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Please login with your user name and your password. Then open the calculation module. This module provides a geometry and a calculation part. The geometry part is the central point where the shaft geometry, the bearings, the loads as well as the notch effects are defined. The actual calculation then takes place in the calculation part. Various calculation possibilities such as bearing forces, deflection, strength or static torsion are available. Click on the ‘Calculate’ button to move between the geometry and calculation part.
The shaft geometry, the loads, the bearing forces and notch effects can be defined in the geometry part. There
are different input options and buttons for corrections in the upper section of this part. In the lower part you find
the coordinate system and the shaft symmetry axis. The data, that you can enter in the upper part of the
module, are represented graphically in the lower part. In addition, the graphical representation is interactive. It is
possible to select, shift, copy or delete the different elements. Use the button 3D view to move between 2D and
3D view.
When you start the calculation module, the shaft properties are displayed automatically in the geometry part. Use the ‘Shaft properties’ button to select the properties at any time you want.
Here you can select or define (during a user-defined input) material, speed as well as the direction of rotation and you can specify the position of the shaft in space. The speed is defined as revolutions per minute. Please note that if you change the speed of an already entered shaft, the torques will change because of the given power and speed. This happens, when a power instead of a torque is given for the force elements. Select the material by using the listbox for the material description or material number.
Click on the ‘Material selection’ button to get more information on the material.
If you choose the entry ‘User-defined’, you can modify the according data of the last selected material or you
can specify an individual material. Thus, materials that are not included in the data base can be
used.
Please note: It is important to consider that the integrated strength calculation according to DIN 743 is valid only for steels.
The coordinate system is a clockwise system where the Y-axis is the axis of symmetry as well as the axis of rotation of the shaft. In the two-dimensional view the Z-axis shows upwards and the X-axis shows out of the screen. A rotation of the shaft around the Y-axis is defined as a clockwise rotation. The left end of the shaft is the point of origin. The forces and torques have to be entered in positive direction without signs and in negative direction with a minus sign.
Please note: The direction of torques is usually defined by the input ‘driving’ and ‘driven’. The input ‘driving’
means that the shaft is driving and the torque counteracts the direction of rotation.
You get more information about the respective elements, for example about the absolute position. It is important that you have to differentiate between a relative position and an absolute position.
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There are segments for the outer contour and axial holes for the inner contour available. Click on the button ‘Segment’ to create a shaft segment.
The segment is represented and the input fields for length and diameter of the segment are displayed.
If you want to generate a conic segment, then activate the option ‘Conic segment’.
If this option is activated, enter a left diameter ‘1’ and a right diameter ‘2’ for the segment. To add another
segment, please click on the ‘Segment’ button again.
To create a hole (an inner contour), click on the button ‘Hole (axial)’. The different possibilities for a data input are now displayed.
In addition, you can extend the axial hole by clicking the button ‘Adjust to shaft length’.
This button adapts the length of the axial hole to the shaft length automatically. Then the entire inner contour goes exactly to the end of the outer contour.
Please note: For the strength calculation notch effects, such as shoulders, are not considered in the inner
contour. There is no applicable calculation method right now.
A calculation with any number of bearings is supported by the shaft module. So an overdefined calculation with more than two bearings is also supported by the shaft module. Select a shaft segment to position the bearing on the shaft, then click on the button ‘Bearing’.
Now the bearing is added.
To define the bearing, different options for an input are available: position, width, diameter, stiffness, and pressure angle. Further you can define the kind of bearing arrangement: fixed bearing, unfixed bearing, axial bearing or swimming bearing.
Please note that the position refers to respective shaft segment, that means a relative position has to be
entered. The absolute position, related to the point of origin and with it related to the left end of the shaft,
is indicated with the element info (see section 5.2.3 ‘Relative and absolute position’). The width
is the overall width of the bearing and the diameter is the outer diameter of the bearing for the
correct representation. For bearings with a pressure angle the changed point of application of load
can be considered for the calculation of the support reactions. In case the (radial) stiffness of the
bearing is known, the stiffness can be considered by appropriate settings for the calculation as
well.
Please note: Bearings cannot be positioned over a shaft segment.
The shaft module offers different possibilities to define loads. Besides a direct input of forces and torques in coordinate direction, so-called intelligent elements for application of load can be positioned on the shaft. Click on the ‘Force elements’ button and you can select spur gear, bevel gear, coupling/motor and load.
At first select the shaft segment on which you want to create the spur gear. Click on the button ‘Force elements’.
A new menu is opened.
Select the menu item ‘Spur gear’.
A spur gear is added.
For the positioning of the shaft, the relative position of the left shaft side is given. Based on further inputs for pitch circle, helix angle, pressure angle, position of action and power/torque, the calculation of forces, that influence the shaft, is determined.
In particular the input of power of action is important for the point of application of load. The power of action indicates the position of the point of the interference with the gear pair.
For spur gears with a profile shift, reference circle and pitch circle are not equal. When you enter the reference
circle with the definition of the spur gear, so the calculated forces are not completely accurate - in particular with
very large addendum modifications. For an exact calculation of the forces, you have to enter the pitch circle
diameter instead of the reference diameter and instead of the pressure angle you have to enter the working
transverse pressure angle.
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You can switch between the input for the power and for the torque by using the ‘T/P’ button.
When you click on the button ‘T/P’, you can enter either the torque or the power or you can let the values convert. Then the description is changed accordingly in torque or power.
Here you can define a multiple position of action, that means that the spur gear, which is on the shaft, is in mesh
with several spur gears.
1. Set a checkmark into the field next to ‘Use multiple position of action’.
The button ‘Multiple position of action’ is activated.
2. Click on the button ‘Multiple position of action’.
A new window is opened.
Select the number of position of action from the listbox.
Further you can indicate either the ‘Power’ or the ‘Torque’. Select power or torque.
3. Confirm your inputs with the button ‘Ok’.
If two external helical cylindrical gears are in mesh, both toothing have the same, but opposite direction of the
helix angle 
. The direction of the helix angle has to be opposite that a left-hand mates a right-hand.
Therefore, you have to differentiate between right-handed helix angle and left-handed helix angle. Please
specify here right or left-hand helix angle.
A driving gear and a driven gear always co-operate and form a gear pair. For the most force elements the direction of torques is specified by the input of driving and driven. The input ‘driving’ means that the shaft drives or that the moment counteracts the direction of rotation. Define here the driving and driven spur gear. You can also define it with the ‘Multiple position of action’.
To add a bevel gear, please mark the shaft segment onto which you want to generate the bevel gear. Then click on the button ‘Force elements’. Select the menu item ‘Bevel gear’.
When you add a bevel gear, additionally inputs are available, for example an input for a bevel angle or for the direction of the bevel angle.
The force element ‘Coupling / Motor’ allows the input and output of torques. Just like the spur and bevel gears you can enter a mass additionally. The positioning occurs relative to the selected shaft segment. The position refers to the left side of the force element. First select a shaft segment to position the force element.
The general force element ‘Load’ can be positioned freely on the shaft independently from a selected shaft segment. Click on the button ‘Force elements’ and select the menu item ‘Load’.
The specification of the position occurs absolutely to the point of origin (left shaft end) and refers, like the other elements, to the left side of the element. (see section 5.2.3 ‘Relative and absolute position’). The element can be defined as a concentrated load (width = 0) or as a stretch load. This general force element offers the possibility to specify lateral forces in X and Z-direction, a axial forces as well as bending moments around the X and Z-axis as a load. Further you can define the power or the torque as driving and driven. The meaning of driven and driving applies here similarly to the other force elements. Find more information in the section 5.2.6 ‘Driving and driven gear’.
The button ‘Extra mass’ allows you to add a several mass.
Please enter here position, width, and mass. An extra mass can be defined as a concentrated load or as a
stretch load.
For the strength calculation according to DIN 743 the definition of the notch effects is necessary. In case you have calculated the equivalent stress before, then it is not necessary to enter all noth effects. Based on the tension peaks, which appear in the process of the equivalent stress, the critical cross-sections can be identified very easily and the notch factors can be defined only for these cross-sections. All defined types of notch effect according to DIN 743 are available.
The notch factors defined in DIN 743 apply for full and hollow shafts with wall thickness where no interference of the notch by the hole is existing. For rotating notches the condition is used, according to DIN 743-2 (field of application),
for orientation (q.v. DIN 743-1, appendix A).
To accomplish a strength calculation also at a strong loaded smooth shaft segment, the special notch effect ‘smooth shaft’ was brought into the calculation. For this type the notch factor is set to ‘1’. The notch factor elements can be positioned on the entire shaft independently of a shaft segment. The position can be entered absolute to the point of origin (to the left shaft end).
With it notch effects at shaft sections can be defined very fast and comfortably. The notch effect is added via the button ‘Notch effect’ and can be placed on the shaft. You can enter the exact position directly into the input field ‘Position’, with the arrow keys you can move the notch effect to a shaft section. With the left mouse button you are able to place the notch effect freely on the shaft. The following notch types are available:
The button ‘Set load and notch factors manually (optional)’ allows you to enter notch factors manually (in addition to the automatic calculation of the notch factors). Here the possibility exits to use experimentally calculated notch factors.
For the calculational consideration of notch effects, which overlap each other (two notches with notch
factors 
and 
), the notch factors can be estimated according to Niemann ‘Maschinenelemente’
volume 1, page 134, equation 3.115 (3. edition) as follows:
The notch factors according to DIN 743 are not suited for notch effects at the inner contour. That means that notch effects of a inner contour are not considered for the proof of strength according to DIN 743.
With your left mouse button elements, for example a shaft segment or a force element, can be selected. By
selecting an element the color changes and it is easier to recognize.
Please note: It is also possible to select individual elements by using the keyboard. If you would like to
change, for example from the value input of shaft segments to the selection mode, you have to
press the ‘Page-down’ key. Afterwards the two arrow keys enable you to move the elements to the
left or to the right side. To move from the shaft segments to the axial hole, please use the cursor
keys ‘Up’ and ‘Down’. By using the ‘Page-up’ key you can change to the value input of a selected
element.
If an element is selected, then different input possibilities for the respective element appear on the top of the calculation module. The element can be placed on the shaft segment via the input field ‘Position’. For positioning an element a further possibility exists. Click on an element, keep the left button pushed and pull the mouse. The arrow keys below the element info allows you to move to the next segment.
Other elements on the shaft, can be jumped over. If a shaft segment is selected, then the segment can be
shifted via the arrow key including the elements sitting on the segment. Thus, you can re-sort shaft segments
comfortable.
Via these two buttons you can copy and add several segments, bearings, or force elements. If you copy an element, all inputs will be confirmed and you do not have to redefine the element again.
Select an existing bearing which you would like to copy.
Click on the button ‘Copy’.
Select the shaft segment, on which you would like to place the bearing.
Click on the button ‘Add’.
The previously copied bearing is added.
Please note: When you click the right mouse-button, a context menu is opend. Select the menu items ‘Copy’
and ‘Add’.
When you copy a shaft segment, then select the appropriate segment in the graphical representation. Click
on the button ‘Copy’. Select the shaft segment. Behind that shaft segment the new segment is
added.
Click on a segment or an element and click the right mouse-button. A context menu is opened and you can choose the menu item ‘Cut out’.
Via this button you can delete individual elements. Before you delete an element, please select the element and then click on the button ‘Delete’.
When you click on this button, then you can delete the entire shaft geometry.
Via this button you can display the three-dimensional representation.
The function 2D / 3D view is available in the geometry part as well as in the calculation part. In the calculation
part for example the deflection of the shaft can be displayed three-dimensional. In addition the respective plane
is drawn in. Several elements, for example a spur gear, can be selected by a mouse-click and can be modified
and positioned again via the input fields. When you click on the button ‘2D / 3D view’ again, you will get the
two-dimensional representation.
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Get here an overview of the several views which are available:
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The calculation module contains a message window. Here you will get all information, warnings and hints. You will find all information, which is displayed in the message window, in the calculation report later. The calculation report can be generated via the button ‘Report’.
Please move the mouse pointer to an input field or to a button, then you will get some additional information. This information is displayed in the quick info line.
After defining of the shaft geometry, bearings, loads, and notch effects, you can start your calculation. Click on the button ‘Calculate’ and you get to the calculation part. In addition to the calculation of the bearing forces and the static torsion, the serveral diagrams of forces, moments, deflection, bending angle, and the equivalent stress will be displayed.
Please note: After clicking on the button ‘Calculate’, the button changes the description into ‘Geometry’. In the calculation part you can accomplish your calculation, but you cannot change the geometry of the shaft. To change the geometry, please go back to the geometry part. For that click on the button ‘Geometry’. The button changes again from ‘Geometry’ into ‘Calculate’:
Go from the geometry part to the calculation part and finally complete your calculation.
The following possibilities for the calculation are available:
Here you can call up the different force/torque diagrams for the selected plane.
With a mouse-click all values for the deflection can be queried directly out of the graphical representation. The values appear in the text field. You can change between the 3D and 2D view in the graphical representation.
Please note: In the calculation part it is possible to compare the different deflections by a changed geometry on
the basis of the representation. Change a value in the geometry part and click on the button ‘Calculate’. Click on
the buttons ‘Redo’ and ‘Undo’ in the calculation part. Now the results are comparable. By clicking on the button
‘Geometry’, you can return to the geometry part. There the button ‘Undo’ enables you to reset your
changes.
The complete strength calculation according to DIN 743 for static and fatigue proof of strength is accomplished automatically.
The exact values of the safety are displayed in a text field and can be called by a mouse click into the graphical representation.
You get all detailed results in the calculation report. Additionally all results for the several cross-sections are represented in three different colors.
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Please note: The button ‘Options’ enables you to define the stress condition as well as the mechanical kind of
material treatment (see section 5.12 ‘The button Options’).
Please note: Please change the default settings through the button ‘Options’ in regard to the calculation of the
critical speeds (see section 5.12 ‘The button Options’).
Finally generate a calculation report. Click on the button ‘Report’.
First the report configuration appears. In the report configurator the several diagrams and the result of the strength calculation are selectable.
During the generation of the report, a waiting screen appears. But you can continue to work with the calculation
module. The length of time for the generation of the report depends on the number of diagrams which have to be
generated.
You can navigate through the report via the table of contents that provides links to the input values, results and figures. All input data as well results are listed. The report is available in HTML and PDF format. Calculation reports, saved in HTML, can be opened in a web browser or in Word for Windows.
‘Save as’ from your browser menu
bar. Select the file type ‘Webpage complete’, then just click on the button ‘Save’.
In HTML the figures are displayed in ‘gif’ format. In case a SVG viewer is available, you can display all graphics in SVG format. Right-click on the picture, then you can zoom in and zoom out.
After the completion of your calculation, you can save the calculation. There you have the possibility to save either on the eAssistant server or on your own workstation. Click on the button ‘Save’. Please find more information in the chapter ‘The general functions’ 4.2.
If you have activated the option ‘Enable file save local’ in the Project Manager and the option ‘Local’ in the calculation module, a standard Windows dialog for saving the file on your workstation appears.
Please note: You should not forget that the calculation module has to be closed to activate the option ‘Enable file save local’.
In case you have not activated this option, a new window is opened and you can save the calculation on the eAssistant server.
Please enter a name into the input field ‘Filename’ and click on the button ‘Save’. Then click on
the button ‘Refresh’ in the Project Manager. Your saved calculation file is displayed in the window
‘Files’.
The button ‘Undo’ allows you to reset your input to an older state. The button ‘Redo’ reverses the undo.
In the top menu bar of the calculation module you will find the button ‘CAD’.
The eAssistant plugin for various CAD systems (e.g., SolidWorks, Solid Edge, Autodesk Inventor and Catia)
enables you to combine calculation and design very easily and intelligently. Based on your calculation, solid and
hollow shafts with an unlimited number of cylindrical and conical elements can be generated via the button
‘CAD’ very fast and easily.
You can generate shafts as a 3D part within just seconds. However, first you have to download and install the
CAD plugin. You can find the plugin on our web site www.eAssistant.de. After installation, an integrated button
called ‘eAssistant’ appears in the CAD system. Accomplish the calculation using the eAssistant and click on the
button ‘CAD 
SolidKiss_nG Interface’. The values are transferred to the CAD system where you can
generate the 3D models through a menu.
Please note: In case you need further information about our 3D CAD plugin (SolidKiss_nG), feel free to contact us. Get also details on our web site www.eAssistant.de or read the CAD plugin (SolidKiss_nG) manual.
The button ‘Options’ allows you to change the settings for your calculation.
A new window is opened.
Here you find different standard settings, for example the minimum dynamic, and static safety, or the settings for
the calculation of critical speeds.
In case you need some help, then click on the button ‘Help’.
You will get directly to the help section of this calculation module.
The following example is to support you with a very fast start into the shaft calculation module with its
numerous possibilities. This example shows a shaft with a fixed and movable bearing and an extra
mass.
Please login with your user name and your password. Select the module through the tree structure of the Project Manager by double-clicking on the module or clicking on the button ‘New calculation’.
The calculation module is opened in a new window.
1. Click on the button ‘Segment’.
2. Enter a length of ‘50 mm’ and a diameter of ‘20 mm’ into the input fields.
Please note: If you right-click into the input field, then you can change the unit of measurement very
easily.
The first segment is represented.
1. Click on the button ‘Segment’.
2. Enter a length of ‘400 mm’ and a diameter of ‘50 mm’ into the input fields.
This segment is represented.
The button ‘Segment’ allows you to add a third shaft segment. But you can also copy and add a segment. The
next step is to create a third segment by using the buttons ‘Copy’ and ‘Add’.
1. Click on the segment that you would like to copy.
2. Click on the button ‘Copy’.
Please note: If you right-click, you can also copy and add a segment. Then a new context menu is opened and
you can select the ‘Copy’ and ‘Add’ options.
3. Select the second segment and place next to this segment the third one.
4. Click on the button ‘Add’.
The copied segment is added as a third shaft segment.
1. Click on the button ‘Hole (axial)’.
2. Enter a length of ‘70 mm’ and a diameter of ‘0 mm’ into the input fields.
1. Click on the button ‘Hole (axial)’.
2. Enter a length of ‘360 mm’ and a diameter of ‘40 mm’ into the input fields.
The hollow shaft is represented.
Please note: A selection of elements directly in the representation by using the keyboard is also possible. If you
would like to change from the value input of shaft segments to the selection mode, you have to press
the ‘Page down’ key. Afterwards the two arrow keys enable you to move the elements to the left
or to the right side. To move from the shaft segments to the axial holes, please use the cursor
keys ‘Up’ and ‘Down’. By using the ‘Page-up’ key you can change to the value input of a selected
element.
1. Select the shaft segment from the representation, onto which the bearing is to be positioned.
2. Click on the button ‘Bearing’.
A bearing is added.
3. Then define the bearing with position, width, diameter and the kind of bearing arrangement. In this case please choose ‘fixed bearing’ from the listbox.
1. Select the existing bearing from the representation.
2. Click on the button ‘Copy’.
Please note: If you right-click, a new context menu is opened. In this context menu you will find the two options
‘Copy’ and ‘Add’.
3. Select the last shaft segment.
4. Click on the button ‘Add’.
The second bearing is added.
5. Because the bearing was copied, it is already defined with position, width and diameter. Define only the kind of bearing arrangement. Please select ‘Movable bearing’ from the listbox.
1. Select a shaft segment, where the load element is to be placed.
2. Click on the button ‘Extra mass’.
The extra mass is positioned on the shaft segment.
3. Please define the extra mass with the entries for position ‘50 mm’, width ‘300 mm’ and mass ‘1350 kg’.
1. Click on the button ‘Notch effect’.
A notch effect is added and can be placed on the shaft.
2. Select the kind of notch effects from the listbox.
3. Define the following notch effects:
(roughness 
= 5 mm and radius 
= 10 mm)
After defining the shaft geometry, bearings, loads and notch effects, the calculation can be accomplished by using the button ‘Calculate’.
Now you reach the calculation part.
Please note: After clicking on the button ‘Calculate’, this button changes from ‘Calculate’ into ‘Geometry’. Thus you can switch to the geometry part again.
In the calculation part you can accomplish your calculation, but you cannot change the geometry of the shaft. To change the geometry, please go back to the geometry part again by using the button ‘Geometry’.
Here you can accomplish the different calculations.
Here you find the different interactive diagrams of forces and moments.
You can select all values for deflection directly from the representation by a simple mouse-click. The values appear in the text field.
Click on the button ‘Strength’ in the calculation part.
The complete strength calculation according to DIN 743 for static and fatigue proof of strength is accomplished automatically.
The most important results are displayed in the text field. The calculation report gives you detailed intermediate results.
Additionally all results for the several cross-sections are represented in three different colors.
Finally you can generate a calculation report. Click on the button ‘Report’.
The report configuration allows you to select different diagrams and results which will appear later in your calculation report.
During the generation of the report, a waiting screen appears.
But you can continue the work into the shaft module. The length of time, for the generation of the report, depends on the number of diagrams that have to be generated.
The report includes a table of contents. Through this all results can be called very fast. All input data and results are listed. You can print the report or you can save the report in a HTML format. Later you can open the generated report in a web browser or open it in Microsoft Word.
The report is available in a HTML format or in a PDF format.
‘Save as’ from your brower menu
bar. Select the file type ‘Webpage complete’, then just click on the button ‘Save’.
In HTML all graphics are displayed in the GIF format. In case a SVG viewer is available, you can display all graphics in the SVG format. Right-click on the picture, then you can zoom in and zoom out.
After accomplishment of your calculation, you can save the calculation. There you have the possibility to save either on the eAssistant server or on your own workstation locally. Click on the button ‘Save’.
If you have activated the option ‘Enable file save local’ in the Project Manager and the option ‘Local’ in the
calculation module, a standard Windows dialog for saving the file on your workstation appears.
Please note: You must not forget that the calculation module has to be closed to activate the option ‘Enable file save local’.
In case this option is not activated, a new window is opened and you can save the calculation on the eAssistant server.
Please enter a name into the input field ‘Filename’ and click on the button ‘Save’. Then click on the button ‘Refresh’ in the Project Manager. Your saved calculation file is displayed in the window ‘Files’.
Here you find another example that shows how easy it is to create a shaft.
Create three shaft segments. Please enter the following input values:
| 1. shaft segment: | length  = 100 mm | diameter  = 30 mm
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| 2. shaft segment: | length  = 40 mm | diameter  = 45 mm |
| 3. shaft segment: | length  = 100 mm | diameter  = 30 mm |
Now you have created the shaft segments.
Then add the second bearing. Please enter the following input values:
| 1. bearing: | position = 10 mm | width  = 15 mm | diameter  = 60 mm | fixed bearing |
| 2. bearing: | position = 80 mm | width  = 15 mm | diameter  = 60 mm | movable bearing |
The second bearing is added.
Create the first spur gear. Select the first shaft segment. Click on the button ‘Force elements’.
A context menu is opened. Select the force element ‘Spur gear’
A spur gear is added.
Define the first spur gear via the input mask.
Input values for the first spur gear:
| Position = 60 mm |
Width  = 40 mm |
Reference circle  = 180 mm |
Helix angle  = 25∘ |
Pressure angle  = 20∘ |
| Position of action = 90∘ |
Torque  = 320 Nm |
Mass  = 0.0 kg |
After you have defined the spur gear, the element will be represented.
To create the second spur gear, select the third shaft segment and click on the button ‘Force elements’ and add the second spur gear. Please enter the following values into the input mask.
Input values for the second spur gear:
| Position = 0 mm |
Width  = 40 mm |
Reference circle  = 80 mm |
Helix angle  = 25∘ |
Pressure angle  = 20∘ |
| Power of action = 270∘ |
Torque  = 320 Nm |
Mass  = 0.0 kg |
Both spur gears will be represented.
Then you can display the shaft in different views. Click on the button ‘3D view’ and select the different views from the toolbar and zoom into the graphic. Click on the button ‘Calculate’ and switch from the geometry part into the calculation part. There you can accomplish the calculations (find detail information in the section ‘How to start the calculation’).The button ‘Report’ allows you to generate a report.
When you click on the button ‘3D view’, you will get a three-dimensional representation. Here you can select, modify or position the elements by using the mouse.
Our manual is improved continually. Of course we are always interested in your opinion, so we would like to know what you think. We appreciate your feedback and we are looking for ideas, suggestions or criticism. If you have anything to say or if you have any questions, please let us know via telephone +49 (0) 531 129 399-0 or email eAssistant@gwj.de.
