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Gerhard Schubert sets new standards in modularity
Key customer benefits from 20 years of experience in cabinet-free drive technology
Traditional machine architectures with central control cabinets are increasingly reaching their limits: They require space, increase the amount of cabling required, and make modular machine designs more difficult to implement. Gerhard Schubert GmbH is therefore continuously developing its packaging machines further and uses the latest generation of cabinet-free drive technology from Bosch Rexroth. ctrlX DRIVE cabinet-free is the third generation of cabinet-free drive technology – incorporating over 20 years of experience. As a key customer, Schubert is involved in the development process and has been able to significantly increase the modularity, integration, and flexibility of its machines through the use of the technology.
Today's modern packaging machines have to be able to handle many tasks simultaneously: short changeover times, flexible adaptation to new formats, and the cost-effective production of ever-smaller batch sizes. At the same time, the pressure to build machines to be more compact and to install them faster is growing. For Schubert, this means consistently improving the existing machine architecture, which already uses fewer control cabinets.
"Modular mechanical engineering has been a key success factor for us for years," explains Jan Köhler, Head of Control Technology/Control Development at Gerhard Schubert GmbH. "With the new generation, we are taking the next step. We are continuing to develop our cabinet-free approach in a targeted manner and creating additional degrees of freedom for our machine architecture."
Drive technology moves closer to the machine
A key factor lies in the drive technology. While traditional designs rely on drives installed centrally in the control cabinet, Schubert, together with Bosch Rexroth, is taking a decentralized approach: The drives are integrated directly into the machine structure. And in the future, this will be done to a much greater extent than in previous solutions, in which some were still housed in the extended cable duct.
The ctrlX DRIVE cabinet-free servo drive technology, supply units from ctrlX DRIVE, and servo motors from the MS2N and MS2S series from Bosch Rexroth are key elements of this development step. The new generation of drives offers seamless scalability – from single-axis to double-axis units and different power ratings. As a result, drive solutions can be optimally adapted to the power requirement of the particular machine.
ctrlX DRIVE cabinet-free uses an IP65/IP67 drive system that does not require a traditional control cabinet. Power supply, communication, and performance are bundled via a hybrid DC cable. This not only considerably reduces the cabling work required but also simplifies assembly and commissioning.
At the same time, the system architecture allows for a flexible topology: In addition to linear structures, star or T-topologies can also be realized, enabling machine modules to be combined and expanded with significantly greater flexibility.
More degrees of freedom for modular machines
For Schubert, this architecture opens up new opportunities in mechanical engineering. The direct integration of the drives into the machine frame results in more streamlined designs. At the same time, this allows for greater flexibility in the arrangement and combination of modules.
In addition, the scalable drive architecture helps further optimize the installation space: The use of double axis devices and decentralized supply units significantly reduces the installation space required and simplifies integration into the machine.
"We can make our modules more flexible and tailor our machines even more to specific customer requirements," says Jan Köhler. This is supported by the flexible integration of control devices without a rigid backplane as well as by topology nodes that enable different structure concepts.
The new cabinet-free drive technology reduces the volume for the servo drives of a Schubert F4 pick and place robot by 46%, showing just how significant the potential for savings is.
The drive technology also offers additional options in terms of functions: Expansions such as additional encoder connections, I/O modules, or safety features can be integrated directly into the drive.
Energy efficiency through common DC link
The energy concept has also been redesigned. In the new architecture, the drives are connected via a common DC bus. This allows them to exchange energy with each other, for example when braking energy from one axis is used by another, without any losses through energy being fed back into the grid. In contrast to previous concepts, in which individual machine modules each require their own power supplies, a central power supply makes it possible to equalize energy across the entire machine. At the same time, the regulated DC bus voltage ensures consistent machine performance, even under varying grid conditions.
This reduces conversion losses and increases the energy efficiency of the entire machine. At the same time, the regulated DC bus voltage ensures consistent performance, even under varying grid conditions and with minimal grid impact. This effectively makes the machine DC-based and allows it to efficiently handle larger distances and numbers of axles.
Reduced complexity – increased serviceability
In addition to flexibility and energy efficiency, Schubert also benefits from reduced system complexity. The elimination of additional cooling systems, such as water-based cooling, reduces the maintenance work required and increases operational reliability. This is made possible by the use of silicon carbide power semiconductors in ctrlX DRIVE cabinet-free. This technology reduces heat loss, eliminating the need for external water cooling – while delivering higher power density. At the same time, the high integration density of the drive technology reduces the number of components required and simplifies the entire machine design.
In addition, the consistent connection technology improves serviceability. Standardized interfaces and a high level of contact protection make installation, diagnostics, and service easier. The single cable technology for motors also reduces the installation effort.
In addition, built-in safety features such as STO and SafeMotion functions in the axes support a consistently safety architecture.
Development in close partnership
The technological development took place in close collaboration between Schubert and Bosch Rexroth. The two companies have a long-standing partnership dating back to the first cabinet-free packaging machine they developed together in 2014.
As a key customer, Schubert was involved in the development process of the new generation of ctrlX DRIVE cabinet-free drive technology from Bosch Rexroth from an early stage. Prototypes were available early on and were tested and validated iteratively in the machine context.
"The close collaboration with Bosch Rexroth has enabled us to incorporate our requirements directly into development and to test the technology under real-life conditions at an early stage," says Jan Köhler.
Architecture for the future
With the new drive architecture, Schubert is laying the foundation for cutting-edge packaging machines. The higher level of integration, the flexible system structure, and the optimized energy concept make it possible to build machines more quickly and operate them more efficiently.
At the same time, the system remains open to future extensions – both in terms of additional functions and for scaling to larger machine concepts and other performance classes.
Schubert first presented the new generation of modular packaging machines at interpack 2026.
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Tobias Gerhard
Game Changer
Consumer Goods
