The magazine of customers and friends of WITTENSTEIN AG

10 years of WITTENSTEIN AG – together into the future

7

October · 2011

move

The magazine of customers and friends of WITTENSTEIN AG

Contents
10 years of WITTENSTEIN AG
Interview with Dr. Manfred Wittenstein

4

Mechatronic drive design
WITTENSTEIN alpha GmbH

6

Sensors with a “money back” guarantee
WITTENSTEIN AG Switzerland

8

RPM+ motor-gearhead unit
For innovative rack-and-pinion solutions

10

Back to the classroom – to help you learn!

Masthead

Certiﬁed trainers train WITTENSTEIN customers

Publisher:
WITTENSTEIN AG
Walter-Wittenstein-Str. 1
D-97999 Igersheim
Phone: +49 7931 493-0
www.wittenstein.de
move@wittenstein.de
Editorial content:
Sabine Maier, Manager Public Relations & Media(Responsible under press law)(Marketing & Communications Dept.)
Circulation:
3.000 copies
Production:
WAJS
Otto-Hahn-Str. 13
D-97204 Höchberg

Italian projects meet German reliability

Title-page: The WITTENSTEIN AG production
team in Igersheim-Harthausen
All rights reserved. This document may not be reprinted orelectronically distributed without the express permission of
the publisher.

WITTENSTEIN Italy

12

14

Haptic technology for ﬂight training
WITTENSTEIN USA

16

Power-IQ-Drives – compact and modular
WITTENSTEIN electronics GmbH

18

Trade fairs

19

Dear readers,
Responsibility pays off. Now that the economy is booming again,
the importance and necessity of developing a successful strategy for “life after the recession” is especially clear. As an export
nation, Germany – and above all the capital goods sector – wasparticularly badly hit by the worldwide slump in demand. In spiteof this, the German engineering industry continues to play an
outstanding role in the international markets, helping to shape
globalization and proﬁting from it more than most. At the sametime, the challenges posed by the present upswing are universally valid: raw material shortages and material supply bottlenecks,
leading to availability problems.
The recession has taught us that value creation must be founded
not only on the past but also on the future. Success does not fall from the sky; it is the outcome of performance, excellence and reliability that have evolved over several decades – and of sustainable value development on the highest
possible level. The WITTENSTEIN Group has risen to technology leadership in numerous disciplines of drive engineering and the intelligent solutions we offer our clients are aligned to the key challenges of the twenty-ﬁrst century, forexample in such ﬁelds as electromobility and resource efﬁciency.
As a trusted partner for industry we show our customers how innovative drive technology – in the form of products,
systems and processes – can be continuously enhanced and optimized while reconciling economic with ecologicalrequirements. This current issue of “move”, our customer magazine, describes a number of interesting examples. We
regularly set benchmarks in linear drive technology. We are an active driver in the “StreetScooter” project – a joint
initiative by RWTH Aachen University and automotive suppliers. A drivable prototype of this affordable electric car for
urban transport was unveiled to a general audience at this year’s IAA exhibition in Frankfurt.
WITTENSTEIN, established in 1949, became a family owned, non-listed public limited company ten years ago thisautumn. Since then, the world has moved on at a dramatic pace. One truth remains unchanged, however: inter-generational management, coupled with specialization on a very high level and a ﬁrm foundation of trust and dependability,
invariably pays off. A company that makes efﬁcient use of resources also works efﬁciently throughout. An employer
that cares about and supports its staff and the society of which it is a part is rewarded with higher motivation, performance and acceptance.
Creating value is about recognition and respect. Our business success centres on people – the people who workfor you, our customers, and us, the WITTENSTEIN Group. “Technology by people for people” – this is the underlying
philosophy. You can make the acquaintance of a part of our team on the cover page.
I would like to end this editorial on a personal note: after 46 years at the company, I have made up my mind to retire at
the end of the year. As a Management Board member with long-time responsibility for Finance and Human Resources,
I know that competent and highly qualiﬁed staff are crucial to win your enthusiasm for our innovative products. Let us
join hands to continue this successful partnership into the future!
The autumn season is also the season for trade fairs. Come along and visit us at the Stuttgart MOTEK and the Nuremberg SPS! We look forward to meeting you there!

Klaus Spitzley

WITTENSTEIN AG Management Board

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3

Interview

move talks to:

Dr. Manfred Wittenstein
President, WITTENSTEIN AG

10 years of WITTENSTEIN AG
Exactly ten years ago, the WITTENSTEIN Group was given a
new corporate structure – on September 13, 2001 it becamea family owned, non-listed public limited company. A decadeago, WITTENSTEIN’s total sales amounted to 148 million
deutschmarks; in the meantime, they have risen to almost
200 million euros. The payroll, too, has easily doubled within
the same period. move takes a look back – and a glimpse
forward into the future – with Dr. Manfred Wittenstein:
move: What were your reasons for changing the legal form andsetting up the new company ten years ago, and what were yourmain objectives? With hindsight, was it a good decision?
Dr. Manfred Wittenstein: Without a doubt! The newly established WITTENSTEIN AG provided us with the necessary
framework to steer our fast-growing company skilfully. The legal
status of a public limited company forced us to optimize our internal workflows and helped us improve our international standing. Our customers have benefited from all of this in the longrun. Our transition to an international business group has now
been completed successfully. As a family owned enterprise, we
consistently adopt a long-term perspective with sustainable value
development as our goal, for which I bear direct responsibility.

4 movemove: Looking back, what were the most important milestones
over the last ten years?
Dr. Manfred Wittenstein: Continuous, systemic evolution has been our chosen strategy from the outset and that is
how and we intend it to stay. WITTENSTEIN has successively
extended its portfolio of services and solutions; all employees
strive to uphold our commitment to being a world class global
partner for the customers of our intelligent mechatronic drive
technology, servo systems and components. One by one, wehave set up independent subsidiaries around the world in order
to offer our customers outstanding performance and expertisein all major technology and sales markets. On top of this, wehave a majority share in attocube systems, the nano technology
specialist based in Munich.
move: Which issue currently takes priority for you?
Dr. Manfred Wittenstein: We place the present and futureneeds and wishes of our customers at the centre of everything we
do. We invest enormous resources in the challenges confronting
us. Despite the adverse conditions prevailing in 2009/10, the yearof the recession, we avoided making any of our staff redundant;on the contrary, we expanded to new locations and built new
manufacturing plants. By making our processes more secure, we
are also in a position to serve our customers faster. The next stepDr. Manfred Wittenstein
President, WITTENSTEIN AG

in this direction will take place very soon: at the end of the year,
WITTENSTEIN bastian will move into a new, 4000 square meterproduction facility in Fellbach. What makes this project uniqueis the ingenious overall concept, integrating the process, building
and power supply components, which will enable us to operatewith a zero carbon footprint – in Fellbach town centre. And in
2012, our company headquarters in Igersheim-Harthausen will
be enlarged once again, with energy efficiency a primary planning criterion. These projects are just two examples of our willingness not only to take on business challenges but also to tackle
the social issues of today.
move: When you look to the future, what do you see?
Dr. Manfred Wittenstein: I’m afraid I haven’t got a crystal
ball to help me answer that question. Nevertheless, I firmly believe that the current crisis can teach us some amazing lessons
about shaping the future successfully. It’s a well-known fact thata crisis is a time for developing new ideas, new concepts andeventually new technologies. The yearning for technologicalprogress is as old as mankind itself; mega trends like mobility,
the efficient use of resources and the insatiable thirst for participation and prosperity of many millions of people in the world’s
emerging economies underlie the social necessity for globalchanges. The contribution we make here is both our raison d’êtreand a golden opportunity: in future, our ability to design highly
complex systems that are capable of intelligent interaction will
be a crucial aspect. We are dedicated to maintaining the successof our customers and to making sure they always stay one stepahead of the competition – hand in hand with us.
move: You once said in an interview that “future is change” andthat you “want to be a part of it”. Where do you see WITTENSTEIN AG ten years from now in 2021?
Dr. Manfred Wittenstein: As I see it, there is no question thatWITTENSTEIN AG will continue to grow worldwide. Our strategies, our know-how and our convictions are consistentlyaligned to the present and future needs of present and future customers; ultimately, they are driven by the great macro-economic
and social challenges of our age. The future success and future
growth of the WITTENSTEIN Group is not simply a personal
goal of mine; above all, it will be the logical outcome of respectful and sustainable value development. The market – the customers whose enthusiasm we excite and win – is our motivation andour reward in one. That’s how it is today and that’s how it will
be ten years from now!

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5

Products

Mechatronic drive design:

Our strategy for a strong head start

By
Jürgen Guckenberger, applicationengineer and expert for drive sizing at
WITTENSTEIN alphaSizing tool for WITTENSTEIN gearheads with fast access totechnical speciﬁcations, 3D models and drawings“Catalogue knowledge” alone results in suboptimal solutions when designing mechatronic drive systems. Enormous
potential for optimization from the mechatronic perspective can often also be tapped in the application itself. The
WITTENSTEIN strategy helps customers realize their objectives faster and more efﬁciently – and it also “pays” in thetruest sense of the word. “Optimizing the task ﬁrst, then the solution” is the name of the game. This strategy sets
WITTENSTEIN clearly apart from its competitors – because it adds technical and commercial value for customers andconserves resources. Extended design and application areas as well as potentials for energy efﬁciency and downsizing powertrains are tapped in this manner – supported by new online conﬁgurators and the “Energie-Assistent”
software tool, which is available in this form for the ﬁrst time.
Intelligent optimization of proﬁles
In the ﬁrst step, the drive is not actually designed at all; instead, the central focus is the analysis and optimization ofloads and motions. cymex® 3, our sizing software tool, makes
a vital contribution. A thorough analysis of the positioning
task and the associated motion and load proﬁles is performed
after recording the fundamental framework conditions of theapplication, e.g. cycle or continuous operation, axial and radial forces, type of motion, permissible torsional backlash or
minimum and maximum speeds. Depending on the proﬁle,the torque actually occurring at the gearhead may substantially exceed the analytically calculated torque in dynamic
applications – especially during acceleration and braking. In
this case, overshoots of thirty or forty percent are likely in thedrive system. After optimization with cymex® 3, the customer
can utilize a so-called shock factor to estimate these effects.
This factor helps size gearheads in such a way that they arecapable of withstanding these peak loads. However, sizing“on the safe side”, in other words allowing power reserves,
conﬂicts with the goal of miniaturization that is speciﬁed foralmost every drive solution. The drives only get smaller if the

6 moveactual loads also get smaller thanks to an optimized motion.
In order to optimize this “how” aspect of the motion, cymex®
3 optimizes the motion design by modelling applicationspeciﬁc motion ideals. These are characterized by acceleration and braking proﬁles limited by load peaks. The actual
torques and the actual motion proﬁle are then much closer
to the analytically calculated values, so that overshoots inthe drive system are reduced to a minimum. In the ideal scenario, the shock factor can be completely dispensed with,in which case the mechanical components can be designed
thirty to forty percent smaller. The loads and size are notsimply reduced, however – at the same time, the quality ofthe motion is improved because excitation of unwanted vibrations is avoided. The noise level is consequently lower
and the drive runs smoothly and more or less vibration-free,which is a great advantage for the machine as a whole. By
eliminating high load assumptions and safety margins in theform of regulation reserves and shock factors, it is possible
to select smaller sizes and design drive systems that are far
more energy efﬁcient.

WITTENSTEIN alpha‘s new High Performance Linear System for highly complex
linear movements

Input power exceeding the catalogue values
Following the optimization of loads and motions, cymex® 3
identiﬁes suitable gearheads and motors. Mass inertias are
considered and gearhead properties deﬁned, e.g. gearhead
type, shaft design, type of construction or output geometry.
The examination of lateral forces, inertia, speeds, torques andthermal criteria is the primary focus as the gearhead selection progresses further. cymex® 3 integrates these properties
in the gearhead design and shows under which conditions
higher speeds and/or radial forces or higher output torques
exceeding the operating points, as deﬁned by the technicalspeciﬁcations, can be realized with a particular gearhead.
This results in extended design areas, i.e. additional usage
potentials of the gearhead which can be safely and simultaneously controlled: more torque at reduced speed or more
speed at reduced output torque. If this “intelligent” gearhead
design is compared to the selection of a gearhead basedon static catalogue data, additional possibilities for downsizing the power, product size and energy consumption of amechatronic drive design beyond the initial load optimization
become apparent.
Recovering energy cuts costs and CO2 emissions
Energy efﬁciency represents one of the biggest potentials forinnovation in electric drive technology; as much as 30% energy can be economized in the mechanical portion of a powertrain. The chances of success are high if the energy that is
utilized to accelerate and brake the drive’s inertia no longer
needs to be completely burnt up during braking – resulting in

wasted heat and lost energy – but can for the most part berecovered and “reused”. It was for precisely this reason thatcymex® 3 has been enhanced with the “Energie-Assistent”.
The only one of its kind in the market so far, this tool calculates a powertrain’s energy consumption dynamically topermit a more energy efﬁcient design. Customers can now
see at a glance exactly how energy recovery technology will
beneﬁt their particular drive. The annual energy saving canbe visualized in hard currency. Optimizing the task ﬁrst, thenthe solution – this strategy for designing mechatronic drive
systems delivers solutions that “pay” – from both a technicaland a commercial point of view.

Analytical comparison of different motion proﬁles, each with 100 mm travelin 0.25 seconds

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7

Products

Sensors with a „money back“ guarantee –Using torqXis to monitor drives is aworthwhile investment

By Stefan Basig
Product Manager Sensors at
WITTENSTEIN AG Switzerland

Machine downtime – especially if it is unscheduled – isusually far more expensive than the repair itself. Whereas
the use of sensors to control and monitor industrial or
logistical processes is nowadays taken for granted, it
remains the exception when it comes to drive trains – asituation that is likely to change in the not-too-distantfuture. The immense interest in WITTENSTEIN’s modular
torqXis sensor system suggests that a new trend is on
the way.
The drive’s “well-being” is paramountFor customers of WITTENSTEIN, the efﬁciency of their machinery and plant is vital. Efﬁciency means a high power yield,
preferably paired with zero maintenance – and guaranteedmaximum availability. All of these objectives can be realized
providing you are thoroughly familiar with your drive and careabout its well-being. A few simple questions are enough to
put yourself in the picture. How can you determine the condition of a drivetrain? Which loads are present and is there arisk of failure with certain load spectra? How can critical operating and load conditions be detected before it gets too late,

8 move

The torqXis SFR sensor measures torque, lateralforces and temperature simultaneously, directly in thedrive train

and what is the best way to reduce response times and alignmaintenance to condition and cost optimization aspects?
torqXis, the intelligent sensor system for drive monitoring,
provides answers to all these questions – in more and more
applications.
Identify, measure and eliminate loads
Torques, lateral forces and temperature – these three process-relevant variables in drivetrains are measured by the
torqXis sensor system. The sensors in the torqXis series canbe mounted easily as a measuring ring between the drive
component and the machine bed. They are rated for nominal
torques from 50 Nm to 3000 Nm and nominal lateral forcesfrom 800 N to 30,000 N. The deformation of the sensor ringis determined whenever a load occurs in the drivetrain, e.g.
in case of unexpected changes in the load proﬁle, if deﬁned
values for measured mechanical quantities are exceeded or
due to overheating, bearing damage, material breakage, slip,
input shaft fatigue or a reduction in the drive belt tension. If
a critical condition develops in the drivetrain or critical load
spectra occur, the sensor immediately generates an alarm

Products

Unique design: the sensor system can be mounted easily as ameasuring ring between the drive and the machine bed

Life cycle histogram of themeasured values

signal that is transmitted to the controller. The load can thenbe reduced or the motor switched off if necessary in orderto prevent serious damage. At the same time, the information supplied by the sensor allows service assignments to be
carried out in a targeted way and service intervals aligned toactual requirements, in other words made pro-cyclical andcondition oriented.
Built-in “money back” guarantee
The combination of torque, lateral load and temperature measurements with torqXis results in smart concepts for condition
monitoring and repair on demand. Economic assessments
have conﬁrmed that users of this innovative drive monitoring technology receive a kind of “money back” guarantee– because it effectively eliminates the costs for downtimes
that are inevitable with unscheduled maintenance. This is
aptly illustrated by a simple example of a customer in Switzerland. A machine that processes 340 parts with a valueof four Swiss francs (CHF) in one hour had to be shut down
twice unexpectedly in 2010 owing to bearing damage and an
undetected reduction in the drive belt tension. The responsetime until the machine was ready to start up again was aroundseven hours in each case. These fourteen hours translated
into lost sales equivalent to approximately CHF 20,000.
To prevent this situation from reoccurring in future, the manufacturer decided to monitor the drivetrain concerned with a
torqXis sensor. The outlay for the initial purchase, commissioning and integration into the control system amounted toa one-off ﬁgure of CHF 10,000. The investment in the sensor
was consequently recovered in approximately six months.
Moreover, the cost saving in the ﬁrst year alone worked out
at CHF 10,000. Added to this, the sensor promises to deliver
sizeable ﬁnancial beneﬁts in the next few years because therisk of unscheduled downtimes has been virtually eliminated
due to the early detection of wear and critical load spectra.
A little torqXis intelligence in the drive train can certainly dono harm – and it could improve both the availability of yourequipment and your return on investment signiﬁcantly…

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9

Products

Sophistication in engineering and design:

RPM+ motor-gearhead unit for
innovative rack-and-pinion
solutions

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

High-tech in an elegant yet functional style, convincing performance characteristics for linear technology, engineering
ideas that add real value – these are the hallmarks of the new RPM+ motor-gearhead unit in its role as an actuator for
the High Performance Linear System.
Servo motor integration as a logical step
Back at the start of the year, the RP+ was introduced at trade
fairs and press conferences as a rack-and-pinion gearhead
to facilitate linear drive solutions at the high end of the market. From the “technical” point of view, it represents the
input stage of the new RPM+ actuator. In terms of applications, it seamlessly unites all the familiar advantages suchas a compact, elegant design, improved tilting moments formore tilting and system rigidity as well as increased positioning accuracy and exceptional ease of assembly thanks tothe alpheno® interface. It is typical of WITTENSTEIN that the
RPM+ is far more than simply a gearhead with a servo motor mounted to it. The new actuator shows how traditional
drive engineering limits can be pushed back when system
expertise in gearhead manufacturing, gearing technology andthe design of motor-gearhead combinations is consolidated
under one roof and condensed in a single product.

10 move

Length savings through intelligent integration
There is probably no other actuator solution for rack-andpinion applications that packs such top-quality engineering
into such a high-quality design as the RPM+. The integrationof the permanently excited servo motor is only one beneﬁt.
The motor shaft is inserted directly into the gearhead, in otherwords the pinion is an integral element of the motor shaft withno intervening parts. This mechanical integration reduces theoverall length. The fact that the brake is now accommodated
in the cavity underneath the winding head rather than at theback of the motor is a second convincing example. All in all,the RPM+ is 30% to 50% shorter than rival actuators boasting
similar performance. The extremely rigid controlled system –and therefore optimal power transmission – of the actuator
concept is a further advantage. Since the bearings are likewise designed for high radial forces, the RPM+ is often built
a size smaller than the industry standard – absolutely in linewith the current trend towards downsizing.

Products

The RPM+ accelerates a mass of 300 kg to 360 m/min
in 0.3 seconds and positions it accurately to 5 μm.

RPM+: an eye-catcher with genuine added value
Functionality and elegance are not necessarily a contradictionin terms – on the contrary, as WITTENSTEIN’s experience inthe last few years with its TPM+ actuators and other products
conﬁrms. This claim is equally valid for the RPM+. In the trade
fair model or a customer machine – the design and colourof the housing transform the actuator into a real eye-catcher
with high recognition value. What is pleasing to the eye iseven more pleasing to the user because the design concept
focuses systematically on providing additional functionalities
and hence added value for the application. The smooth,rounded surface without any edges – and embellished with a
two-component metallic coating – prevents dirt deposits fromforming on the actuator. The pinion has a stylish cap featuring
the WITTENSTEIN logo which not only protects against dirt
but also looks good and conveys the same impression of top
quality engineering as the seal that covers the transition to thegearhead. The mechanical interface with eight slotted holes

permits optimal adjustment of the pinion and rack – with noneed for a separate adjustment plate that would cost moneyand detract from the visual message.
Optimized for linear applications, open to customer requirements
The High Performance Linear System with the RPM+ actuator
integrates the motor, gearhead, pinion and rack in an optimally controllable system. It is available in four sizes withan air or water-cooled motor in several possible versions.
WITTENSTEIN’s cooperation with lead customers in multiple
industries will determine which variants are manufactured infuture and with which characteristics. Thanks to its high degree of ﬂexibility and modularity, the RPM+ is excellently suited
for almost any task in grinding, turning, portal milling, boring,laser, punching and pipe bending machines, water jet cutters,machining centres for wood-plastics compounds and basically any axes found in automation systems.

move 11

Human Resources

View inside the auditorium of the WITTENSTEIN academy

Back to the classroom – to help you learn!

Certiﬁed trainers train WITTENSTEIN customers
WITTENSTEIN regularly places its own know-how at its
customers’ disposal in the framework of training courses
and seminars – a service we take for granted and one
that, thanks to a convincing, new train-the-trainer concept, will be distinguished by even greater excellencein future. For the ﬁrst time, our trainers have undergone
speciﬁc training at the WITTENSTEIN academy, to enable
customers to proﬁt even more from the technical expertise and vast experience of our engineering and productspecialists.
Providing high-quality training – tailored to the needs of eachindividual customer – is not so much a kind of mysterious talent as plain hard work. Trainers today are expected to have awide range of competencies at their ﬁngertips over and above
their actual technical know-how. In a recent trainer certiﬁcation seminar geared to practical needs, they learned how todesign, prepare, deliver and follow up user training in a didactically sound way – both theoretically and in a series ofrole-playing exercises. The certiﬁed WITTENSTEIN trainers

12 moveare now better equipped than ever to empathize with different participant proﬁles and apply optimally adapted learning
formats. The communication of complex technical content
was explicitly addressed in a separate, compact module. The
WITTENSTEIN academy was supported by its longstanding
partner Claus Harten (Harten & Breuninger, Weikersheim/
Baden-Württemberg), which designed and implemented
the certiﬁcation programme together with the personnel development department.
The ofﬁcial objective is to improve the quality of the training
provided to WITTENSTEIN staff and customers and hence
increase the long-term beneﬁt for participants. The establishment of a network of trainers who advise and support eachother is a welcome knock-on effect of the systematic training
concept.
A start has been made – and there are already plans to repeat the project: between December 2011 and March 2012
another twelve trainers will take part in the certiﬁcation programme under the motto “train the trainer”!

Human Resources

Marion Gakstatter is a certiﬁed WITTENSTEIN trainer

Marion Gakstatter, Bachelor of Business Engineeringand WITTENSTEIN trainer, took part in the ﬁrst “trainthe-trainer certiﬁcation” seminar. In an interview withmove, she reports on her experience:

every single participant and take account of intercultural backgrounds where necessary. The qualification programme has
showed me how to adapt my content more accurately to specifictarget groups and individual trainees.

move: Which training do you provide to external customers?
Marion Gakstatter: I provide training in our cymex ® sizing
software as well as on products in the WITTENSTEIN alphaportfolio together with our Product Management.

move: WITTENSTEIN markets highly complex mechatronic
drive systems. How do you communicate such complicated content without totally confusing the trainees?
Marion Gakstatter: By imparting my technical knowledge
with the help of clearly structured, easy-to-understand productmodels and drawings that are based on real situations, for instance. By resorting to multimedia, I can make a seminar more
exciting and more instructive, in line with the “see – touch – tryout” principle. That’s one of the many skills a trainer has to master – which is why it was on the agenda at the qualification seminar.

move: Could you describe a few of the key challenges involvedin customer training?
Marion Gakstatter: No two customer seminars are ever thesame. For this reason, it is vital to clarify exactly what the client
is seeking upfront and design the training to meet these individual needs. The train-the-trainer certification programme taught
us what to watch out for here and helped us consolidate what wealready knew. We will be better able to consider specific interests
and wishes in future as a result.
move: You also work as an international trainer on behalf of
WITTENSTEIN alpha. Where do the potential traps lie there?
Marion Gakstatter: I come into contact with a variety of personalities and learner types. As a trainer, I must do justice tomove: Who should our customers turn to if they would like you
to bring them up to date with the latest developments in drive
engineering?
Marion Gakstatter: Just get in touch with the WITTENSTEIN
sales engineer responsible for your area. We’d be delighted todesign a seminar concept based on your particular requirements
and interests.

move 13

Applications worldwide

Italian projects meet German reliability

Machining centre for door and window frames

Images: Working Process“Working Process”, a company based in Settima di Gossolengo (Italy), specializes in planning and manufacturingmachining centres for door and window frames. The machines it produces are capable of making up to a hundred
windows a day with extreme precision – often as accurate as a tenth of a millimetre – in almost any shape andsize, for example arched.

enough to come up with innovative production systems thatare capable of surviving in the competitive global arena. A
concept for preﬁnished, premilled, presquared and prepareddoor and window frames is currently being launched basedon its systems. This process could prove to be the starting
point for the most important modern revolution in the woodframe production sector.

High productivity, ﬂexibility and reliability are the attributes on
which the reputation of Working Process machines is founded – regardless of whether they are used in the manual tradesor on highly automated industrial production lines. Stefano
Schegginetti and Massimo Schiavetta, the ﬁrm’s two proprietors, have their roots in the manufacturing industry: “Innovation is an integral ingredient of our projects and patents
that is invariably the outcome of speciﬁc user requirements.
This is where our main strength lies.” Ever since Working Process’ establishment in the year 2000, its two founders havebeen keen to place the development of this strongly capitalized company on a ﬁrm footing, which is why they prefer tothink in the long term. Working Process is a young enterprise
operating in a mature market that is nevertheless creative“Sapiens”, “Antropos” and “Logos” – step one is always
the innovation
Working Process invests a substantial amount in sustainable
research and development, often penetrating deep inside thecompany’s internal resources. “Working Process has a heavy
export leaning – mainly within Europe – with a clear focus on
high-tech advances and innovation. Our investments in products, technologies, marketing and R&D give us a clear lead in
combination with dynamic entrepreneurship. We endeavour
to capitalize on this advantage by selecting ﬁrst-class suppliers like WITTENSTEIN”, says Schiavetta.
A large number of WITTENSTEIN systems are installed in
Working Process machines. The two ﬁrms make a good
match because they identify with similar values and attach

14 moveVertical axis of the machining centre
with the WITTENSTEIN alpha Linear
SystemTypical Working Process machine

similar importance to excellence. “Sapiens”, “Antropos” and“Logos” – each of these three models has more than thirty
axes that are moved by WITTENSTEIN gearheads, servo actuators and linear rack-and-pinion systems. Working Process
chose these components because they guarantee precise
motion, high acceleration, reliability, quiet running and signiﬁcant energy savings.
Optimal solutions made by WITTENSTEIN
The products integrated in Working Process machines include highly precise planetary gearheads and servo actuators: the compact TP+ planetary gearhead with output ﬂange
offers better power and torque transmission from the same
footprint. The high torque version achieves an impressive
10,000 Nm. Thanks to its helical toothing and optimized components, the gearhead makes very little noise (≤ 58 dB(A))
while the torsional backlash of ≤ 1 arcminute ensures unusually high positioning accuracy. “The SP+ planetary gearhead,on the other hand, has a smooth, slotted or involute output
shaft”, Schiavetta continues, “that guarantees high energy efﬁciency, as it can also be designed smaller owing to the highpower density”. The new series has up to 25% higher torquevalues than its predecessor and is characterized by exceptionally quiet running, high positioning accuracy and absolutereliability. The reduction ratios vary from i = 3 to i = 100, withacceleration torques up to 4500 Nm and input speeds up to6000 rpm.
The TPM+ servo actuators, which are ideal for both rotaryand linear applications, are another successful solution. They
feature a compact design that makes them less sensitive to
dirt. This product range comprises the highly dynamic andquiet-running TPM+ dynamic, the TPM+ power with hightorques condensed into a tiny space and the compact TPM+
high torque, which unites extremely high torsional rigidity withtorques up to 10,000 Nm. The TPM+ servo actuators are especially suitable for polar axes on tool heads or additionalaxes as well as for magazine axes used for tool changing.
Finally, the “made-to-measure” alpheno® planetary gearhead,
which is explicitly conﬁgured for the individual requirementsof each application, is likewise found in Working Process machines.
In short, WITTENSTEIN supplies the optimal solution for any
axis.

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WITTENSTEIN international

WITTENSTEIN aerospace & simulation control loading system
Top: Cyclic stick
Bottom: Collective stick

Haptic technology for flight training
Researching and creating technology that positively impacts our environment takes more than drive and determination. It relies heavily on engineering expertise and collaboration, from the genesis of an idea to its realization for thegreater good. WITTENSTEIN aerospace & simulation recognizes the hard work involved in cutting-edge technology
and was inspired by the team at Deakin University when they started discussing their latest research project – theUniversal Motion Simulator.
Deakin University’s Centre for Intelligent Systems Research(CISR), based in Geelong (Australia), focuses on developing
and analyzing state-of-the-art algorithms and methodologies
that provide practical solutions to real-world problems. The
Universal Motion Simulator (UMS) is one of the latest research
projects from the team at CISR and uses WITTENSTEIN’s
control loading systems (CLS) to replicate helicopter control.
This CLS includes a cyclic stick, a collective stick and directional pedals. CISR’s UMS is a haptically enabled, full motion simulator for ﬂight and vehicle training and performance
analysis which uses customized control algorithms. Providing
a realistic training environment, the simulator introduces aﬂexible, modular, high-ﬁdelity motion system that can represent a variety of immersive training scenarios.
“The goal of this project is to gain a better understanding ofvehicle and aircraft design and operator control. Research
into user control with open and closed-loop scenarios
will inﬂuence strategies aimed at improving performance and reducing the risk of accidents in vehicles
and ﬂights”, says Prof. Saeid Nahavandi,

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Director of the Centre forIntelligent Research
Systems. “This projectis another opportunity for CISR to discover and deliver
innovative researchthat directly beneﬁts society throughthe creation ofknowledge andthe provision of solutions toreal-world problems.” Additional support in thedevelopment
process for the project came fromthe Australian Department of Defence, theAustralian Research Council and Rockwell
Collins.
WITTENSTEIN aerospace & simulation
contributed the rotary wing control loading
simulator system. This haptic control loading system enhances the training experience
while the UMS is in closed-loop control. Integrated into the design, the cyclic stick, collective
stick and directional pedals allow the simulator user tofeel completely immersed in the real-world training environment.

WITTENSTEIN international

The Universal Motion
Simulator is a state-ofthe-art platform for training and performance
analysis. With its special
kinematic interface, twoaxes of continuous rotation are permitted, providing realistic g-force
acceleration.

The simulator is intended to be used in two modes: open-loop control and closed-loop control. When in open-loop control
mode, the user is automatically ﬂown through predeﬁned paths and sequences, from beginner through to expert training
modules. During closed-loop control, the trainee has full control of the rotary wing aircraft via the active technology systems
provided by WITTENSTEIN.

“The cyclic stick, collective stick and directional pedals utilized in the Universal Motion Simulator represent excellence inengineering, showing the synergy of the core WITTENSTEIN
elements of mechanical, motor, electrical and software technology”, Scott Metcalfe, General Manager of WITTENSTEIN
aerospace & simulation, Inc., continues.
This system is a perfect component for the UMS because it
possesses the key performance and aesthetic characteristics
that align with the objectives of the simulator: reconﬁgurable,compact and haptically enabled. WITTENSTEIN’s active

technology utilizes a unique control scheme which communicates the force realism to the operator. The feedback via
the control loading system provides the user with full sensory
involvement. Making the rotary wing ﬂight conditions as realistic as possible beneﬁts CISR with the most valuable data
for analyzing training results.
Taking today’s technology and applying it to research thatwill positively impact the future shows the kind of engineeringcollaboration in which WITTENSTEIN will also participate in
the coming years!

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Products

POWER-IQ-Drives – compact and modular
Compact motion control in mobile applications

By
Peter Schuster
Sales Manager at WITTENSTEIN electronics GmbHThe new POWER-IQ-Drives of WITTENSTEIN electronics
are a complete series of compact and intelligent controllers with very high power density. The liquid-cooled
converters can be used to control 3-phase machines inmobile applications with a maximum DC supply voltageof 750 V and provide peak power of up to 250 kVA. The
power electronics system can be operated at high temperatures (max. 105° C ambient).
This exceptionally compact controller, that is roughly equivalent to a 12 V car battery in size, permits speed and torquecontrol of permanently excited synchronous motors.

POWER-IQ-Drives 250

Above the nominal rotating ﬁeld frequency, the motors canalso be operated in ﬁeld weakening. The high PWM-frequency of 16 kHz guarantees precise control response and extreme dynamics, even for high-speed motors with high stator
frequencies and low leakage inductance. It also facilitates
reliable control of multi-pole motors. The hardware consistsof a modular DC link, the power and driver modules and thesignal electronics system that is responsible for the control
loop, monitoring and safety functions. The feedback interface
is designed to evaluate a resolver signal.

Intelligent safety concept
Aided by a very powerful dual processor system, the intelligent electronics monitor the following parameters, amongst
others:• High battery voltage• Overcurrent on the motor• Short-circuit at the motor terminals• Earth fault• Position, motor current and temperature sensors• Temperature measurements in the motor and output stage• CAN errors• Memory errors
The response to these monitoring functions can be adapted
to take account of actual conditions and safety requirements.
Output currents of power electronic systems as a function of
the cooling water ﬂow temperature

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POWER-IQ-Drives – powerful and ﬂexible
The various POWER-IQ-Drives series add up to a modular
controller concept that is characterized by very high integration density as well as maximum ﬂexibility and scalability.
POWER-IQ-Drives – customized solutions
The consistent application of a modular design principle generates crucial advantages for our customers. From the initialdrive concept through the development process to the trial
run, we take pleasure in supporting you with our extensive
expert know-how.

Basic technical data of the converter family

For more information, please contact Peter Schuster, Sales Manager at WITTENSTEIN electronics GmbH, e-mail:peter.schuster@wittenstein.de.

TRADE FAIR CALENDAR 2011/12 (selection)
Motek 2011, Stuttgart (Germany)International Trade Fair for
Assembly and Handling Technology
WITTENSTEIN alpha GmbH,WITTENSTEIN motion control GmbH,WITTENSTEIN cyber motor GmbHHall 9, Stand 9121
October 10 to 13, 2011

Forum Maschinenbau, Bad Salzuﬂen(Germany)
Trade Fair for Suppliers in the
Machinery Manufacturing Industry
WITTENSTEIN alpha GmbHHall 20, Stand A57
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 GmbHHall 4, Stand 221
November 22 to 24, 2011

HISPACK 2012, Barcelona (Spain)
International Packaging Exhibition
WITTENSTEIN S.L.U.
May 15 to 18, 2012

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

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

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

Hanover Fair 2012, Hanover (Germany)
Industrial Automation
WITTENSTEIN Group
April 23 to 27, 2012

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