move

The magazine for customers and partners of WITTENSTEIN AG

PRODUCTION CONCEPT FOR THE FUTURE

April 2014

What lies in store at the WITTENSTEIN Innovation Factory from May 2014

ENTREPRENEUR 4.0 AWARD 201412

The artists‘ view of the 4th Industrial Revolution

move

The magazine for customers and partners of WITTENSTEIN AG

Contents

Masthead
Publisher:
WITTENSTEIN AG
Walter-Wittenstein-Str. 1
97999 Igersheim / Germany
Phone: +49 7931 493-0
www.wittenstein.de
move@wittenstein.de
Editorial content:
Sabine Maier,Manager Press & Public Relations(Responsible under press law)(Marketing & Communications Dept.)
Circulation:
900 copies
Production: IMMAGIS
Otto-Hahn-Str. 13
97204 Höchberg / Germany
All rights reserved. This document
may not be reprinted or electronically
distributed without the express
permission of the publisher.

2 move4

Interview with Professor Dieter Spath

6

The WITTENSTEIN Innovation Factory
New Mechatronics Centre in Harthausen

10

Industry 4.0 reflected in photography
ENTREPRENEUR 4.0 AWARD 201416

Secure mechatronic drive technology
WITTENSTEIN Group18

Servo actuators take the place of hydraulics
WITTENSTEIN motion control GmbH

20

More efficiency just a mouse click away
WITTENSTEIN alpha GmbH

22

Leading-edge technology protects Germany‘s position
WITTENSTEIN motion control GmbH

24

Robots arouse interest in mechatronics
WITTENSTEIN Switzerland

27

Trade Fair Calendar 2014

Dear readers,
Entrepreneurs and artists have a lot in common. They bothneed a heightened awareness of what‘s going on aroundthem and of what people are thinking and feeling. They both
wonder what the future will hold and respond with their“works“. These “works“ sometimes influence what goes onaround them as well as what people think and feel, so thatthey ultimately play a part in shaping the future.
Our own “work of art“ – the WITTENSTEIN Innovation Factory – will officially open at ourheadquarters at the end of May. First and foremost, it is a new, innovative factory building
integrating future production methods under the umbrella of Industry 4.0. It will allow us tolay the foundation for our company‘s future. And reflecting our position as a global mechatronics corporation, it also represents yet another sign of our commitment – clearly visible
and vehemently asserted – to Germany as a high-tech manufacturing location.
Yet the new building simultaneously symbolizes our creative entrepreneurial and artistic
drive. Entrepreneurial responsibility is far more than keeping a sharp focus on our own sales
development. In addition to the languages and technologies used by people to communicate with one another there is also a universal language that is understood by everyone –art. Art builds a bridge between individuals and the wishes and will of previous generations,and it gives us the ability to see the big picture. The “ENTREPRENEUR 4.0 AWARD 2014“
photography competition initiated by WITTENSTEIN and IMMAGIS, the Würzburg photoagency, examines possibilities for shaping the future in the context of the 4th Industrial Revolution with precisely this aim in mind. The award winning works of art will be the subjectof an exhibition at the new WITTENSTEIN Innovation Factory – and thanks to the article inthis magazine you can now have a sneak preview.
Speaking of shaping the future: WITTENSTEIN will continue to be a world class partner
for its customers, driven by a passion for innovation and unconditional excellence. Thereis no doubt at all in my mind: not least because we have succeeded in persuading such aprominent figure as Professor Dieter Spath to succeed me as President of WITTENSTEIN
AG. In the light of his knowledge, his experience and his inimitable human approach, I am
convinced that the traditional family firm of WITTENSTEIN is in the best possible hands. As
for myself, I will carry on making an active contribution to the well-being of “my“ company.
You can rest assured that I will remain as dedicated to the WITTENSTEIN cause as ever – inmy future role as Chairman of the Supervisory Board of WITTENSTEIN AG.
Let us look to the future with confidence – none of us can predict what it holds, yet all of
us can actively help to shape it. After all, we are all in the same boat on a journey into no
more and no less than – the future itself.

Dr. Manfred Wittenstein

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move talks to:Professor Dieter Spath

Professor Dieter Spath, President of WITTENSTEIN AG

4 moveProfessor Dieter Spath
Born in north-west Bavaria, he is a highly reputed technology manager
and occupational scientist and the candidate expressly favoured by his
predecessor: Professor Dieter Spath, aged 61, new President of
WITTENSTEIN AG. For many years Head of the Fraunhofer Institute forIndustrial Engineering (Fraunhofer IAO) in Stuttgart, he took over fromDr. Manfred Wittenstein last October. He describes his move back fromacademia to industry as an “attractive and interesting challenge“.

move: Could you tell us what persuaded you to accept theoffer from WITTENSTEIN?
Professor Dieter Spath: I‘ve known Manfred Wittenstein for a very
long time now from a series of joint projects and personal encounters. This acquaintance has gradually evolved into a profound andvery personal relationship of trust which was a fundamental aspect
for both of us – and I‘m sure Mr. Wittenstein will agree with me. This
much I can tell you: I made up my mind to say “yes“ quickly andemphatically.
What is your assessment after the first few months?
The stocktaking phase is coming to an end. I’ve already visited our
two main international production sites in the US and Romania andI’ve also taken the time to form my own personal impression of thesituation in Switzerland and Italy. What impressed me most was thateverywhere I’ve travelled so far, both at home and abroad, I’ve comeacross staff who are highly motivated. I don’t think I’ve ever experienced such widespread openness and enthusiasm at any company
before.
What will be your first and most important priorities?
WITTENSTEIN is in great demand in Germany as a recognized driverof Industry 4.0 – even though as a family owned firm with 1800 or so
staff we can hardly be classed as a large corporation. I intend to utilize my longstanding experience and network ties in applied, industry-relevant research to thrust ahead with the technology shift frommechanical engineering to mechatronics. Software and electronics
are two key aspects of the envisaged advances in drive technology. We’re staunch advocates of “tomorrow’s smart production“ andthis vision is now a reality at our Future Urban Production facility,

which opened a while ago in Fellbach. The new manufacturing plantfor gearing solutions is closely aligned to tomorrow’s challenges as
identified within the Industry 4.0 project. It’s a trend that will open up
new product worlds and business models for us.
What is an occupational scientist doing at WITTENSTEIN?
It’s an excellent company with excellent staff – and please don’ttake that as a meaningless compliment. It’s no accident that thecompany has turned out that way and it’s an achievement we mustnever take for granted. We can only succeed in fostering talentand getting the best out of our staff if we adapt our programme oftraining and continuing professional development to the changing
requirements of globalization, new technological challenges, novel business and production processes and demographic trends.
That’s why strengthening and – wherever it makes sense to doso – realigning our in-house vocational and further training at the
WITTENSTEIN academy is a matter especially close to my heart.
The WITTENSTEIN Group’s new fiscal year 2014/15 began on
April 1 – would you care to give us your forecast?
For one thing, we will continue to grow owing to our innovative vitality! We see particular potential for global growth in the ongoing
expansion of the Asian and American markets – and we’re determined to intensify the Group’s strategy of systematic specialization
in mechatronic solutions.
The new WITTENSTEIN Innovation Factory – the single biggest investment in the history of the company – is a visible symbol and an
important milestone on this ambitious path. This 35 million euro newbuilding will be officially opened just under two months from now.
We’re all looking forward to a fantastic opening ceremony!

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5

6 move

The WITTENSTEIN Innovation Factory“Industry 4.0 in the provinces“ was the headline of an article inFrankfurter Allgemeine Zeitung earlier this year on WITTENSTEIN‘s
new, ultra-modern Mechatronics Centre.
The title was altogether apt: the Innovation Factory at the company
headquarters in Igersheim-Harthausen, south-west Germany, inwhich the production of mechatronic drive systems got under way
a few days ago, plays a key role in terms of “tomorrow‘s products
and production processes“.

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7

Fruitful proximity: The officeareas in the Innovation Factory
encourage close networking –both in specific projects andacross different functions.
Optimized interfaces and shorter lead times are the outcome.

Open and transparent
Designed by HENN Architekten, the internationally renowned firm of architects, the newbuilding makes a stunning impression with
its seven metre high glass façade and hugeshade sails. Glass – symbolizing transparency – also dominates on the inside of the newcomplex with its extremely ambitious architecture, three storeys, overall height of 14 metres and footprint measuring 133 x 97 metres.
With around 18,000 square metres of usable
floor space, the Innovation Factory is roughly
the same size as the six existing production
shops at the WITTENSTEIN headquarters andoffers room for 500 staff. A gallery provides
visitors with a panoramic view of the facility:
spacious, light production areas create optimal opportunities for innovative production
processes in terms of resource efficiency, environmental awareness and work conditions.
Short lines of communication are guaranteed
to the office workplaces with their insulated
acoustic ceilings and glass fronts looking out
onto several inner courtyards – there is never
any shortage of daylight here. The triple glazing familiar from so-called passive houses, ourown combined heat and power plant for energy production and the photovoltaic systemon the roof are only a few instances of theconsistent ecological and economic concept
applied throughout, which has already been
awarded a pre-certificate in gold by the DGNB
(German Sustainable Building Council). Innovative products inevitably go hand in hand with
innovative production strategies. The WITTENSTEIN Innovation Factory sets an outstanding

8 move

The aim is the smart factory,
which will sustainably enhance
productivity and flexibility.

example here: the Development, Sales andProduction functions of our three mechatronic subsidiaries WITTENSTEIN motion control,
WITTENSTEIN cyber motor and WITTENSTEIN electronics will in future be united under one roof. The “articles of manufacture“ aremechatronic components and systems comprised of mechanics, controls, sensors andsoftware for customer applications in a variety
of industries such as semiconductors, power
generation or automotive. The fusion of innovation and manufacturing represents a conscious decision to promote networking acrosstraditional function boundaries. Whereas in thepast work groups went about their respective
tasks more or less in (physical) isolation, tightlyinterconnected units are now emerging. All activities linked to a particular project take place
within a thirty metre radius – a fruitful proximitythat allows interfaces to be optimized and leadtimes shortened.

Ground-breaking dig on April 30, 2012 –topping-out ceremony in time for Christmas the same year
Following a construction phase lasting just under two years, the first 350 staff moved into theInnovation Factory from the main plant nextdoor in spring 2014. The timespan was very
short compared to the history of the rock foundation on which the Innovation Factory stands:
shell limestone was formed by marine sediments deposited on this very spot between
205 and 215 million years ago. Stone blocks
discovered among the enormous quantity ofmaterial excavated at the site are now piled
up in one of the courtyards like an abandoned
quarry, where they remind staff and visitors of
the rugged subgrade and provide a fascinating
lesson in geology. Shell limestone, which varies in colour, texture and hardness, has traditionally shaped the local Franconian landscapeand made it what it is today.

The future production space offers ample room for business growth.

Industry 4.0 is a vision
Experts estimate that this process will takearound thirty or forty years. The aim is no longer simply to facilitate the continuous optimization of industrial processes; we are also engaged in a quest for completely new methodsof production involving intelligent interaction invalue added networks. In addition to technological advances and innovative products, it isparticularly new processes and services andin some cases complete business segments
and social innovations that are important focal areas. “Computerized production“ provides answers for the future. The goal is thesmart factory, which will sustainably enhance
productivity and flexibility. The WITTENSTEIN
Innovation Factory will be inaugurated at theend of May 2014 – in the presence of numerous illustrious guests from the worlds of industry, science and culture. The award ceremony
for the winners in the ENTREPRENEUR 4.0
AWARD photography competition – initiatedjointly by WITTENSTEIN and IMMAGIS, theWürzburg photo agency, as an international
artistic event to examine the role of entrepreneurial activity against the background of the
4th Industrial Revolution – will undoubtedly be
one of the main highlights of the official opening under the motto “GROWING TOGETHER“.
The exhibition will remain open to visitors forseveral months, shedding new light on the dialogue between industry and art.

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9

How photographers see
INDUSTRY 4.0

Sascha Weidner wins the “ENTREPRENEUR 4.0 AWARD 2014“art prizeIt‘s a topic on everyone‘s lips. Google returns more than five million
hits if you search for “smart manufacturing“ or “Industry 4.0“. Yet
how many people really know what is meant by the term? Whichfuture are we talking about? What actually happens when machinescommunicate with one another? And how will we have to prepare
ourselves if we want to stay successful in the future?
Dr. Manfred Wittenstein, the leading entrepreneur and initiator of the“ENTREPRENEUR 4.0 AWARD“ photographic competition, appealed
to contemporary artists to address the issues linked to responsible entrepreneurship in the next few decades. A small cross sectionof the winning works, which will be on show at the WITTENSTEIN
Innovation Factory from the end of May, is reproduced in this issueof move. The thematic focus of the ENTREPRENEUR 4.0 AWARD isthe changing conditions for entrepreneurial activity in the context ofthe 4th Industrial Revolution. A total of thirty international photographers and twelve talented newcomers from the renowned Ostkreuz
School of Photography in Berlin were invited to present their viewon the fusion of the physical and digital worlds associated with what
has become known as Industry 4.0 through the medium of artistic
photography. The works selected under the theme “Portraying Visions“ use art as a means to highlight possibilities for, and shifting
perspectives on, a future that has yet be designed while simultaneously providing us with motivation. The award will be conferred forthe first time in 2014.

10 move»Symbiosis II« from the »Hanami 4.0« cycle©Sascha Weidner“Sascha Weidner‘s images bear witness to working withouta safety net and demonstrate a great willingness to takerisks in his personal quest for pictures – and in such acompetition it is artistic autonomy that should be rewarded.
To continually permit oneself a fresh view of the reality that
one encounters, therein lies the extraordinary quality of theoeuvre and a testament to its unique poetological power“.
(From the jury‘s report)

Sascha Weidner
His “Hanami 4.0“ cycle of pictures (literally “flower viewing“) follows
the Japanese traditional custom of enjoying – once a year in springtime – the transient beauty of flowers, “flower“ in this case almost
always meaning cherry blossoms. Born in 1976 not far from Osnabrück (Germany), the artist sums up his cycle as follows: “And theway nature constantly reconstructs and renews itself, adapting to
the most various situations, can also be exemplary of industry; recreating itself in groupings and connections, blossoming in all its glory

and withering away, paying tribute to new conditions, the cycle ofnatural evolution thus going hand in hand with the industrial revolution“. Weidner graduated in Photography, Fine Arts and Communication Design at Braunschweig University of Art, where he was amaster-class student under Professor Dörte Eißfeldt. He has alreadyreceived several awards for his oeuvre, including the Alison & Peter
Klein Foundation advancement award “Stiftungspreis für Fotokunst“
in 2011 and the Berlin Art Prize in 2010.

move 11»Industry 4.0 affects us all – the whole of society. That‘s
why it‘s important to be aware of how artists perceive us
entrepreneurs. Tunnel vision would be fatal.«DR. MANFRED WITTENSTEIN, WITTENSTEIN AG»How we love, reproduce ourselves,
feed ourselves and die
reveals who we are, where we are
and when we are.«
BASTIAN GEHBAUER
WINNER OF THE ENTREPRENEUR 4.0 AWARD 2014
IN THE STUDENTS CATEGORY

Art produces knowledge
How will our society change as a result of the
4th Industrial Revolution? This is a questionthat no-one can answer precisely at present,
not even a highly reputed expert like Professor
Heiko Röhl, managing partner of “Die Denkfabrik“, a think tank that has been studying organizations and the transformations they experience for the past twenty years: “We all sensethat we have reached a threshold, however, because innovations with their origin in industry
have invariably led to profound – and above all
irreversible – changes.“ From his point of viewas a future researcher, therefore, we would bewell advised to engage in the interdisciplinary
debate surrounding Industry 4.0 at the earliest
possible stage, for example in the form of the
WITTENSTEIN-initiated ENTREPRENEUR 4.0
AWARD photography competition. This recommendation is even more important if – like
Heike Catherina Mertens, Director of Art andCulture at the Schering Foundation – you areconscious of the active role played by art inany kind of structural change: “Art produces»Greenhouse« (top) and »Sperm Tank« (bottom) from »Circle I.«

12 move©Bastian Gehbauer

ENTREPRENEUR 4.0 AWARD»Will the new generations be able to tell thedifference between the virtual and the real?
Will the human essence as we know it today beable to keep pace with technology or willtechnology devour us?«
MARA PLOSCARURUNNER-UP IN THE ENTREPRENEUR 4.0 AWARD 2014
IN THE STUDENTS CATEGORY»Bright New World« ©Mara Ploscaru»Whoever wishes to change the future
must not be afraid to think in unconventional dimensions.«
JULIA RUNGERUNNER-UP IN THE ENTREPRENEUR 4.0 AWARD 2014
IN THE STUDENTS CATEGORY

implicit knowledge“. For Oliviero Toscani, photographer and jury chairman, photography isin any case the most appropriate art form forunderstanding the future: “Our work inevitably presupposes that we have understood thepresent. We can only photograph somethingthat actually exists, though we obviously also
make use of the opportunities opened up to
us by picture editing technologies.“ Professor
Eckard Minx, Chairman of the Daimler andBenz Foundation, concurs absolutely: “Thestarting point for any photo artist is what theysee. That‘s why the theme of the competition
was tailor made for photographers. And any
entrepreneur worthy of the name is a good artist by definition.“
From the »Growing Hope« cycle©Julia Runge

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ENTREPRENEUR 4.0 AWARD»Yet the point is not merely to leave the earth behind us but to reflect on our world and what it means
to us and the generations who‘ll come after.«
MICHAEL NAJJARPARTICIPANT IN THE ENTREPRENEUR 4.0 AWARD 2014

Photography embedded in the daily production routine of a mechatronics corporation –the WITTENSTEIN Innovation Factory will soon
be transformed into an art gallery. At the endof May 2014 the “industry versus art“ dialogue
will be continued with a major exhibition inhonour of the award winners and other nominated artists in the new building at the WITTENSTEIN headquarters. The exhibition will
be curated by Felix Hoffmann, Chief Curatorof C/O Berlin and member of the ENTREPRENEUR 4.0 AWARD jury: “Photography is theideal medium for getting to grips with such

14 movea red-hot issue on a technical level.“ A comprehensive catalogue containing the works of
all artists nominated for the ENTREPRENEUR
4.0 AWARD and including their accompanying
statements will be published in May 2014.

unternehmer4punkt0.de
entrepreneur4point0.com

»Liquid Gravity«
From the »Outer Space« cycle©Michael Najjar»Actually, we inhabit, we take up residence
in a filter which rejects all that is undesirable to us.«
»Dauphin VII« from the »Busan / Dauphin Island / Favela« cycle©Dionisio González

DIONISIO GONZÁLEZPARTICIPANT IN THE ENTREPRENEUR 4.0 AWARD 2014

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Security
in mechatronic drive technology
At the very latest when you board the Airbus A380 as apassenger you begin to wonder – at least indirectly – about
safety and security in mechatronic drive technology.

Faults in mechatronic components and systems soaring through the skies must be prevented at all costs. The doors of the A380 areautomatically opened and closed by WITTENSTEIN actuators – absolutely reliably. Fatal
consequences for people and animals would
also be the likely outcome in other areas suchas medical technology, robotics or offshore oil
extraction if security and safety were not systematically accorded top priority. For many
years now, WITTENSTEIN has offered a concise but powerful answer to complex challenges such as these: “control complexity, minimize risks, engineer safety“.
Complex tasks complicate the solution
Throwing a ball up into the air and catching it
again as it comes down is not a problem formost people. As soon as there are two balls,
however, the task is less easy – your left andright arm have to be coordinated. The artisticfeat becomes more complex with each newball – it gets more and more difficult to juggle
and a few dropped balls are unavoidable. It‘sa similar story with mechatronic drive systems:
the products are increasingly customized while
the solutions are more powerful and multifunctional, and they‘re also smarter and more interconnected. The complexity grows along withthe desire to control it safely and reliably. This
is where it starts to get complicated – what dosafe, secure and reliable actually mean in thiscontext? Manifold, varied, constantly changing –like a kaleidoscope, we discover new perspectives on these topics every time we focus
our attention on them. Personnel protection,
the need to avoid damage to machinery andplant and optimal reliability embrace many of

16 movethe numerous possible meanings and interpretations. Safety, security and reliability are vital
signposts in the world of mechatronic drive
technology. The goals include functional reliability, freedom from defects, data security
and safe operation – in a word, controllability.
Secure engineering
WITTENSTEIN has long had its eyes firmly on
this desire for security, safety and reliability ina wide range of industries, including medical
technology, the aerospace sector and energy supplies, when developing and designingmechatronic drive systems. “We are seeking
to mitigate the risk that systems could become
uncontrollable with efficient, controllable drive
technology for complex mechatronic challenges“, says Professor Dieter Spath, President of
WITTENSTEIN AG. Security, intelligence, resource efficiency – each of these three aspects are seamlessly integrated into the development of our products and system solutions.
Security is impossible without expertiseCompanies like WITTENSTEIN that are aiming to develop, design, size, manufacture andmaintain their solutions safely and reliably must
be able to draw on rich technological knowhow and application experience. Aspects suchas product and process expertise are fundamental for anticipating emergency situations
and thus ensuring that a swivel actuator in theA380, for instance, or an electric drive in a vehicle is operated correctly and works perfectly
every time. Smart hardware and software embedded in the actuator enables pilot training to
be optimized in flight simulators and helps improve aviation safety. Security through redundant design reduces the environmental risks

WITTENSTEIN Group

when AC servo actuators are used in offshore oil extraction. Our knowledge ofthe hygienic requirements in the foodprocessing industry contributes to thedevelopment of “axenic“ – or germfree – servo actuators and protects
us as consumers by preventing
contamination in foodstuffs.
Industry 4.0 depends on securedata“Data security is a key prerequisite
in the Industry 4.0 landscape“, explains Dr. Bernd Schimpf, Director Mechatronics at WITTENSTEIN
AG. “We can only succeed in interconnecting smart components toform complex production systems if
the data at our disposal is interpreted, transferred and stored accurately
and securely.“ As far as WITTENSTEIN
is concerned, this means that without secure data there can be no reliable communication in intelligent mechatronic drive systems.
Security hierarchies are unknown
Security is a very diverse field; it always plays
an important role and it defies any form of categorization in a priority hierarchy. One or moresecurity, safety and reliability aspects may be
relevant depending on the product or system solution and on the industry and intended application. Safety needs may change – but
WITTENSTEIN will continue to keep a watchfuleye on the “Factor S“, our set of design principles for secure mechatronic drive technology.

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Applications

Oil-free and low-maintenance, small footprint, energy
efficient: the X2000NC processing centre profits inmany ways from the TPM+ power 050.

Modular technology is a claim to which Schmale is deeply committed. “We see ourselves as anengineering consultant that also builds machines“, explains Managing Director Daniel Schmale.
Amongst other things, the company sets benchmarks with its consistent integration of servo
solutions – notably servo actuators – in the construction of machinery and control systems. The
X2000NC processing centre, featuring TPM+ power 050 servo actuators from WITTENSTEIN
motion control, is the latest in a long line of examples: it is driven without hydraulic assist andcontrolled electronically.

18 moveServo actuators for a“hoseless“ future
No hydraulic oil, no hoses, no problems
There are several good reasons why WITTENSTEIN motion
control‘s TPM+ power 050 servo actuators play a central
role in the innovative wire, pipe and strip processing centres
manufactured by Schmale Maschinenbau GmbH in Altena,
about 25 miles south of Dortmund. As key components ofthese oil-free machines they also knock about seventy percent
off energy consumption.

One with the future – Schmale‘s innovative
machine concepts are a good example of how
the WITTENSTEIN vision is transformed into asustainable reality together with the customer.
Schmale heralds in a new era informing technology“The X2000NC constitutes a minor revolution
as the first machine that‘s virtually oil-free“,
says Schmale‘s Andreas Goseberg. As Service & Sales Manager, he is thoroughly familiar
with the key benefits of this system concept.
“The servo axes of the processing centre manage without any hydraulic assist. Instead we
use TPM+ power 050 servo actuators madeby WITTENSTEIN motion control. The decision
to do away with all hydraulic hoses and units
means the spectre of leaks in the hydraulic circuit is no longer hanging over users. What‘s
more, the amount of maintenance work has
been reduced because the hydraulic system
no longer has to be filled, bled and cleaned –quite apart from the problem of disposing of
the hydraulic oil.“
TPM+ power 050: a compact, muscle
packed solution for all servo axes
A motor output of 18.4 kW, maximum acceleration torques of 750 Nm at the output andan overall length of just 346 mm including

the brake and the encoder are what make
TPM+ power 050 motor-gearhead units sucha viable alternative to hydraulic pressure systems when it comes to power and integration.
“In machines with several dozen auxiliary axes,
these servo actuators can reduce the size ofthe footprint by as much as forty percent“,
Schmale enthuses. And as far as energy consumption is concerned, the TPM+ power 050
is a true champion saver. “Sample calculations
with different machine configurations, numbers of axes and cycle rates demonstrate theenormous potential for improving energy efficiency“, confirms sales engineer Andrea Esser
of WITTENSTEIN alpha‘s Engineering OfficeWest in Oberhausen. “Up to seventy percentof the total energy demand can be economized compared to traditional hydraulic manufacturing.“ The machine is far more simple tooperate thanks to the servo driving technology. The electronic control system merely needs
to be told a few parameter values such as thestroke and the number of degrees, which canbe entered on a touch screen. All mechanicalcams have been eliminated from the forming
processes – as has the time consuming taskof retooling the machine. Servo control simultaneously makes the system extremely flexible.

Daniel Schmale: “If the worst comes to theworst, it‘s much quicker to replace an actuator
than to repair a hydraulic problem. The TPM+
power 050 also helps optimize machine uptime, in other words.“
Schmale relies consistently on servo
technology
The manifold advantages have also persuaded
Schmale to rely consistently on Igersheim-built
servo actuators in other projects. “A project
involving several servo actuators in the TPME
500 series is currently under way“, reports
Siegfried Wallauer, Product Manager at WITTENSTEIN motion control. This actuator series
uses a water cooled motor with 107 kW peak
power and 63 kW continuous power. “Owing
to the innovative cooling technology, the continuous power has been doubled and there’s
been a significant improvement in productivity“,
adds Wallauer proudly. “Yet in spite of this highpower density the maximum surface temperature is no more than 50°C.“ Schmale forming
technology and WITTENSTEIN servo actuators
have joined forces to bring the hydraulic era inthis segment to a close and pave the way fora new age.

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Products

1

WITTENSTEIN alpha‘s optimized software tools evidently keep their promise of“more efficiency just a mouse click away“. Feedback so far has been overwhelmingly positive – with satisfied users reporting energy savings, optimal powertrain sizing and even more convenient creation of essential documents.

More efficiency just a mouse click away
Software tools provide access to expert know-how

1

cymex® 3 sizing software: The softwaretool for reliable and efficient drive sizing aswell as optimal power density

2
Online Product Configurators:
Step by step to the optimal solution withall key parameters such as torque, speed,
precision and forces

3
With its intuitive navigation andcustomizable 3D animations, the newest
release of the Info & CAD Finder is moreversatile than everBenefits of WITTENSTEIN alpha softwaretools at a glance:+ With more than 2000 licenses a year thecymex® 3 sizing software is one of themost successful tools of its kind.

+ The three Online Product Configurators
already get more than 18,000 clicks a year.

+ The download figures for the new releaseof the Info & CAD Finder are rising every
month.

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In November 2013, new releases were issuedof three different tools for customized efficiency engineering: cymex® 3, the proven sizing
software, our versatile Online Product Configurators and the comprehensive Info & CAD
Finder. Each of these tools is available online
and makes a perfect complement to the professional consulting expertise of WITTENSTEIN alpha‘s highly qualified engineers. The
operator interface and navigation concept aredesigned to facilitate a short learning curve fornovices or experts and occasional or regularusers alike. Detailed, accurate product selection, sizing calculations and documentation
are now a reality.
Optimized powertrains
The cymex® 3 sizing software has many hidden
talents. Sizing and evaluating complete powertrains is now quick, easy and reliable thanks

to the large, regularly updated database of
motors and gearheads. At the same time, thesoftware is capable of optimally abstracting
all important influencing factors and customer-specific parameters – by identifying extended drive design spaces that are not apparent
simply from the catalogue data. The WITTENSTEIN engineering team‘s longstanding experience “hidden“ in the software is leveraged, forinstance, in order to calculate higher maximum
gearhead loads or reveal downsizing opportunities for the drive system. The benefits for users are undeniable: they profit from reliable andefficient drive sizing as well as optimal power
density.
Online Configurators“What came first, the chicken or the egg?“ This
question of causal links, which will probably
remain unresolved in biology for ever more, is32elegantly answered by our Online Configurators for mechatronic drive technology. It ultimately makes no difference which of the two
you consider first: each user can either selectthe optimal gearhead for their particular application and then add a motor to match (Gearhead-Motor Configurator) or choose a suitable
gearhead for that application and combine itwith a motor that already exists (Motor-Gearhead Configurator). There is a third ProductConfigurator for rack-and-pinion systems,
which likewise provides a fast and convenient
way to configure exact fit components. The
chicken and our software tools do have one
thing in common, however: they both have tobe “fed“. The Online Product Configurators aresupplied with key parameters such as torque,
speed, precision and forces in order to guideusers step by step to the optimal solution. They

are absolutely intuitive to use and all relevant
application and configuration information is visible at a glance. Even drawings and 3D models
can be downloaded with a simple mouse click.
Documentation on demand
The Info & CAD Finder is especially popularwith external users. A broad database comprising more than 11,000 motor types helps
the online tool select the optimal product specifications, CAD files, operating manuals andmotor mounting instructions for each customer‘s individual needs. The complete WITTENSTEIN alpha product range is covered, fromlow-backlash planetary and servo right-angle
gearheads through mechanical systems tocouplings and rotary actuators – and all information is just a mouse click away. Once theproduct has been selected or the solution defined, the Info & CAD Finder is an invaluable

tool not only for compiling the documentation
but also for creating 3D animations or generating complete order codes. Optimal system configuration, efficient sizing, customized
product documentation – well-honed softwareand know-how guarantee consistent efficiency
engineering in mechatronic drive technology.

move 21

WITTENSTEIN motion control recognized the signs of the times early on:“tool drives“, the world‘s first direct drive CNC woodworking system, wasdeveloped a while ago.

Optimized drilling technology: simpler, cheaper, more transparent production!

tool drives
The insights gained in this connection are currently being put to use within a high-tech support programme to safeguard Germany‘s position as a manufacturing location and a centre
for innovation. WITTENSTEIN motion control‘s
new technology is making an active contribution to what could turn out to be a crucial future
project.
Leading-edge achievements withleading-edge clusters
The Leading-Edge Cluster competition was
launched by the Federal Ministry of Education
and Research in the summer of 2007 under
the slogan “Germany‘s Leading Edge Clusters – more innovation, more growth, more
employment“. In one of these clusters – “it‘s

22 move

OWL“, Intelligent Technical Systems OstWestfalenLippe – Ostwestfalen-Lippe University ofApplied Sciences is cooperating with WITTENSTEIN motion control and its tool drives Business Division. it‘s OWL is presently engaged
in the development of intelligent direct drives
for furniture production in the framework of thegovernment funded “NoVHoW“ project (novel,
self-optimizing feed for high speed drilling withdirect drive spindle systems in the mechatronic
CNC system construction kit). The goal is tomake the machining processes more flexible,
more precise, more repeatable, more resource
efficient and more economical. There are numerous drilling systems still in use where themain drive‘s rotary power is distributed to themachine tools of a rigid drilling head by the pinions, belt drives and deflection gears – which
are forced to rotate too if the drilling plan does
not show any holes to drill. The self-optimizing,
individually controllable drill drives designed by
the it‘s OWL cluster represent a new technology which, though still in its infancy, offers awhole string of benefits for engineering firms
and furniture makers. It improves the quality
and precision of the drilling process while significantly reducing energy consumption, not tomention the time and effort for adjusting andmaintaining the drilling spindles and machine
tools. This project could potentially double theproductivity of woodworking machinery – atruly leading-edge achievement!

Projects

Leading-edge technology protects Germany‘s position“it‘s OWL“– a Leading-Edge Cluster
Intelligent Technical Systems OstWestfalenLippe
The intelligent products and production systems developed by cluster partners in 45
projects worth a total of 100 million euros
will hopefully generate fresh momentum forGermany as a manufacturing location and acentre for innovation. WITTENSTEIN motion
control is one of 24 core companies. In the“NoVHoW“ cluster project, WITTENSTEIN is
engaged in joint research with its partners
at Ostwestfalen-Lippe University of Applied
Sciences, the laboratory for power electronics and electric drives and the laboratory forwood and production technology.
One part of this project, which will run until
September 2014, involves the developmentof a demonstration model for self-optimizing drilling processes. WITTENSTEIN and Ostwestfalen-Lippe University will show the
new system at the Hanover Fair 2014 (Hall16, Stand A04).

More than the sum of its component parts:
tool drives – the mechatronic system construction kit.

Top-level research and a technology
shift as an opportunity for the furnitureindustry
The cluster thus acts as a driver of innovation for one of Germany‘s core industries ina difficult economic climate. The associationof the German furniture industries (VDM) estimates around 16.1 billion euros in sales for2013 – down approximately 3.5 percent on
the figure for the previous year. At the sametime, furniture making is one of the Federal
Republic‘s biggest economic sectors – withnearly 90,000 people employed at more than
500 companies. Germany is the most important market, accounting for some seventy
percent of the total turnover – despite fierce

competition from foreign manufacturers sellingat cut-throat prices. In this kind of environment,
where flexibility, productivity and cost efficiency are more vital than ever, crucial long-term
growth momentum can be generated by implementing the outcomes of the “NoVHoW“
research project. Experts see the tool drives
concept with its self-optimizing drill drives aslaying the foundation for a new generation ofmachinery and equipment concepts in theGerman furniture making industry – absolutely
in line with the objectives of the Leading-Edge
Cluster competition.

move 23

WITTENSTEIN international

FIRST® LEGO ® League:
With WITTENSTEIN on
a journey to the world championshipThe robot (red bricks) designed by “Electronic Machines Schiers“is capable of solving the most diverse kinds of challenge. In theconfiguration shown here it is lifting a house which is under threat ofbeing flooded with the help of an ingenious, electropneumatic add-on
module.

24 moveChur, Locarno, Paderborn, Pamplona – these are the stages on
the Electronic Machines Schiers (EMS) team‘s impressive march
to the “Robotics Competition“ championship in the FIRST® LEGO®
League (FLL). The successful team – five pupils from Evangelische
Mittelschule, a private, state-approved school on a Christianfoundation in Schiers in the Swiss canton of Grisons – is receiving
moral and financial support from a near neighbour: WITTENSTEIN
Switzerland resides just down the road in Grüsch.

move 25

WITTENSTEIN international

Brilliant if it works: The “Electronic Machines Schiers“ team“rocks“ the FIRST® LEGO® League.

The FIRST® LEGO® League (FLL) is aworldwide programme, which, since its inception in 1999, has attempted to capture
young children‘s inherent curiosity anddirect it toward discovering the wondersof science and technology through arobotics competition in combination witha research mission. More than 200,000
teams from around the globe took part inlast year‘s competition, which was initiatedby FIRST® (For Inspiration and Recognitionof Science and Technology), an American
non-profit organization, and LEGO®, theDanish toy manufacturer. Apart from themobile robots‘ table performance, the jury
also awards marks for their mechanical andsoftware design.
Teamwork, motivation and stamina in agroup context are core ingredients alongwith each team’s general strategy fortackling the scientific research project anda presentation related to the challenge
theme. The competitions are organized ona regional, country and finally international level. The top European teams, like
“Electronic Machines Schiers“ in 2013
for example, are subsequently invited totravel to the FLL World Festival – the world
robotics championship.

26 move“We think it‘s fantastic the way youngsters are
introduced to science and technology in theatmosphere of a sporting competition.“ Armin
Jud, Business Division Head, is the WITTENSTEIN contact for the EMS team, which wasformed in 2010. Last year, for the first time, theschool also entered a junior team sponsored
by WITTENSTEIN in addition to “Electronic
Machines Schiers“: the “Robotic Pirates“ camesixth in the regional competition, a very encouraging result.
Robots arouse interest in mechatronics
LEGO® – there‘s probably no other toy in theworld that has remained so well-known over
several generations. “I‘m reminded of my own
childhood“, Jud admits, “though nowadaysit‘s something completely different. There‘smuch more to it than simply assembling plastic
bricks; LEGO® today is the preliminary step on
the way to developing mechatronic systems.“
The toy manufacturer also provides the necessary electronics and software for its LEGO®
Technic sets through its Mindstorms series. You
can buy programmable bricks as well as electric motors, sensors and assorted other parts
such as gears, axles and pneumatic components which can also be used to design andprogram robots. Every year, between 100,000
and 200,000 girls and boys worldwide have achance to draw on unlimited technological resources in the FFL. “Their experience on thissmall scale is very similar to ours on a muchlarger one“, Jud comments on the surprisingparallels between the robotics competition andreality. “Not every technically sound approachis also stable and not every design is failsafe
and convertible – and the quality of the teamwork can make a huge difference. In the end,
though, it gives a tremendous boost to theseyoung people when their own ideas actuallywork in practice.“ Their enthusiasm increases even more if – like the Swiss EMS team –they end up among the FLL champions. Afterbeing named runners-up at the regional competition in Chur last November, they went on to
victory only three weeks later at the Semi-Final
Switzerland in Locarno. The list of successes
has got even longer in 2014: at the Final Central Europe in Paderborn (Germany) at the endof January the team qualified for the FLL Open
European Championship in May in the Spanish city of Pamplona. In finishing eighth, they
beat not only sixteen other teams at the event
itself but also the awesome 858 who originallyentered the qualifying rounds throughout Central Europe. “It will certainly be another toughchallenge in Pamplona“, anticipates Matthias
Liesch, team coach and teacher. “More than
three thousand participants in ninety teams
from seventy different countries are expected
to be there – and we want to rock them all!“Trade Fairs

Trade Fair Calendar
2014

Hanover Fair

Eurosatory

Hanover (Germany)
Industrial Automation, Hall 15, Stand F08
WITTENSTEIN Group
April 4 to 11, 2014

Paris (France)
International Exhibition for Land andLand-Air Defence
WITTENSTEIN motion control GmbH
June 16 to 20, 2014

OTC
Houston / Texas (USA)International Offshore Technology Conference
WITTENSTEIN motion control GmbHMay 5 to 8, 2014

components
Dusseldorf (Germany)
Platform for Components andAutomation Solutions – Especiallyfor the Packaging Industry
WITTENSTEIN alpha GmbH,WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbHMay 8 to 10, 2014

MECANICASão Paulo (Brazil)International Machinery Trade FairWITTENSTEIN do Brazil
May 20 to 24, 2014

Farnborough International Airshow
Farnborough (UK)International Aerospace Exhibition and Airshow
WITTENSTEIN aerospace & simulation GmbH
July 14 to 20, 2014

World of Technology & Science
Utrecht (Netherlands)
Forum for Technology
WITTENSTEIN bvba
September 30 to October 3, 2014

Motek
Stuttgart (Germany)International Trade Fair for Assemblyand Handling Technology
WITTENSTEIN Group
October 6 to 9, 2014

Forum Maschinenbau
SPS IPC Drives Italia
Parma (Italy)
Exhibition for Electric Automation
WITTENSTEIN S.P.A.
May 20 to 25, 2014

Bad Salzuflen (Germany)
Trade Fair for Suppliers in the
Machinery Manufacturing Industry
WITTENSTEIN alpha GmbH,WITTENSTEIN cyber motor GmbH,WITTENSTEIN motion control GmbH
November 5 to 7, 2014

BIEMH
Bilbao (Spain)
International Machine Tool Exhibition
WITTENSTEIN S.L.U.
June 2 to 7, 2014

Metalloobrabotka

SPS/IPC/Drives
Nuremberg (Germany)
Exhibition for Electric Automation –Systems & Components
WITTENSTEIN Group
November 25 to 27, 2014

Moscow (Russia)
International Exhibition for Materials
Processing Technologies,
Machines and Tools
WITTENSTEIN alpha GmbH
June 16 to 20, 2014

move 27