move

The magazine of customers and friends of WITTENSTEIN AG

WITTENSTEIN AG:

The revolution in linear drive technology

6

April · 2011

move

Das Magazin für Kunden und Freunde der WITTENSTEIN AG

Contents
Controllable drive solutions
from a single supplierInterview with Axel Leidner

4

Revolution in linear drive technology
WITTENSTEIN alpha GmbH

6

WITTENSTEIN shapes the
future of eMobility

8

Litmus test in Hockenheim
Electric drive made by WITTENSTEIN

10

Made-to-measure solutions: a tooth for a tooth
WITTENSTEIN bastian GmbH

Masthead
Publisher:
WITTENSTEIN AG
Walter-Wittenstein-Str. 1
D-97999 Igersheim/Germany
Phone: +49 7931 493-0
www.wittenstein.de
move@wittenstein.de
Editor:Sabine Maier, Manager Public Relations & Media(Responsible under press law)(Marketing & Communications Dept.)
Circulation:
5000 copies
Production:
WAJS
Otto-Hahn-Str. 13
D-97204 Höchberg/Germany
All rights reserved. This document may not be reprinted orelectronically distributed without the express permission of
the publisher.

12

TPM+ family: rotary power for exacting
requirements
WITTENSTEIN motion control GmbH

14

Active implants
WITTENSTEIN intens GmbH16

Double honours

18

Trade press day / trade fairs

19

Dear readers,“I prefer to remember the future.”
This quotation by Salvador Dalí, the famous Spanish artist, hits
the nail right on the head. Following a whole year in which acrisis mood prevailed, the global economy is meanwhile looking
to the future again and discovering that the financial turmoil ofrecent months has resulted in a transformation of the establishedeconomic order. The world has changed irreversibly. There is nogoing back to the pre-recession days. Raw materials will become
scarcer and more expensive. Resource productivity will have a
crucial bearing on a company’s competitiveness. At the sametime, the drives segment will also be influenced by the gigantic Asian growth market.
The WITTENSTEIN group is excellently placed again worldwide and we have more than made up for the recession
year: fiscal 2010/11 will end on March 31, 2011 with record sales. Investments are the entrepreneurial gateway tothe future – and we deliberately left the door wide open throughout the recession, investing a sum in the double-digit
million euro range in our new production and development facility in Grüsch, Switzerland. The new Production Arena
for High Performance rack-and-pinion systems was officially inaugurated in the autumn of 2010. I hope you will accept my invitation to take a personal look at WITTENSTEIN’s new linear systems at Hannover Messe 2011 – wherea genuine technological revolution will await you in Hall 15. By combining the rack, new gearhead and pinion in an
integrated system, we have succeeded in almost trebling the feeding forces. We offer you complete drive solutions
from a single supplier – as the only manufacturer of linear drive systems in the world to unite all three core competencies (transmission engineering, gearing technology and sizing) under one roof.
The chief point in our favour during the critical months has been our delivery reliability of 96% to 100% despite extreme
fluctuations in the engineering industry’s incoming order situation. With our help, you too have been able to maintainpunctual deliveries to your customers. After all, we have a long tradition of developing and shipping individually tailoredsolutions quickly and flexibly, regardless of the application. This is a pledge that will remain just as valid in the future.
Energy efficiency is one aspect of drive technology that holds huge potential for innovations. The total energy consumption that could be saved in this way with technologies for machinery and industrial plant would suffice to takeseveral power plants off the grid in Germany alone. Today, with its vast experience in the field, WITTENSTEIN plays apioneering role as a developer of drive systems that make sparing use of resources. It is only logical that our profoundengineering know-how and this rich experience should contribute to the achievement of optimal interaction between
electrical and mechanical components and be applied to the development of electric and hybrid vehicles. At the“MobiliTec” flagship exhibition in Hall 25 in the framework of Hannover Messe, WITTENSTEIN will present itself as ahigh-end partner for the development and manufacture of high-performance electromechanical motors.
Come along and visit us at the Hanover Messe 2011.

Karl-Heinz Schwarz

Spokesman of the Board of WITTENSTEIN AG

move

3

Interview

move talks to:

Axel Leidner

Controllable drive solutions from a single supplier
The theme of the WITTENSTEIN exhibit at Hannover Messe
2011 will be “Revolution in linear drive technology”. In an interview with move, Axel Leidner, Head of Product Management at WITTENSTEIN alpha GmbH, explained what lies behind this message, which form it will take in practice – beyond
the limited duration of the trade fair – and how it will benefit
you, our customers.
move: What will be the focus of your exhibit at the Hanover
Fair?
Axel Leidner: We want to emphasize explicitly that drive solutions are invariably linked to system solutions and integrated
concepts, in other words they presuppose the simultaneous sizing
and optimization of all relevant drive components. At the sametime, we are aiming to show that we, as part of the WITTENSTEIN group, are in constant contact with our customers. We
unite several core competencies under one roof and make them

4 moveavailable to customers in the framework of projects through oursingle-source strategy. WITTENSTEIN alpha does this as a matter of course, though it’s an attitude that certainly can’t be taken
for granted in the market as a whole.
move: Which exhibit best illustrates this philosophy to visitors
to the WITTENSTEIN stand?
Axel Leidner: Our new alpha linear system is an ideal example. It was unveiled to the international trade press only a
few weeks ago at our new Swiss plant in Grüsch. The journalists were deeply impressed both by the system itself and by
the holistic development process that took place at WITTENSTEIN alpha. This process was inspired by customer calls foran optimized, modular rack and pinion system that is capable oftransferring much higher maximum feeding forces. We achieved
this with an intelligent combination of specifically developed
drive technology and gear teeth. Our new linear system represents a genuine revolution because it delivers more than double
the usual feeding force and opens up extensive opportunities

Axel Leidner
Head of Product Management
at WITTENSTEIN alphafor downsizing drive systems. The intelligent design concept
is a further convincing feature. The modified alpheno® interface provided on the new gearhead is currently the only one ofits kind in the world. With only eight fixing holes instead of
the traditional 32, it makes the system easier to assemble andreduces assembly times enormously. All in all, the new linear
system offers a renewed demonstration of our expertise in transmission technology and drive sizing; it underlines our ability
to control them reliably, harmonise them perfectly and team up
the gearhead, pinion and rack in an integrated system solution.
move: WITTENSTEIN alpha as a system partner for its customers – what is the advantage for them?
Axel Leidner: By focusing on holistic drive solutions, we present ourselves as a partner for all customers seeking a single supplier for complex mechatronic tasks. From a technical point ofview, this firstly means optimised drive solutions. Secondly, it isequally important that we relieve our customers of some of theburden of coordination work and thus save them valuable time.

They only have to deal with one contact, so that there is no riskof confusion over responsibilities in case of discrepancies. Finally, they derive added security from our comprehensive system
expertise: we warrant the optimal functionality of the solution as
well as the reliable achievement of, and compliance with, defined performance characteristics. Many existing customers haveconfirmed to us that the all-inclusive package they get fromWITTENSTEIN alpha is exactly what they are looking for. And
at the Hannover Messe, we will communicate to potential new
accounts how they too can profit from integrated drive solutions
from a single source – starting with, but definitely not restricted
to, the advanced technology.

move

5

Products

The new High Performance Linear System from WITTENSTEIN alpha“Every revolution was first a thought in one man’s mind” – these words of wisdom by Ralph Waldo Emerson, theAmerican poet and philosopher, can also serve as a metaphor for a technological revolution from which WITTENSTEIN
alpha customers can profit immediately: the new High Performance Linear Systems. These systems unite the company’s expertise in transmission engineering, gearing technology and sizing of complete drive trains in a mechatronicsystem solution, which is the only one of its kind in the world.

Holistic development provides the highest technology
standards
An optimally sized mechatronic drive solution can be definedas one where the underlying basic technologies are controlledin such a way that they are utilised as efficiently as possible,
bringing out the maximum performance in all components.
This may seem an obvious fact, but it is still far from being an
automatism. WITTENSTEIN alpha is the only manufacturer oflinear drive systems in the world to unite the essential corecompetencies under one roof, control them reliably, harmonise them perfectly and optimise them systematically. Not
only do customers benefit from solutions to the highest technology standards – WITTENSTEIN also assumes full system
responsibility1. The new alpha linear systems are an excellent
example.

1

For the design, based on the information submitted

6 moveChallenging specifications
The development process was inspired by customer specifications that were challenging to say the least: what wasneeded was a rack and pinion system that was capable oftransferring much higher maximum feeding forces than any
other solution so far offered in the market. “What’s more,
the new system needed to be comprised of optimized packages that can be put together to obtain solutions for different
performance classes”, says Jochen Endres, WITTENSTEIN
alpha Product Manager.
It was this and a series of other desired characteristics, suchas a compact design with a higher power density or a simplified assembly concept – despite the higher feeding forces– that spawned the new linear system.

A revolution in linear drive technology

By Jochen Endres
Product Manager
WITTENSTEIN alpha GmbH

Linear technology in a new performance class
Out developers and designers have pushed back the boundaries of what is technically possible in several areas:
The permissible torques of the new gearhead are significantly
higher. As a result, the high forces that are produced when
the teeth of the rack and pinion are meshed can be controlled
more effectively.
The complete system consequently delivers much better rigidity – which in turn has a positive influence on positioning
accuracy. The core components – gearhead, pinion and rack
– are designed to achieve the maximum possible power density in a very small space.
The design concept meets the specified modularity requirements; the unusual ease of assembly is a further convincing
feature, because the modified alpheno® interface provided
on the gearhead only has eight fixing holes instead of the
traditional 32.
The adjustment device that is fully integrated into the gearhead case is also new in this kind of system solution; it not
only considerably shortens the time needed to design theconnection, it also speeds up the assembly process andmakes it more reliable.
Several different sizes and versions, which are mounted at thefactory prior to shipping, can be supplied as the gearhead’s
output pinion. A welding method that has already worked
successfully for several years is used for this purpose. Evensmall pinions can be connected without any problems andthe screwed connection of the output pinion, which is ex-tremely critical with high feeding forces, can be dispensed
with. Feeding forces up to 112 kN per drive are now possible,
depending on the gearhead version.
Great opportunities for downsizing
Compared to other servo gearheads employed in conjunction
with a rack and pinion, the new system is clearly superior inmany applications in terms of positioning accuracy, systemrigidity, power density and feeding force. These advantages
often allow the complete drive system to be downsized. The
same feeding forces are achieved with smaller gearheads,
pinions and racks. If the customer prefers not to downsize,
the new system offers far more power reserves than alternative drive systems of a similar size.
Open for any application
The sum of all these benefits opens up new potential for enhancing the performance of a wide range of equipment andmachinery such as grinding, turning, portal milling, boring,laser, punching and pipe bending machines, water jet cutters or machining centres for wood-plastics compounds.
“Our new, high-end linear system is suited for any type of
application – from high-precision machine tools to automation technology”, Endres predicts, looking ahead to Hannover
Messe 2011.

move

7

Products

Electric drive technology for vehicles

WITTENSTEIN shapes the future of eMobility

The motor for the eMobile drive (photo left, without the housing) is characterized by ahigh power / weight ratio, very good efficiency and a high force / torque density.

For several years now, WITTENSTEIN has presented thelatest developments in eMobile drive technologies fromits R&D labs at the Hanover Messe, as the leading international platform. Twelve months ago, WAG’s integrated
drive unit, which boasts performance data to rival thatof Formula One cars, generated considerable interest.
The central theme running through the 2011 exhibit will
be a presentation of the newest drive platform from the
WITTENSTEIN stable. This modular system for mobile
electric drives further underlines WITTENSTEIN’s drive
expertise when it comes to highly dynamic and emissionfree mobility in tomorrow’s world.
In-house system expertise
The future electrification of transport calls for intelligent drive
systems, in which the electronics, motor and gearhead are
optimally matched. As a pioneer in the high-tech market foreMobile drive solutions, WITTENSTEIN learned to master thisinteraction between electrical and mechanical components
several decades ago; thanks to this know-how, the company
now develops trailblazing drive concepts for the upcoming

8 movegenerations. These concepts owe their success to two main
characteristics: integration and modularity. eMobile drives
made by WITTENSTEIN are integrated systems, in otherwords a unit comprised of a motor, gearhead and powerelectronics, each of which is designed to achieve maximum
efficiency. At the same time, they are built from a modular
building block system embedded in a non-variable parts
strategy that allows different drive modules to be constructed
for different vehicle types and eMobile performance classes
from identical components with the help of simple interfaces.
In addition, this modularity further underlines WITTENSTEIN’s
innovation and development expertise in the eMobility field byfacilitating the creation of completely new drive architectures
as well as high-end mechatronic drive solutions noted fortheir extremely high power densities.
Manufacturing know-how for a sharper competitive edge
As technology leader in the crucial electromobility market,
WITTENSTEIN is in demand as a partner throughout all theimplementation phases of eMobility projects – from consulting on alternative drive systems through the performance ofProducts

The gearhead in the electric
drive system impresses with:• High power density because
the load is distributed
between five case hardened
planets• High power / weight ratio
thanks to the use of lightweight materials• Customized design

feasibility studies and system engineering, the developmentof hardware, software and components or solutions for special applications to trials of new concepts and the construction of test models and prototypes. The production of small
to medium-sized series at WITTENSTEIN represents the interface to the market, in other words to the manufacture of
real electric and hybrid vehicles. This is critical for the successof electromobility. It is not adequate simply to develop drive
concepts that conform to the strictest imaginable operating,safety and reliability requirements – they must also be realized
economically. WITTENSTEIN contributes its profound knowhow in the manufacture of high-performance electromechanical motors, for instance for the aerospace and medical technology industries, in which compact and even miniaturized
solutions characterized by maximized efficiency and power/ weight ratios are sought after – just like in electromobility.
Partner for industry
As a trusted partner for industry, WITTENSTEIN shows how
electromobile drive technology can be developed in an integrated way – embracing both the product and the process.

Only if the drives can be developed and produced efficiently
and economically will electromobility succeed in becoming
competitive in terms of the vehicle purchase price and also
the running costs for the user. The immense importance ofefficiency for tomorrow’s eMobile drive solutions is demonstrated by the “StreetScooter” project, a joint initiative byautomotive suppliers like WITTENSTEIN and RWTH Aachen
University. They are collaborating on the development of anaffordable electric car for urban transport and simultaneously
evolving a concept for cost-efficient series production.
The modular eMobile system
The three innovative drive systems for emission-free mobility
on show at the WITTENSTEIN stand at the Hanover Messe
2011 prove the vitality of the modular eMobile system. Moresystems for a variety of vehicle and performance classes will
gradually become available. Thanks to WITTENSTEIN’s modular product and production concept, they can be configured
in different quantities. After all, the ability to produce electric
drives sufficiently cheaply is essential to prepare electromobility for a broad mass market.

move

9

Application

The new mosTEC.racing-Team is looking forward to a sucessful season.

Litmus test in Hockenheim:

electric drive made by WITTENSTEIN
By Leonhard Rödl, Assistant Manager mosTEC.racing
BWCSU Student of Business Engineering,International Technical Sales Management at WITTENSTEIN AG

The goal is both challenging and exciting: a team of students are in the process of building a Formula One racing carthat will subsequently have to convince a jury of experts from the motor sports, automotive and supplier industries
with an overall package consisting of construction, performance and financial and sales planning. The “mosTEC.
racing” team from Baden-Württemberg Cooperative State University (BWCSU) has until August this year to come up
with a competitive electric with the ability to race in the Formula Student Electric contest at Hockenheimring. The
electric drive for this car is being supplied by WITTENSTEIN.
The schedule is extremely tight and the students are working all out to get their car ready on time. The highly motivated team, about forty in number, will be participating in theelectric version of the competition for the second time in the
2010/11 season, with the WITTENSTEIN group acting as astrong partner and platinum sponsor (the highest category).
This year, WITTENSTEIN will be responsible for the heart of

10 movethe drive: the traction motor from WITTENSTEIN cyber motor
installed at its centre achieves a fantastic power output of 80
kW, considering that the total weight of the racing car is no
more than 300 kg. This theoretically suffices to accelerate thevehicle to 60 mph in around three seconds flat. These awe-inspiring values are the outcome of the very high starting torqueand the fact that there is no switching delay. The POWER-IQ

Application

The POWER-IQ 150 from WITTENSTEIN electronics is a highly
compact power electronic system that is used to control the
racing car‘s motor.

WITTENSTEIN will be responsible for the heart of the drive thisseason. The electric drive shown here was made by WITTENSTEIN
and will be on show at Hannover Messe 2011.

What is Formula Student?
“Formula Student” (www.formulastudent.de) is aninternational design competition for students organized by the Association of German Engineers (VDI).

150 from WITTENSTEIN electronics is a highly compact power electronic system that is used to control the motor. The
control electronics with the “MicroAutoBox 1401/1501” andsoftware to match will be provided by dSPACE, another ofthe student project’s sponsors. This is where all vehicle data
is integrated, for example in order to incorporate a traction
control system. Several of the students concerned are also
WITTENSTEIN employees, which means they are guaranteed
the excellent support and close cooperation that are essential
to adapt the drive optimally to these special conditions andrequirements. The mosTEC.racing team is looking forward toa successful 2010/11 season.

Student teams from universities all over the world
will meet at Hockenheim for four days in August tocompare their design and performance results anddemonstrate their creative capabilities to industry.
A separate event for all-electric vehicles was introduced at this world famous racetrack in the 2009/10
season. Each team develops and builds a racing carover a twelve-month period together with selectedsponsorship partners in industry. This car is then required to race on various circuits worldwide in directcompetition with the other teams.

move 11

Made-to-measure solutions:
A tooth for a tooth
High-end hypoid bevel gearset from WITTENSTEIN bastian

WITTENSTEIN bastian‘s HRH hypoid bevel gearset: maximum positioning accuracy and repeatability combined with extreme dynamics.

Professional, affordable engineering for prototypes andend products, a high level of manufacturing and quality
expertise in gearing technology, speed and teamwork –all of these were vital ingredients in the development of anovel positioning drive. The product of our concerted efforts – the WITTENSTEIN bastian HRH hypoid bevel gearset – is meanwhile benefiting a manufacturer of sheet
metal processing and pipe cutting machines.
The HRH (High Reduction Hypoid) hypoid bevel gearset isthe first axially offset transmission of its kind in the world toachieve a reduction ratio of i = 24 in gear tooth quality 1 withjust one bevel gear stage. “That makes it particularly interesting for applications where very high positioning accuracy
and repeatability are specified in combination with extreme
dynamics”, says Erik Roßmeißl, General Manager of WITTENSTEIN bastian in Fellbach. The hypoid bevel gearset is theoutcome of a process of intensive cooperation with the customer’s R&D department. Precise and highly dynamic positioning of tool heads in processing machines was not the sole

12 movedevelopment objective, however. The new solution also had
to be much quieter, lighter and cheaper than the old gearhead concept.
Gearing solutions from a single supplier“WITTENSTEIN bastian offers its customers in motor
racing as well as in the aerospace, robotics, engineering andcar-making industries comprehensive manufacturing andengineering expertise from a single supplier”, Claus Stoll,
Sales Manager at WITTENSTEIN bastian, reports proudly.
From bevel or spur gears through internal gearings to customized gearheads – the more complex the gearing task,
the earlier the collaborative development and design processwith the customer needs to begin. Contrary to common practice in the industry, the engineering services are not restricted
to simply designing the gearing; they form part of an allinclusive package consisting of development, design,detailed calculations, load testing and product optimization.

Application

High-end gearing solutions from WITTENSTEIN bastian have to comply with thehighest quality standards.

Erik Roßmeißl, General
Manager of WITTENSTEIN
bastian in Fellbach

Claus Stoll, Sales Manager at WITTENSTEIN
bastian in Fellbach

The challenge: to position the tool head precisely
The hypoid bevel gearset supersedes the more complicatedsolution traditionally employed, namely a motor with two spur
gear stages. The specification for the new transmission solution not only called for maximum positioning accuracy andrepeatability together with very high dynamics; it also demanded a significant reduction in weight and operating noise.
The prototype was developed and designed in close consultation with the customer. It underwent preliminary testingin the form of numerous measurement, testing and correction cycles and was subsequently optimized in the course of
the development process. Further potential for improvement
was generated by tests undertaken on the customer’s testing
facility. The result of the prototype phase was the high-end
HRH hypoid bevel gearset, comprised of a bevel gear with 72
teeth and a pinion with three teeth in gear tooth quality 1. “It’sthe very high contact ratio that makes this design so unique:several teeth engage at once and each tooth engages at several points”, Claus Stoll explains. This, along with the targeted design of the component macro and micro geometry, theAll characteristics and any changes in them during the various
production processes – such as machining or thermal treatment– were documented and optimized by WITTENSTEIN bastian innumerous measurement, testing and correction cycles.

surface design and the modification of the flanks to achieve
optimal running performance and stress behaviour, assuresmaximum functional reliability in the presence of high dynamics, exceptionally quiet running and a very long service life.
The outcome: better, lighter, cheaper
The hypoid bevel gearset impresses in several ways in themachine for which it was developed – thanks to the higher
dynamics and precision, the path control achieved by thetool head is much more accurate. The design of the bevel
gear means that media and cables or hydraulic hoses can be
fed through the large centre opening. The number of components to be assembled is less than it was before – with theresult that the weight has been reduced by about 60%. The
operating noise emitted by the hypoid bevel gearset has been
approximately halved. Last but not least, the customer profits
from the 30% lower costs for components.
It comes as no surprise to learn that specific plans to use thetechnology in other types of processing machine are alreadywell under way.

move 13

Products

Rotary power for exacting requirements
TPM+ family: two new sizes			
TPM+ / TPM+ high torque 300 und 500

The new TPM+ high torque 300:
Rotary actuators from WITTENSTEIN motion control
achieve up to 10,000 Nm in a compact space envelope.

A powerful unit
A system can only work efficiently if all its components are
perfectly integrated.
A TPM+ servo actuator from WITTENSTEIN motion control
is made up of a TP+ low-backlash planetary gearhead fromWITTENSTEIN alpha and a servo motor from WITTENSTEIN
cyber motor. The gearheads are characterized by minimal
backlash as well as high torsional and tilting rigidity. The
synchronous servo motors in the 220 series provide optimal
power density and a maximum peak torque of 165 Nm. The
integration of all these aspects in one system results in the

14 movehigh-precision, highly dynamic and compact TPM + servo
actuator.
• Advantages of the TPM+ high torque
The actuators have a high transferable torque and very hightorsional rigidity. The integration of the gearhead pinion in the
motor shaft means smaller motors can be used. As a welcome side-effect, the energy consumption of the drive train is
reduced, leading to lower costs for the customer. The optimal
rangeability improves the precision of the machine, thus helping to reduce lead times and make production more efficient.

By Siegfried Wallauer
Product Manager Rotary Drive Systems at WITTENSTEIN motion control

The servo actuators in the TPM+ product family impresswith their high dynamics, torque and torsional rigidity.
In combination with their extremely short overall length,
high power density and quiet running as well as power
steps geared to practical requirements, this translates
into more efficient production. WITTENSTEIN motion
control recently extended the TPM+ family with two newsizes: 300 and 500.
A major European manufacturer of blow moulding machines
has already opted for our powerful, compact and torsionallyrigid TPM+ / TPM+ high torque 300 and 500 servo actuators to meet the tough specifications of its application. The
polymer melt is injected at high pressure, and this can easily
cause the moulds to slip. The high-torque version of the TPM+
500 keeps the two halves of the mould – in other words, thenegative image of the product – tightly closed because eventhe slightest movement will result in scrap. It was the hightorsional rigidity and the unbeatable performance data thattipped the scales for the customer in favour of the WITTENSTEIN motion control actuators. Their superior quality and• Suitable for exacting requirements
The TPM+ 300 and TPM+ 500 are suited for any reduction
ratio up to i = 100. The TPM+ 500 is capable of transferringa maximum acceleration torque of 6000 Nm. The new TPM+
high torque 300 and TPM+ high torque 500 with reduction
ratios up to i = 220 can be used for higher loads and higher
torques. In this case, the maximum transferable acceleration
torque is increased to 10,000 Nm. Although the actuators
are only 418 mm long, their power density is very high. The
TPM+ 500 achieves a maximum torsional backlash of 1.5
arcminutes. The high torsional rigidity of up to 2000 Nm
per arcminute enhances the performance of the customer’s

reliability and their long service life also played a role.
Just the right application
The technical requirements of a gantry-type milling machine
belonging to a big-name European manufacturer of machine
tools proved to be a similarly difficult challenge: the machine
is so huge that a mid-range car would fit inside it without
any problems. The application calls for an actuator with a robust control response, optimal positioning accuracy and hightransferable torques. The new TPM+ 300 has certainly performed impressively so far, effortlessly shifting more than 30
tons at a speed of around 50 metres a minute!
WITTENSTEIN – a system supplier you can trust
The drive train for this application also includes a few other
innovations made by WITTENSTEIN: a high-precision pinion
welded to the TPM+ 300 is responsible for the linear motion
together with a high-performance rack. The fact that all ofthese matched components were provided by a single supplier is greatly appreciated by the customer.

machine.
• Optional extras
Various feedback devices such as rugged resolvers, optional
single or multiturn encoders for detecting the absolute position (complete with a holding brake on request) are also available.
• For further information, please contact Siegfried Wallauer,
Product Manager Rotary Drive Systems at WITTENSTEIN
motion control GmbH,e-mail: siegfried.wallauer@wittenstein.de.

move 15

Products

Active implants withwireless power and data transmission

How can movements and processes inside the human body be measured and actively influenced?
The answer to this question is as simple as it is exciting – with power! Yet how can this power be introduced into ourbodies, for example in order to drive a so-called intramedullary distraction nail for lengthening short limbs? WITTENSTEIN intens has developed a system that supplies wireless power direct to the implant – enabling the patient to betreated much more comfortably. Other human anatomy applications are now also within reach.

This innovative technology for wireless power transmission
has already been used successfully in FITBONE®, the fully
implantable intramedullary distraction nail for lengthening
extremities, for a number of years. The electronic device required for this purpose can be accommodated in a spaceno bigger than 2 cm³ – only slightly larger than a dice. The
FITBONE® nail is implanted into the marrow cavity of a tubularbone, enabling the limb to be lengthened up to several inches– at a rate of about 0.04 inches a day – over a period of a few
months. The miniaturised drive electronics that are essential to achieve this have been condensed by WITTENSTEIN
electronics into a mere 8 x 20 mm² (top right). These
components control a motor, evaluate various sensors and transmit power and data wirelessly to the implant. The implant’s functions are controlled directly by
the patient using a hand-held external sensor. The prin-

16 move

ciple of wireless power and data transmission is similar tothat of an electric toothbrush: power is transmitted fromone coil to another via an electromagnetic connection.
The technology employed for wireless power and datatransmission is not only useful in FITBONE®; it is also being
continuously evolved by WITTENSTEIN intens and adapted
for other applications. The first development project has already kicked off, in which a synthetic muscle substitute has
to be supplied with power. The technology can additionallybe transferred to applications such as an adjustable gastricband for patients suffering from adiposity (obesity) as well as
for measuring stress values in implants, drug pumps, heart
support systems or artificial hearts. In the near future, it could
even be possible to supply power to the autonomous axesof a robot in this way.

Products

Miniaturised drive electronics act as the control centre for the intramedullary nailFor the good of the patient:intelligent drive technology
Fully implantable FITBONE® intramedullary distraction
nail with control

External limb lengthening method

For the time being, however, let’s get back to – or rather backinside – the human body: power transmission systems for
implants traditionally have to be operated manually owing totheir complex technology and can only rarely be controlled by
the patient themselves. They also have to be replaced after acertain period – as soon as the energy store has been used
up – or supplied with power via “transcutaneous” cables that
protrude through the skin. A battery operated pacemaker,
for example, needs to be renewed after about eight years.
Wireless power and data transmission renders surgery of thiskind unnecessary. And whereas the systems so far available
in the market for treating urinary incontinence are can neverbe guaranteed to be one hundred percent reliable, and in
extreme cases may even result in the loss of the urethra,
wireless alternatives enhance patient comfort and security.

FITBONE® technology• Techniques for lengthening limbs (callus distraction) havebeen around for a long time; up to now, they have mainly
been performed using external fixators such as the ring type
(photo left). The bone concerned is first of all cut in two artificially and the two segments then stabilized by means of an
external fixator. The principal drawback of this method is that
so-called Kirschner wires are required to provide an anchor
for the bone segments and the rings attached to the limbs.
These wires have to be driven through the skin, soft tissue
and muscles.
• In contrast to external fixators, fully implantable systems areinserted directly into the bone marrow cavity. The FITBONE®
system (photo right) is stabilized by a telescopic, intramedullary distraction nail, which extends the limb similar to the aerial on a car roof.

move 17

Awards

Double honours:
Competence and Axia Awards
In mid-2010, WITTENSTEIN alpha was honoured with the coveted “Baden-Württemberg Competence Award”. Threemonths ago, in January 2011, the “Axia Award 2010 Baden-Württemberg” was conferred on WITTENSTEIN AG. The
awards were made in recognition of the company’s innovative tradition, superior products and strong innovation
culture.

The “Baden-Württemberg Competence Award” was presented to WITTENSTEIN alpha as an authentic and exemplarycompany that has set new benchmarks in drive engineering. The cymex® and cymex® statistics sizing software additionally testifies to WITTENSTEIN alpha’s role as a holis-

tically operating system, provider of inspiration and driving
force in the market. The award was personally received by
Dieter Derr, General Manager of WITTENSTEIN alpha (photoright), Thomas Krämer, WITTENSTEIN alpha Quality Officer(left) and Volker Metzger, Manager Customer Service at
WITTENSTEIN AG.

The “Axia Award 2010 Baden-Württemberg” was won by
WITTENSTEIN in the “Culture of Innovation – a Success Factor for SMEs” category for its strong innovation culture, whichis particularly exemplified by the President and principal
shareholder, Dr. Manfred Wittenstein. Ulrich Boelcke, General

Manager WITTENSTEIN intens GmbH and Head of Marketing& Communications at WITTENSTEIN AG (photo left, together
with Thomas Traub of Deloitte & Touche, the leading auditing
and consulting specialist) travelled to Stuttgart to receive theaward in January 2011.

18 moveTrade fairs

European trade press
visits WITTENSTEIN AG (Switzerland)
The new production facility at the WITTENSTEIN group’s
Swiss site in Grüsch in the canton of Grisons was in the limelight at a special trade press day organized in February 2011.
The event also focused on topics like linear systems, sensor
technology and energy efficiency. The unveiling of WITTENSTEIN alpha’s new linear systems was a particular highlight.
Twenty-one lead journalists from Germany, Italy, France andSwitzerland had a chance to get hold of exclusive and upto-the minute information direct from source, notably regarding the company’s exhibits at Hannover Messe 2011. Not
only the respective product managers but also Karl-Heinz
Schwarz, Spokesman of the Board of WITTENSTEIN AG, and
Dr. Anna-Katharina Wittenstein, General Manager of WITTENSTEIN AG (Switzerland) and the event’s host, were in attendance and available for interviews.

TRADE FAIR CALENDAR 2011 (selection)
Hanover Fair, Hanover (Germany)
Industrial Automation (Hall 15, Stand F08),
MobiliTEC (Hall 25, Stand L13/09),
Job & Career Market (Hall 7, Stand A30/12)
WITTENSTEIN group
April 4 to 8, 20111

EMO 2011, Hanover (Germany)
The World‘s Premier Trade Fair for Metalworking
Technology
WITTENSTEIN alpha GmbH,WITTENSTEIN motion control GmbH
September 19 to 24, 2011

ITEC, Cologne (Germany)
Trade Fair for Simulation(Hall 11, Stand D160)
WITTENSTEIN aerospace & simulation GmbHMay 10 to 12, 2011

Motek 2011, Stuttgart (Germany)International Trade Fair for
Assembly and Handling Technology
WITTENSTEIN alpha GmbH,WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbH
October 10 to 13, 2011

Metalloobrabotka 2011, Moscow (Russia)
11th International Exhibition for Materials Processing, Technologies, Machines and Tools
WITTENSTEIN alpha GmbHMay 23 to 27, 2011
Paris Air Show, Le Bourget (France)
Salon International de l‘Aéronautiqueet de l‘Espace(Joint stand of the German Aerospace
Industries Association (BDLI),Hall 2C, Stand B338)
WITTENSTEIN aerospace & simulation GmbH
June 20 to 26, 2011

Forum Maschinenbau, Bad Salzuflen(Germany)
Trade Fair for Suppliers in the
Machinery Manufacturing Industry
WITTENSTEIN alpha GmbH
November 9 to 11, 2011
SPS/IPC/DRIVES 2011, Nuremberg(Germany)
Exhibition for Electric Automation –Systems & Components
WITTENSTEIN alpha GmbH,WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbH,WITTENSTEIN electronics GmbH
November 22 to 24, 2011

move 19