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Hardened and ready for use ...
The spray valves of the WSV series are designed for a variety of applications in a wide range of production areas. When manufacturing the valve components in our company, we therefore consistently rely on protective processes such as potting. This process offers comprehensive protection of the electronic components against mechanical influences, moisture, contamination, extreme temperatures and thermal fluctuations.The WSV valve heads shown here were recently encapsulated with a high-quality two-component polyurethane resin. After curing, the resin reinforces the mechanical strength and ensures functionality and durability so that our valves can reliably perform their tasks even under the toughest conditions.
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Ready, steady, go: let's start the second day of Lubricant Expo ...
Our team at Lubricant Expo North America is ready to help you find solutions for reliable manual and automated lubrication processes and answer your questions about the transfer, dispensing and application of lubricants in manufacturing.To talk about your specific needs, visit us at booth 225. Let us explore options and discuss concepts that meet your unique requirements.
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Specialising in the lubricant industry: Lubricant Expo North America 2024
In a few weeks, from 19 to 21 March 2024 to be precise, Lubricant Expo North America will open its doors. This event is dedicated to the lubricant industry and presents itself as a unique platform that connects solution providers directly with a diverse group of end users and the entire chemical and equipment supply chain.
As specialists in the field of dosing and application of lubricants, we are looking forward to our participation with great anticipation. Our expertise covers the entire application process - from supply, transfer and preparation to precise dosing and dispensing. At Lubricant Expo, we offer an effective link between the diverse range of lubricant producers and the needs of users and end customers.
Visit us and discover how our solutions are helping to revolutionise lubrication applications and improve both the efficiency and reliability of application processes. We are particularly pleased to have Chris Ludwig from Airflo Equipment with us, who shares our passion for innovative fluid technologies. Don't miss this opportunity to discuss with us the latest trends and the future of lubricant application. We look forward to welcoming you in person!
March 19 - 21, 2024 / Huntington Place - Detroit, Michigan / Booth 225
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Lubrication of rolling bearings: Project completed ...
We have developed an advanced lubricant application system for rolling bearings that precisely addresses the challenges of component lubrication. Through the use of pulse valves, the system offers a pinpoint solution for component lubrication requirements, especially for small batch sizes with a high number of variants. It has been designed to enable fast and efficient adaptation to different production needs in bearing manufacturing by integrating automation, low set-up effort, recipe management and process control.
Flexibility and adaptability: The system allows quick adaptation to different bearing dimensions and types by simply changing the gripper jaws.
Automated processes: The manual insertion of the rolling bearings is supplemented by a fully automated process that includes component pick-up, alignment and lubricant application on one or both sides, as well as component removal. This ensures consistently high quality and reproducibility.
Recipe management: The ability to store and recall lubricant recipes and application programmes specific to different bearing types not only improves production efficiency, but also ensures that each bearing type is treated according to its particular requirements.
Process control: Integrated monitoring functions monitor and ensure precise lubricant application, ensuring accurate dosing and high process reliability.
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Pump system for highly abrasive thermal paste ...
This pump system is a real powerhouse. It is exactly the right choice when it comes to supplying demanding media. As a customised solution, it is characterised by an application-specific design and has been specially designed as a tandem solution for the uninterrupted delivery of highly abrasive thermal paste in order to optimally meet the basic requirements in the growing field of electronics and PCB production.
The integrated homogenisation ensures continuous mixing of the rapidly separating medium. To ensure the accuracy of the media supply, a downstream gear flow meter was also integrated to monitor the volume flow. The result: constant delivery, precise dosing and increased efficiency in the production process. Incidentally, the heat-conducting paste is applied using a hand-guided outlet valve.
Our team has worked hard to develop a solution that fulfils the highest requirements. We are all the more pleased with the result, which offers real added value in terms of reliability and performance.
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The Walther Pulse Valve WPV: Innovative evolution of process technology ...
Precise dosing without component contact: Pulse valves represent an excellent solution for dosing a variety of viscous media. Through the repetitive and accurate dispensing of drops, very small quantities can be discharged at high speeds without compromising precision. Therefore, pulse valves are particularly suitable for applications that require high speeds, such as in mass production. In this context, even hard-to-reach and uneven component geometries are rarely a problem. However, the need for a usually complex control and programming presents significant disadvantages, such as associated high acquisition and commissioning costs, as well as an increased potential for errors. To minimize the costly complexity and make this type of media application even more efficient and user-friendly, we have developed the Walther Pulse Valve WPV.
Technological sophistication and integration: The WPV pulse valve is characterized by an optimized design that not only allows for a very small footprint but also incorporates advanced technologies for control, monitoring, and process evaluation. This enables a cost- and time-saving system integration without additional control technology, software, or programming. The motto "parameterize instead of program" extends from commissioning to process monitoring, offering additional possibilities to control and evaluate additional peripheral elements without overarching control.
Access to the valve's own dashboard is easily done via a web interface, providing extensive new options with remote parameterization and diagnosis. Additionally, multiple parameter sets can be stored, and process variables documented. Software add-ons also offer flexibility for future challenges. Other features include a pressure sensor, a valve heating system with temperature control, as well as analog and digital connections for comprehensive connectivity. Remarkably, the fully electric operation eliminates the need for compressed air lines, further reducing integration effort and space requirements while lowering operating costs.
Overall, the WPV impresses with well-thought-out functions and offers a high level of process control, positively impacting process capability, overall equipment effectiveness (OEE), and product quality. Thus, the WPV pulse valve represents a groundbreaking development in dosing technology: the combination of contactless material application and innovative features opens up new possibilities for efficient, highly automated production processes.
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Product presentations
The Walther Pulse Valve WPV: Innovative evolution of process technology ...
Precise dosing without component contact: Pulse valves represent an excellent solution for dosing a variety of viscous media. Through the repetitive and accurate dispensing of drops, very small quantities can be discharged at high speeds without compromising precision. Therefore, pulse valves are particularly suitable for applications that require high speeds, such as in mass production. In this context, even hard-to-reach and uneven component geometries are rarely a problem. However, the need for a usually complex control and programming presents significant disadvantages, such as associated high acquisition and commissioning costs, as well as an increased potential for errors. To minimize the costly complexity and make this type of media application even more efficient and user-friendly, we have developed the Walther Pulse Valve WPV.
Technological sophistication and integration: The WPV pulse valve is characterized by an optimized design that not only allows for a very small footprint but also incorporates advanced technologies for control, monitoring, and process evaluation. This enables a cost- and time-saving system integration without additional control technology, software, or programming. The motto "parameterize instead of program" extends from commissioning to process monitoring, offering additional possibilities to control and evaluate additional peripheral elements without overarching control.
Access to the valve's own dashboard is easily done via a web interface, providing extensive new options with remote parameterization and diagnosis. Additionally, multiple parameter sets can be stored, and process variables documented. Software add-ons also offer flexibility for future challenges. Other features include a pressure sensor, a valve heating system with temperature control, as well as analog and digital connections for comprehensive connectivity. Remarkably, the fully electric operation eliminates the need for compressed air lines, further reducing integration effort and space requirements while lowering operating costs.
Overall, the WPV impresses with well-thought-out functions and offers a high level of process control, positively impacting process capability, overall equipment effectiveness (OEE), and product quality. Thus, the WPV pulse valve represents a groundbreaking development in dosing technology: the combination of contactless material application and innovative features opens up new possibilities for efficient, highly automated production processes.
Price on request
Dispensing with Euro cartridges in industrial applications
Germersheim, 24 August 2021: The cartridge system from Walther Systemtechnik professionalises the use of Euro cartridges.With the WKS cartridge system, Walther Systemtechnik presents a new product that has been specially developed for the use of Euro cartridges in industrial applications. The innovative and compact emptying system enables the automated and reliable supply of adhesives, silicones and other high quality media, which are typically supplied in Euro cartridges.The advantages of Euro cartridges as a media storage system are undeniable. In addition to excellent transport and storage options, uncomplicated handling with maximum media cleanliness and easy disposal of empty cartridges, the manageable filling quantity is the main argument in favour of using cartridges. If only a small amount of media is dispensed, this reduces the need to exceed maximum processing times and thus production costs. However, the potential of cartridges in industry has been limited by restrictions on use at manual workstations and production interruptions when changing cartridges.The WKS cartridge system from Walther Systemtechnik overcomes the usual disadvantages and opens up new possibilities for the use of Euro cartridges in automated production environments.With an integrated pressure regulator and pressure indicator, as well as optional pre-empty and empty signalling, the extremely compact and powerful system operates autonomously and ensures consistent medium delivery without pressure fluctuations. The closed-loop pressure system, which pushes the cartridge's plug towards the outlet when the medium is primed, prevents the cartridge from inflating and deforming, and also allows for upside-down installation.Cartridge replacement is extremely simple and requires no tools: unscrew the cartridge tube, remove the empty cartridge, insert the new cartridge, close the cartridge - done. The Walther cartridge system has a non-return valve which allows the cartridge to be changed even when the supply line is pressurised during operation. The optimised design and built-in safety feature prevent air from entering the fluid system.The module-based connection of multiple cartridges gives the system an additional strength: it can be cascaded and ensures an uninterrupted supply of media despite the use of standard cartridges. This closes the gap between systems for larger containers and the use of individual cartridges.In addition, the cartridge system is fully compatible with all Walther MODULAR components and offers a wide range of options for building and expanding dispensing systems. For example, in combination with the Walther Booster Pump module, complete pressure independent dispensing up to 150 bar is possible, even over longer distances.The interchangeable holder with different connection threads for plastic and aluminium cartridges also multiplies the possible applications and provides additional flexibility in use.
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Saved in the pulse of time: Non-contact dispensing of media
Germersheim, May 9, 2008: Precise and reproducible application of media with varying viscosities is essential for many production and assembly processes.
The increasing automation and miniaturization in nearly every industrial sector, coupled with rising prices for various media, necessitate the contactless dispensing of minute quantities. Existing systems in the market are often complex and costly. The new Micro Point Pulse Valve (MPP) offers a solution, surpassing the performance of more expensive devices with its compact dimensions and reduced cost.
The market has seen several technologies for media dispensing, with contactless dispensing becoming increasingly focused on both new designs and integration into existing systems.
It's crucial for many processes to accurately apply even tiny amounts of highly viscous media. The MPP is preferred for the contactless pulsing of media of various viscosities, such as greases, oils, adhesives, paints, fluxes, and solvents. The continuous miniaturization of components and rapidly shortening cycle times place ever-higher demands on the technical equipment for media application. Currently, very few systems offer contactless dispensing that combines precise functionality with a solid price point. This synergy has been achieved with the Micro Point Pulse Valve developed by Walther Systemtechnik GmbH.
The valves were developed from a full-stream variant for applying beads and larger quantities of media. This was based on extensive endurance testing that exposed the weaknesses of the initial system. The accuracy and placement of the media could not be considered process-safe before optimization.
The main goal of the development was to create a system for generating small quantities of media. This involved altering individual system components in terms of materials and geometries to achieve significantly longer service lives.
The objective was to develop a market-ready product from the initial system, achieving not only a certain cycle number but also reproducible dispensing results throughout the test series.
Endurance tests were conducted with partially highly viscous, pasty media. The results were recorded through weight measurement and visual inspection. Compared to the original component, the quantities could be significantly reduced. Variations in application pattern and quantity were less than 10 percent from the original value. The tests worked with quantities of 700µg, yet the system also allows for the application of larger amounts and still realizes a bead-shaped media application.
In single dosing, quantities up to 0.5g were applied. Even during operation, the quantity can be quickly adjusted by altering the detent pin.
Nozzles with diameters ranging from 0.3mm to 2.0mm are easily interchangeable in a short time. The valve is designed for material pressures up to 100bar.
The valve's drive is maintenance-free, and the overall system's maintenance and cleaning are straightforward. Depending on the media, the system can accurately pulse free-flying media elements over a distance of more than 100mm. This not only saves significant media costs but also time in the dispensing process. Contactless application further shortens throughput times in assembly processes and processing cycles. The travel distances required for contact dispensing are eliminated.
Another advantage is the prevention of grease carryover, ensuring cleanliness and medium application only where selected on the component.
The MPP offers a cost-effective alternative to the current state of technology, providing numerous advantages.
Tests with the MPP achieved significantly more accurate dispensing results in terms of quantity and placement than comparable but much more expensive competitive products. Compared to the competition, no heating was required. Heating is not always permissible due to fluid properties, as it can lead to separation of components or changes in the medium's characteristics. In medical technology, heating is not always feasible as it could alter the active ingredients.
However, unlike the expensive solution, optional heating can be provided. With fast cycle times of up to 40Hz, integration into existing continuous processes is possible, as is the supplementation of individual manual workstations.
The precise and safe operation ensures a clean working environment. Numerous systems have been in industrial use for several months.
A major German dowel manufacturer uses the technology to apply 30mg of lubricant to components, preparing them for further processing. Over 115,000 components per day are treated with the required amount of lubricant in a shift operation.
An electronics component manufacturer uses the technology to apply a contact grease amount of 300µg before final assembly.
Depending on the media, additional options can be used. The variability in installation and the generation of free-flying media elements open up a wide range of applications. The minimization of the dispensed quantity makes applications in microtechnology or microelectronics conceivable, as well as in the food industry.
Due to the generation of the smallest free-flying media elements and the associated sterility, the technology is suitable for use in medical technology.
Besides contactless dispensing of small quantities, it is also possible to dispense large amounts, allowing for significant time savings in filling large storage areas. The very fast media output makes it conceivable to lubricate machines or machine parts during operation.
This could extend maintenance intervals and significantly reduce associated downtime. Otherwise, mandatory maintenance-related disassembly for lubricating moving parts can be specifically minimized. The enormous time savings in dispensing, due to the eliminated travel movements, combined with material savings due to precise operation, result in very short amortization periods. Further development work aims to also point-dose low-viscosity media in small quantities.
This raises the question: Can the MPP replace traditional contact dispensing in many areas?
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Press releases
Change in the management of Walther Systemtechnik
Germersheim, July 18, 2022: Henning Wagner and Frederic Förster Take Over as New Dual Leadership.
Since July 1, 2022, Dr.-Ing. Frederic Förster and Dr.-Ing. Henning Wagner have been leading Walther Systemtechnik GmbH as managing directors. Both have been serving as business leaders of the company for several years and are now taking over the comprehensive leadership and development at the Germersheim location.
Frederic Förster oversees the technical and sales departments. The close interlinking of market and technology will further sharpen the technological orientation to meet customer needs. Henning Wagner heads the operational area and finances. The focus on process efficiency will increase the processing speed of customer projects and position the company as a modern and digital player. The new leadership duo takes over from Philipp Unterhalt, who has been acting as interim CEO of Walther Systemtechnik on behalf of the HAHN Group since February 2021.
Frederic Förster has been with the Germersheim company since 2016. As head of development, he has created a range of solutions that lead in technology through significant investments in new technologies and products over the past years. The PhD in production engineering has also led the reorientation of sales and, with his team, oversees the global distributor network.
Henning Wagner is responsible for the fields of application engineering, special machine construction, and operational business. In the future, the PhD in production engineering will focus even more on Operational Excellence to optimize quality, customer focus, process management, and speed, thereby further increasing the company's competitiveness.
"I am very pleased that we have Henning and Frederic, two experienced and entrepreneurial leaders within our ranks, who enjoy high trust among employees and stand for reliability and continuity with our customers," says Philipp Unterhalt, CEO of the HAHN Group. "The company's innovative strength was recently confirmed by the Innovation Award from the State of Rhineland-Palatinate for Walther Systemtechnik, and I am confident that Henning and Frederic will continue this successful path."
"We thank Philipp for his dedicated commitment and trust. Under his leadership, we have successfully navigated Walther Systemtechnik through a challenging time and taken important steps for strategic and structural realignment," emphasizes Henning Wagner. "Our goal now is to further expand our position as a manufacturer of dosing technology and provider of customized application systems," he explains the plans for the coming years. "To do this, we will continue to develop our team, continuously improve processes, and make our system landscape more efficient."
"Walther Systemtechnik has enormous growth potential, and we look forward to driving its development together," adds Frederic Förster. "Walther Systemtechnik has developed exciting solutions that are used in almost every industry. Of course, we continue to place great importance on the exchange with users, as customer feedback plays a crucial role in product development. But being a reliable partner requires more. To offer our customers long-term benefits, we not only implement their wishes but also think ahead."
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Innovation award for smart spray valve WSV
Koblenz, 3 June 2022: Walther Systemtechnik wins Rhineland-Palatinate Innovation Award in the category "Cooperation".In awarding this year's Rhineland-Palatinate Innovation Prize, Economics Minister Daniela Schmitt honoured the innovative spirit and capabilities of eight companies in the region. The prize, which is endowed with a total of €60,000, is awarded by the Ministry of Economic Affairs, Transport, Agriculture and Viticulture together with the regional working groups of the Chambers of Industry and Commerce and the Chambers of Skilled Trades. It includes the categories "Company", "Craft" and "Cooperation". The winner in the "Cooperation" category was Walther Systemtechnik from Germersheim - in cooperation with the Karlsruhe University of Applied Sciences.Together with the Karlsruhe University of Applied Sciences, the Germersheim-based company has developed an intelligent spray valve with integrated process monitoring and control via a web interface. This means that the various parameters for the spraying process can be visualised, adjusted and monitored via the valve's own dashboard without the need for additional software or programming. Various components such as valve heating, temperature control and a pressure sensor for analysing the process pressure curve have been integrated into the spray valve for this purpose. Additional peripherals can also be connected via analogue or digital interfaces. The spray valve is based on a modular system and additional functions for valve control and sensor data analysis can be activated by means of activation codes.Context:
Spray valves are often used in industrial production processes to apply viscous media such as lubricants, release agents, paints or adhesives. Existing spray valves are not Industry 4.0 compliant. Adjustments are made manually on the valve. This takes time and requires expert knowledge based on years of experience. In addition, separate additional components are often required to optimise the application pattern. The WSV intelligent spray valve not only ensures more reliable and consistent application of different media, it also saves the cost of additional equipment and significantly reduces commissioning and integration work. The additional fieldbus interface integrated into the valve rounds off its suitability for Industry 4.0 applications.
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Digitalisation in the field of dosing technology: Walther goes digital
Germersheim, 23 September 2021: The reliable conveying, dosing and application of liquid and pasty media plays a central role in ensuring the function and safety of products in almost all industries. Walther Systemtechnik GmbH has been developing dosing components and systems for over two decades and has established itself as a reliable partner for the realisation of standard solutions through to individual complete systems.As a driver of innovation, Walther's current I4.0 product family is the latest step in the digitalisation of dosing technology, thus ensuring the future viability of its customers' applications. Whether pumps, media reservoirs, filter systems or modules for air bubble ejection, within the new product family important process and status variables can be recorded in real time using suitable sensors and transferred via analogue and digital interfaces - for example to the system control. This provides the user with new opportunities to increase process capability, Overall Equipment Effectiveness (OEE) and product quality.This is illustrated by the latest addition to the I4.0 product family, the WSV spray valve. Designed from the ground up for the application of low to medium viscosity fluids, the valve's integrated design provides a high level of functionality in a small footprint. It combines a pressure sensor, a valve heater with associated temperature control and the electronics for controlling, monitoring and analysing process data. An analogue output, four digital inputs/outputs and an Ethernet connection allow extensive connectivity to peripheral devices as well as remote parameterisation and diagnostics of the valve. In addition, software ADD-ONS and firmware updates can be installed and activated at a later date if required, giving the operator maximum flexibility.Thanks to its compact design, the smart valve can be easily integrated into both new and existing systems. No external control technology or additional programming is required, significantly reducing the cost and time of commissioning.The greatest added value can be achieved by combining it with other fluid components from the I4.0 product family. Various process data can be evaluated and the resulting process understanding can be used to maximise the system performance indicator.
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Smart solutions for automated conveying, dosing and application processes
Germersheim, 10.09.2019: At Motek 2019, Walther Systemtechnik GmbH will be presenting intelligent systems for material preparation with optimum practical benefits.Whether material preparation systems with intelligent analysis functions, extremely compact modular components or cobot-dominated application processes - at Motek 2019, Walther Systemtechnik GmbH will be presenting innovative new products that measurably increase output and can be easily integrated into existing production chains.The Germersheim-based company is increasingly relying on intelligent solutions and digitalised products to avoid or identify production obstacles. This is also reflected in the new product portfolio.Just in time for Motek, the company is presenting the WFSD-01, a diagnostic-capable filter system for lubricants, and the WADS-01, a stand-alone solution for detecting and ejecting gas inclusions in liquid and viscous materials, two production-supporting add-ons that record process-related parameters by means of real-time monitoring.Recorded data includes planned and unplanned downtime, error messages and numerous target/actual comparisons. The permanent logging of parameters enables a cycle-accurate response. Since it is also possible to report when definable thresholds are exceeded or not reached, direct action can also be taken. Intelligent diagnostics therefore significantly speed up fault analysis and provide an essential basis for calculating OEE.In summary, the common denominator of the two product innovations is their intelligent control functions, which ensure maximum accuracy and efficiency: both solutions sustainably stabilise the production process, avoid waste and save costs.In addition, they are vendor-independent and can be easily integrated into any system, offering complete flexibility to both existing and new customers.
In addition to the WFSD-01, which is part of the new Walther Modular product line, six other very compact innovations will be presented. This year, the company is focusing on the efficiency and process reliability of dispensing and application applications in terms of system effectiveness.Of course, visitors will also have the opportunity to familiarise themselves with the extensive product range on all days of the exhibition. In addition to customised solutions, Walther Systemtechnik GmbH offers a wide range of standard products. Drum lift pumps, dosing and outlet valves or testing technology such as pressure and optical sensors are just a small selection from the product portfolio.Contact us; appointments can be made by telephone on 07274-7022-0. You will find the company in Hall 3, Stand 3211.
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