Production line for Lisocore® lightweight material with maximum availability
Lightweight Solutions GmbH produces Lisocore®, a high‑tech lightweight material. WITTENSTEIN delivered engineering support, simulations and servo gearboxes to ensure flexible, reliable automated handling.
Engineering support and simulations for a new lightweight production line
With the Lisocore® production line, Lightweight Solutions GmbH and its subsidiary Iws maschinenbau GmbH entered completely new territory. The goal was an automated production line for up to two million square meters of Lisocore® per year with high availability and flexibility. WITTENSTEIN supported the project with comprehensive engineering support, including large‑scale simulations and detailed sizing calculations. Using SAM and cymex® 5, load and motion data of conveyor elements, gantry axes and lift units were simulated and optimized. This made it possible to adapt motor‑gearbox combinations precisely to the application and to size the gearboxes so that maximum motor load remains at 75 to 80 percent. The result is smooth operation, design reliability and sufficient reserves for future requirements such as thicker materials.
Servo gearboxes and sizing software for around 100 axes
The Lisocore® production line covers around 500 square meters and includes drilling, gluing, feeding and combining of cover layers with the three‑dimensional core. Around 100 axes are used, all equipped with servo gearboxes from WITTENSTEIN. Size 240 SPK+ right‑angle gearboxes with an integral output stage are used for lift arms due to their high performance and torsional rigidity. The Z axis of the board turner is equipped with power‑dense planetary gearboxes in the RP+ series, ensuring maximum positioning accuracy. In conveying and positioning modules, economical CP series gearboxes are used, while compact XP+ and TP+ gearboxes dominate in the flat press, gantry axes and rack‑and‑pinion systems. The entire drive train was designed using cymex® 5 with access to thousands of motor and gearbox variants.
Our products in use at Lightweight Solutions GmbH
SPK+
Used for the lift arms of the board turners, their high performance and torsional rigidity enable precise and dynamic handling of the cover layers.
RP+
Installed in the two actuators of the Z axis of the board turner, their highly rigid design ensures maximum positioning accuracy during lifting and positioning.
CP
Applied in conveying and positioning modules directly downstream of the double feeding station as an economical entry-level model for reliable material flow.
XP+
Predominantly used around the flat press and in gantry axes, these extremely compact and power dense gearboxes are partly designed as rack-and-pinion systems.
TP+
Implemented in gantry axes of the automatic drilling and gluing stations as well as the gantry palletizer, supporting compact and high-performance axis designs.
Rack and pinion systems
Integrated in selected axes of the production line, particularly in gantry applications, to support dynamic positioning tasks.
WITTENSTEIN has supported us in a manner with large-scale simulations and detailed sizing calculations.
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