Setting a course for the future

Wessel-Hydraulik GmbH, a company rich in tradition and with over 60 years’ experience in the development and production of hydraulic control technology, has consistently modernised its production processes in recent years. With 130 employees and an annual turnover of about 20 million euros, the company is one of the leading suppliers in the field of hydraulic control valves for mobile and stationary applications which require maximum precision and reliability. Wessel-Hydraulik fulfills these requirements with the support of machine tool manufacturer Grob-Werke.

Wessel-Hydraulik recently faced a number of challenges that made it necessary to modernise production, especially as its existing infrastructure had reached its limits, particularly in the area of five-axis machining. The goal was not only to enhance highly complex machining tasks, but also to increase efficiency through fewer clampings and greater automation. Roman Getz, production manager at Wessel-Hydraulik, said: “We were looking for a partner who could offer us the option of five-axis simultaneous machining and at the same time guarantee a high degree of automation. Grob convinced us right from the start tht they were the perfect partner.”

Another important concern was the replacement of outdated systems in order to remain technologically up-to-date and secure a clear competitive edge.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. Mr Getz added: “Competition is tough and we wanted to stay ahead in terms of technology.”

After intensive planning and an extensive selection process, the decision was made to invest in Grob machines. Uwe Dierks, head of the machining centres department at Wessel Hydraulik, said: “Grob was part of this project right from the start, and we developed many ideas during the planning phase, which the Grob team always implemented quickly and precisely.”

Pictured right: the robot cell from Grob in use at Wessel Hydraulik

The upgrade began with the integration of the first G550, a five-axis universal machining centre, combined with a PSS-L900 linear pallet storage system. This combination enables the flexible, automated production that meets the requirements of Wessel-Hydraulik.

In the next step, a GRC-R150 robot cell was installed which ensures fully automated loading of the machine and reduces the need for manual intervention. Ralph Birkle, project planning team leader at GRO, explained: “We combined pallet automation with robot automation in order to achieve the best utilisation in production.” Automation was then 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. Mr Dierks added: “We installed the machines step-by-step to ensure a smooth transition.”

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 extends the machine running times per clamping fixture and significantly increases efficiency.

Particularly impressive
Clamping towers with up to eight parts also ensure optimum utilisation 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. Mr Getz said: “This combination provides us with maximum flexibility. 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. Mr Dierks added: “This saves us an enormous amount of time and makes production even more flexible.”

The implementation of the Grob machines has led to noticeable improvements at Wessel-Hydraulik. Mr Getz explained: “Our throughput times for production orders have been significantly reduced, and we also benefit from faster tool management and better component accessibility.”

Pictured from left to right: Ralph Birkle, team leader project planning Grob-Werke; Uwe Dierks, head of the machining centres department Wessel Hydraulik; and Roman Getz, production manager Wessel-Hydraulik

Precise five-axis simultaneous machining also enables higher product quality. Mr Getz said: “Thanks to overhead machining, we can produce cleaner parts which gives us a clear advantage over the competition.”

Collaboration with Grob was characterised by trust and professionalism right from the start. Mr Dierks continued: “Every service call was handled quickly and competently. The technicians were very familiar with the systems and we always received support when we needed it.”

The long-term outlook is also promising as Wessel-Hydraulik plans to further expand its partnership with Grob. Mr Dierks aded: “Further projects are already being planned, depending on economic developments. The combination of innovative technology, reliable service and partnership-based cooperation makes Grob the ideal partner for us in the future.”

The modernisation at Wessel-Hydraulik shows how well planned solutions and close cooperation can yield outstanding results. Mr Getz concluded: “The planning and implementation with Grob was simply outstanding and together we have set the course for the future.”