ctrlX AUTOMATION offers automation solutions for a variety of packaging applications for form, fill and seal machines
Example applications for packaging solutions
Package consumer goods the intelligent and efficient way
Nowadays, consumer goods such as potato crisps and chocolate bars but also non-food products need to be packaged and dispatched more and more quickly and cheaply. However, the high packaging speed must not be at the expense of sealing, which plays a key role in ensuring a longer shelf life and product safety. This requires supporting technologies that can speed up and automate packaging processes.
By using automation solutions in packaging machines, manufacturers can increase efficiency: They can achieve faster production cycles and package more products per unit of time. This offers significant economic benefits. In addition, systems can be adapted to meet different or new packaging requirements much more quickly. Automation solutions also help to ensure consistently high quality by guaranteeing compliance with specific standards and requirements and minimizing errors in processes that were previously performed manually.
With ctrlX AUTOMATION, Bosch Rexroth offers integrated, modular automation solutions for the packaging industry – and for consumer goods in particular. The open complete solution includes all hardware and software components for automatically controlling, regulating, monitoring and optimizing packaging machines, e.g. form, fill and seal machines. The automation toolkit provides hardware and software as well as services and offers a modular complete system which connects, controls and orchestrates all components. The package is rounded off with apps that are available as needed to expand the range of functions for applications in the packaging industry.
New automation solutions for packaging machines
The ctrlX AUTOMATION toolkit offers almost unlimited freedom and can provide drive as well as control and connectivity solutions in many areas of the packaging industry. One area of application is so-called form, fill and seal machines or flow wrappers with vertical and horizontal seals, i.e. VFFS (Vertical Form, Fill and Seal) and HFFS (Horizontal Form, Fill and Seal). The vertical version of the flow wrapper is particularly suitable for packaging products such as potato crisps, while the horizontal version can be used to package chocolate bars for example – at high speed and with reliable sealing.
ctrlX AUTOMATION provides ideal support for both types of flow wrapper – in low range application (LRA), mid range application (MRA) and high range application (HRA) systems.
VFFS - Vertical Flow Wrapper In the smallest solution (LRA), the control system is integrated into the drive for the first axis. The other two axes are packaged in a double axis drive. The ctrlX CORE control system is connected to the decentralized ctrlX I/O and the ctrlX SAFETY system via EtherCAT. Sensors for temperature, contrast or the master axis encoder are frequently used in this type of application. Safe Torque Off is achieved with the help of discrete wiring. The web-based ctrlX HMI is also connected to the compact control system. The HMI server can run in the controller itself in combination with a web panel or on a Windows PC (e.g. panel PC) to optimize and safeguard the performance of the ctrlX CORE. This results in a space-saving, safe and economical overall solution for very high efficiency.
If necessary, the solution can be expanded with additional components and scaled to meet the very highest requirements. The app architecture allows easy integration of Bosch Rexroth's own know-how and applications from Bosch Rexroth or third-party providers, for example in the field of motion and IoT. The ctrlX MOTION app and the Bosch DeviceBridge app are examples of these.
ctrlX AUTOMATION was designed for simplicity. Bosch Rexroth allows easy engineering with intuitive usability. A ready-to-use, open application project for flow wrappers offers users numerous advantages such as: Starting the first project in just 10 minutes, up to 60% time savings during coding, increased code reusability, web HMI in a responsive design and open source code.
The automation system is also future-proof and with “Security by Design” offers maximum security on all levels. Thanks to integrated IoT solutions, it even opens the door to the smart factory.
With the ctrlX Configurator, you can design your automation solutions intuitively. The procedure for individually configuring them is easy, quick and reliable. The desired system topologies can be put together exactly as needed and retrieved 24/7. Go to ctrlX Configurator
LRA form, fill and seal machine solution
Space-saving, safe and economical automation with integrated control system in the drive.
Schematic example LRA solution
Application example LRA solution
Configurator example LRA solution
LRA Solution | Form, Fill and Seal | CTRLX350143
MRA form, fill and seal machine solution
A high level of flexibility thanks to integrated SafeMotion functions in the drive and ctrlX CORE in the embedded version, additional connection options to 3rd party controllers as well as the option of connecting the ctrlX I/Os to the ctrlX CORE directly without a bus coupler.
Schematic example MRA solution
Application example MRA & HRA solution
Configurator example MRA solution
MRA Solution | Form, Fill and Seal | CTRLX635613
HRA form, fill and seal machine solution
Maximum performance and connectivity thanks to ctrlX CORE, numerous sensors and I/O Link integration, extended safety portfolio and clever combination of ctrlX DRIVE and IndaDrive Mi. Any extension of the application example possible by adding solutions from ctrlX World partners, e.g. WAGO, ifm or SICK.
Schematic example HRA solution
Application example MRA & HRA solution
Configurator example HRA solution
HRA Solution | Form, Fill and Seal | CTRLX527634
The machine manufacturer ILLIG is helping to make the changing food packaging industry more flexible and future-proof by relying on the technological openness of the automation toolkit ctrlX AUTOMATION from Bosch Rexroth. “The modular approach is a good platform for developing future-proof machines,” said Markus Peter, head of electrical development at ILLIG Maschinenbau. “The open hardware and software modules ensure high process quality and allow us to obtain data which can be used to continuously improve productivity and energy efficiency.” Further information
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Shape cutting machines are systems that can cut materials up to a certain thickness using a NC-guided machining head. In general, cutting is not done mechanically but with laser, plasma, oxyfuel and water jet cutting.
CAD/CAM Nesting Software – Lantek Expert Inside
Adaptive height control
Laser power control
Re-entry functions of NC-Program
High speed cutting
MTX control (XM42-S, XM42-P or XM42-A)
Drive controller (IndraDrive CS/M/Mi, ctrlX DRIVE)
For height control: Capacitive sensor with an analog output Drive with an analog input (X32 or X38) or another Sercos field bus device with an analog input
For laser power control:
Analog output: Drive controller with analog output (IndraDrive CS/M, ctrlX DRIVE) S20-AIAO-2, S20-AO-4, S20-AO-8 analog output module
PWM output: S20-DIDO-2-CSOVS high-speed output module
For FlyCut: S20-DIDO-2-CSOVS high-speed output modul
IndraWorks Engineering for CNC system MTX 15VRS R911396002: SWL-IWORKS-MTX-NNVRS-D0-ENG /Single license
Programming and project planning software for MTX
Win Studio lite Editor
IndraWorks Operation 2 for CNC system MTX 15VRS R911396004: SWL-IWORKS-MTX-NNVRS-F2-OPD2 /Single license
HMI-software for standard CNC operations
WinStudio runtime, Lite-license inclusive
Technology Shape Cutting 2 R911396571: FWS-MTX-SHC2*****-NNVRS-NN-NNN /Single license
Standard project template for shape cutting
Gantry axes with command value coupling
Splines and Placements
Cylinder surface transformation
Retrace - travel backwards on programmed contour
MTX fast actions
System axes coupling
Distance control for 2D machining
Laser power control and Fly Cut
R911396023 FWS-MTXFA*******-NNVRSNN-NNNFast Actions
R911396019 FWS-MTXGEAR*****- NNVRS-NN-NNN Electronic Gear
R911393958 FWS-XM42**MTX-OPCUA OPC UA server & Client
IndraWorks Workstation 2 for CNC system MTX 15VRS R911396002: SWL-IWORKS-MTX-NNVRS-F2-WORKSTATION2 /Single license
Engineering + Operation
IndraWorks Virtual Machine Builder (VMB) R911394065: SWA-MTX***-ENG-01VRS-D0-VMB-DOWNL /Software R911394064: SWS-MTX***-ENG-01VRS-D0-VMB-DGL /USB-Dongle
IndraWorks Virtual Machine Simulation R911374010: SWS-MTX***-RUN-NNVRS-D0-VMS /Single license
Lantek Expert Inside CAD/CAM nesting software for sheet cutting machines R911398450: SWL-MTX***-RUN-01VRS-NN-LANTEK /Single license
The MTX template for beam cutting is provided with the MTX installation. After installing IndraWorks, please go to File / Open / New and restore the beam cutting project.
Step 1: Restore Beam Cutting Template
Step 2: Restore Beam Cutting Template Documentation
MTX15VRS Shape Cutting Technology (EN) Commissioning Manual R911399147: DOK-MTX***-TECHCUT*V15-CO
MTX 15VRS Technologie Strahlschneiden (DE) R911399148: DOK-MTX***-TECHCUT*V15-CO08 Inbetriebnahmebeschreibung
Solution Set for Beam Cutting applications
ctrlX AUTOMATION online documentation (ctrlX DRIVE, ctrlX SAFETY)
Collection of How-to videos, blogs and examples for ctrlX AUTOMATION
FAQ Licensing with ctrlX AUTOMATION
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