If your machines run on Bosch Rexroth hardware or your factory depends on the Nexeed software ecosystem for production management, you know how powerful these platforms can be — and how frustrating it is to find consultants who truly understand them. Most automation service providers treat Nexeed as a niche footnote. We treat it as our core specialization. Our engineers have commissioned Nexeed Control Plus projects across automotive, packaging, and special-purpose machine building — the same industries where Bosch developed and battle-tested the platform in its own plants worldwide.

Nexeed Control Plus is not just another PLC engineering tool — it is a fundamentally different approach to machine software. Instead of writing thousands of lines of code from scratch for every new machine, Control Plus lets you model your machine using pre-built, field-proven software objects (the Nx library), configure the behaviour, and automatically generate both the PLC code and a ready-to-use HMI. Our engineers understand this paradigm deeply and exploit it to deliver machine software projects significantly faster than traditional methods.

We bring hands-on experience with Control Plus Studio — the engineering environment where machine models are built, SFC step sequences are programmed, library parameters are configured, and the complete deployment package is generated. Whether your target controller is a Rexroth VPB40, a Beckhoff CX series, or the latest ctrlX CORE X3/X5/X7, we handle the full workflow from initial project setup through commissioning and handover.

Our consultants have worked extensively with the NxBase object framework, custom add-ons such as NxDdlEventAddon for Direct Data Link MES communication, NxLogger for runtime event recording, and the system health check add-on for monitoring controller resources. We know how to configure DDL v4 communication FBs, manage PDA/MDA event transmission, and ensure seamless data flow between your machine PLC and Nexeed MES — eliminating the integration headaches that derail so many projects.

One of Control Plus's most powerful features is its automatic HMI generation — with a single click, a fully functional operator interface is created directly from your machine model. But getting the most out of this requires careful object configuration, proper symbolism setup, and correct ePlan import procedures. Our engineers ensure your auto-generated HMI is not just functional but genuinely useful for your operators — with clear alarm visualization, intuitive navigation, and the production data your line managers actually need.

We also specialize in the advanced assistance systems that set Nexeed apart from conventional PLC platforms. Virtual Assist brings 3D machine visualization directly into your HMI — when a fault occurs, operators see exactly where on the machine the problem is, with color-coded highlighting and guided resolution steps stored in a knowledge database. This capability, once reserved for high-volume production lines with massive budgets, is now achievable even for batch-size-one special-purpose machines through Control Plus V2 and later.

Our Cycle Time Assist implementation helps your production team detect deviations the moment they occur, while the Integrated Vision add-on (powered by HALCON) enables direct image processing on the PLC — minimizing hardware costs and simplifying your machine architecture. For applications requiring robotic integration, we configure Integrated Robotics to control Stäubli, KUKA, and FANUC robots directly from the PLC using standardized, vendor-neutral function blocks.

Bosch Rexroth's ctrlX AUTOMATION platform represents a fundamental shift in industrial control — replacing proprietary, closed architectures with an open, Linux-based ecosystem where automation apps can be installed, updated, and combined as easily as apps on a smartphone. As early adopters and practitioners of this platform, AAPL helps manufacturers and machine builders transition from traditional Rexroth controllers to ctrlX CORE hardware without losing their investment in existing Nexeed Control Plus projects.

Our ctrlX consultancy covers the complete lifecycle: selecting the right ctrlX CORE variant (X3, X5, or X7) for your application, setting up the ctrlX WORKS engineering framework, developing PLC applications using the ctrlX PLC app, deploying snap packages, managing licenses through the ctrlX license server, and automating deployment workflows using PowerShell scripts and WebDAV file transfers. We ensure your transition to ctrlX is smooth, de-risked, and fully validated before go-live.

What makes ctrlX AUTOMATION truly powerful is its openness. The ctrlX OS (based on Ubuntu Core Linux) allows you to run not just PLC apps but also custom applications written in Python, C++, Node.js, or virtually any language — directly on the controller. This IT/OT convergence means you can deploy edge analytics, AI inference models, custom communication gateways, and data processing pipelines right where the data is generated, without additional hardware.

We help you architect solutions that exploit this openness responsibly — ensuring real-time determinism for your motion and logic tasks is never compromised by IT workloads, that your app ecosystem is properly sandboxed and secured, and that your engineering team has the documentation and training to maintain the system independently. Whether you are building a next-generation machine from scratch or retrofitting an existing Rexroth-controlled line, we make ctrlX AUTOMATION work for your specific requirements.

The Nexeed Manufacturing Execution System is the production management backbone used across Bosch's own global manufacturing network — and AAPL brings that same enterprise-grade capability to your plant. We deploy and customize Nexeed MES to provide real-time production transparency, seamless quality documentation, end-to-end traceability, and active production control across your entire value stream.

Our MES integration expertise includes configuring the Direct Data Link (DDL) interface for reliable PLC-to-MES communication over TCP/IP, setting up automated PDA/MDA event transmission (operation mode changes, charge changes, shift changes, error events, jam detection, and operator requests), connecting to SAP and other ERP systems through standardized interfaces, and implementing multi-layered escalation management so deviations are detected and acted upon before they become costly quality escapes.

We also implement the material management module to coordinate goods flow from receiving through production consumption — ensuring timely material supply, reducing inventory carrying costs, and eliminating the manual tracking that slows your operations down.

Beyond traditional MES, the Nexeed Industrial Application System (IAS) represents Bosch's vision for the connected factory — a modular, interoperable IIoT platform that gives every user group in your plant exactly the information they need. Production managers get live shopfloor dashboards. Maintenance engineers get condition monitoring with AI-driven anomaly detection. Quality teams get real-time process quality analysis. Logistics teams get material localization and transport optimization.

AAPL deploys and configures the Nexeed IAS modules that match your priorities — starting with high-impact quick wins and scaling systematically across your plant. We handle the infrastructure setup, device connectivity, dashboard configuration, API integrations, and user training. Because all IAS modules are interoperable and access the same data lake, every module you add increases the value of the ones already running.

For plants with legacy equipment that was never designed for digital connectivity, we implement Bosch's proven retrofit solutions — adding IIoT sensors and edge gateways to existing machines so they can participate in your connected manufacturing ecosystem without expensive hardware replacements. This is often the fastest path to measurable ROI from your Nexeed investment.