX World. The solution is “secure by design” and is already compliant with the Cyber Resilience Act. Ideal for scalable, future-proof automation solutions.

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