The challenge: Venturing into the future
Before the project began, Wessel-Hydraulik faced a number of challenges that made it necessary to modernize production. The existing infrastructure had reached its limits, particularly in the area of 5-axis machining. The goal was not only to enable these highly complex machining tasks, but also to increase efficiency through fewer clampings and greater automation. Roman Getz, Production Manager at Wessel-Hydraulik, emphasizes: "We were looking for a partner who could offer us the option of 5-axis simultaneous machining and at the same time guarantee a high degree of automation. GROB convinced us right from the start."
Another important concern was the replacement of outdated systems in order to remain technologically up to date and secure a clear competitive edge. The challenge was to process heavy parts safely and efficiently while retaining flexibility. Furthermore, both small and large lot sizes were to be manufactured economically. "Competition is tough and we wanted to stay ahead in terms of technology," Roman Getz explains.
The path to the optimum solution: Gradual integration of GROB machines
After intensive planning and an extensive selection process, the decision was made in favor of GROB. The careful preparation, the well thought-out concepts, and the fast response time of the GROB team were particularly convincing. "The collaboration was excellent right from the start," recalls Uwe Dierks, Head of the Machining Centers Department at Wessel Hydraulik. "GROB was part of the project right from the get-go, and we developed many ideas during the planning phase, which the team always implemented quickly and precisely."
The project began with the integration of the first G550, a 5-axis universal machining center, combined with the linear pallet storage system PSS-L900. This combination enables flexible, automated production that meets the requirements of Wessel-Hydraulik.
In the next step, the robot cell GRC-R150 was implemented. This cell ensures fully automated loading of the machine and thus reduces the need for manual intervention. "We combined pallet automation with robot automation in order to achieve the best utilization in production," explains Ralph Birkle, Project Planning Team Leader at GROB. Automation was successively expanded: The first G550 was followed by two more machines of the same type, each equipped with an additional tool magazine to further increase production capacity. "We installed the machines step by step and were thus able to ensure a smooth transition," explains Uwe Dierks.
Technical highlights and special solutions for maximum flexibility
A central element of the new production solution are the nine clamping pyramids, each with three long-stroke clamps of the SMW type SLX Digit 125-325. This special configuration enables multiple clamping, which significantly extends the machine running times per clamping fixture. "Multiple clamping enables us to achieve long running times, which increases efficiency enormously," explains Roman Getz.
Clamping towers with up to eight parts also ensure optimum utilization of the machine capacity. The combination of manual loading via the linear pallet storage system PSS-L900 and fully automated loading by the robot cell GRC-R150 is particularly impressive. "This combination provides us with maximum flexibility," emphasizes Roman Getz. "We can process both small series and large production quantities efficiently."
Another highlight is the robot cell's gripper, which is equipped with automatic gripper finger adjustment. This means that different components can be processed without the need to manually change the gripper fingers. "This saves us an enormous amount of time and makes production even more flexible," adds Uwe Dierks.
The result: Significant increase in efficiency and higher quality
The implementation of GROB machines has led to noticeable improvements at Wessel-Hydraulik. "Our throughput times for production orders have been significantly reduced," reports Roman Getz. "We also benefit from faster tool management and better component accessibility."
Precise 5-axis simultaneous machining also enables higher product quality. "Thanks to overhead machining, we can produce cleaner parts," explains Roman Getz proudly. "This gives us a clear advantage over the competition."
Partnership and support: A success story
Collaboration with GROB was characterized by trust and professionalism right from the start. "Every service call was handled quickly and competently," says Uwe Dierks, praising the GROB team. "The technicians were very familiar with the systems and we always received support when we needed it."
The long-term outlook is also good: Wessel-Hydraulik plans to further expand its partnership with GROB. "Further projects are already being planned, depending on economic developments," explains Uwe Dierks. "We would recommend GROB at any time. The combination of innovative technology, reliable service and partnership-based cooperation makes GROB an ideal partner for our future."
Conclusion: A joint path into the future
The modernization at Wessel-Hydraulik shows how well thought-out solutions and close cooperation can yield outstanding results. "The planning and implementation with GROB was simply outstanding," summarizes Roman Getz. "Together we have set the course for the future."
