move

The magazine for customers and partners of WITTENSTEIN AG

April 2015

DISCOVER INFINITE POSSIBILITIESWorld first: Galaxie Drive Systemrevolutionizes high performance engineering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)
Issue:
14 / April 2015
Circulation:
German: 4000 copies
English: 1000 copies
Production:
IMMAGIS
Franziskanergasse 1
97070 Würzburg / Germany
All rights reserved. This document may
not be reprinted or electronically distributed without the express permission of
the publisher.

2 move4

Interview with Thomas Bayer,
Head of Galaxie Drive Systems WITTENSTEIN AG

8World first: Galaxie Drive System revolutionizes
high performance engineering

12More precision and performance for a packaging line
WITTENSTEIN alpha GmbH

14

"Master movers" drive automated guided vehicles
WITTENSTEIN motion control GmbH

16

Precise dispensing – with precisely dosed driving power
WITTENSTEIN cyber motor GmbH18

The latest generation of servo actuators
WITTENSTEIN motion control GmbH

20

Services as a crucial competitive factor
Customer Service

24

7th European Opera Singing Competition: DEBUT 201426

Trade fair calendar 2015

Dear readers,
Examples of visionary personalities abound throughout history – leaps in terms of productivity, quality and energy consumption.
revolutionary inventors like Leonardo da Vinci or James Watt The cornucopia of new possibilities is seemingly infinite. Don't
who do things in a different way to anyone else before them. just take our word for it – see for yourself at the Hannover Messe
Not only that but they also do them fundamentally better. In the 2015! Come along and visit us in Hall 15, Stand F08, and "disbeginning is always what appears to be an impossible objec- cover infinite possibilities". This motto will continue to motivate
tive. To achieve it, existing design strategies must be completely and inspire us long after the exhibition week is over, howevoverturned and rebuilt. A "no compromise" approach – or put er. Every single day rapid technological advances, embedded
another way, unlimited power – must be the guiding principle. in globalized business flows, leave us – and our customers allover the world – with no option but to question the status quo.
For several decades now, WITTENSTEIN has enjoyed a global Engineering services to facilitate self-optimization and diagnosreputation for innovation and excellence in the field of mecha- tics are nowadays increasingly important alongside accelerated
tronic drive technology. Over the last few years, technology pi- development processes.
oneers at our family firm have subjected drive concepts to a The reason is Industry 4.0: in the factories of the future, intelfundamental, no-compromise reassessment. The outcome: a ligent cyber-physical production systems will exchange digitalunique combination of specifications that were hitherto unat- information continuously. They will lay the foundation for servictainable. The Galaxie Drive System is a genuine world first with es and software to identify weaknesses in a machine before sea brand new gearhead generation at its innovative core. It is a rious problems develop. As with the new Galaxie Drive System,
German invention which fills us with pride and which is set to WITTENSTEIN is your innovative partner for tomorrow's world –revolutionize high performance engineering. It will enable auto- the world we all inhabit together. With all the opportunities ofmated manufacturing processes to make huge developmental infinite possibilities.

Karl-Heinz Schwarz

Professor Dieter Spath

Board of Directors WITTENSTEIN AG

Chairman of the Board and CEO WITTENSTEIN AG

move

3

Thomas Bayer, Head of Galaxie Drive Systems at WITTENSTEIN AG, explains the revolutionary kinematics behind the Galaxie Drive Systemwith the help of a functional model.

4 movemove talks to:Thomas Bayer

The brand new Galaxie Drive System provides the next machine generation
with productivity, precision and dynamics many times greater than has everbeen possible in the past. "These are real, verifiable results that have beenreported to us by our customers", explains Thomas Bayer,
Head of Galaxie Drive Systems at WITTENSTEIN AG. A seasoned engineer
and inventor, he takes a look back at the creation process.

move

5

Interview»The logarithmic spiralis a fundamentally new function forgear teeth that was discovered and developed by us.
It has yet to feature in any textbook.«
Thomas Bayer, Head of Galaxie Drive Systems at WITTENSTEIN AG

move: There are already several very mature precision gearheads based on the hollow shaft principle in the market today.
What made you decide to invent and develop a brand newgearhead generation?
WITTENSTEIN specializes in innovations in the gear sector. Our planetary gearheads, in particular, are among the stiffest and the mostprecise on offer anywhere. Although they still hold potential for optimization, we could see no likelihood of any major developmental
leaps. I therefore started wondering what form the gearheads ourcustomers need for the next generation of high performance machines could take. All gear concepts – spur gears, planetary gears,
hypoid gears, Harmonic Drive principles, eccentric gearboxes andcycloidal gears – have specific strengths and weaknesses. I couldn't
think of one that performs equally well regardless of the application,
however. Stiffness, load carrying capacity, zero backlash, precision,a large hollow shaft and so on − we were looking for everything at
once and much, much better!
So where did you find the hidden potential you were just waiting to unlock?
The majority of teeth on a gear only rarely engage – they just turn idly.
Involute teeth make linear contact, which severely limits the transmissible torques owing to the high Hertzian pressure. Those two basic
problems of all gearboxes add up to considerable wasted potential!
How did you solve those problems?
There are two main toothing types in gear design: involute and cycloid plus a few subtypes. The logarithmic spiral is a fundamentallynew function for gear teeth that was discovered and developed byus. It has yet to feature in any textbook. Spirals also exist in nature.
Many species of plants, the shell of a snail and even galaxies in outerspace are "designed" according to the logarithmic spiral principle.
That's why "Galaxie" was an obvious choice of name for the newdrive system.
What sets the Galaxie Drive System apart from other typesof gearhead?
We developed the tooth contact as a true ring gear based on thelogarithmic spiral! The gearwheel is segmented into individual teeth,
which means that almost all of them can now engage simultaneously.

6 moveCompared to even the best helical-toothed planetary gearheads the
Galaxie Drive System has a 6.5 times larger torque transmission surface! We verified that with FEM. The Galaxie Drive System achieves
several times better torsional rigidity and overload capability thanother gearhead types without any increase in physical volume. All
contacts were developed with low surface pressure in mind. A hydrodynamic lubricating gap forms both in the guide holes of the individual teeth and in the gearing itself. Up to 91 percent efficiency has
already been measured for this high-ratio gearbox. At the same time,the drive boasts extreme precision and virtually no backlash.
Do the gearhead's new teeth and kinematics also provide
exactly uniform transmission?
Indeed – perfectly uniform transmission is achieved if the input polygon is designed to ensure a sliding movement of the individual teeth
along the ring gear – both following a logarithmic spiral as tooth geometry. A suitable polygon first had to be developed to drive theteeth. A bi- or triangular bearing was therefore needed. That meant
we had to invent and develop a rolling contact bearing with a polygonal inner race ring and a segmented outer race ring.
What other advantages does the Galaxie gearhead have forusers?
The gearhead is virtually wear-free; even after running 24/7 for two
and a half years, it shows no increase whatsoever in backlash. It caneven be realized with zero backlash by selecting the parts accordingly – without any reduction in the maximum transmissible torques!
Since there is no measurable wear, it remains permanently backlash-free. There's one more defining feature I should mention: thebacklash-free version of the gearhead retains its full, incredibly highstiffness at the zero crossing, even with alternating loads. What'smore, it combines the largest hollow shaft with a very low noise levelthat isn't perceived to be a nuisance. And to get the same torques
as we do with the Galaxie, we'd have to build any other type of gearhead at least two, if not three, sizes bigger.
Won't the electric motor need to be relatively large in order toexploit the gearhead's full potential?
WITTENSTEIN cyber motor developed an extremely high powered
motor for the Galaxie Drive System and tuned it specifically to thegearhead's characteristics. The motor and gearhead form a mechatronic unit of roughly equal diameter and length. The integrated sensors are designed to fuse this newly developed high performance
motor with the gearhead, forming an ultra-compact, hollow-shaft
drive system with Industry 4.0 connectivity.
What benefits can engineers realize with the Galaxie Drive
System?
The Galaxie Drive System beats all rival products hands down in allimportant details. Despite this, it doesn't cannibalize other systems
because the production costs are still higher at the moment. However, in the last two years our lead customers have discovered thatwith up to 580 percent more stiffness and far greater precision in
production use, the Galaxie Drive System easily breaks through traditional limits and enhances productivity dramatically. Against thisbackground, the price of the Galaxie Drive System is undoubtedly
secondary.
Could you describe a few concrete applications?
The Galaxie Drive System significantly extends the life of machine
tools because it unites permanent freedom from backlash withextreme stiffness and precision. Higher cutting speeds and feed
rates are possible as a result. There's also a clear improvement in

manufacturing quality. The moving cutting heads required for machining are only half the normal size, and even more compact andpower dense are no longer a problem. The Galaxie Drive Systemis particularly ideal for the A, B and C axes of precision machines
as well as for wafer handling axes or whenever precise rotational
and tong movements and very high forces are essential but spaceis limited. It also represents a very attractive alternative to expensive
direct or tensioned drives because it is permanently backlash-free.
It's now up to engineers to completely rethink their existing machine
designs and realize developmental leaps that have never been possible in the past.
Why did WITTENSTEIN wait a good two years before goingahead with the official market launch? Wasn't the market ripeenough?
The market was certainly ripe. However, the functional principles –like the hydrodynamic tooth contact over the full surface and the
Galaxie Drive System's kinematics – are so fundamentally new andthe results for all important parameters so enormously improved that
we didn't want to be accused of simply blowing our own trumpet. We
believed that testimonials from the first real customers would carry
more weight. After more than two years in production use, the time
has now come.

move

7

Produktion der Zukunft

8 moveIt's the kind of innovation that only happens once every fifty years, amasterstroke of engineering, a brand new gearhead generation –WITTENSTEIN's new Galaxie Drive System has already been showered withpraise by users. "The innovative core is formed by the completely redesigned
gearhead kinematics, where each tooth is an independent and dynamic
entity, and the hydrodynamic tooth contact over the full surface", reports
Thomas Bayer, Galaxie's inventor and Head of Galaxie Drive Systems at
WITTENSTEIN AG. The decision to dispense with the gearwheel as thegearhead's key component and the innovative tooth geometry mean Galaxie
can unleash forces that no-one ever imagined were possible before.

Galaxie Drive Systemrevolutionizes the stateof the art

Discover infinite possibilities• 6.5 times larger tooth contact surface than with a planetary gearhead• Up to 5.8 times more torsional rigidity than any gearhead of comparable design
currently available in the market• Three times better overload capability than cycloid gearheads• Extremely high stiffness at the zero crossing in the backlash-free version• Excellent dynamic positioning accuracy as a result• No measurable wear = no increase in backlash• Best efficiency in its class• Exceptionally quiet operation even at maximum loads

All performance features upgraded – "no compromise" approach"Galaxie's kinematics represent a paradigm shift with far-reaching consequences for electric drive
technology", says Volker Sprenger, Head of Sales Galaxie Drive Systems, WITTENSTEIN AG. For
the first time, it isn't just one or two performance features such as load carrying capacity, torsional
stiffness or dynamic positioning accuracy that are upgraded by a new gearhead but all features
simultaneously.
And the improvement is not just a few percentage points but several times over. It's been several
decades since new doors were last opened so wide. Engineers and designers are now all set todevelop the next generation of high performance machines and launch into a totally new universe
with Galaxie.

move

9

Innovative core:
Gearhead kinematics reinvented
Galaxie is the key to a revolutionary new way of
thinking in drive engineering. For the first time
ever, a gearhead dispenses completely with a gear
wheel – instead, each of the 24 teeth involved
in torque conversion is an independent anddynamic entity, which is supported by a needle
roller bearing, grouped around a non-circular input
polygon and guided along the teeth of a ring gear.
As a result of this principle, almost all teeth now

Record breaking in every discipline
Thanks to its revolutionary new kinematics, the Galaxie Drive
System is light years ahead of all rival gear principles today, regardless of the drive engineering discipline. The tooth contact
surface is extremely large and the hydrodynamic lubrication film
guarantees a constant pressure distribution with neither friction
nor wear; the teeth which engage are hardly deformed at all andthe automatic alignment results in an optimal transverse load
distribution. Owing to the design principle, the Galaxie Drive
System allows very large hollow shaft diameters. It is thus extremely compact even when high torques are specified – opening up enormous downsizing potential for designers.
"All this will make Galaxie the enabler for the next generation inhigh performance engineering", Volker Sprenger predicts. His
optimism is not entirely unfounded; after all, the first customer
projects in the metalworking, robotics, handling technology andmachine tools sectors are already offering impressive confirmation – for instance, with up to double the usual productivity.

The new Galaxie kinematics
give a tooth contact
surface which is about 6.5
times larger than with ahelical-toothed planetary
gearhead.

engage simultaneously and participate in thetorque transmission process, contributing to thetorsional rigidity. "No standard gearhead types in
the market today do it that way: normally, only a
few of the teeth engage at once while the rest justturn without actually doing anything", explains
Thomas Bayer. Another fundamental differenceis that the novel tooth geometry corresponds toa logarithmic spiral. In contrast to conventional
technologies, the tooth contact is no longer a line
but a surface.
Benchmark calculations with a helical-toothed
planetary gearhead show that the new Galaxie
kinematics give a tooth contact surface which
is more than six times larger for the same hollow
shaft diameter. In addition, a hydrodynamic lubrication film is built up by the teeth in contact –even at low speeds and up to very high torqueloads.
The sum of these features – Galaxie's multiple
teeth, surface contact and hydrodynamic lubrication – leads to a unique combination of specifications that were hitherto unattainable.

10 move

Benefits for industry...
The Galaxie Drive System is a technological innovation that wasdeveloped explicitly for industrial applications. Its stiffness andits permanent freedom from backlash, for example, permit machine tools with a longer life, higher cutting speeds, more dynamic feed rates and highly precise motion control, especially atreversal points. All of this results in higher productivity and lower
unit production costs. Thanks to Galaxie's high power density, it
is now possible to design more compact machines and optimize
the weight of robot structures or other handling actuators. Moreeconomically efficient machine concepts – as well as major productivity and quality improvements – can be achieved by using
Galaxie as an alternative to expensive direct drives.

Products

Learn more about the
Galaxie Drive System

The Galaxie Drive Systemfuses a brand newgearhead generation
with a newly developed
high performance motor,
forming an ultra-compact
hollow-shaft drive systemwith integrated Industry
4.0 connectivity.

the environment and...
True innovations are also characterized by the attention that is
paid to environmental compatibility and the benefits for society. The high efficiency which is built into the Galaxie Drive System also means less energy consumption. A compact design
can be accommodated in a smaller space – and the smaller thedrive system, the lower the material usage, CO2 emissions andenvironmental impact when the machine is manufactured. Better process and product quality automatically implies fewer tool
failures and less scrap – and hence less wastage of valuable
resources.

...society
Sustainability arguments are a very effective way to make surean innovation like Galaxie gains rapid social acceptance. Energy
efficiency through reduced power consumption is one important
aspect. An overload-proof design for the drives used in windturbines, leading to a long service life with low costs for maintenance, is another. In the medtech sector, the Galaxie Drive
System's extremely high torque density and overload capability
pave the way for new exoskeletons for the elderly and disabled.
The combination of very high power density and very small size Technological highlight at Hannover Messe 2015is also an advantage in space travel – as long ago as 2012, a After almost three years of continuous operation in selected
total of four Galaxie Drive Systems were on board the SHEFEX II industries and applications, WITTENSTEIN will officially unveil
sounding rocket launched by the German Aerospace Center the Galaxie Drive System at the Hannover Messe 2015. It will
(DLR). Their mission in this exciting development project for a then be up to designers and engineers to realign their existing
future space transporter was to drive the craft in such a way that machine concepts to the Galaxie Drive System and make real
active position control and vibration damping would be possible developmental leaps in terms of productivity, quality and energy
on its re-entry into the Earth's atmosphere. The Galaxie Drive consumption. Traditional markets and applications will undoubtSystem won the contract because it was the only candidate that edly be joined by many new ones, for which a power dense drive
met the requirements for size, weight and robustness in every system like Galaxie has so far been lacking.
respect.

move 11When it comes to packaging consumer goods, no compromises are allowed –speed, precision and optimal availability are vital. That's why the designers at sema
Systemtechnik of Hüllhorst (Germany) put their trust in gearhead technology madeby WITTENSTEIN alpha.

Precision and performancefor 34,000 yoghurt cups per hour

The packaging machinery specialist has an easy task convincing customers like Yeo Valley of the advantages of worm, bevel
and planetary gearheads made in Igersheim. sema recently built
a high speed carton sleever for this British manufacturer of dairy
products, which is rated for a throughput of 34,000 cups perhour, twenty-four hours a day and seven days a week.
Carton sleever transforms individual cups into sales
friendly multi-packs
The carton sleever designed for Yeo Valley's dairy products
transforms the individual yoghurt cups entering the machine intotransport and sales friendly multi-packs. The sleever is loaded inthree different ways: with the filled and sealed cups, with blanksleeves from a magazine and with pre-folded trays supplied by
an upstream sema tray former. Screw conveyors inside the machine separate and position the cups precisely in four lines. Dualaxis robot modules each pick up four double cups and insert
them into the blank sleeves, which are cycled into the machinein four lanes. The sleeves are then glued to the flaps with hot
melt adhesive in the sealer – a process that calls for similarly
precise handling. Finally, sixteen containers per cycle, each with
2x2 stacked cups, are placed in four pre-positioned trays byanother robot module and conveyed to the next step. Wolfgang
Beckmann, Manager Packaging Solution Design at sema, is visibly proud of the machine's performance: "The carton sleeverdelivers up to 17,000 single-layer multi-packs an hour in this way
with a cycle time of 3.4 seconds".
Extreme precision, extreme reliability – experience pays
He and his team realized all servo applications in the carton
sleever with gearhead solutions from WITTENSTEIN alpha.
Beckmann is particularly admiring of the V-Drive+ series of servo worm gearheads – and that isn't just because of their foodgrade lubrication: "Throughout my fifteen years in the engineering profession, this gearhead type has consistently proved to
be absolutely dependable. It also convinces me with its efficiency, excellent performance data, high overload protection
and very low operating noise." All in all, about a dozen of these
V-Drive+ gearheads are installed in the Yeo Valley line: at themain drive and for feeding the sleeves, gripping the cups, gluing the sleeves or placing the multi-packs in the trays. "Whendynamic positioning is called for, the high precision they allow
in all these functions is quite awesome", Beckmann confirms.

12 move

V-Drive+
All in all, about a dozen servo
worm gearheads in the
V-Drive + series are installedin the carton sleever's various freely programmablerobot units.

Applications

LPBK+
LPBK+ right-angle gearheads on a
special separating system makesure the trays are accurately positioned and spaced before the sleeved
products are placed in them.

LPB+

Generation 3

LPB + Generation 3 planetary gearheads help position the sealed cups
exactly on screw conveyors.

The special tooth geometry of the V-Drive+ gearheads assuresthe constant, lifelong accuracy that is vital in high-precision servo applications such as this. "Owing to their hollow-flank teeth,
the increase in torsional backlash that is normally accepted overtime is virtually zero", explains Karl Schmitt, Product Manager at
WITTENSTEIN alpha GmbH in Igersheim. "This geometry also
permits higher efficiency and there is no tendency to slip back,which could be detrimental to the precision of the motions. As aresult, the V-Drive+ gearheads achieve constant, high positioning accuracy."

The sema carton sleever at Yeo Valley is rated for a throughput
of 34,000 cups per hour, twenty-four hours a day.

Specialist for secondary and tertiary
packaging solutions
sema Systemtechnik GmbH & Co. KG
sema Systemtechnik – at home in Hüllhorst,
twenty miles north of Bielefeld in North-Rhine
Westphalia (Germany) – has been in the packaging technology business for about four years
now. The firm develops and distributes clean
design systems for packaging, transporting,palletizing, erecting and re-packing primary packaged products in cups, jars, cans or dishes. Tray
formers, top loaders, case packers, re-packers
and carton sleevers are in great demand in thedairy and food processing industries.

All gearhead technology from a single supplier
In addition to the servo worm gearheads, sema also trusts in
WITTENSTEIN gearhead technology elsewhere throughout
the machine: right-angle gearheads in the HG+ series for handling the blanks in the sleeve magazine and LPB+ Generation 3
low-backlash planetary gearheads on the screw conveyors toposition the cups before they are gripped by the robot modules.
Innovative, technically reliable and economical – these are thehallmarks of the WITTENSTEIN alpha gearheads installed insema Systemtechnik's packaging machines.

move 13

Applications"Master movers"
drive automated guided vehicles

TAS
Intralogistics is their domain:
Automated guided vehicles – or AGV for short – glidearound the factory as if by magic; they dodge obstacles, stop off at docking stations and are capableof driving forwards, backwards and sometimes
even sideways. The vehicle masses moved in thisway, either with or without a load, can be anythingfrom a few hundred kilos to ten tons or more. AGVs
are powered by electric drives. DS AUTOMOTION has
realized a flexible transport solution for engine assembly on behalf of John Deere, Germany's biggest
manufacturer of agricultural machinery, based on
TAS, the innovative traction drive system fromWITTENSTEIN motion control.

Until recently, vehicle manufacturers tended to put their drive systems together themselves using standard components. However,designing and sizing your own drive takes time and compact, energy
efficient solutions offering high power density are rare. Moreover, important features such as speed sensors, service brakes or integrated
safety technology are frequently missing. Thanks to TAS, the innovative traction drive system, all these limitations are now a thing of thepast. WITTENSTEIN motion control's "master movers" have alreadyimpressed early adopters with their operational performance.
Four performance classes in plug-and-play design
Install it, switch it on and go – TAS is a traction drive system thatlets manufacturers of automated guided vehicles (AGV) purchase acomplete drive unit as an easy-to-integrate module. Per vehicle axle

14 move

this module comprises two servo actuators belonging to the TPM+
family and distributed servo amplifiers in the simco drive series. "We
supply TAS as an integrated motor-gearhead unit in four different
performance classes and sizes", explains Elena Eberhardt, a sales
engineer in WITTENSTEIN motion control's Industrial Systems Business Division. "At the same time, the drive systems are designed toadapt very easily to a wide range of AGV solutions." Regardless ofthe version, the TAS doesn't simply drive the vehicle; as a differential
drive, it is also capable of steering it. Steering and turning are controlled according to the speed difference between the two drives on
the vehicle axle.
Ingenious, energy efficient design
A TAS features a whole series of technical highlights that are essential for AGV applications. The gearheads are integrated directly inWITTENSTEIN traction drive systems (TAS) are used at
John Deere in Mannheim in automated guided vehicles
for the flow assembly line.

the driving wheels, for instance, so that on the one hand, no valuable space is wasted in the warehouse and on the other, each TAS
is exceptionally compact and slim. "Amongst other things, this is aparticular advantage for hospital logistics, where the vehicles often
have to drive underneath the load in order to pick it up", says Wolfgang Hillinger, Business Unit Manager Customized Solutions at DS
AUTOMOTION in Linz (Austria), one of the leading manufacturers ofautomated guided vehicle systems. The low energy consumption ofthese integrated drive units is a further highlight: the less electricity
they consume, the longer the driving cycles and the charging intervals, in other words the higher the availability of the vehicle.

John Deere engines assembled using TAS
DS AUTOMOTION has realized a flexible, high availability
transport solution for the agricultural engine assemblyline at John Deere's Mannheim plant. A three-minutevideo clip on YouTube shows how the AGVs there – poweredby TAS – transport heavy loads from one assembly station
to the next. The traction drive systems installed in the vehicles are almost invisible yet utterly convincing with theirquiet running, low energy consumption and high reliability and availability. The TAS concept meets all the requirements for tomorrow's AGV drive solutions –as confirmed by the large number of visitors it
regularly attracts at international exhibitions
like LogiMAT.

move 15

Applications

Global supplier of dispensing systems
for processing reactive resins
bdtronic GmbH is one of the world's leading manufacturers of machinery, equipment and complete
processing solutions for dispensing, impregnation,
hot riveting, low and atmospheric pressure plasma
treatment and related automation tasks. Its customer
base includes numerous big names in the automotive
and automotive supplies industries, the electric andhybrid drives sectors, electric, electronic and solar
products as well as filters and medical technology.
Approximately 200 staff have helped write the company's success story at the main plant in Weikersheim(Germany) and at various sales and service offices
in Belgium, Italy, the U.K., the U.S. and China. To date,bdtronic has shipped more than 3000 units to customers all over the world.

Single and two-component reactive resins such as polyurethanes,silicones, epoxy resins and thermal conductive pastes are processed in
the dispensing machine with high precision and reliability.

Getting the mixture exactly right is vital – notonly when dispensing medicines or baking
a cake but also in mechatronic drive technology. bdtronic dispensing machines forprocessing reactive resins are a good example of what this actually means in practice.
This world market leader from south-west Germany is excellently prepared to meet ever higher customer expectations – such as increased
positioning and dispensing accuracy or optimal machine productivity – whenever necessary thanks to a comprehensive drive solution
developed by WITTENSTEIN cyber motor.
Reactive resins – and what they're for
Polyurethanes, silicones, epoxy resins andthermal conductive pastes are all typical single
and multi-component reactive resins. They are
employed in all kinds of industrial processes –encapsulating cable penetrations and sensors,sealing casings, bonding vehicle door handles,
spraying protective coatings onto PCBs andelectronic components or applying foamed
gaskets to windows and filters. "Every material
has different dispensing properties and evensubstances with the same name but fromdifferent manufacturers – whose properties

The performance of the simco drive servo amplifiers is perfectly
matched to the performance potential of the cyber dynamic 40 servo motor with its fast current control and high current resolution.

16 movePrecise dispensing –with precisely dosed driving powershould theoretically be identical – frequently
react in different ways in real processes. The
quality of the processed material must conform to the specification in spite of this, in otherwords it must have the right mixing ratio andit must be homogeneous and fluid with noair bubbles, to ensure an optimal output rateand dispensing results", replies Markus Rieger,
Sales Manager Germany at bdtronic, when
prompted to describe the challenges facing
fully automated dispensing machines.
Premium performance from a brushless
DC motor
Yet finding a reliable way to control such heterogeneous influencing factors is not the sole objective. "The market is demanding increasingly
high levels of dispensing precision and repeatability", Rieger continues. One technologicalapproach favoured by bdtronic for mastering
these challenges is the so-called Performance
package, which is comprised of a simco drive
servo amplifier and matching brushless DC
motor in WITTENSTEIN's cyber dynamic line
family. "The cyber dynamic 40 servo motors
have an integrated planetary gearhead. Whenthey drive our progressive cavity pumps, eventiny quantities of no more than a few microlitres can be dispensed extremely precisely",
he explains, adding: "The simco drive servo
amplifier controls everything so accurately that
we can regulate each dispensing flow rate individually, reduce our tolerances to a minimum,
achieve repeatable results and ensure optimal
process control".
Comprehensive solution for optimized
performance
The cyber dynamic 40 servo actuator and thesimco drive servo amplifier chosen by bdtronicinteract optimally with one another in a mechatronic package – and are the ideal drive solution. The cylindrical design of the servo motor
matches the dispensing systems perfectly.
With a length of just 81 mm and a maximum
torque of 12 Nm depending on the mounted
gearhead, the motor also provides high torquedensity – while weighing no more than 700 or
900 grams. The dispensing systems are often
integrated in moving gantry axes, and theserequire much less kinetic energy than withcomparable servo motors. "The brushless DC
motors also reduce the need for the complex
mechanical adapter parts between the motor

and the dispensing pump that are normallymandatory for integrating non-WITTENSTEIN
motors which are bigger in size", Rieger comments. The simco drive servo amplifier combines very high-resolution current control inmeasuring applications with fast current sensing. "These features enable even the smallest
quantities to be pumped exceptionally precisely, even if the travel speeds of the gantry axes
vary", he confirms.
The optimized performance of the brushless
DC motor system is not simply a product ofchance: the unique demands of the application were analyzed in close cooperation between bdtronic and WITTENSTEIN. This dialogue between engineers and techniciansat the two companies resulted in a perfectly
matched solution that meets the specific requirements of the dispensing machines reliably.

The cyber dynamic line family of brushless DC motors is offered in four sizes with a 17 mm, 22 mm, 32 mm
or 40 mm diameter and is suitable for all performance ranges from 25 to 335 watts.

move 17

With their incredible power density, outstanding flexibility and high energy efficiency,
WITTENSTEIN motion control's new servo actuators represent a genuine innovation inmechatronic drive technology. The stylish, functional housing underlines the futuristic concept
by emphasizing the technological aesthetics of each performance class in this product family.
Thanks to the interfaces for Endat 2.2, DRIVE-CLiQ and one-cable HIPERFACE® DSL, these
servo actuators are optimally equipped to face the challenges of the digital future.

Mechatronics in an innovative new look
The latest generation of servo actuatorsfrom WITTENSTEIN motion control
Value added

200

150
100

Acceleration torqueMax. power

50

0

New servo actuator
Performance class 3
TPM+ dynamic 025

LengthFlexibility

First impressions"Futuristic" is often the first word that springs
to mind the first time people set eyes on the
new servo actuators. The surface gives theimpression of having been designed in a windtunnel – it is absolutely smooth with no deadspaces and no visible screwing elements. "Itwasn't the lowest possible drag coefficient wewere aiming for as in automotive development,
however, but a hygienic design that prevents
fouling or residues from adhering to the surfaces, for instance if the new servo actuators areused in filling or packaging machines for foodproducts", explains Siegfried Wallauer, Product Manager at WITTENSTEIN motion control GmbH. The mechatronic drive units area real eye-catcher that also make a stunning
impression in the open-type machines that are
frequently preferred today to simplify cleaning.

18 move

Genuine amazement
The new servo actuators are equally pleasing
to look at in each of the first three sizes, which
cover all torques from 55 Nm to 380 Nm. A
wide range of reduction ratios are also offered,the most popular so far being i=10 and i=100.
Despite this, only minimal space is required
to install the new servo actuators, especiallycompared to their performance – in practice,they deliver up to 80 percent more power fromthe same physical volume.

Products
Lower costs
It's a similar story when it comes to energy
efficiency: up to 60 percent more torque with
virtually no increase in current consumption
represents another new benchmark. "These
values help the new servo actuators push backtraditional power density boundaries", says
Wallauer. The version with digital, one-cable
HIPERFACE® DSL technology also offers theadvantage of fewer connectors, space-saving
wiring arrangements in cable carriers or bushings and reduced weight – and hence less kinetic energy – when installed on the verticaland handling axes.

More flexibility
The new servo actuators are surprisingly flexible, giving mechanical and electrical designers
unprecedented degrees of freedom. The interface to the machine is freely designable withseveral possible variants, while the interface
to the servo controller provides almost unlimited connectivity due to the maximum voltage
range of 750 V and the wide choice of analogue and digital encoders.

Overview of performance features
Performance Max.
class
power [kW]Acceleration
torque [Nm]Length [mm]

1
2
3

55
143
380

From 155
From 185
From 221

1.55
2.50
8.50

Excitement with safety features

It isn't just the impressive performance features that make the
new servo actuators such a decisive innovation in mechatronic
drive technology but also the futuristic, functional design.

A compact, modular design, significantly improved performance and energy efficiency
and fully prepared for innovative digital encoder technologies – the new servo actuators
have already excited considerable enthusiasm
among users. Safety, security and reliability
aspects are also optimally integrated. The significantly higher holding torque and the digital
encoders – which meet all the requirements ofrelevant international standards for functionalsafety, opening up numerous safety applications for the new servo actuators – are just two
examples. Customers profit from double added value: the sum of these technical characteristics and the economic benefits.

move 19

Maintenance and repairs

Services
as a crucial competitive factor

They're a valuable unique selling point for some and an economic
benefit and competitive advantage for others – engineering services are equally important for OEMs and machine operators. With its
comprehensive service portfolio, WITTENSTEIN is excellently positioned in the mechatronic drives sector as more than simply a supplier of quality products. "Each customer can put together an optimal, no-hassle package from the wide range of services on offer
and ensure maximum uptime with appropriate, efficiently planned

20 movemaintenance measures", explains Volker Metzger, Manager Customer
Service at WITTENSTEIN.
Maintenance and repairs: an often underestimated efficiency
potential
There cannot be many technical products that manage completely
without spare parts: a certain degree of wear is inevitable after running for several years or due to heavy duty, overloading or insufficient –Service

Regardless of whether a new
standard drive needs to beassembled within just a few
hours or a faulty unit has tobe expertly repaired in an
emergency – if you're desperate
for assistance, our Customer
Support department guarantees
prompt support.

WITTENSTEIN's service portfolio
is at least as innovative as ourmechatronic drive technology.
Our range of services is regularly
extended and optimized in response to new customer needs.

or incorrect – maintenance. It is therefore a great advantage if a component supplier like WITTENSTEIN can provide its customers not
only with high quality products but also with the services necessary
to safeguard this high quality in the long term. According to estimatesby experts, about forty percent of a company's total costs can be influenced by maintenance and technical services. This is a significant
proportion when you consider that the personnel and material costs
which are directly related to maintenance amount to something in

the order of 250 billion euros a year in Germany, with another 750
billion annually in additional, indirect costs for machine downtime,shortfalls, drops in quality, warehousing and spares. Maintenanceand other technical services are investments that promise a fast return – and a crucial competitive factor for any engineering manufacturer.

move 21

»Technology considerations mean the future belongs to condition
monitoring. The reason is Industry 4.0.«
Volker Metzger, Manager Customer Service at WITTENSTEIN AG

Maintenance strategies for more availability
All maintenance activities share the same basic objective, namely tomake sure a drive (or any other item of equipment) remains fully functional. Yet what is the best time for them? How many hours should
the equipment run for before maintenance action is recommended?
Not every maintenance routine is the outcome of a well-thought-out
strategy – in practice, reactive maintenance is closer to repair. "It'sin this kind of situation that our customers particularly value our 24hour service hotline and our speedline® service, which makes a commitment to deliver spare parts for all WITTENSTEIN alpha's standard
series very promptly", Metzger continues. Preventive maintenance isseveral steps ahead of this. It involves carrying out proactive maintenance work at regular inspection times between scheduled stoppages. "Even if vulnerable parts are not actually worn, they are nevertheless replaced proactively – especially if they're unlikely to last until
the next scheduled maintenance stoppage", Metzger adds. To extend the life of a machine's parts and components still further, it isnecessary to resort to condition monitoring. Metzger sums up thechallenge: "The trick is getting hold of precise information on the

22 movecondition of a machine's components and then predicting the best
time to carry out maintenance before expensive downtime becomes
unavoidable".
Intelligent maintenance with Industry 4.0
Technology considerations mean the future belongs to condition
monitoring. The reason is Industry 4.0. In the factories of the future,
intelligent cyber-physical production systems will exchange digital
information continuously – not simply in order to optimize production
processes and make them more flexible but to facilitate self-optimization and diagnostics.
Julia Lanig, Service Engineer at WITTENSTEIN AG, outlines the futurescenario: "They will lay the foundation for services and software to
identify weaknesses in a machine before serious problems develop.
By collecting and storing machine data in this way, it will be possible
to analyze wear at an early stage and predict at any time exactly how
it will advance. Faults can be detected before it gets too late andappropriate measures taken to correct them – and at the same time,
optimum use can be made of the means of production."

Service

Customer Service

Our services at a glance

Individual consulting
and services in allphases of interaction

WITTENSTEIN's pick-up and return service coordinates
the collection of faulty drives and their subsequent return to the customer – including all shipping formalities.

Maintenance Meetings generate great interest
On-site consulting, extensive inspections, maintenance recommendations, a 24-hour service hotline,
speedline® spare parts deliveries – WITTENSTEIN
customers can take advantage of a broad portfolioof services. The special service seminars offered tocustomers and the regular Maintenance Meetings
are also very popular. "Amongst other things, participants learn the proper way to mount the motor
to the gearhead or replace wearing parts and gear
assemblies in a mixture of theory and practice", Lanig reports proudly. "Our tips and tricks are designed
to help customers assess damage cases more reliably in future andoptimize their operational processes."
The feedback from the events held so far has been overwhelmingly positive – and the first enrolments have already been received
for the next Maintenance Meeting in the autumn. Please contact
service@wittenstein.de if you are interested in attending.

move 23

To (literally) give a voice to youth and enable talented young opera singers
to be discovered and showcased – the mission of DEBUT, the European
Opera Singing Competition is certainly an admirable one.

7th European Opera Singing Competition

DEBUT 2014

Winners of DEBUT 2014:
Adriana Ferfecka, winner of the Golden
Victoria 2014 (centre), Maria Chabounia,
Silver Victoria (right) and Jakub Józef Orlinski,
Bronze Victoria (left).

When the very first DEBUT was staged back in 2002, Dr. Manfred Wittenstein, already a successful entrepreneur, finally realized his vision of bringing together industry, technology andculture as three particularly innovative and creative forces insociety. This singing competition in the beautiful Tauber Valley has long become an internationally celebrated event. Onceagain, the General Managers of several major opera houses andleading representatives of the theatre and cultural management
scene took advantage last autumn of this unique chance to discover and hire fledgling performers. 247 young singers from
44 different countries originally applied to enter. In the end, six
talented newcomers remained. In the grand finale they faced
the critical verdict of the jury and the acclaim of an enthusiastic audience. As in previous years, this glittering opera gala at
the Bad Mergentheim Wandelhalle was hosted by Jan Hofer,

24 move»Singing people
are happy people«
Dr. Manfred Wittenstein, Chairman of the Supervisory Board of WITTENSTEIN AG

Senior Newsreader on ARD's television news, who presided
over the event in his familiar charming style. "Singing people
are happy people – because singing is both heart-warming andheart-opening", said Dr. Wittenstein, Chairman of the WITTENSTEIN AG Supervisory Board, in an interview with Hofer. Christa
Ludwig, Kammersängerin and DEBUT patron, was suitably impressed by the outstanding renditions given by the participants.
She summed up her commitment to the event as follows: "The

Culture
Exceptionally talented and only 17 years old:
Yurii Yushkevich of St. Petersburg

DEBUT 2014 began with the qualifying
rounds at Weikersheim Castle Music Academy and ended with the traditional galaconcert in Bad Mergentheim.
The best of the best: Polish soprano Adriana
Ferfecka (Golden Victoria), Maria Chabounia from Belarus (Silver Victoria) and Polishcounter-tenor Jakub Józef Orlinski (Bronze
Victoria). The competition was endowedwith prizes worth more than 30,000 euros.
Professor Christa Ludwig (Kammersängerin) and BDI President Ulrich Grillo acted as
joint patrons.
The DEBUT competition (www.debut.de) has
forged a novel link between industry, technology and culture. It manages without any
form of public sponsorship and as such iscompletely independent.
It was initiated by Dr. Manfred Wittenstein,
Chairman of the Supervisory Board of WITTENSTEIN AG. Jeunesses Musicales Germany (JMD) has been a DEBUT partner since
2010.

Video reporton DEBUT 2014

Adriana Ferfecka, the Polish soprano andwinner of DEBUT 2014, delivers her winning
performance at the Wandelhalle in Bad
Mergentheim

Dr. Manfred Wittenstein, Chairman of the Supervisory
Board of WITTENSTEIN AG and initiator of the European
Opera Singing Competition DEBUT (left), in conversation
with Jan Hofer (right)

biggest challenge for any vocalist is to express a thought or an
emotion that has been set to music in such a way that every single note is inspired. When I accept this invitation to lend supportand encouragement talented newcomers, my role as I see it is tocommunicate this essential aspect, which is not actually visible
in the notes themselves." Adriana Ferfecka, the Polish soprano,
was presented with the Golden Victoria and 10,000 euros incash. She was equally convincing in all four categories: vocal
quality, technique, repertoire and artistic interpretation.

move 25

Trade fair calendar
2015

Hannover Messe

Indumation

SMART

Hanover (Germany)
Flagship Trade Fair for Motion, Drive & Automation
WITTENSTEIN Group
Hall 15, Stand F08
April 13 to 17, 2015

Kortrijk (Belgium)
National Trade Fair for Factory,
Process and Infrastructure Automation
WITTENSTEIN bvba
May 6 to 8, 2015

Linz (Austria)
Trade Fair for Industrial Automation
WITTENSTEIN GmbHMay 19 to 21, 2015

Sino Corrugated

SPS IPC Drives

Shanghai (China)
The World's Leading Corrugated ManufacturingShow
WITTENSTEIN (Hangzhou) Co. Ltd
April 14 to 17, 2015

Parma (Italy)
Europe's Leading Exhibition forElectric Automation
WITTENSTEIN S.P.A.
May 12 to 14, 2015

CIMT

FEIMAFE

Beijing (China)
International Machine
Tool ShowWITTENSTEIN (Hangzhou) Co. Ltd
April 20 to 25, 2015

São Paulo (Brazil)International Machine Tools andIntegrated Manufacturing Systems Trade FairWITTENSTEIN do Brasil
May 18 to 23, 2015

Friedrichshafen (Germany)
Regional Exhibition for Industrial Automation
Technology
Stand 209
WITTENSTEIN alpha GmbH
June 9 to 10, 2015

OTC

IPACK-IMA

Paris Air Show

Houston, Texas (USA)International Offshore Technology Conference
WITTENSTEIN motion control GmbHMay 4 to 7, 2015

Milan (Italy)
International Exhibition of Technology
and Materials for Processing
and Packaging
WITTENSTEIN S.P.A.
May 19 to 23, 2015

Le Bourget (France)
Salon International del'Aéronautique et de l'Espace
Hall 2c, Stand B354
WITTENSTEIN aerospace & simulation GmbH
June 15 to 21, 2015

26 move

Metalloobrabotka
Moscow (Russia)
International Exhibition for Materials Processing
Technologies, Machines and Tools
WITTENSTEIN alpha GmbHMay 25 to 29, 2015

all about Automation

Trade Fairs

WITTENSTEIN is represented at numerous trade fairs and exhibitions worldwide.
We look forward to meeting you!

Essen Welding & Cutting
Shanghai (China)
International Trade Fair for
Joining, Cutting and Surfacing
WITTENSTEIN (Hangzhou) Co. Ltd
June 16 to 19, 2015

automation & electronics
Lausanne (Switzerland)
Switzerland's Trade Fair for Industry
and Science
WITTENSTEIN AG
June 17 to 18, 2015

Taipei International
Industrial Automation Exhibition
Taipei City (Taiwan)International Automation Industry
Exhibition
WITTENSTEIN Co., Ltd.
August 26 to 29, 2015

Aberdeen (UK)Oil & Gas Conference & Exhibition
WITTENSTEIN motion control GmbH
September 8 to 11, 2015

Pack Expo

Zürich (Switzerland)
Switzerland's Trade Fair for Industry
and Science
WITTENSTEIN AG
June 24 to 25, 2015

Las Vegas, Nevada (USA)
Advanced Processing and Packaging
WITTENSTEIN Inc.
September 28 to 30, 2015

Shanghai (China)
China International Robot ShowWITTENSTEIN (Hangzhou) Co. Ltd
July 8 to 11, 2015

Milan (Italy)
The World's Premier Trade Fair for Metalworking
Technology
WITTENSTEIN S.P.A.
October 5 to 10, 2015

SPE Offshore Europe

automation & electronics

CIROS

EMO

Motek
Stuttgart (Germany)International Trade Fair for Assembly andHandling Technology
WITTENSTEIN Group
October 5 to 8, 2015

Current trade fair calendar

move 27