Health Index for Drive Systems – cynapse® by WITTENSTEIN

Welcome to the Industrial Internet of Things (IIoT): With cynapse^® and smart services, you can achieve maximum transparency in your machine and your smart factory. Connect physical and digital components, analyze operating data in real time, and increase the efficiency of your processes—easily, securely, and without any programming effort.

cynapse^® – the smart feature for gearboxes:

Space-saving sensor solution for measuring temperature, vibration, and operating time
IO-Link interface for easy integration into existing systems
Digital name plate for quick product identification
Data logger throughout the entire life cycle for greater transparency

Smart Services – the perfect extension:
Smart Services expand cynapse® with digital functions for greater transparency in the drive train, fewer unplanned downtimes, and a longer service life for your products.

Data integration and visualization: Operating data is recorded in a structured manner and presented clearly
Data analysis: Critical changes are detected at an early stage, allowing you to take targeted action before failures occur
Targeted recommendations for action: Based on our decades of experience in drive technology, you will receive notes on maintenance requirements and optimization.

Your advantages with cynapse^® & Smart Services

Plug & Play

cynapse^® and Smart Services can be integrated without any programming effort. This saves time, reduces costs, and makes it easier to get started with Industry 4.0.

Utilization radar

Full transparency: The utilization radar detects overloads in real time. This allows you to optimize sizing, increase efficiency, and avoid costly damage.

Process monitoring

Processes remain stable through temperature and vibration monitoring. Real-time data enables proactive measures and prevents problems.

With cynapse^® and Smart Services, you can monitor processes, detect critical conditions early on, and use utilization data to maximize plant availability.

See how a mechanical gearbox becomes an IIoT-enabled data source. The video shows how cynapse^® collects operating data and makes it available via IO-Link, ensuring maximum transparency and efficiency.

cynapse – It's new. It's connective. The smart gearbox.

From theory to practice: cynapse^® in action

Schreyer Sondermaschinen

Schreyer Sondermaschinen boosts the performance and uptime of its packaging systems with advanced drive technology and intelligent condition monitoring – powered by WITTENSTEIN’s integrated solutions.

Koch Pac

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With cynapse^® in our K4.0 smartpacks, we can make the component manufacturer’s know-how available to our end customers as added value

Simon Brehmer, Head of Technology & Digitalization KOCH Pac-Systeme GmbH

Select the appropriate option for your application for easy integration and maximum impact:

Internal memory

With a 24V power supply, cynapse^® stores operating data directly in the gearbox, including minimum and maximum values as well as histograms. Ideal for subsequent analysis and tracking throughout the entire life cycle.

PLC integration

Live and process data as well as IO-Link events from cynapse^® can be seamlessly integrated into the control system. This enables advanced real-time analysis while local data storage remains active.

IPC / Gateway / Cloud

Integration into higher-level systems expands the range of functions for comprehensive evaluations and use of smart services. Real-time data and IO-Link events are available for detailed analysis and combine the data with our expertise in intelligent drive solutions.

This is how cynapse^® adds value to your machine

cynapse^® turns your gearbox into an intelligent data source. With Smart Services, this data can be used directly:

cynapse^® Connect transfers data to your systems in a structured manner without any programming effort
cynapse^® Monitor visualizes values and alarms and helps to set threshold values
cynapse^® Analyze detects anomalies and evaluates the current gearbox status with a health index and utilization radar

This gives you transparency over your drive trains and reduces unplanned stops to a minimum.

The data flow is standardized: Gearbox with cynapse^® → IO‑Link → IO‑Link master → PLC or IPC with Smart Services. This allows you to seamlessly integrate temperature, vibration, and operating data into PLC, HMI, MES, or cloud. Container-enabled Smart Services such as cynapse^® Connect, Monitor, and Analyze run locally on your IPC/edge system without depending on internet connections. For analyses of the current load on the gearbox with the Health Index, speed and torque via OPC UA are also important information.

The Health Index in cynapse^® Analyze evaluates the actual gearbox condition with an intuitive traffic light system. The utilization radar shows in real time how close the gearbox is operating to its permissible load limits. This allows overload situations to be identified, wear to be assessed in advance, and unplanned downtime to be avoided. At the same time, maintenance can be planned in a targeted manner and the service life of components can be extended.

With our starter kit, you can experience cynapse^® & Smart Services without any setup stress. IO‑Link master, IPC, cabling, and software are preconfigured. Whether as a proof of concept, for training, or as a pilot installation, you can start in the digital world quickly, reliably, and without risk. Do you have a ctrlX OS‑enabled device? Our Smart Services are available directly in the store and greatly simplify the infrastructure!

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The future of manufacturing is digital, networked, and efficient. With cynapse^® and the smart services from WITTENSTEIN alpha, your gearbox becomes an intelligent data supplier. Condition data such as temperature, vibration, and load are recorded directly in the drive train and made available in real time – the basis for predictive maintenance, process monitoring, and maximum plant availability.
cynapse^® Analyze - Health Index analyzes the actual load on your gearbox and detects critical conditions at an early stage. This helps you avoid unplanned downtime and reduce service costs. The utilization radar clearly shows overloads and helps to identify efficiency potential and optimize the sizing.

Integration is flexible and easy:

Internal memory for historic data over the entire life cycle
PLC integration for live and process data directly into your control system
IPC / gateway / cloud for comprehensive analyses and the use of smart services – combined with our expertise in intelligent drive solutions and Industry 4.0.
With cynapse® and smart services with cynapse, you are ready for the digital transformation: plug & play integration, real-time data, utilization analyses, and process monitoring – all from a single source.

cynapse^® & smart services