Wittenstein introduces smart gearboxes with integrated cynapse® sensors

In the packaging industry, reliability and efficiency are critical for achieving high productivity and minimising downtime

WITTENSTEIN alpha gearboxes, equipped with integrated cynapse® sensors and IO-Link interface, are designed to meet the most challenging packaging requirements. These gearboxes directly measure and analyse essential process parameters such as temperature, vibration, acceleration and mounting position in real time.
With cynapse® smart gearboxes, industrial packaging achieves even higher performance. In fact, advanced monitoring capabilities, predictive maintenance and integration with digital systems enable companies in the industry to reduce operating costs, boost productivity and improve competitiveness in an increasingly demanding market.

Configurability for efficient monitoring

WITTENSTEIN gearboxes allow users to monitor individually configurable threshold values such as the vibration level considered ‘normal’ or the acceleration force that triggers an alarm for excessive vibration. The advanced features of the WITTENSTEIN solution ensure more sustainable packaging processes and improved packaging quality.

Optimised maintenance with advanced sensor technology

With cynapse®, gearboxes can detect anomalies in operating parameters in advance, sending alarms before failures occur. This capability prevents transmission damage and costly production interruptions. Integrating gearbox data into maintenance schedules optimises technical interventions, reducing repair costs and minimising downtime. This proactive approach extends the life of gearboxes and enhances production processes, reducing waste and energy consumption.

Easy installation, full compatibility

Gearboxes equipped with cynapse® sensors maintain the same design and overall dimensions as the standard series, ensuring easy integration without the need for structural modifications. The only difference is the sensor, which is fully integrated into the gearbox.
This feature can be requested for various WITTENSTEIN alpha gearbox families, including the Premium series featuring extra-performance gearboxes with XP+ shaft outputs and the series with output flange and torsional backlash ≤ 1 RP+.

Real-time data analysis

One of the smart services offered by cynapse® is the recently introduced Health Index, which analyses transmission system data in real time and assesses the gearbox's actual load. The gearbox's ‘health status’ is displayed using a traffic light system, accompanied by corresponding recommendations for users. These advanced diagnostics prevent malfunctions, optimise the lifespan of components, and ensure continuous operation of packaging lines.