Lubrication of rolling bearings – project successfully completed
16 Jan 2024, 09:00:00
For the precise lubrication of rolling bearings, Walther Systemtechnik has developed and successfully implemented an advanced lubricant application system. The system specifically addresses the high requirements for component lubrication in rolling bearing production, particularly for small batch sizes and a high degree of product variation.
The core of the solution is the use of pulse valves, which enable pinpoint and reproducible lubricant application. The system is designed to be adapted quickly and efficiently to changing production requirements. Automation, low set-up effort, integrated recipe management and continuous process monitoring are consistently combined within a single solution.
- High flexibility and fast changeover: By simply replacing the gripper jaws, the system can be quickly adapted to different bearing dimensions and bearing types. This enables short set-up times and economical production even with frequent product changeovers.
- Automated lubrication process: Manual loading of the rolling bearings is complemented by a fully automated sequence. This includes component pick-up, positioning and alignment, single- or double-sided lubricant application, and subsequent component removal. The result is consistently high quality and excellent repeatability of the lubrication process.
- Integrated recipe management: Lubricant recipes and application parameters can be stored and retrieved on a bearing-type-specific basis. This increases process reliability, reduces operating errors and ensures that each bearing variant is lubricated exactly in accordance with its technical requirements.
- Reliable process control: Integrated monitoring functions continuously safeguard the lubricant application process. Dispensed volume and application position are monitored, ensuring precise dosing and a high level of process stability.
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Employee in focus: Kai-Uwe Garthe
Today we would like to introduce you to Kai-Uwe Garthe - our Sales Manager at Walther Systemtechnik! Kai-Uwe has been part of our team for just over a year and brings his passion for communication and direct customer contact to his work every day.What makes his job so exciting? For Kai-Uwe, the greatest attraction of his work is its versatility. He is particularly enthusiastic about communicating with customers and building long, successful partnerships. It's exciting to see how a conversation and an idea turn into a functioning system - and you get to know lots of interesting companies and people in the process. What motivates him? Kai-Uwe has the clear goal of constantly developing himself further and thus continuously advancing the company. His greatest strength? Kai-Uwe is characterised by his ability to work in a team, communicate and always have a customer-friendly attitude - qualities that are simply essential for his role as Sales Manager. And in his free time? When he's not in the office, Kai-Uwe likes to spend his time playing football or with his family and friends - the perfect balance to his working day. His advice to his younger self: ‘First do an apprenticeship and then a dual study programme or a bachelor's degree at a university of applied sciences.’ Kai-Uwe, it's great to have you in the team!
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9 Monate voller Engagement – Wir sagen Tschüss, Ayse!
Thank you for 9 months of commitment, Ayse! After 9 months, it's time to say goodbye to our intern Ayse, who completed the practical part of her retraining programme with us. During this time, she enriched our team with a great deal of commitment and dedication - and we really appreciated her motivated nature!Dear Ayse, we would like to thank you for your great work and wish you every success for the future - both professionally and personally! Perhaps our paths will cross again!
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Team spirit, action and shared experiences!
At Walther Systemtechnik, we not only focus on innovation and precision, but also on working together! This year, we have planned many exciting after-work events for our employees - and their families are also very welcome. We kicked things off in February with an energetic indoor soccer tournament. After some exciting matches, we rounded off the evening with a convivial meal together.A big thank you to everyone who took part - we are already looking forward to the next events! Here are a few impressions from the evening!
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Employee in focus: Sebastian Meyer
Today we are introducing you to Sebastian Meyer - our dedicated Team Leader Internal Sales at Walther Systemtechnik! He has been an important part of our team since 1 March 2019 and, with his structured and solution-oriented approach, ensures that our internal processes run smoothly.What makes his job so exciting?
No two days are the same! New challenges and unexpected events ensure that there's never a dull moment - and that's exactly what Sebastian loves about his work.What motivates him?
Quite clearly: his team and the goal of constantly developing Walther Systemtechnik further. Working together on solutions and driving the company forward is his greatest driving force.His greatest strength?
Sebastian is a real problem solver! He has an impressive flair for finding the right information and learning from the past to make the best decisions for the future.And after work?
Then it's all about football, skiing and his family - the perfect balance to his varied working day.His advice to his younger self?
‘Do it exactly the same way! I'm happy with my life and have found my place in it.’Sebastian, we're glad to have you in the team!
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Efficient dosing processes: Control vs. regulation - what makes the difference?
In industrial dosing processes, controlling the quantity dispensed is crucial for quality and efficiency. But how can you ensure that dosing is always precise? We compare four different control models and show how the Walther Valve Controller (WVC) drastically reduces the integration effort. Figure 1 (🇬🇧 5): Classic PLC control without feedback
The valve is opened for a fixed time ⏱️, but the actual quantity discharged can fluctuate - e.g. due to changes in pressure or viscosity. Without measuring the actual discharge quantity, process reliability remains limited.Figure 2 (🇬🇧 6): PLC with volume flow meter for process evaluation (IO/NIO)
Measuring the discharged quantity is possible, but involves a high level of integration effort (additional hardware, software adaptations, calibration and fine adjustment). Figure 3 (🇬🇧 7): WVC control with volume flow meter for process evaluation (IO/NIO)
Low integration effort via plug-and-play: Automatic calibration and compensation of dead times facilitate commissioning. The volumetric flow is controlled directly via the WVC, without complex PLC adaptations.Figure 4 (🇬🇧 8): WVC as a control system
The highest level of process control: regulation instead of control! The WVC dynamically adjusts the valve opening time to ensure a constant discharge rate - regardless of external influencing factors such as pressure or viscosity fluctuations. Conclusion: If you want process reliability with minimum effort, there is no way around a solution with the WVC!
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Employee in focus: Tom Oswald
Today we would like to introduce you to Tom Oswald - our Sales Manager at Walther Systemtechnik! Tom has been an important part of our team since 1 May 2020 and is shaping our customer relationships with his expertise and commitment. What makes his job so exciting?
Tom loves the daily dialogue with our customers, whether in person or on the phone. He finds factory tours at our customers' sites particularly exciting, as he can experience the diverse applications of our portfolio up close - from primary moulding and forming to highly automated assembly systems. There are always new challenges and the opportunity to help develop solutions for new technologies - a perfect mix of variety and innovation. What motivates him?
Tom is particularly motivated by the team spirit, finding solutions together and the satisfied customers. When everyone pulls together and the best possible solution is found for the customer in the end - that's his greatest reward! His greatest strength?
Tom has a real gift for communication and is a master of troubleshooting, especially when it comes to complex processes. No problem is too big for him - he stays calm and always finds a solution. And in his spare time?
Tom likes to get creative as a DJ and ensures that people experience emotions through music. He also likes to be active in the gym or playing ball sports and loves doing sports. His advice to his younger self?
‘Life isn't always easy and sometimes it feels unfair. But it's important not to give up and to always keep your goal in sight. Success is a staircase, not a door!’ And what does Tom say about his career?
‘I would want to relive my career 1:1 in exactly the same way. Maybe I would give English more importance in my school days.’Tom, we're proud to have you in the team!
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Dosing technology meets Christmas magic
In our new video, we show you how our technology even shines in the Christmas bakery. Marvel now at how sweet dosing technology can be - and discover how we build a gingerbread house at Walther!
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35th anniversary - Thomas Danz
35 years with Walther Systemtechnik - a reason to celebrate! Today we would like to honour our colleague Thomas Danz, who has been part of our team for an impressive 35 years. Thomas started his career with us in design and project planning and later moved to the field, where he proved his expertise and customer focus. Today, he is a trusted member of our technical office staff. His extensive knowledge, experience and dedication make him a valuable member of our team. Dear Thomas, thank you very much for your commitment, your reliability and the many years you have helped to shape Walther Systemtechnik. We look forward to many more successes together!
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Ready, set, go: Day two of Lubricant Expo
Our team is on site on the second day of Lubricant Expo North America and available for technical discussions on reliable manual and automated lubrication processes. We support you with questions relating to the conveying, dispensing and precise application of lubricants in industrial production environments.Visit us at Stand 225 to discuss your specific requirements. Together, we analyse application scenarios and develop solution approaches that are technically and process-wise tailored to your individual tasks.
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Cured and ready for operation
The spray valves of the WSV series are designed for use in industrial production environments with increased mechanical, thermal and environmental loads. For this reason, Walther Systemtechnik deliberately relies on protective methods such as potting of electronic components during the manufacture of the valve assemblies. The potting process reliably protects the integrated electronics against mechanical impact, moisture, contamination, as well as extreme temperatures and thermal cycling, thereby making a significant contribution to long-term functional reliability. The valve heads shown here have been potted with a high-quality two-component polyurethane resin. After curing, the resin increases the mechanical stability of the assembly and ensures reliable operation of the spray valves even under demanding industrial conditions.
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Specialised in the lubricants industry: Lubricant Expo North America 2024
Lubricant Expo North America will take place in Detroit from 19 to 21 March 2024. The trade fair is specifically focused on the lubricants industry and provides a specialised platform bringing together solution providers, users and the entire supply chain for lubricants, chemicals and equipment. As a specialist in the conveying, dispensing and precise application of lubricants, Walther Systemtechnik will be exhibiting at Lubricant Expo North America. Our expertise covers the entire application process – from media supply and conditioning through to delivery, reproducible dosing and process-reliable application in industrial environments. In this way, we create a functional link between the requirements of lubricant manufacturers and the technical needs of users and end customers. At the exhibition, we will present solutions designed to make lubricant application more efficient, reliable and economical. The focus will be on dispensing systems and application technologies that ensure consistent lubricant quantities, clean processes and a high level of process stability. We are also pleased to welcome Chris Ludwig from Airflo Equipment at our stand. Together, we stand for innovative fluid and lubricant technologies and invite visitors to engage in technical discussions on current developments and future requirements in lubricant application. Visit us at Lubricant Expo North America 2024:19–21 March 2024Huntington Place, Detroit, MichiganStand 225
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Lubrication of rolling bearings – project successfully completed
For the precise lubrication of rolling bearings, Walther Systemtechnik has developed and successfully implemented an advanced lubricant application system. The system specifically addresses the high requirements for component lubrication in rolling bearing production, particularly for small batch sizes and a high degree of product variation.
The core of the solution is the use of pulse valves, which enable pinpoint and reproducible lubricant application. The system is designed to be adapted quickly and efficiently to changing production requirements. Automation, low set-up effort, integrated recipe management and continuous process monitoring are consistently combined within a single solution.
High flexibility and fast changeover: By simply replacing the gripper jaws, the system can be quickly adapted to different bearing dimensions and bearing types. This enables short set-up times and economical production even with frequent product changeovers.
Automated lubrication process: Manual loading of the rolling bearings is complemented by a fully automated sequence. This includes component pick-up, positioning and alignment, single- or double-sided lubricant application, and subsequent component removal. The result is consistently high quality and excellent repeatability of the lubrication process.
Integrated recipe management: Lubricant recipes and application parameters can be stored and retrieved on a bearing-type-specific basis. This increases process reliability, reduces operating errors and ensures that each bearing variant is lubricated exactly in accordance with its technical requirements.
Reliable process control: Integrated monitoring functions continuously safeguard the lubricant application process. Dispensed volume and application position are monitored, ensuring precise dosing and a high level of process stability.
Price on request
Professional exchange: training successfully completed with our Hungarian partners
We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. We would like to express our gratitude to our Hungarian partners for their active participation and valuable input during the three-day intensive technical training, which covered both theory and practical application. Their dedication and expertise were evident and greatly contributed to the success of the meeting. We appreciated the chance to improve their understanding of our latest dispensing and application technology and strengthen our teams' bonds through experience sharing. We anticipate continued knowledge sharing and mutual learning in the future.
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Pump system for highly abrasive thermal paste
This pump system is designed for the handling of demanding media. As a customised solution, it features an application-specific design and is configured as a tandem system to ensure uninterrupted conveying of highly abrasive thermal interface material. The integrated homogenisation ensures continuous mixing of the medium, which is prone to rapid separation. To guarantee uniform media supply, a downstream gear-type flow meter is integrated to continuously monitor the volumetric flow rate. This enables constant conveying, an accurate dosing basis and increased process efficiency. The application of the thermal interface material is carried out via a hand-held outlet valve, making the system suitable for flexible application processes. The pump system was developed to meet high requirements for reliability and performance and provides clear added value when handling highly abrasive media.
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Walther WPV Pulse Valve: An innovative evolution in process technology
Pulse valves enable contactless dispensing of viscous media with a high level of repeatability. By dispensing individual droplets in rapid succession, even very small quantities can be applied at high frequencies while maintaining consistent precision. This makes pulse valves particularly suitable for applications with high cycle rates, as typically found in series production and automated processes. Even difficult-to-access or uneven component geometries can be handled reliably. Conventional pulse valve systems, however, are often associated with a high level of integration effort. External control technology, complex programming and additional software increase both investment and commissioning costs and at the same time raise the potential for errors. Against this background, the Walther WPV pulse valve was developed to combine the functional advantages of pulse dispensing with significantly reduced system complexity. Functional integration instead of external control: the WPV pulse valve is characterised by a high degree of functional integration within a compact design. Control, monitoring and process evaluation are integrated directly into the valve. No additional external control system, dedicated software or programming effort is required. Operation consistently follows the principle of “parameterising instead of programming” – from commissioning through to ongoing process monitoring. Access to the valve’s own dashboard is provided via a web interface. Functions such as remote parameterisation and remote diagnostics enable flexible adjustment of process parameters as well as rapid analysis of process conditions. In addition, peripheral components can be controlled and evaluated without the need for a higher-level control system. Equipment and operating concept: the standard equipment of the WPV includes an integrated pressure sensor, a valve heating system with temperature control, as well as analogue and digital inputs and outputs for connecting external components. Fully electric operation eliminates the need for compressed air lines, reduces installation effort and space requirements, and lowers operating costs. By combining contactless dispensing with integrated control and monitoring technology, the WPV opens up new possibilities for efficient, highly automated dispensing processes while at the same time reducing overall system complexity. Process control and expandability: multiple parameter sets can be stored and process-relevant variables documented. This has a positive effect on process capability, overall equipment effectiveness (OEE) and product quality. In addition, software add-ons can be activated retrospectively as required to flexibly address future requirements.
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Successful training of our Polish sales partners
As part of a two-day technical training programme, our Polish sales partners once again visited us at our site in Germersheim. The aim of the event was to present current product innovations in a practical setting and to explain their application possibilities in detail. The focus included, among other things: The WVC valve controller, which can be used to operate the full range of electric and electro-pneumatic spray, pulse and dispensing valves from Walther Systemtechnik GmbH, as well as many conventional valves. The fully electric WPV pulse valve, which enables particularly simple, cost- and time-efficient integration thanks to its integrated control and monitoring technology – without the need for additional external control systems, software or programming. The WDBS pressure tank series for media supply, equipped with integrated control for agitator, level detection and process valves, ensuring reliable and process-safe delivery of liquid media. During the training, our guests were able to commission the systems themselves, test them and explore typical application scenarios. The intensive technical exchange made it possible to delve deeper into technical details and discuss specific practical questions. We would like to thank our partners for their visit, their interest and the valuable exchange, and we are already looking forward to welcoming them again in the future.
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World Savings Day – and what it has to do with dispensing technology
Saving is not only a matter of cost, but above all of efficiency. Those who deploy resources in a targeted and controlled manner increase productivity while simultaneously reducing material and process costs. For this reason, integrated process monitoring plays a central role in the development of new products at Walther Systemtechnik. Whether pump systems, valve control units or smart application valves, integrated monitoring functions create transparency regarding the current process status. Using pressure monitoring with the Walther ValveController WVC as an example, it becomes clear how relevant process parameters can be continuously recorded and evaluated. Users thus gain a reliable real-time overview of their fluid application process. Systematic process monitoring makes it possible to detect quality deviations at an early stage and correct them in a targeted manner. This reduces scrap and rework, directly contributing to cost savings. In addition, further benefits arise: Early detection of process faults to avoid unplanned downtime and increase system availability Process optimisation through more efficient use of media, energy and resources Data-driven decision-making that supports continuous improvement of process stability and quality Process monitoring is therefore a key element in increasing quality, efficiency and productivity in industrial manufacturing. At the same time, it helps to sustainably reduce costs and strengthen the long-term competitiveness of companies.
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A simple trick for challenging containers
As part of a recent project, we encountered a particular challenge: a subsequent delivery arrived in a container with a special design feature. Similar to a paint tin, the upper rim was fitted with an encircling collar that narrowed the opening. This made it more difficult to insert the follower plate of our conveying system into the container.In principle, the medium could be transferred into a suitable standard container in such cases. However, a far more efficient solution is to adapt the container itself. By cleanly cutting off the lid, the collar can be removed and the container can continue to be used without issue. A smooth, burr-free cutting edge is essential to ensure reliable operation of the follower plate.A surprisingly simple tool proves highly effective here: a standard household tin opener allows the lid to be cut evenly and cleanly along the rim. This enables the container to be prepared quickly and without additional tools for use in the conveying system.A small, practical tip that saves time and simplifies material handling when dealing with non-standard containers.
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Efficient drum emptying for greases and lubricants
For the reliable conveying of greases and highly viscous lubricants directly from the drum, Walther Systemtechnik offers high-performance pumping systems for process-reliable emptying of OEM containers. In addition to proven standard solutions, application-specific customised versions are also available, precisely tailored to the respective process requirements. One example is the integration of an air bubble elimination unit. With many viscous media, the reliable detection and removal of air inclusions is critical, as these can impair downstream components and negatively affect dispensing processes. The integrated air bubble elimination protects the overall system and ensures that subsequent processes run in a stable, reproducible and precise manner. Advantages of the integrated air bubble elimination: Continuous monitoring of the medium for air inclusions Automatic discharge of the affected portion of the medium Minimal media loss, as only the contaminated portion is removed Uninterrupted media release, even during venting and drum changeover In addition, the system enables the acquisition of production-relevant process parameters. This contributes to increased process capability and improved overall equipment effectiveness (OEE). If you would like to learn more about the conveying of viscous media, drum emptying systems or customised solutions, please feel free to contact us.
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Review of Motek
Motek has come to an end and we have begun the post-event follow-up. Below, we would like to share a few impressions from our trade fair appearance.We would like to sincerely thank all visitors for the strong interest, the many in-depth technical discussions and the consistently positive feedback. The personal exchange on dispensing and application solutions for industrial applications was particularly valuable to us.We are already looking forward to upcoming events, as professional dialogue and the ongoing development of innovative dispensing technology continue without interruption.
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The secret behind our bright shoes
A frequently asked question at Motek is: what is behind the bright shoes we wear at our exhibition stand?The answer lies in adhesive technology. Bonding processes play a central role in modern footwear manufacturing. They enable efficient production processes while at the same time offering a high degree of design flexibility.One key application is bonding the shoe upper to the sole, ensuring durability, functionality and mechanical strength. In addition, adhesives are used in interior assembly processes, for example when bonding linings, footbeds and cushioning elements. This ensures clean workmanship and makes a significant contribution to wearing comfort.Adhesives are also widely used for reinforcements, fastening elements such as eyelets, buckles or zips, as well as decorative components including metal applications, rhinestones or synthetic leather elements. In all of these applications, high demands are placed on dispensing accuracy and reproducibility.As a specialist in the dispensing and application of viscous media, we offer application-specific solutions for the precise application of a wide range of adhesives. Whether applied as areas, dots or lines – pulsed, sprayed or dispensed – our technologies ensure uniform, reproducible application in the required quantity.In this way, we support reliable and efficient manufacturing processes, for example in automated production lines within the footwear industry.
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Visit us at Motek – Stand 5413
Discover solutions at Motek for the dispensing and precise application of viscous media, enabling industrial processes to be designed with greater efficiency, reproducibility and process reliability. The focus is on modular dispensing systems for demanding application tasks in assembly and manufacturing processes. Our systems enable the precise application of adhesives, glues, silicones, polyurethanes, acrylates, epoxies and joint fillers. Thanks to their modular design, adhesive pumps, piston dispensers and outlet valves in various sizes and configurations can be flexibly combined. This results in application-specific solutions for 1K and 2K adhesive applications, precisely tailored to the respective process requirements. Take the opportunity for personal technical discussions and experience our dispensing and application technology live. Visit us in Hall 5, Stand 5413 – we look forward to welcoming you.
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Motek 2023: The doors are open
Motek 2023 has started, and our team is looking forward to engaging in professional discussions with you. Visit us in Hall 5, Stand 5413 at the Stuttgart exhibition centre. We are presenting proven solutions and current innovations for the feeding, conveying and precise application of liquid and viscous media. The focus is on dispensing and application technologies designed for reproducible process control, high efficiency and practical integration into industrial production environments. We would be pleased to discuss specific applications, requirements and optimisation opportunities for your dispensing and application processes. We look forward to your visit.
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All in one: Live on Motek with a small metal tin
Our small metal tins demonstrate, in a compact format, what modern valve and application technology can achieve. With a diameter of just under 4 cm, they serve as a clear demonstration object at Motek for typical application scenarios involving viscous media. In line with the “all in one” approach, we will demonstrate three key application methods live: the medium is pulsed, sprayed and dispensed directly into the tin – each process being reproducible and reliable. As a practical takeaway, visitors can take their tin with them afterwards. Register free of charge and visit us at Motek from 10 to 13 October. In Hall 5, Stand 5413, we will present manual and automated applications as well as components and systems for conveying, dispensing and the precise application of viscous media. We look forward to engaging in professional discussions on site.
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