move

The magazine for customers and friends of the WITTENSTEIN AG

WITTENSTEIN AG:

PIONEER = ( KNOW HOW + VISION + COURAGE)28

April · 2012

move

The magazine of customers and friends of the WITTENSTEIN AG

Contents

High-performance motors for tomorrow‘s world
Interview with Dr. Bernd Schimpf

4Dr. Manfred Wittenstein:
Nominated for the“World Entrepreneur of the Year 2012“ awards

6

LP+ Generation 3 planetary gearheads
WITTENSTEIN alpha GmbH

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 Public Relations & Media(Responsible under press law)(Marketing & Communications Dept.)
Circulation:
3500 copies
Production:
WAJS
Otto-Hahn-Str. 13
97204 Höchberg / Germany

Cover: Andreas Mei, Sales Manager Germany,
WITTENSTEIN alpha GmbHAll rights reserved. This document may not be reprinted orelectronically distributed without the express permission of
the publisher.

8

Future urban production
WITTENSTEIN bastian GmbH

10

Fluid cooled adapter plate
WITTENSTEIN USA

12

Generators for wind turbines
WITTENSTEIN cyber motor GmbH14

SPM endurance servo actuator
WITTENSTEIN motion control GmbH

16

Ideas learn to fly“Creative Young Minds” competition now ten years old

18

Trade fairs

19

Dear readers,
Leonardo da Vinci – the artist who gave us the Mona Lisa’s
mysterious smile. Yet not only that: he also sketched ideas forflying machines that were not actually built until several centuries
later. Today, they soar through the skies as “helicopters”. It is notwithout reason that this gifted Renaissance painter and sculptor is still held to be one of the most outstanding polymaths of
all times. Like the more modern-day Montgolfier brothers, Otto
Lilienthal or Ferdinand Graf von Zeppelin, he was an undisputed
pioneer of aviation with his revolutionary studies of flight.
Pioneers inspire awe and admiration. They are standard-bearers who break new ground in their chosen field. With their creative ideas they venture into new dimensions. Their pioneeringachievements make possible what was previously impossible – and hence unimaginable. Pioneering technologicalachievements help people, change societies and give rise to new, global needs. Research and industry respond tomega trends like mobility or resource efficiency by developing innovative products, intelligent production technologies
and sustainable processes. Lasting success on an international scale presupposes a good balance between ecology,
economy, technology and social responsibility. Ideally, this fragile equilibrium should be decoupled from the volatilityof world markets.
The WITTENSTEIN Group confronts this challenge every single day – as a development partner and solution provider
for highly complex applications. Our new record sales in the 2011/12 fiscal year represent renewed confirmation thatmechatronic drive technology made by WITTENSTEIN helps control motion in almost every industry and every futuretechnology. Pay us a visit at the Hanover Fair 2012 and see for yourself!
We are determined to carry on investing our experience and know-how in this way in the years to come. In doing
so, we hope not only to excite your enthusiasm for WITTENSTEIN’s pioneering achievements but also to spur you tosimilar achievements of your own. We want to provide our customers all over the world with the same, optimal support no matter where they happen to be located – in Europe, the US, Asia or South America. That’s why we launched
our “Pioneers hit the road” initiative last autumn: as a complement to the traditional foreign placements for current
trainees and students, all young entrants now have a chance to spend several months on a “life-changing journey”
before settling down into their professional lives. Society as a whole – and each of us as individuals – needs to adopt
a new, uncomplicated attitude to globalization.
To succeed in the global arena, however, investments in the future must be driven by firm resolve and a long-term
perspective at the grass roots. Earlier this year, we moved into a new, pioneering “future urban production” facility in
Fellbach, near Stuttgart (see pages 10/11). During the next few months, we will start preparing for the extra expanse
we need to continue growing at our Igersheim-Harthausen site. A new Mechatronics Centre designed to make sparing
use of resources will go up directly adjacent to our existing headquarters.
As Antoine de Saint-Exupéry once said, “Our task is not to foresee the future, but to enable it”. Our goal is to enable
the future – for you and in partnership with you.

Dr. Manfred Wittenstein

President of WITTENSTEIN AG

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3

Interview

move talks to:

Dr. Bernd Schimpf

High-performance motors for
tomorrow’s world
Electromobility is currently arousing great expectations worldwide. Wherever the challenges waiting to be mastered areparticularly daunting, WITTENSTEIN demonstrates its uniqueexpertise and leverages drive engineering experience spanning multiple industries. The aim is not to serve the mainstream but to capture and retain niche segments. Several
successful cooperative ventures have already been launchedwith automotive manufacturers. A WITTENSTEIN motor andpower electronics are installed in every hybrid vehicle taking
part in VW’s “twinDRIVE” fleet test, for example. WITTENSTEIN is also contributing valuable input to the Electric
Motorsport Grand Prix – Dr. Bernd Schimpf explains why.
move: Electromobility is a hot topic on everyone’s lips. The
world of motor sports is no exception – eMotorcycles are rapidly becoming an established category in major race series.
Where do the main challenges lie for emission-free drives in motor racing?
Dr. Bernd Schimpf: WITTENSTEIN’s activities in the electromobility sector cast a spotlight on two fundamental questions.

4 moveWhat form could the future take? Which aspects of drive technology are in need of further development? Motor racing is an ideal
terrain for us – after all, where else does being the best and thefastest dominate to such an extent? The WITTENSTEIN claim
to develop high-performance motors for tomorrow’s world interacts here with an environment in which maximum power density,
the highest possible torque and a compact space envelope are amust.
move: If the present trend continues, electromobility could become commonplace on race circuits all over the world in the longterm. Where do we stand today?
Dr. Bernd Schimpf: : Electric drives are still in their infancy,of course. It’s a novel sensation to hear such a totally different
engine noise at the start of a Grand Prix. Certainly as far as motorcycle racing is concerned, today’s electric bikes are alreadynudging the performance of conventionally powered models.
When the first race for electric cars will be staged is something
we can’t predict at the moment. Right now, WITTENSTEIN
is lending its support to an extremely successful pioneeringachievement by the Würzburg based Münch Racing Team (www.
muench-racing.com). Last year, a machine driven by Matthias

Dr. Bernd Schimpf
Head of Generating Process Management
at WITTENSTEIN AG

Himmelmann finished first, way ahead of the rest, at the eGrandPrix in Spa Francorchamps, Belgium. His TTE2 eBike reacheda maximum speed of 214.9 km/h – not least thanks to a motor
manufactured by WITTENSTEIN cyber motor and electronics
from WITTENSTEIN electronics.
move: The 2012 racing season has only just begun. How would
you rate the chances of the team sponsored by WITTENSTEIN?
Would you care to give us your forecast?
Dr. Bernd Schimpf: Last year’s successes speak for themselves: the Münch Racing Team is setting the pace in electricmotorcycle racing.
They dominated the 2011 season and at the end of the year they
were only a few seconds behind the supersport motorcycles witha combustion chamber that race on the same tracks. They won the
double as world champion in the FIM and TTXGP electric racing
series for the second year running. The prospects for 2012 areexcellent, in other words. Whatever happens, we’ll be keeping
our fingers crossed tight for them.

WITTENSTEIN technologies in future?
Dr. Bernd Schimpf: WITTENSTEIN has sponsored the Münch
Racing Team for the last two seasons and we intend to consolidate this partnership further in the future. We have plans to set
up a WITTENSTEIN motor racing team made up of company
staff with a particular interest in motorbikes, engines, electronics
and the sweet smell of tarmac. We’d like them to provide additional technical support on the spot in the pit lane as pioneers andmotor racing enthusiasts.
move: Let me wind up with a sneak look into the future.
WITTENSTEIN will exhibit at MobiliTec, the Hanover Fair’s
flagship exhibition for electromobility, for the third time in succession in 2012. What are the main trends?
Dr. Bernd Schimpf: WITTENSTEIN will exhibit in Hall 25,
Stand M11/02 as a competent development partner for electromobility. Our aim is to show visitors what we can do today – andwhat we might be able to do in the near future...

move: How does WITTENSTEIN propose to support thedefence of the world championship with innovative

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5

WITTENSTEIN international

A visionary among machine builders
Dr. Manfred Wittenstein to represent Germany in the
search for the world‘s top „Entrepreneur of the Year“

The “World Entrepreneur Of The Year” will be announced by aninternational jury in Monte Carlo in June 2012. Fifty award-winning
entrepreneurs from fifty different countries will compete. Dr. Manfred Wittenstein, President of WITTENSTEIN AG, will be among
them. He will participate as Germany’s representative, having already won the national competition last autumn as “Entrepreneurof the Year” in the “Industry” category.
Dr. Manfred Wittenstein

The “Alte Oper” opera house in Frankfurt rolled out its red carpet in honour of the numerous distinguished guests from the world of politics and industry who attended the official presentationof the prestigious “Entrepreneur of the Year 2011” awards. The jury cited clear and unequivocal reasons for its decision to confer the award on Dr. Wittenstein: “He inherited a small, ailing,family-owned sewing machine business and turned it into the world’s premier manufacturer ofdrive technology. Wittenstein is a visionary among machine builders.”
Every year, this coveted business award seeks to identify and honour exceptional entrepreneurial achievements worldwide. Out of three hundred companies nominated in Germany in 2011,
sixty-five qualified for the final round. In addition to outstanding entrepreneurial commitment, thecriteria assessed also included a clear employee focus, proven innovative vitality and a policy of
responsible growth.
Dr. Wittenstein primarily regards the competition as a golden opportunity to measure his company
against the international business elite. “After all, WITTENSTEIN has pledged itself to excellencein many different areas.” The high demands he makes on his own company are consistent withthe definition of a model entrepreneur by Ernst & Young, the leading auditing and advisory services firm and competition organizer: “Entrepreneurs are pioneers in their respective industries
who realise visions in a focused way without neglecting their responsibility to the community inwhich they operate. High growth rates go hand in hand with a deep involvement in social andenvironmental projects.”
Looking ahead to the election of the “World Entrepreneur” on the French Riviera only a few weeks
from now, Dr. Wittenstein intends to relax and enjoy: “I, or rather we – the entire company – areproud just to be there.”

6 move1. Dr. Manfred Wittenstein, Vorstandsvorsitzender der
WITTENSTEIN AG, ist „Entrepreneur des Jahres 2011“ in derKategorie Industrie.

2. Preisverleihung in der Alten Oper in Frankfurt: Von links nach rechts:
Wolfgang Glauner (Ernst & Young), Dr. Manfred Wittenstein (Vorstandsvorsitzender WITTENSTEIN AG) und Laudator Holger Steltzner (F.A.Z.).

3. Logo des Wettbewerbs „Entrepreneur des Jahres 2011“

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7

LP

+

Generation 3

Innovation
sets standards

LP planetary gearheads made by WITTENSTEIN
alpha have been up among the cream of theworld’s drive technology ever since 1996 – andeven more so since the LP+ upgrade in 2004.
Yet the specifications demanded by the market
are constantly changing. Less noise, smaller
sizes and reduced energy consumption currently top of the list of priorities.

Quieter, more powerful and more energy efficient – thesewere WITTENSTEIN alpha’s three most important development objectives for the LP+ Generation 3 series of planetary
gearheads. This new series extends the product portfolio,
providing designers of feed axes, handling systems, packaging machines and industrial machinery in general withmultiple technical and economic benefits.
Improved performance as the key to downsizing
New design and machining processes at WITTENSTEIN alpha have enabled an impressive performance leap to be realized with LP+ Generation 3. The transmittable torques are
now up to 75% higher than the industry standard. At thesame time, the enhanced performance of the LP+ Generation
3 gearheads may open up important downsizing options forusers. Downsizing will in future be a viable option in many
applications that were not originally conceived to leverage the

8 movemaximum transmissible torque. If the application features onboard drives mounted on a robot, for example, downsizing
additionally improves energy efficiency. By choosing a smallersize, the mass to be accelerated can be halved without compromising the drive’s output – and energy consumption is accordingly lower. Downsizing is also a good way to bring down
the noise level. If it is possible to manage with the T2N torqueof 28.5 Nm that is achieved with the new LP+ Generation 3
gearhead in the 070 size, for instance, rather than the 40 Nm
required by the equivalent “old” size 090, the noise producedby the application can be reduced from 72 dB (A) to 64 dB(A) – less than half the audible volume.
“Whisper-quiet” drives – less than half the normal noise
emission“Less noise” was also a separate development objective of
the LP+ Generation 3 series in its own right. The operating

Products

Thomas Krämer
Product Manager, WITTENSTEIN alpha GmbHAll gearheads produce significantly less operating noise regardless of their size.

More torque is now transmitted with all sizes and all reduction
ratios.

noise has been reduced by 6 dB (A) on average thanks to
the optimized manufacturing and finishing processes for thegearing parts and the improvements to the tooth flank geometry, in other words the noise level has been more thanhalved. The noise reduction by the LP+ Generation 3 series isgreatly appreciated by users of packaging machines and handling systems because it is achieved without any additional
acoustic enclosure on the gearhead side or noise abatement
measures in the periphery.

backlash of just 10 arcmin with a 2-stage reduction ratio.
LP+ Generation 3 is consequently ideal for servo applications
where highly precise positioning is a must.

Less torsional backlash, even higher precision
However, LP+ Generation 3 is not only more powerful andquieter but also more precise. The torsional backlash, for instance, is far less than with the predecessor series. Whereas
the “old” LP+ was already very precise for its class with amaximum of 15 arcmin (size 090, 2-stage), LP+ Generation
3 goes a step further. The 090 size has a maximum torsional

Express speedline® delivery guaranteed
The development of the new LP+ Generation 3 was a holistic
process: the goal was not simply to come up with technical improvements but also to examine ways to optimize theproduction and assembly workflows in order to reduce shipping times to a minimum and maximize delivery reliability.
Short standard delivery times and the WITTENSTEIN alphaexpress speedline® delivery service are also guaranteed forthe new series.
From noise reduction through energy efficiency to downsizing– with the LP+ Generation 3 series, WITTENSTEIN alpha has
set new performance benchmarks for planetary gearheads.

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9

Urban production and Industry 4.0
WITTENSTEIN‘s production concept for the future

Even the location is altogether unusual: WITTENSTEIN has invested twelve million euros in an ultra-modern production facility right next to a passive house estate in Fellbach on the fringe of the Stuttgart conurbation. The outcome isan innovative overall concept comprised of optimized processes, the building itself and the energy supply systems forthe group’s WITTENSTEIN bastian subsidiary christened “Future urban production” – a low-noise, low-emission plantthat successfully reconciles economic with ecological requirements. It is closely aligned to tomorrow’s challenges as
identified within the Industry 4.0 project – the “fourth stage of industrial development”.

Economic, ecological and socio-cultural sustainability
The new building, covering 5400 m², is only 300 yards fromthe present head office as the crow flies, yet the former “gearfactory” and the new, urban production facility are worlds
apart. This facility is unquestionably something special: boththe building services and the machinery have been fine-tuned
to minimize resource usage and maximize precision.
Thorough consideration has been given to all technical details such as noise, waste gas, refuse, CO2 emissions, water
and waste water as well as to the harmonious integration of
the plant’s architecture in the neighbouring residential area.
The power required to run the facility is generated by biogasoperated micro turbines, for instance, while the waste heatfrom the company’s production processes is recovered andutilized to heat the offices.
A photovoltaic system produces enough electricity to supply
a hundred households. Amongst other things, this power is

10 moveutilized to continuously dehumidify the fully conditioned air in
the production shop – and thus create an optimal working
climate that is conducive to the good health of the WITTENSTEIN bastian workforce. The constant room climate also benefits customers by ensuring precise engineering and stableprocesses, which are vital for high product quality and firstrate supply performance. Rainwater serves a similarly important function, by the way – it is collected in a cistern and used
for sanitary facilities.
These diverse innovative solutions have had a remarkable impact: despite the fact that the new production shop is fully air
conditioned, the energy costs per square metre are around
35% lower than for the old building. So far, the standard requirements laid down by the German regulations on energy
saving (EnEV) have been exceeded by more than fifty percent
and the latest versions of the directives on energy and buildings are easily fulfilled.

Production

Innovative new building at the group‘s Fellbach site

View of WITTENSTEIN bastian’s new “Future urban production” facility.

Industry 4.0 –the “fourth stage of industrial development”
WITTENSTEIN bastian has made all the necessary preparations in its new building for a very exciting vision, which has
already attracted considerable attention under the name “Industry 4.0”. The aim is that machinery, means of production
and semi-finished products will one day be permanently hooked up to one another online, so that last-minute changes
to a gear wheel’s specification, for example, are no longer a
problem. In other words, the foundation has been laid for all
elements of a future “intelligent” production concept – socalled cyber-physical systems – to be successively integrated
into WITTENSTEIN bastian’s processes.
Above all, new and innovative processes lead to higher product quality – and more satisfied customers. In the long term,
however, the evolution to Industry 4.0 will also strengthen thecompany’s German location.
President Dr. Manfred Wittenstein is well aware of his entrepreneurial responsibility towards society and nature: “WITTENSTEIN is seeking wise and sensible answers to tomorrow’s
production requirements. Our claim is to reconcile optimal
product quality with effective environmental protection andsocial responsibility.”

Integration in the urban environment“Urban production” improves the quality of life and working
conditions without any detriment to living space. The new
production facility blends harmoniously into the urban environment while the outside area has been successfully integrated with the adjoining plots of land. Noise emissions,which were in any case very low, have been further reduced
by a special noise barrier. And in addition to a biotope anda children’s playground, WITTENSTEIN bastian will in futurealso share two publicly accessible charging stations for electric cars with its new neighbours.
Certified pilot project
WITTENSTEIN bastian gear wheels have driven technological advances throughout the last hundred years. From theworld’s very first motor driven vehicle through robotic systems to modern space travel and motor racing, demand forgearing solutions made in Fellbach has remained consistently
high. In future, these solutions will carry a written guaranteeof “greenness”: the entire facility, including all office space, will
shortly be certified by the DGNB (German Sustainable Building Council) as the first building of this kind. A pre-certificate
in gold has already been awarded.

move 11

The optimized adapter plate significantly improves performanceby lowering the temperature in the motor / gearhead combination.

Motor / gearhead combinations are often limited by temperature. The higher the torque load and / or rpm, thehigher the system-generated temperature.
WITTENSTEIN is constantly working with customers
to understand their needs, identify current limitations
and design solutions which allow optimal system performance. The result is an optimized adapter plate thatsignificantly improves performance by lowering the temperature in the motor / gearhead combination.
To understand the design constraints as a precondition of
successful development, WITTENSTEIN discussed all relevant details with customers. The main requirement was toreduce the operating temperature of the combined gearhead
and motor and to accomplish this in the minimum amount of
space. Not wanting to add additional elements to the overall

12 movedrive system, a decision was made to optimize the existingelements. The final design focused on optimizing the adapter
plate, which is typically a solid piece of aluminium used toconnect the motor to the gearhead. WITTENSTEIN´s speciallydeveloped adapter plate has an internal channel allowing circulation of fluid (liquid or air) to remove the heat more efficiently.
Testing was performed on a servo motor mated to a WITTENSTEIN alpha SP 140 MC 1-3 planetary gearhead. The output
bearing of the gearhead reached a steady state temperatureof 87°C (189°F) with natural convection. When 23°C (73°F) air
was run through the internal adapter channel, a steady state
temperature of 63°C (145°F) was achieved, representing a reduction of 24°C (44°F) over natural convective air cooling. On
the other hand, when 7°C (45°F) water was run through thechannel, the steady state temperature was 53°C (127°F) – a

WITTENSTEIN international

Designed for efficiency:
Fluid cooled adapter
Heat reduction improves overall motor / gearhead performance

WITTENSTEIN’s fluid cooled adapter
in the customer environment.

reduction of 34°C (62°F) over the natural convection method.
The new solution was put into practice in the US customer
environment. The result confirmed the significant heat removal using the fluid cooled adapter. Lower motor winding
temperatures were also observed. This was possible because
the cooling takes place directly between the motor and thegearhead, extracting heat from both pieces of equipment.
As the temperature is lower throughout the motor / gearhead,the drive combination can now be run at a higher torque load
and / or rpm. Customer results showed that a motor / gearhead combination which with a traditional adapter plate ran
at 500 rpm and 50% torque load could now run with a fluid
cooled adapter plate at up to 2000 rpm and 50% torque load
without any increase in temperature. This represents a substantial improvement in performance.

Downsizing options
Optimizing the overall system components by employing a
fluid cooled adapter plate increased performance and reduced heat. This new design resulted in a general system
improvement. Instead of operating the same size servo motor
at a higher torque load and / or rpm, a smaller motor is now
allowed to be selected. Downsizing in this way was previously
not possible due to temperature limitations.
The fluid cooled adapter plate was the outcome of very good
cooperation between WITTENSTEIN and its customers. It’sa part of the WITTENSTEIN philosophy to design solutions
based on exceeding customer expectations.

move 13

Noses to the windWind power “made” by WITTENSTEIN

Gregor Stühler
Sales Engineer, WITTENSTEIN cyber motor GmbHThe permanent magnet synchronous servo motor with
about 2 kW maximum output that is used as the generator
for this small wind turbine has been gradually perfected,
with the result that the generator and the turbine are now
optimally harmonized with an efficiency of about 95%.

Can wind power really be produced on the rooftop of private homes or factory buildings? WindTec Systems, the Swiss
manufacturer of wind turbine technology, is not afraid to tread completely new paths with this cutting-edge idea. The
permanent magnet synchronous motors that drive the compact ENFLO 0110 wind turbine, which can be installed
without a permit, are supplied by WITTENSTEIN cyber motor. The MRSx series to which they belong was perfected
for this highly specific application.
Wind of change in the energy production market“There’s no reason why house roofs should remain the exclusive domain of photovoltaic systems for ever more”, says Dirk
Süss, Managing Director of WindTec Systems. The company
is currently the only vendor in the market that is capable oferecting small yet efficient wind turbines on urban sites or at
off-grid locations. Uwe Steffens-Paal, Managing Director of
ENFLO Service, explains why: “The ENFLO 0110 wind turbine
has a rotor diameter of 1.10 m, making it very compact andalso relatively light at around 50 kg. Planning permission is
not required. Last but not least, the specially designed ge-

14 move

ometry assures quiet operation.” The ability to produce windenergy and convert it to electricity without any loss of poweris crucial, of course. “That’s why, when WindTec Systems wason the lookout for a suitable generator solution, they decided
to get in touch with us”, Dieter Bauch-Panetzky, a development engineer at WITTENSTEIN cyber motor, recollects. “We
recommended a permanent magnet synchronous servo motor with about 2 kW maximum output as the starting point
for the generator. The generator then ‘grew’ with the windturbine as the project progressed. It was gradually perfected
for this highly specific application, with the result that theApplications

Permanent magnet synchronous motors like the MRSx series from WITTENSTEIN cyber motor are very much in demand in the wind power sector.

generator and the wind turbine are now optimally harmonizedin the ENFLO 0110 with an efficiency of up to 98%.”
Versatile generators produce wind energy
without any loss of power
MRSx generators from WITTENSTEIN cyber motor are verymuch in demand not just with WindTec but in the wind power
sector in general. They feature very quiet running, a spacesaving design, a greatly reduced weight / power ratio (kg /kW) and far higher efficiency than can be achieved with asynchronous technology. “Added to that, WITTENSTEIN has theexperience and expertise to design drive solutions for specificapplications”, Süss continues. Another argument in favourof generators from WITTENSTEIN cyber motor that is crucial for the success of his small turbines is their exceptionalruggedness. “Operators of conventional small wind turbines
don’t just complain about the noise and poor output; they’realso dissatisfied with the short lifespan and the high costs
for maintenance and repair”, Süss adds, speaking from experience. These are issues that neither he nor his customers
have to worry about any more: “The rotor and stator are well
protected inside the generator and the bearing technology
has already demonstrated its suitability in harsh industrial environments. They’re virtually maintenance-free and at present
there are hardly any restrictions on the service life”, BauchPanetzky reports. WindTec Systems evidently concords withthis view – and guarantees a minimum life of twenty-five years
for its wind turbines owing to the general robustness of the
WITTENSTEIN generators. President Dr. Manfred Wittenstein
has already underlined his faith in this claim by ordering awind turbine from Dirk Süss and Uwe Steffens-Paal for his
Igersheim-Harthausen premises.
WITTENSTEIN technology also suited for large
wind turbines
The ENFLO 0110, which is sold with increasing success via
industrial wholesalers, specialist installers and the electricalindustry, will drive WindTec Systems’ future growth. “The 1.5
kW wind turbine for rooftop installation on private homes isonly the beginning”, Süss predicts. “Turbines with a rotor
measuring anything from 2 to 22 m will follow for a broad
range of applications such as mobile towers or charging stations for electric cars – electromobility is the big buzz.” The
new applications and sizes will simultaneously create newrequirements that have to be taken into account by the generators. “Once again, the chief problem will be to convert thelow speeds as efficiently as possible without a gearhead”,
concludes Dr. Michael Geier, General Manager of WITTENSTEIN cyber motor. “Our aim will be to maximize the overall
efficiency of the system.”
Knowing which way the wind is blowing is a central part of
the WITTENSTEIN creed…

move 15

The SPM endurance rotary actuator made by
WITTENSTEIN motion control.

Cool and energy efficient – SPM servo actuator for
high-performance injection moulding machines
Precise dosing, low energy consumption and very short cycle times are vital for high-performance injection moulding
processes, for instance in the manufacture of plastic caps. Electromechanical dosage drives are ideal for achieving
these objectives. ARBURG, the leading manufacturer of injection moulding machines, has fared very well with SPM
endurance, the rotary servo actuator from WITTENSTEIN motion control.
The German firm of ARBURG is one of the leading global
manufacturers of injection moulding machines for plastics
processing applications with closing forces from 125 kN to5000 kN. Amongst other things, its products are used tomake plastic parts for the automotive and communications
markets, consumer electronics, medical technology, household appliances and packaging equipment. Robotic systems,
complex projects and various peripherals round off the portfolio. All manufacturing takes place at the German parent
plant in Lossburg.
Injection moulding demands exceptionally high precision
The high-performance machines in ARBURG’s Allrounder H

16 moveseries are characterized by high production capacities, shortcycle times and low energy consumption. They are tailormade for manufacturing thin-walled packaging products inlarge quantities. The drive technology not only has to satisfy
strict requirements with regard to precision and energy efficiency, however; reliable cooling is also imperative.
SPM endurance servo actuators consistently provide thespecified precision. They consist of a highly precise planetary
gearhead and a servo motor with very high power density;
the sun wheel of the gearhead is pressed into the motor shaft
directly. The decision to dispense with the usual shaft coupling reduces the moment of inertia and improves mechanicalApplications

A one-piece motor housing made of cast aluminium was developed specifically for WITTENSTEIN’s SPM servo actuator;
at its heart is a stainless steel cooling coil.

The electromechanical dosage drive works absolutely
precisely thanks to the WITTENSTEIN SPM endurance
servo actuator (circled).

Image: ARBURG GmbH + Co KG

rigidity. As a key component of the electromechanical dosage drive, these servo actuators increase the accuracy andreproducibility of the injection moulding process by switching
off the machine precisely at the end of the dosage step, thus
ensuring absolutely repeatable dosage volumes.

tegrated in SPM endurance actuators is crucial for the sustained operation that is often expected of injection moulding
machines in the Allrounder H series with their high production capacities. The machines are connected to the moulding
company’s cooling circuit.

Compact, energy efficient design
The WITTENSTEIN motion control actuator also convincesin terms of energy efficiency – an aspect that has been highon ARBURG’s list of priorities for many years. The interaction of several different factors allows smaller motor sizes tobe chosen. The pinion integrated in the motor shaft and therigid output bearing increase the overall rigidity and stabilize
the control response while the low torsional backlash in thegearhead helps eliminate dead times in the control loop. Allof this improves the ratio of the external to the intrinsic moment of inertia, frequently adding up to a smaller motor, reduced energy consumption and lower costs for investmentsin the powertrain as a whole. SPM endurance boasts a very
high level of integration and extraordinary power density. Itsvery high torque and exceptionally short length are the twomost outstanding benefits, however. The total length saving
is around fifty percent compared to conventional gearhead
motors.

The fact that open circuits and river water are sometimes
also used for cooling represented a major challenge for WITTENSTEIN motion control. If this is the case, the corrosion
protection agent must not contain any additives. A one-piece
motor housing made of cast aluminium was developed toovercome this problem. At its heart is a stainless steel coolingcoil with a higher corrosion resistance to coolants from open
cooling circuits. Another advantage of cooling the housingwith an integrated stainless steel cooling coil is that the cooling circuit can be designed as a single system and there is nolonger any need to seal the individual sections. As a result,the servo actuators are more robust, and this reliability is aprime success factor.

Ingenious cooling solution
The development engineers attached particular importanceto efficient in-process cooling. The fluid cooling system in-Customized engineering
The SPM endurance servo actuator is a customized drive
solution developed jointly by ARBURG and WITTENSTEIN
motion control. The actuator design unites WITTENSTEIN’s
drive know-how with ARBURG’s process requirements forhigh-performance injection moulding machines.
The result is an optimized product based on customized engineering.

move 17

Competitionwww.kreativekoepfe.info

Ideas learn to fly“Creative Young Minds” competition
now ten years old

The erector spinae, designed by Markus Michelbach

Iris Lange-Schmalz
Competition Director

A mobile phone that is only switched on if someone calls?
An erector spinae that reminds the wearer to straighten
up? A skylight that dampens the sound of raindrops beating on the window pane? These clever little helpers were
thought up not by great minds but by youngsters in theirteens.
It is now ten years since Dr. Manfred Wittenstein initiatedthe (highly successful) “Creative Young Minds” foundation. “Creative Young Minds” is a regional competition
for young inventors that is sponsored by business enterprises, public authorities and organizations in three
local areas.
Back in 2002, the signs were unmistakable: the steady decline in the number of engineering science students was acause of great concern for Dr. Manfred Wittenstein. Technology was perceived as a very complex subject in which theoretical knowledge was too detached from day-to-day practice.
One alarming repercussion of this trend was that companies
in the local region were finding it increasingly difficult to attract
trainees. Dr. Wittenstein resolved to tackle the implications ofGermany’s demographic development there and then before
it became too late – with a competition for inventors.
Every year ever since, the competition has encouraged teenagers of both sexes to apply what they have learned about
engineering and natural sciences to the problems of the real

18 moveworld. It provides schoolchildren with a platform on which to
put their creative ideas into practice and gives them an insight into business processes. What sets it apart from other,similar initiatives is the fact that the young people taking partare mentored by experts in the various firms who help them
formulate and realize their projects.
The result is a win-win situation for all stakeholders. In themeantime, a well-established network has been built up between pupils, schools, local authorities and business enterprises, and the ties between schoolchildren and their homeregion have become closer. Whereas the competition was
originally confined to Bad Mergentheim and its near neighbours – in other words, the immediate geographical surroundings of WITTENSTEIN AG – children from other, more
remote schools in the Main-Tauber district are now equallykeen to demonstrate their inventive abilities.
Incidentally, the idea for the above-mentioned erector spinae
was submitted by a 16 year-old boy in last year’s competition.
Two sensors attached to a rubber band detect incorrect backposture and activate vibrating motors, which subtly remind
the wearer to straighten up. The invention has already beenregistered as a utility model. The motto for this summer’s
official award ceremony in the WITTENSTEIN talent arena relates to another form of motion: Creative Young Minds – ideas
learn to fly.

Trade Fairs

TRADE FAIR CALENDAR 2012 (selection)

Hanover Fair 2012, Hanover (Germany)
Industrial Automation, Hall 15, Stand F08
MobiliTec, Hall 25, Stand M11/02
WITTENSTEIN group
April 23 to 27, 2012

ILA 2012, Berlin (Germany)
Salon International de l’Aéronautique etde l’Espace
WITTENSTEIN aerospace & simulation GmbH
September 11 to 16, 2012

XYLEXPO 2012, Milan (Italy)
Biennial World Exhibition for Woodworking
Technology and Furniture Supplies
WITTENSTEIN S.P.A.
May 8 to 12, 2012

BI-MU 2012, Milan (Italy)
Showcase for Metal Forming and Metal
Cutting Machine Tools, Robots, Automation
Systems and Auxiliary Technologies
WITTENSTEIN S.P.A.
October 2 to 6, 2012HISPACK 2012, Barcelona (Spain)
International Packaging Exhibition
WITTENSTEIN S.L.U.
May 15 to 18, 2012

Motek 2012, Stuttgart (Germany)International Trade Fair for Assembly andHandling Technology
WITTENSTEIN group
October 8 to 11, 2012

BIEMH 2012, Bilbao (Spain)
International Machine Tool Biennial
WITTENSTEIN S.L.U.
May 28 to June 2, 2012

Forum Maschinenbau 2012, Bad Salzuflen(Germany)
Trade Fair for Suppliers in the Machinery
Manufacturing Industry
WITTENSTEIN alpha GmbH
November 7 to 9, 2012

Metalloobrabotka 2012, Moscow (Russia)
13th International Exhibition for Materials
Processing Technologies, Machines and Tools
WITTENSTEIN alpha GmbHMay 28 to June 1, 2012

SPS/IPC/DRIVES 2012, Nuremberg(Germany)
Exhibition for Electric Automation –Systems & Components
WITTENSTEIN group
November 27 to 29, 2012

Eurosatory 2012, Paris (France)
International Exhibition for Land andLand-Air Defence
WITTENSTEIN motion control GmbH,Special Applications Business Division
June 11 to 15, 2012

move 19