Wittenstein Components & Systems. Catalog 2012/2013 - page 42

alpha IQ

Achieving compatibility. 
Utilizing intelligence. 
Increasing efficiency. 
WITTENSTEIN alpha gearhead with integrated 
sensors – helping you better understand your 
processes.

torqXis sensors

Modular sensor solution 
for measuring mechanical  
parameters in the drive train.

Intelligence in mechatronic drive technology

Low backlash planetary gearheads with integrated sensor technology

Modular sensor systems

348

alpha IQ

tor

qXis

Mechanical

 

systems

 

Rack and

 

pinion

  

system

Today, intelligence is an absolute must in industrial applications. Particularly in 
mechatronic drive technology, revolutionary solutions have been implemented 
thanks to state-of-the-art sensor technology. 

From high-quality sensors for drive components and custom-specific sensor 
solutions, through to engineering services.

349

Use and benefits of sensors

Understanding processes

 

Intelligent sensor systems

Whether integrated in the gearhead or as modular 
solutions, sensors permit the direct measurement, 
diagnosis and evaluation of process parameters, 
i. e. all mechanical loads processed by the gearhead 
can be measured at the output.

Cost savings – drive design

Thanks to this innovative technology it has now be-
come possible to take real values into account dur-
ing drive design. This not only saves costs, but also 
enables a compact design.

Controlling the forces in the drive train

Unforeseen failures in the drive train result in enor-
mous costs. The acting load spectra are measured, 
analyzed and diagnosed using innovative sensors.  
 

Preventive tool wear warning system

With the aid of sensor technology, conclusions can 
be drawn regarding the condition of the driven tools 
based on changes in the applied torque or the lat-
eral force in the drive train. 

Diagnosis

Process monitoring

Process control

Enhancing machine availability

Intelligent systems continuously monitor the drive 
status, allow maintenance measures to be planned 
more effectively and shorten the response time for 
maintenance deployments to a minimum.

Efficient drive control

Load-dependent process control is made possible 
through online calculation of the torque and lateral 
force. Innovative sensors used as an active control 
element not only improves process quality, but also 
helps in understanding and improving the process.

Quality verification in the drive train

The top priority is of course to prevent faults. However, 
when a fault does arise, it is just as important to 
analyze it as accurately as possible! In many cases, 
this can be achieved with the aid of sensor technology. 

For further information, please visit: 

www.wittenstein-sensors.com

alpha iQ / torqXis

 

Measured parameters

Torque

X direction

Y direction

Temperature

350

alpha IQ

tor

qXis

Mechanical

 

systems

 

Our services

 · Customer-specific sensor solutions
 · Empirical drive design
 · On-site service
 · Rental systems
 · Measurement service

alpha IQ

torqXis

Solution

Integrated solution – intelligent sensors and  

low backlash gearhead in one unit

Modular solution – the sensor can simply installed like 

a flange between the output and the machine bed.

1-3 measured parameters 

Simultaneous measurement  

of torque and/or lateral forces

Standard version (S)

Simultaneous measurement of torque and lateral 

forces in X and Y directions

Light version (L) 

Measurement of torque or lateral  

force in one direction

Size

TP

+ 

025 IQ

TP

+ 

050 IQ

TP

+ 

110 IQ

TP

+ 

300 IQ

SFR 004 

for

TP

+

 004

SFR 010 

for 

TP

+

 010

SFR 025 

for 

TP

+

 025

SFR 050 

for 

TP

+

 050

SFR 110 

for 

TP

+

 110

Torque measurement range

250 Nm

500 Nm

1,500 Nm

3,000 Nm

50 Nm

100 Nm

250 Nm

500 Nm

1,500 Nm

800 Nm

1,500 Nm

3,000 Nm

8,750 Nm

300 Nm

800 Nm

1,500 Nm 3,000 Nm

Lateral force measurement 
range (X/Y)

2,500 N

5,000 N

10,000 N

15,000 N

850 N

1,500 N

2,500 N

5,000 N

10,000 N

10,000 N

15,000 N

30,000 N

44,000 N

4,500 N

10,000 N 15,000 N 30,000 N

Type of measurement

Reaction forces / reaction torques – sensors not corotating

Absolute accuracy

< 2%

Repeat accuracy

< 0.5%

Evaluation

torqXis software for measurement, storage and evaluation of data / configuration of sensor system

Analog interfaces

Voltage interface, current interface

Digital interfaces

RS 232, USB, Ethernet/IP

Product overview

351

Shrink discs –  

Clamping element for attachment of our  

shaft-mount gearhead with your load shaft 

Highly loadable shaft/hub connection: 

whether for continuous hollow shafts 

or load shafts, always perfectly adapted 

to your drive.

Couplings –  

High-tech components for the harmonious 

transmission of power and movement. – in 

all applications where improved performance 

means progress.

352

Accessories

Details

Accessories

 

Couplings

353

d

D

A

H*

H2*

J 

[kgcm²]

SP

+

 060

SPK

+

 060

HG

+

 060

20000744

20048496

20048491

18

44

30

15

19

0,393

SP

+

 075

SPK

+

 075

HG

+

 075

20001389

20047957

20043198

24

50

36

18

22

0,753

SP

+

 100

SPK

+

 100

HG

+

 100

20001391

20048497

20035055

36

72

52

22

27,3

3,94

SP

+

 140

SPK

+

 140

HG

+

 140

20001394

20048498

20047937

50

90

68

26

31,3

11,1

SP

+

 180

SPK

+

 180

HG

+

 180

20001396

20048499

20048492

68

115

86

29

35,4

31,1

d

D

A

H*

H2*

J 

[kgcm²]

VDH 040

20001389

20047957

20043198

24

50

36

18

22

0,753

VDH 050

20020687

20047934

20047885

30

60

44

20

24

1,82

VDH 063

20020688

20047530

20035055

36

72

52

22

27,3

3,94

VDH 080

20020689

20047935

20047937

50

90

68

26

31,3

11,1

VDH 100

20020690

20047927

20047860

62

110

80

29

34,3

27

Shrink disc 

Gearhead type

Article code

Standard

Chemically nickel 

plated

Stainless steel

Gearhead type

Article code

Standard

Chemically nickel 

plated

Stainless steel

* in unclamped state

* in unclamped state

One shrink disc per gearhead is sufficient.

Please refer to the operating instructions for information on 
correct shrink disc installation. The instructions are enclosed with the order.

Recommendation for the load shaft:
Tolerance h6
Surface roughness ≤ Rz 10
Minimum yield strength Rp 0,2 ≥ 360 N/mm²

Our shrink discs ensure a frictional hub/shaft connection between the hollow shaft and your 

load shaft. Perfectly matched to our gearheads, they enable the transmission of high torques.

The shrink disc is not included in the scope of delivery for the gearhead (except V-Drive, see order code) and must be ordered 
separately as an accessory (see table). 

354

alpha

BC3

BC2

EC2

BCT

EL6

ELC

TL2

TL1

TL3

Accessories

Couplings

Couplings portfolio – Always well connected

Wherever high demands need to be met regarding precision, reliability, balance and safety. 

Precision transmission of torques

 · 2-10,000 Nm
 · Shaft diameter: 4-180 mm

For precise, backlash-free and torsionally-rigid torque 
transmission and simultaneous compensation of lateral, 
angular and axial misalignment.

Metal bellows couplings

Backlash-free and vibration-damping torque 
transmission

 · 2-2,150 Nm
 · Shaft diameter: 3-80 mm

For the damping of torque peaks and vibration in the 
drive system and simultaneous compensation of lateral, 
angular and axial misalignment Plug-in and electrically 
insulating couplings with selectable elastomer rings to 
maintain the required damping and torsional rigidity.

Elastomer couplings

Safe torque limitation

 · 0.1-2,800 Nm
 · Shaft diameter: 3-100 mm
 ·  4 available function systems: single position,  

multi-position, load holding, full disengagement

Separation of input and output in the event of unex-
pected overload. Precisely-adjustable disengagement 
torque for protection of drive and application

Torque limiters

Couplings

355