WITTENSTEIN alpha
WITTENSTEIN alpha

Individual drive solutions

From gears to gearboxes

There isn’t always a standard solution available for extraordinary ideas; that´s why our team of experts by WITTENSTEIN is at your disposal to transform your particular vision into a complete, customized solution. 

We’ve been in the business of developing gears and gearboxes for more than 30 years now. With this experience and know-how, we have recognized experts when it comes to designing, calculating and optimize mechanical drive systems.  

As an active member of the German Research Association for Power Transmission (FVA), WITTENSTEIN profit from the most recent research findings and is very well connected to several universities, with significant advantages for its customers. 

Our engineering team makes your drives highly efficient

Our engineering team makes your drives highly efficient

For extreme applications where standard solutions are no longer adequate, we develop customized spur gears (straight gear, helical gear or conical gear) and bevel gears (Gleason circular arc) tailored to your particular needs and requirements.  

Starting from a blank sheet or basing on an already existing solution, together with you we explore new optimization options in terms of load carrying capacity, working speed, efficiency and noise excitation of spur or bevel gears. By modifying the macro geometry as well as the micro geometry of the teeth, we are able to obtain the optimum contact pattern for each application. 

Our strenghts are optimization of the gear design for

HIGH TORQUE requirements

For high power density application

HIGH SPEED requirements

For up to 120.000 revolutions/minute

LOW NOISE requirements

To achieve significant noise reduction

TEST requirements

To achieve significant noise reduction

Development and design

Our engineering team makes your drives highly efficient

Our engineering team makes your drives highly efficient

The experts at WITTENSTEIN alpha design gears and gearboxes using the most advanced software tools such as KissSoft, FVA-Workbench, Bearinx or Ansys for the calculations.  In some cases, proprietary strategies are supported by self-written programs. The components are modelled using Siemens’ NX 3D CAD system.

From virtual models to advanced production processes

From virtual models to advanced production processes

Our developers derive production-compatible drawings from virtual gear models, with definitions of the required contact and clamping surfaces, in cooperation with Production and Quality Assurance. Where possible, we resort to existing tools and workholders for designing and manufacturing prototypes. If special tooth geometries are called for, we achieve them using the most flexible production methods. 

Product capabilities

Bevel Gears

Bevel gears by WITTENSTEIN alpha are all about maximum precision, load-bearing capacity and low noise. We develop and manufacture spiral and hypoid bevel gears in milled or ground designs – in the closed-loop of our high-precision production system. 

In addition to this, we have accrued years of expertise in the areas of bevel gear design, optimization and testing. For special applications, we supply DIN Q1 in series production. 

 

Test Toothing type: straight, sfafa
Test Module: 0.3 - 0.8 mm
Test Diamter: up to 400 mm

Test DIN3

Test

 

Spur gear

Straight toothing gears, helical toothing gears and conical toothing gears can be declined in a complete range of different geometries, production processes and quality levels.

WITTENSTEIN is recognized as system supplier for high-speed, low-noise and high-torque applications. 

We also boast exceptional expertise in spur gears in ground designs for prototype and series applications. 

Internal gear

Internal gearing by WITTENSTEIN alpha: Whether you need straight, helical or bevel gearing, we can provide you with the full range of high-precision internal gearing. All under one roof, including thermal treatment, and in different production processes (gear shaping, broaching and skiving) and quality levels.  

Special gearboxes

The development of special gearboxes at WITTENSTEIN begins with an analysis of the requirements; the technical details are then clarified and solution oriented consulting provided – all in close cooperation with the customer. 

The basis for the development process is a specification, which in particular must define and prioritize the design objectives. Close consultation between the Engineering team and Production is a key feature of all our development activities. 

Being part of the WITTENSTEIN group, the solution provider for mechatronic drive systems, we provide individual gear unit solutions with high focus on the complete drive train system.  Our manufacturing opportunities range from prototypes, small-scale production up to series.  

Many good reasons to choose WITTENSTEIN

Manufacturing concentrated at the "Future Urban Production" facility

Our gearboxes are built at the “Future Urban Production” facility in Fellbach. Every year, 1.4 million gearwheels are manufactured there. All machining steps can be completed directly on the premises: turning and milling, hard turning, cylindrical grinding, gear milling, gear slotting, generating or profile grinding and joining. The in-house heat treatment line is another core process at WITTENSTEIN.

Our quality assurance strategy

We check the surface hardness and hardness depth curve of every hardened batch in our own materials test lab. We can also carry out an optical analysis of the structure on an etched specimen on request. In our Class 2 precision measuring room we make sure that every single tooth, shaft and housing conforms to the highest quality standards. Based on the results of these measurements, Engineering and Production then optimize the gear and the gearbox for production use in collaboration with the customer. 

Our quality assurance strategy

We check the surface hardness and hardness depth curve of every hardened batch in our own materials test lab. We can also carry out an optical analysis of the structure on an etched specimen on request. In our Class 2 precision measuring room we make sure that every single tooth, shaft and housing conforms to the highest quality standards. Based on the results of these measurements, Engineering and Production then optimize the gear and the gearbox for production use in collaboration with the customer.