move

The magazine for customers and friends of WITTENSTEIN

One philosophy. One identity. One brand!
The strong WITTENSTEIN brand1

July · 2008

move

The magazine for customers and friends of WITTENSTEIN

Content
Masthead
Publisher:
WITTENSTEIN AG
Walter-Wittenstein-Strasse 1
97999 Igersheim / Germany
www.wittenstein.de
move@wittenstein.de
Editor:Miriam Spangenberg (Responsible under press law)
Contributing Editors:
Dr. Christoph Schumacher (Marketing & Communications)
Sabine Maier (Press Relations)Peter Schuster (WITTENSTEIN electronics)
Ulrich Boelcke (WITTENSTEIN intens)
Michael Knoblauch (WITTENSTEIN aerospace & simulation)
Katja Horn (WITTENSTEIN alpha)Claus Stoll (WITTENSTEIN bastian)
Sonja Fahrbach (WITTENSTEIN cyber motor)
Fabienne Isabey (WITTENSTEIN motion control)
Dr. Karl-Dietrich Gräwe (DEBUT)
Markus Glaser (Research & Development)
Anne Roels (WITTENSTEIN BVBA, Belgium)
Circulation:
15,000 copies
Production:
WAJS
Otto-Hahn-Str. 13
97204 Höchberg / Germany
Printing:
Printed in Germany
All rights reserved. This document may not be reprinted orelectronically distributed without the express permission of
the publisher.

A strong brandWe are all WITTENSTEIN

4

Robokeeper
EURO 2008 driven by WITTENSTEIN alpha

6

FITBONE®
Mechatronics drives bone growth

10

cymex® 3.1“Intelligent” calculation and sizing of drive trains

14

Active Stick
Just like in real life

16

News

18

Hard treatment
The heat is on at WITTENSTEIN bastian20

DEBUT 2008
WITTENSTEIN stages European
Opera Competition

22

Fairs and exhibitions 2008/2009

26

Dear readers,
Welcome to the first issue of „move“, our new customer magazinethat will help us broaden and deepen our relationship with the many
partners and friends of the WITTENSTEIN Group. „move“ will take theplace of the old „alpha newsletter“, which some of you have beenfamiliar with for years. The title „move“ was chosen to reflect our corecompetence: „intelligent drive systems“. This new magazine will keep
you regularly informed about the varied fields in which the companiesof the WITTENSTEIN Group operate. Our high-tech products are inaction all over the world wherever systems and parts have to be driven
and controlled with utmost precision – from machine building throughaerospace to medical technology. You profit from a wealth of experience encompassing all aspects of mechatronic drive technology that wehope will provide you with interesting food for thought. As a globally successful enterprise whose products perform reliably and precisely in countless blue chip applications, we are aware of our immense responsibility. We keep a keen eye on
the future in our everyday lives, thinking and work. Together with the other four values of our company philosophy – trust,
openness, innovation and change – our tradition of responsibility forms the basis for our corporate principles.
For us at WITTENSTEIN, „being one with the future“ is not an empty slogan but a maxim that we constantly strive toembody in our relationship with customers and suppliers. With effect from July 1, 2008 the WITTENSTEIN Group and all
Business Units will operate under a single umbrella brand: WITTENSTEIN. The standardised logo and the new company
colour will underline – both internally and externally – the rich diversity of our portfolio that will in future be integrated under a common corporate strategy. We would like to take this opportunity to emphasise that we are not restructuring thecompany group. Our number one priority are still our customers – they always have been and they always will be.
On this note, we look forward to continuing our fruitful dialogue with you in an environment of mutual trust as the foundation for our shared success. I wish you pleasant reading with the new magazine.
Karl-Heinz Schwarz
Spokesman of the Board of WITTENSTEIN AG

move

3

Headquarter

One philosophy.
One identity.
One brand!

We are all WITTENSTEIN:
on July 1, 2008 our company acquired an internationally standardised brand identity.
All Business Units and worldwide subsidiaries will in future be united under the WITTENSTEIN
brand. When WITTENSTEIN AG, headquartered in Igersheim-Harthausen (South-West Germany),
was established in 2001, the foundation was laid for a globally operating corporate group – anambitious project that is now being taken an important step further.

The transition from a set of individual company brands to a
globally standardised identity with strong Business Units andsubsidiaries is a logical result of our Group‘s increased convergence and muscle. With some 60 subsidiaries and agentsin 40 countries around the world, WITTENSTEIN is uniquely
identifiable with its claim „WITTENSTEIN – being one with the
future“.
This claim embodies a lofty goal – a company that aspires
to be one with the future must contemplate tomorrow‘s solutions today! We believe we are firmly on the right road.
Fit for the world market
The standardised brand identity will fit our company for theworld market and the central challenges of the future. Manfred
Wittenstein, President of WITTENSTEIN, has made his namesynonymous with excellent precision and innovative products:„Our aim is to demonstrate how every single WITTENSTEIN
product is the outcome of several decades of experience anddevelopment work that today profits all Business Units. Our
know-how and our core competencies are pooled in a common development and production platform. We leverage these synergy effects to the benefit of our customers.“

4 moveManfred Wittenstein is also President of the German Engineering Federation (VDMA) – and hence the top representative of
one of Germany‘s leading branches of industry. The umbrellaassociation for more than 929,000 jobs and sales of 195 billion euros in 2007, VDMA is the country‘s biggest industrial
employer.
New names – familiar services
With effect from July 1, 2008 the WITTENSTEIN subsidiaryalpha getriebebau GmbH, established in 1984, will be known
as WITTENSTEIN alpha GmbH.
Our six other Business Units – WITTENSTEIN electronics GmbH, WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbH, WITTENSTEIN intens
GmbH, WITTENSTEIN bastian GmbH and WITTENSTEIN aerospace & simulation GmbH – will keep their existing names
but appear in the new corporate colour under the standardised WITTENSTEIN logo („three wings“). Also from July 1, allinternational subsidiaries will be renamed WITTENSTEIN (plusthe legal form for each country, for example WITTENSTEIN
S.P.A. in Italy instead of the present alpha riduttori s.p.a.).

alphael ect roni cs

mot i on cont rol

cy ber m ot o r

int ensbas t i ana e rosp a c e& s i mu la t io n

Products for challenging applications
Our products are in action wherever systems and parts haveto be driven and controlled with utmost precision. High-precision planetary gearheads, complete electromechanical drive
systems and AC servo systems and motors, to name but afew, are developed, produced and marketed by more than
1200 employees in every corner of the globe. The products
sold by our seven Business Units are typically used in robotic systems, machine tools, the packaging industry, materials
handling and process engineering, Formula One racing, paper
and printing presses, medical technology and aerospace.
The mainstays of our successAcknowledged technological expertise and a tradition of innovativeness are the mainstays of our company’s success. With
our fundamental orientation towards intelligent, mechatronic
drive systems and a blend of micro and macro technologies,
we will continue to develop our core know-how and competencies. Our company is a setter and promoter of trends inthe development, production and marketing of components.
85 percent of all WITTENSTEIN products sold are less than

five years old. Every tenth euro is spent on, and 12 percent of
employees engaged in, research and development.
Satisfied customers worldwide
It is our declared objective to make our customers even more
successful. We tirelessly endeavour to justify the trust theyplace in the pioneering technical expertise, total reliability andpremium quality of WITTENSTEIN services. As an innovative
mechatronics specialist, we owe this success in no small partto our first-rate team of employees spanning roughly 60 locations and agents all over the globe.
Without their enthusiasm, dedication and know-how, allpast and future achievements of our young and dynamic
company would be unthinkable. We promise to uphold ourcommitment to being a world class global partner for the customers of our intelligent mechatronic drive technology, servo
systems and components in the years to come.

move

5

6 moveTechnology

RoboKeeper
Qualified for Euro 2008 –WITTENSTEIN alpha‘s drive technology adds fuelto the goalkeeper debate with a new name
Report: Andreas Kaiser I Photo by courtesy of 4attention

Imagine the following situation: as manager of the German national team, you are lucky enough to be able
call up a goalkeeper who not only saves almost any penalty on the line but never loses his cool or utters acritical word. Wouldn‘t that be a fantastic position to be in? Believe it or not, this perfect goalkeeper really
does exist! And his inimitable reliability and speed are thanks to WITTENSTEIN alpha technology. RoboKeeper is a highly acclaimed sports personality. And thesecret of his success was finally revealed following a toughtest of his performance at the Ideas Expo in Hanover in
October 2007: RoboKeeper‘s virtual invincibility – and his
formidable reputation as the world‘s best penalty killer – isattributable in no small part to the TPM+ drive concept
developed by WITTENSTEIN motion control (WMC).

The 6’5” tall RoboKeeper has none of the airs andgraces of his star colleagues and never gives anything
less than his all in the game. He dives into the farcorner of the goal in just 0.3 seconds and holds balls
coming at him at speeds of up to 65 mph. He has
already demonstrated his speed at numerous footballmatches, sports fairs and events.

More information:www.robokeeper.com or www.fraunhofer.de

move

7

Technology

TPM+ –
the heart of the RoboKeeper

In the course of this nine-day event, the „ace keeper“ – who
measures six foot five from his fingertips to his toes – faced atotal of 8000 would-be scorers, among them Lower Saxony
state premier Christian Wulff and Federal Minister for Family
Affairs Ursula von der Leyen. Out of 10,000 shots at goal,
RoboKeeper let in just 500.
Fast and precise thanks to TPM+ and engineering support
This unprecedentedly fast and precise goalkeeper was developed and built by the Fraunhofer Institute for Material Flowand Logistics (IML) in Dortmund. The research team was advised and supported regarding the engineering for the complete drive unit by alpha sales engineer Andreas Kaiser of ourEngineering Office West in Oberhausen. Thomas Nied, an
experienced solution architect at WITTENSTEIN motion control, steered the drive to maximum dynamic performance by
optimising the traverse profiles and the parameter settings in
the field.
Motor/gearhead combination is the key
RoboKeeper is basically an outsized Tipp-Kick figure mounted on a gearhead/motor combination. Above the goal are twocameras that recognise the ball and follow its trajectory. Using
this data, the image processing software calculates the ball‘s
probable point of entry into the goal. It sends this information
to the motor control, which turns the goalkeeper to the angle

8 moverequired to save the shot. All this takes place in a fraction of
a second – if the penalty shooter kicks the ball hard, it caneasily reach a speed of 65 mph, equivalent to about a hundred feet a second. It covers the 36 feet to the centre of thegoal in just 0.4 seconds and needs only marginally longer(0.42 seconds) to complete the 38 feet to either of the top
corners. RoboKeeper‘s working conditions are even more difficult than usual, however, because the distance between the
penalty spot and the goal is no more than two or three yards,
depending where he is standing.
WITTENSTEIN as sole supplier
These figures clearly illustrate the dynamic requirements thesystem – including the servo actuator, of course – has tomeet. A mere 0.3 seconds are all that is available to move thefifteen-pound goalkeeper, comprised of a foam body and analuminium spine, into the right position.
WITTENSTEIN was the only supplier capable of delivering
the motor/gearhead combination (TPM+ 110 with a ratio of61) necessary to turn RoboKeeper into a true “penalty killer”.
The performance displayed by the image processing computer is no less impressive: each of the two cameras takes
a staggering 60 photographs a second. Five images, which
the software evaluates in a tenth of a second, are needed to
calculate the ball‘s trajectory. The motor starts to turn just
50 milliseconds (0.05 seconds) after the kick has been delivered. It reaches its final speed (33 mph at the fingertips) 0.07

seconds later. This acceleration is 17 times faster than that ofa Formula One racing car. The time to brake the motor frommaximum speed to standstill is exactly the same, namely 70
milliseconds.
All in all, the robot is 15 milliseconds faster than the ball.
Put another way, RoboKeeper is ready and waiting when theball is still 45 cm away from the goal line. With this kind of reaction speed, he would have no trouble saving pen-alty shotsin the German Bundesliga.
RoboKeeper versus Dédé
Irrefutable proof of RoboKeeper’s enormous talent was provided in a duel with Dédé, the Brazilian professional who
plays for Borussia Dortmund. RTL documented this exciting
challenge on nationwide television – interested customers arewelcome to ask their responsible WITTENSTEIN alpha sales
engineer for a copy of the video. To stand a chance of beating
the robot, the ball must either cross the line spot on in oneof the top corners or approach it at a speed of more than 65
mph – neither of which happens that often.
Two years to develop
It took almost two years to develop RoboKeeper, the idea forwhich was originally conceived during the last World Cup.
“Research meets entertainment” was the motto of the development team, led by Fraunhofer IML Director Prof. Michaelten Hompel. Their efforts have meanwhile been rewarded bynumerous enquiries from journalists and a packed diary forthe new keeper. Amongst other things, he is due to feature in
the European Football Championships (Euro 2008) from June
7 to 29, with several firm bookings at venues in Switzerland
and Austria. His job won’t be to boost one of the competing
teams, however, but to take part in promotional and marketing activities.
His exclusive marketing rights are held by the sports
marketing and event agency 4attention (www.4attention.de)in Cologne. And of course, RoboKeeper also has his own
website (www.robokeeper.com), offering further useful information, details of his forthcoming match schedule and videos
of his best performances.
Award winning performance
RoboKeeper does not only excel between the goalposts.
Together with his creator, Andreas Kaiser, the high-speed
robot won first prize in the “Application Award” competitionat the “VII International WITTENSTEIN Sales Meeting 2007”,
when 150 sales engineers from around the globe paid a visit
to Harthausen. High-tech from WITTENSTEIN alpha is morethan simply dynamic and precise, in other words. It also has
the stamina and fitness required for everyday applications – inmodern machines or in the world’s best penalty killer.

move

9

Applications

FITBONE®
Mechatronics drives bone growthReport: Roman Stauch I Photos: WITTENSTEIN intens

The FITBONE® intramedullary distraction nail corrects
leg length discrepancies with mechatronic actuator / Internal synergy effects leveraged

Miniaturisation, integration, network, intelligence –WITTENSTEIN‘s MINI strategy is a motor for synergies, as
modern medicine can testify. The world‘s only fully implantable FITBONE® intramedullary distraction nail with an integrated mechatronic actuator that is both adjustable andcontrollable – enabling leg length inequalities to be corrected
precisely and virtually painlessly – is the outcome of collaborative efforts on the part of the Group‘s Business Units.
It was originally discovered back in the mid-19th century
that bone length growth can also occur in adults under certain circumstances. This phenomenon, referred to as callus
distraction, is based on the same principle as bone growth inchildren and adolescents. So-called growth plates, which are
invaded by bone cells, form during the development phasebetween the joint pieces and the long bones of the upperand lower extremities. When growth is complete – generally
around the age of nineteen – these plates close. The formation of bone tissue (callus) was initially observed by physicians
several centuries ago as part of fracture healing processes.
To prevent the legs from shortening due to muscular spasms
following fractures of the long bones, special tensioning andfixing devices were invented way back in the Middle Ages.
These paved the way for the first – though unfortunately
vain – attempts to stimulate long bone growth with a view to

10 movecorrecting leg length discrepancies or deformities. The basic principle has remained unchanged to this day: the longbone is cut in two and fixed, so that an artificial growth plate– in which new bone tissue forms – remains at the site of
fracture. However, it was not until the early 21st century thatWITTENSTEIN intens, based in Igersheim (South-West Germany), succeeded in developing an implantable FITBONE®
intramedullary distraction nail characterised by unprecedented, reproducible precision that facilitates virtually painlesstreatment of patients. The FITBONE® intramedullary distraction nail is born. In 1988, researchers at Ludwig-Maximilians
University in Munich embarked on a project that would enable
the advantages of callus distraction to be exploited without
the drawbacks of external fixators. The FITBONE® intramedullary distraction nail is the only leg lengthening nail in theworld with an integrated mechatronic miniature actuator thatis both adjustable and controllable.
Design and principle
Since space is very restricted, the intramedullary distraction
nail is designed with a high integration density and a corresponding degree of miniaturisation. It is nevertheless imperative that the FITBONE® can withstand the heavy loads that
occur in the femur and tibia. During the distraction phase,
almost the entire strain must be borne by the nail. The loadon the implant is then gradually reduced during the consolidation phase until the newly formed bone has completely
hardened. Translating requirements such as these into a fully
functional product is one of the WITTENSTEIN Group‘s core

The following are typical indications for the use of
the FITBONE® intramedullary distraction nail:• Congenital leg length inequalities• Leg length discrepancies due to an accident ortrauma• One-sided impaired growth• One-sided abnormal growth• Poliomyelitis• Tumours / sarcomas• Pseudarthroses
The intramedullary distraction nail is also used totreat two-sided growth retardation or dwarfism aswell as to lengthen amputation stumps.

move 11

competencies. In this particular instance, expert know-how
was pooled from the areas of actuators, electronics, sensors
and software.
Located inside the FITBONE® – which has a diameter of
10 mm and an overall length of 245 mm (shorter versions
have been realized as well) – are a miniaturised motor-gearhead combination, a planetary roller screw, a correspondinganti-rotation mechanism and the seal for the telescopic tube.
The modular design permits easy adaptation to the installation space available in the bone as well as to the required
distraction length. Femur extensions up to 85 mm and fibia
extensions up to 65 mm can currently be achieved.
The „connection“ to the outside is established by couplinghigh-frequency power. The intramedullary nail is equippedwith a receiver that is installed in the subcutaneous adipose
tissue. The control unit – the remote station – contains atransmitter head. To connect the power supply and start thelengthening process, the patient simply places the control
unit on the skin for a short time and couple energy.
The limits of miniaturisation have still not been reached.
In the meantime, it would also be technically feasibly to integrate force and position sensors – including the necessary
electronics – in the same space as the intramedullary distraction nail. The reciprocal exchange of information between the

12 move

implant and the external control electronics takes place via atelemetric connection. Finally, the integration of the receiveraerial in the intramedullary nail simplifies not just the implantation itself but also the subsequent removal of the implant oncompletion of the treatment.
Medical benefits and improved quality of life throughout
the treatment phase
The intramedullary distraction nail permits far more comfortable treatment than any alternative method. The risk of infection is almost zero. This minimally invasive surgery technique results in only small scars – also an advantage from acosmetic point of view. The actual lengthening is practically
painless.
The numerous advantages of this treatment method extend beyond purely medical aspects, however: the hospitalisation period after surgery is significantly reduced, so that
re-integration into regular school, domestic or working life ispossible at an earlier stage and with fewer problems.
Patients are able to wear their ordinary clothes, take a shower
or bath and generally lead a more or less normal life. The only
real restriction concerns the maximum load on the operated
leg – and the need to take physiotherapy seriously.

Applications
Characteristics:• No transcutaneous connection from the outside• Wireless, transcutaneous power transmission• Controllable bone lengthening• No infections• Good cosmetic result

Treatment schedule for leg lengthening
The operation is performed under general anaesthetic. The
artificial fracture – the new growth plate – is then stabilisedwith the FITBONE® intramedullary distraction nail. The patientis able to get out of bed with help and manage a few steps
on crutches only one day after the operation. On the sixth
post-operation day the distraction phase begins. The patient
receives precise instruction in the use of the microcomputer
together with a personal treatment schedule. The FITBONE®
actuator can be activated up to three times a day, dependingon specific circumstances. The bone segments are normally
moved apart at a maximum daily rate of one millimetre.
In addition to each patient‘s individual progress, active cooperation is the single biggest factor influencing the lengthening success. Strict discipline with regard to physiotherapeuticmeasures is vital along with personalised exercises to tension
the soft parts – after all, the muscles, blood vessels, ligaments, tendons and nerves need to be extended too. Oncethe desired lengthening distance has been achieved, the leg
lengths are measured exactly and any necessary adjustments
carried out. The load on the leg can now be increased slowly
but steadily. This phase inevitably depends on the length of
the gap and the patient‘s individual healing progress. The
mandatory removal of the implant is undertaken after around
one or two years. A hospitalisation period of three to fourdays is envisaged. In Germany, the cost of FITBONE® treatment is usually financed by the social insurance system inmedically indicated cases.

to be almost compulsory, the use of special surgical techniques nowadays enables doctors to salvage the limbs ofmore and more patients. Assuming good progress is made,the patient can then be given an endoprosthesis. As soon
as the healthy leg starts to grow again – usually after thechemotherapy has been completed – the length discrepancy compared to the operated leg becomes increasingly
marked throughout the growth phase. Instead of compensating this inequality with a follow-up operation, relief can now
be provided with another WITTENSTEIN intens product – themechatronic growth endoprosthesis. The endoprosthesis
developed in collaboration with implantcast GmbH, at homein the North German town of Buxtehude, and Munich Professor Rainer Baumgart is based on the proven distraction
principle of the FITBONE® technology and does not lengthen
the bone but the prosthesis. The telescopic lengthening device has a diameter of 16 mm and is suitable for distraction
lengths from 50 to 100 mm. 			
Owing to the special design of the planetary roller screw,
this endoprosthesis is exceptionally compact and short – animmense advantage for implantations. The treatment procedure is similar to that with the FITBONE intramedullary distraction nail. Leg length differences are corrected with the aidof a microcomputer in small, comfortable steps either ambulatorily or with a short stay in hospital. Ideally, if the patient
makes good healing progress, the growth endoprosthesis
can later even stimulate the callus growth of the remaining,
healthy bone.

Mechatronics helps young tumour patients
The most common form of malignant bone cancer amongchildren and adolescents is the osteosarcoma. It mainly attacks the long bones in the legs or upper arms close to thejoints. More than half of all cases diagnosed occur aroundthe knee, with the result that the growth plates are also affected. Patients are treated with a combination of chemotherapy and the complete surgical removal of the infiltrated
bones and surrounding tissue. Whereas amputations used

Visions within reachThe development work goes on – and our cooperation with expert partners continues to inspire new ideas and approaches.
The newest projects at WITTENSTEIN intens concern novel
applications in the field of inductive power and data transmission such as intelligent implants, „navigation systems“ forminimally invasive surgery and haptic feedback systems for
robot assisted surgery.

move 13

Technology“Intelligent” calculation and sizing ofdrive trains with cymex® 3.1

Newest version of the alpha sizing tool /40 percent better performance achieved
with broad knowledge baseIn the olden days, the only way for engineers to size and design different drive trains of servo controlled machines was touse complex mathematical formulae. Not only did this tend
to be extremely time-consuming, it was also not particularly
accurate owing to the difficulty of including multidimensional
perspectives in an analysis of this kind. For the last ten years,
design experts have profited immensely from cymex®, thesizing tool from WITTENSTEIN alpha GmbH, which handles
these complicated tasks quickly, easily and reliably. The new
Version 3.1 now also integrates the technical know-how ofthe entire Group as the basis for all calculations.
The problems associated with calculations of movement
and load profiles increases parallel to their complexity. Traditional calculation methods fail to provide the necessary depthof detail. This is where cymex®, the drive sizing software,comes in: this tool allows you to determine and select thedrive component design that is best adapted to the application at hand.

this area for more than a decade. Calculation and sizing experts praise the WITTENSTEIN alpha software tool above allfor its high speed, intuitive operation and absolute precision.
Sizing an application, motor and gearhead – in other words,
the complete drive train of a machine – becomes child’s playwith cymex®, and the effectiveness of their interaction canbe easily assessed. Exact calculations are enormously simplified by standard applications. Belt, tape, spindle, rotary table
and rack & pinion drives are predefined and can be skilfully
integrated in the calculations in this way. Customer-specificparameters as well as any other important influencing factors
are extensively considered, assuring not only a reliable andefficient design but also a perfect drive system.
One particularly interesting feature of cymex® is its scalability: from standard geometric alignments – which gearhead
and which attached components best match my motor? –through the design of simple or complex movement profiles
to optimised positioning accuracy or energy consumption.

cymex®: Proven yet brand new
cymex® provides developers and designers with comprehensive support spanning every aspect of drive sizing. The system has been enjoyed a reputation as the ultimate solution incymex® 3.1: “intelligent” software
The newest version – cymex® 3.1 – has been enhanced evenfurther and the label “intelligent” is certainly no exaggeration.
The software combines the amassed experience of WITTEN-

14 moveTechnology

cymex®, the innovative sizing software fromthe alpha stable, reduces routine work to aminimum and assures a maximum degreeof innovativeness. cymex® 3.1 Motion Edition lets you design a complete drive train(application - gearhead - motor) quickly,
easily and reliably with only a few mouseclicks.
With more than 7000 motors from a variety
of manufacturers, the cymex® database is
the biggest library of its kind anywhere in
the world.

cymex®

STEIN alpha getriebebau with specialist know-how in areas
such as system simulation, FEM calculations, sensor technology and QA inspections as the basis for its sizing calculations. The design space for the gearhead load limits is thus
simultaneously extended in several dimensions.
The outcome: up to 40 percent better performance,
leading to increased reliability in drive train design, an improved power yield, smaller gearheads and greater cost efficiency. The value “T2Cymex” in the alpha catalogue is justone reflection of the sizing tool’s unique importance.
“Extended design space” offers key benefits!
The significantly higher performance – up to 40 percent compared to the catalogue – speaks for itself. Owing to the multidimensional design principle, drive trains can be optimallyand reliably sized regardless of the application. Using an offline CAD generator, 3D data of the motor and gearheads –including all attached components – can then be created ina matter of seconds and instantly imported into the design
environment.
Users can reap the benefits of the world’s biggest motor
database with more than 7000 different types plus all alphaproducts like gearheads, bellows couplings and torque limit-

ers. A wizard provides intuitive and systematic support for theselection of the most suitable components. Input modules
for creating simple or complex movement and load profiles,
an integrated bearing life and shaft calculation, predefined
standard applications, functions for importing movement profiles from third-party programs and the documentation of all
application and technical data in Word files with a few simple
mouse clicks round off the impressive features of the cymex®
software.
Your chance to become a cymex® professional!
Knowledge is useless unless it is applied. In the framework of
the WITTENSTEIN Academy, WITTENSTEIN alpha clients are
therefore invited to take advantage of special seminars on abroad range of drive engineering topics as well as on the useof our cymex® software. The portfolio covers everything fromone-day seminars for cymex® novices to expert training for
power users.
Customers and other interested persons wishingto enrol are requested either to get in touch directly with theirusual contact at WITTENSTEIN alpha or to send an e-mailto
Stefanie
Klingertofthecymex®-Teamat
cymex@wittenstein.de.

move 15

Technology

Just like in real life
Report: Michael Knoblauch I Photos: WITTENSTEIN aerospace & simulation

Active stick from WITTENSTEIN aerospace & simulation takes the place of conventional
joysticks / Stress on pilots eased because dangerous situations are recognised faster

Modern joysticks can do far more than simply pass on information entered by the pilot. “Active sticks” – the name given
to the latest generation – adapt to individual flight missions
and can alert the cockpit to hazards reliably.
WITTENSTEIN aerospace & simulation GmbH‘s active
stick was originally designed for use in flight simulators. In themeantime, however, this control unit – which has been optimised in cooperation with BAE Systems – also has so many
advantages for real aircraft that the T-50 Golden Eagle, theSouth Korean supersonic trainer, has already been equippedwith active sticks from the Igersheim stable.
From virtual simulation to the real cockpit
When a flight simulator simulates the real world, the realtechnology is traditionally transposed into the virtual training world. The simulation technology has therefore always
aimed to be a map of the technology in the real aircraft. The
development of the active stick has overturned this philosophy. The technology was initially realised by WITTENSTEIN
aerospace & simulation specifically for simulation applications
like this and gradually also gained acceptance in the cockpits
of real training aircraft.
The way in which the reactions of each aircraft are passed
on to the pilot via the active stick as flight computer feedback
through flight models is particularly fascinating. It would not
be exaggerating to claim that in this field an almost “historic”
evolution has culminated in the active stick. Prior to the invention of servo assisted systems, the pilot used to feel the
aerodynamic forces of the control surfaces directly on the joystick via control rods and cables. The above-mentioned servo
technology, also known as “fly-by-wire”, was a further stepin the development of flight control. The pilot no longer receives any direct mechanical feedback because the rudders
are controlled by hydraulic actuators. The joystick is not connected to the rudders and is consequently a passive system

16 movefeaturing mechanical spring devices and a standardised force
characteristic. It is not possible to simulate any aerodynamic
forces with this control system, in other words. Fly-by-wireis the standard method of flight control in modern aircraft
cockpits.The active stick takes this technology a crucial stepfurther: since it can be explicitly programmed for a particularaircraft type, it can supply the pilot with (vitally) important additional information through different joystick movements.
The full benefit of the WITTENSTEIN control unit is revealed in high-end training aircraft. The joysticks of the twopilots can be programmed, and electronically linked, in such a
way that all movements executed by the second crew member with the active stick in a fly-by-wire control system are
directly communicated to both the instructor and the student.
Master-slave applications (instructor-student function) in flighttraining can likewise be programmed without any problems.
Various downloadable software programs can be adapted tothe student pilot‘s actual skill level. The requirements can beincreased accordingly as they acquire more practical experience. The reduction in weight and physical volume that results from dispensing with control rods is another advantagethat ultimately also has a positive impact on the emissions
produced.
Continuous, systematic development since 1999
WITTENSTEIN aerospace & simulation GmbH has been developing active sticks since 1999. They were initially employedin simulators for American combat aircraft. In the meantime,these sticks are also used in other simulators for fixed-wing
airplanes and rotorcraft, for example in the US Army‘s AVCATT
for training complex helicopter missions. Active stick systems
are not just reliable and compact, in other words, but also extremely flexible. The fact an the active stick can be freely andreconfigurably programmed permits different action-reaction
models: if a passenger aircraft veers off course, tripping avibration alarm on the stick, the pilot of another plane flying
over the same area on a crisis mission is alerted to the danger
by means of this vibration or similar haptic information. The
active stick system is synchronised with the flight computer,enabling the pilot to concentrate on the most important taskof all, namely flying. This system improves safety and saves
lives in both civilian and military use!
The integrated technology with brushless motors andplanetary gearheads in several different sizes, originally developed for robotics applications, is of course mainly intended
for the high end of the market. However, the insights gained
there also benefit all other WITTENSTEIN customers because
the results can be applied to the series production of gearheads, servo motors and electromechanical drive systems,
for instance. The potential of WITTENSTEIN aerospace &simulation‘s active sidestick is nowhere near exhausted. An
excellent future awaits the system in many other cockpits allover the world – and the demand curve continues to rise at a
steady angle.

move 17

News

Anniversary in Belgium
Report: Anne Roels I Photos: WITTENSTEIN aerospace & simulation

This year WITTENSTEIN benelux(formerly alpha Benelux) exists 5 years.
The subsidiary of WITTENSTEIN alphawhich is responsible for the sales in the
Netherlands, Belgium and Luxemburg
was founded on the third of April 2003.
In those 5 years the turnover almost
doubled and the number of employees
has risen from 2 to 7, (8 in the near
future).

WITTENSTEIN breaks into South-East European markets
Report: Helmut Ortmeier I Photo: WITTENSTEIN transilvania

The inauguration of our new production
facility in Sura Mica (not far from Sibiu)
on June 19, 2008 marks the launch ofoperative business – the manufactureof drive components, initially with 15
employees – at WITTENSTEIN‘s Romanian subsidiary. From its Sibiu base,18 move

WITTENSTEIN aims to break into thelucrative markets of Eastern (Ukraine,
Belarus) and South-Eastern Europe(Bulgaria, Turkey) and will systematically strengthen the site‘s role as ahub. Plans are already in the pipeline
to extend the facility to an impressive

11,000 square metres in the next few
years, with space for up to 400 staff.
WITTENSTEIN will invest a total of 15
to 20 million euros in the „Sura Mica“industrial park, which is also known by
the German name of „Kleinscheuern“.

News

Grüsch site set to expand
Report: Dr.-Ing. Anna-Katharina Wittenstein I
Photo: WITTENSTEIN schweiz

Delighted at the “green light” for the joint construction project (from left to right):
Dr. Ulrich Gadient, Member of the Administrative Board of WITTENSTEIN Switzerland,
Georg Niggli, Chairman of Grüsch Local Council, Dr.-Ing. Anna-Katharina Wittensteinand Manfred Wittenstein

WITTENSTEIN AG‘s Swiss subsidiary is set to expand at its Grüsch site:
there are plans to erect a new building
measuring around 3000 m² on 35
acres of land by the end 2009. Up to
50 employees will in future develop andproduce innovative drive components
in these scenic surroundings: industrial
sensors, for example for simulation andindustrial systems, and mechanicaldrive components for machine tools
and assembly robots. WITTENSTEIN
intends to invest about 17 million Swiss
francs at its Swiss location over the
next five years. The company currently
resides in INNOZET Grüsch, a centre
for startup companies. As a worldwide centre of competence for sensor
technology within the WITTENSTEIN
Group, the Grüsch plant will develop,
apply and market sensors and sensor
components for simulation and industrial systems.

move 19

Technology

Hard treatment – the heat is on at WITTENSTEIN bastian
Report: Claus Stoll I Photo: WITTENSTEIN bastian

Another core process under the WITTENSTEIN umbrella /New heat treatment plant up and running since February

Another core process under the WITTENSTEIN umbrella/ New heat treatment plant up and running since February.
A new heat treatment plant went into operation at WITTENSTEIN bastian GmbH (Fellbach, near Stuttgart) at the beginning of February. As a result, one of the central core processes necessary to manufacture gearing parts can in future
be carried out within the company. This increased degreeof vertical integration will protect the continued high qualityof our products.The extensive specialised know-how that is

20 moveneeded to harden gearing parts can now remain within the
WITTENSTEIN walls, helping us maintain that all-importantedge over our competitors. At the same time, however, thehigh quality stipulated for these parts can only be guaranteed
if the hardening process – including heat treatment – is one
hundred percent controllable.
Two bell furnaces
Series production takes place in two bell furnaces. The parts

to be hardened are initially enriched with carbon at 930°C,
then cooled down again “abruptly” – in other words quenched– in a molten salt bath. They are placed on a kind of transport platform for this purpose and the electrically heated bell
furnace is raised. The parts are subsequently heated to thetemperature setpoint, enriched and quenched. Following
this, they must be cleaned to remove any salt residues fromthe surfaces. In the final heat treatment step – referred to as
tempering – they are reheated to approximately 170°C. This
serves to reduce their brittleness and make them even moreresistant in daily duty. Greater flexibility to respond to specificclient needs and the above-mentioned ability to assure thehigh quality insisted on for the gearing parts are further advantages of the new heat treatment plant.
Monitoring in our own test lab
Quality controls are carried out in bastian’s own test lab, sothat if any variations occur in the production process, we canrespond promptly and efficiently to iron them out. We are
equipped to handle the complete spectrum of standard hardness tests, such as Vickers HV, Rockwell HRC and Brinell
HB. Microstructure analyses, damage analyses and weld inspections are performed under a microscope. The detectionof grinding burn by nital etching is another important stationin the test series.
Tougher than the rest in daily use
The material passes through several temperature stages withdifferent residence times during the heat treatment cycle. It
is then cooled down at different rates in different media, depending on the process. The possible processes range fromfurnace cooling to rapid quenching designed to achieve defined technical properties (strength, hardness, toughness,structure).
Since the parts to be hardened at WITTENSTEIN bastian areused for gearings, surface hardening was chosen to achieve
the required high internal toughness of the workpieces. By
using this method, only the surface is actually hardened andhence made resistant to wear. Another key benefit of the application is that the compressive residual stresses producedin the surface of the gearing parts result in long-term vibration
resistance.
Technology with many specific benefits
So much for the basic principle behind the technology. Karlheinz Pfaff explains why it is employed at WITTENSTEIN
bastian: “We opted for this heat treatment plant because
it permits a short process time per 0.1 millimetre depth of
hardening, enabling the process to be controlled quickly andprecisely. What’s more, the aftertreatment in the molten saltbath allows quenching with only minimal distortion. Finally,
the complete plant is so highly automated that unmanned
operation is possible 24 hours a day”.
The underlying strategy
The implementation strategy for the plant and the technology’s main advantages are summed up by Sales Manager
Claus Stoll: “Hardening in-house is more cost-intensive thanoutsourcing. However, the WITTENSTEIN philosophy is forcore processes to remain within the confines of the company,
to prevent basic technical know-how that is crucial to ourcompetitive success from getting into the wrong hands.
WITTENSTEIN bastian additionally benefits time-wise if thehardening process is integrated. The internal hardening plantis an important milestone on the road to our vision of ‘a complete gear wheel in 24 hours’. It enables us to process evensmall batch sizes fast and flexibly, and thanks to the minimised grinding stock allowances we can also manufacture
more efficiently. Last but not least, confidentiality is always animportant issue. Our motor racing customers, for example,
demand absolute discretion in connection with all parts destined for their vehicles. And careful handling of high-precision
gearings is essential along the entire process chain. Transport
damages are virtually eliminated, in other words, and quality consistency guaranteed end-to-end. In the final analysis,that’s what counts for both us and our customers”.

move 21

DEBUT 2008

22 moveCompetitions

The common chord struck by culture and thevisual and vocal arts is echoed in the triad ofindustry, society and cultural awareness. In
both cases it is not the individual note but
the simultaneous sounding of different pitches that creates the music.

Report: Dr. Karl Dietrich Gräwe
Jury Chairman DEBUT 2008 and SWR2 presenter |Photos WITTENSTEIN / WAJS

The interplay of contrasting elements is equally essential to
all forms of social interaction. Richard Wagner brought his
rich life experience and genius to bear on the complex of “lifeand art based on sound economic and financial foundations”.
He wrote an exhilarating four-and-a-half hour opera on justthis theme, full of plot-driven consonances and dissonances
which are finally resolved into a happy end in the denouement: “The Mastersingers of Nuremberg”.
As we all know, every finale is always preceded by adebut. Or in our particular case DEBUT 2008, which is not
fixated on its finale but which places equal value on the intermediary steps that link the competition’s beginning andend. It may be some consolation for today’s aspiring mastersingers around the world to remember that, in Wagner’stale, the candidate’s debut attempt does not at first meet withthe general approbation of listeners. The important aspect for
Wagner was that while the members of the guild of mastersingers would ultimately judge the song contest, the people
too would have a say in its outcome.
This is far more than simply a fairy tale from Germany’s
dim and distant past. Contemporary composers working on
the same philosophic and discursive scale as Wagner ought
surely to feel challenged to write an opera or an episodic cycle of music dramas called the “Die Meister-SängerInnen” – amore emancipated title that would embrace both male andfemale vocalists! The singers we have in mind, of course, arethe ones confronting each other in a singing competition in
Bad Mergentheim, Weikersheim and Igersheim. The 2008
contest will begin on October 12 with a lieder recital and end
on October 18 with the awarding of the prizes and a galamove 23

Engineering as a stepping stone to a career in opera: Burcu Uyar (centre), winner of DEBUT 2006, is currently“Queen of the Night” in Mozart’s “Magic Flute” at the German National Opera House in Berlin. Olga Peretyatko (left),runner-up, has since performed to enthusiastic audiences at the Théâtre des Champs-Elysées in Paris and the
Stanislavsky Theatre in Moscow. Right: Tae-Joong Yang (third place)

24 moveInitiator of Debut:

Manfred Wittenstein

Managing Directors:

Klaus Spitzley, Ulrich Boelcke

Distinguished jury:

Chairman Dr. Karl Dietrich Gräwe

Prizes worth more than € 30,000- Winners’ awards (gold, silver, bronze): Viktoria statues specially designed by Viennese artist Ernst Fuchs- Special prizes, e.g. engagements
Patron:Günther H. Oettinger, Baden-Württemberg state premierRepresentative:

Prof. Dr. Wolfgang Reinhart MdL, Minister of Federation and European affairs and head of the state chancellery

February 1 to June 30,
2008

Period for applications

July 1, 2008

DEBUT 2008 will be showcased at the “Stallwächter Party”, the traditional summer celebration of the state of BadenWürttemberg, in Berlin

October 12 to 18, 2008

Competition week in Weikersheim and Bad Mergentheim with approximately 50 participants

October 12, 2008

Lieder recital “Arie & Canzoni” with Burcu Uyar (Turkey), winner of DEBUT 2006

October 16, 2008

Opera question time in the WITTENSTEIN talent arena

October 18, 2008

Gala concert with finalists, host: Jan Hofer, Senior Newsreader on ARD’s television news

concert given by the finalists. Yet this is just the beginningand end of a musical and singing crescendo that will build up
throughout an entire week. The competition itself will draw
considerable power from painstaking preparation, intenseconcentration and the challenge of mastering pre-performance butterflies. During the course of the week the immeasurable and priceless added value of practical musical experience, growing self-knowledge and pedagogical insights will
all melt together into a harmonious whole of social gatherings
and friendly encounters. DEBUT 2008 offers the professors,
mentors and teachers accompanying young singers on theirvoyage of discovery into the world of song at universities, colleges of music, academies, conservatoires or schools or in
private tuition an opportunity to test out their performanceand gain understandings that can be put to use in their own
teaching practice. DEBUT 2008: a kind of “Olympic Games”
with a character all of its own. An Olympic contest for singers only, in which all those eager to learn, gather experienceand win prizes and awards are cordially invited to take part.
Manfred Wittenstein, whose normal professional role is as
President of WITTENSTEIN AG in Igersheim, and his teamturned a dream into reality six years ago. WITTENSTEIN AG isequally committed, as it were, to terrestrial and interplanetary
progress. This may well have inspired the initiator to combine
his ideas about the earth, celestial stars and singing stars
in one single harmonious event. He launched the European
Opera Singing Competition DEBUT, which was held for the
first time in 2002 – a competition of rare talent which he has
not only consistently supported ever since but also intends
to continue promoting in the future. The Baden-Württemberg
state premier has acted as sponsor of this business and musical initiative since its inception.
DEBUT Concerts GmbH was established specifically to promote this artistic competition, which takes place every two
years and will be staged for the fourth time in 2008 financed
without public funds. Art will again encounter art this year

in a more resplendent setting than ever before. Not only willcompetition participants be measuring their talents against
each other and delighting listeners with their bel canto technique against the Tauber Valley’s charming backdrop of rolling
hills in surroundings that fittingly heighten mood and sharpen
perceptions, and not only will the event organisation and catering service provide an optimum competitive environment
for every single candidate. The A and B preliminary rounds
will also be held for the first time in the incomparably inspiring
atmosphere of Weikersheim Castle. The conditions are suchthat, while not every singer will be able to claim ultimate victory, they will all come away from the event as winners. The
singer who won the previous competition traditionally contributes their own concert evening to the new event: this year’s
concert will be given by the 2006 winner, Burcu Uyar fromTurkey. The jury will once again be made up of personalities
with a variety of professional backgrounds – practising singers, singing tutors, theatre professionals and culture journalists. Representatives from concert agencies and the media
will be listening intently, on the lookout for the potential starsof tomorrow and the coming years. Jan Hofer, Senior Newsreader on ARD’s television news, will act as host and turnthe final concert into an entertaining gala. After pitting theirtalents (and nerves) against each other in the final round, thecompetition winners will once again be presented with theirgold, silver and bronze awards, designed especially for theoccasion by the famous Viennese graphic artist, painter andsculptor Ernst Fuchs, in the Wandelhalle of the Bad Mergentheim Kurhaus. Art renews its encounter with art.

Countdown to DEBUT 2008!

move 25

Fairs and exhibitions 2008/2009

Medizin Innovativ, Nuremberg (Germany)
WITTENSTEIN intens GmbH, Congress & Exhibition
July 9 - 10, 2008
Semi, San Francisco (USA)WITTENSTEIN Inc. / WITTENSTEIN motion control GmbH
July 15 - 17, 2008
IMTS 08, Chicago (USA)WITTENSTEIN Inc. / WITTENSTEIN motion control GmbH
September 8 - 13, 2008
AMB, Stuttgart (Germany)International Exhibition for Metal Working
WITTENSTEIN alpha GmbH / WITTENSTEIN bastian GmbH
September 9 - 13, 2008
MSV, Brno (Czech Republic)
International Engineering Fair
Agent: Consenta spol.s.r.o
September 15 - 19, 2008
MOTEK, Stuttgart
International Trade Fair for Assembly and Handling Technology
WITTENSTEIN alpha GmbH, WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbH and WITTENSTEIN electronics GmbH
September 22 - 25, 2008
Aandrijftechniek, Utrecht (Netherlands)
International Trade Fair for Drive Technology
WITTENSTEIN BVBA
September 30 - October 3, 2008
Mechanical Elements Fair Kansai, Osaka (Japan)
WITTENSTEIN ltd.
October 1 - 3, 2008
BI-MU, Milan (Italy)
International Trade Fair for Machine Tools
WITTENSTEIN S.P.A.
October 3 - 7, 2008
MiNaT, Stuttgart (Germany)International Trade Fair for Micro and Nano Technologies
WITTENSTEIN cyber motor GmbH
October 7 - 9, 2008

26 moveMocon, Ghent (Belgium)
WITTENSTEIN BVBA
October 14 - 15, 2008
Pack Expo, Chicago (USA)WITTENSTEIN Inc. / WITTENSTEIN motion control GmbH
November 9 - 13, 2008
Emballage, Paris (France)
WITTENSTEIN S.a.r.l.
November 17 - 21, 2008
Automation Fair 08, Nashville (USA)WITTENSTEIN Inc. / WITTENSTEIN motion control GmbH
November 19 - 20, 2008
SPS/IPC/Drives, Nuremberg (Germany)
Electric Automation, Systems and Components, Exhibition & Conference
WITTENSTEIN alpha GmbH, WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbH and WITTENSTEIN electronics GmbH
November 25 - 27, 2008
IITSEC 08, Orlando (USA)Interservice/Industry Training,
Simulation & Education Conference
WITTENSTEIN aerospace & simulation Inc.
November 26 - 29, 2008
SCS, Paris (France)
Systems, Components, Solutions
WITTENSTEIN S.a.r.l.
December 2 - 5, 2008
WIN, Istanbul (Turkey)
Electric Automation, Systems and Components, Exhibition & Conference
WITTENSTEIN alpha GmbH
February 2009
Intec, Leipzig (Germany)
Trade Fair for Manufacturing, Tool and Special-Purpose Machine Construction
WITTENSTEIN alpha GmbH
February 24 - 27, 2009
Ipack-Ima, Milan (Italy)
Processing, Packaging and Material Handling
WITTENSTEIN S.P.A.
March 24 - 28, 2009

move 27