Wikov Gear Ltd Upgrades Production with Advanced CNC Grinding Machine

Wikov Gear Ltd, a renowned Czech manufacturer of high-quality gears and gear wheels, has made a significant investment to boost its production capacity for the railway sector. The company has recently acquired a Studer S41 CNC universal cylindrical grinding machine, enhancing its production speed by up to 60%.

In Hronov, the company’s factory features the Wikov Museum, which showcases polished engineering legends, including the striking red Wikov 7/28 racing car. Each classic car proudly displays the iconic Wikov logo featuring a hammer-carrying worker, highlighting the company’s esteemed reputation as the “Czech Rolls-Royce.” Founded in 1918 as ‘Wichterle & Kovářík,’ the company initially focused on agricultural machinery, becoming the largest manufacturer in that field in the Czech Republic.

Today, as part of the Wikov Group alongside other prestigious Czech brands, the company employs over 1,000 individuals across multiple sites. The Hronov factory primarily manufactures gearboxes for the railway industry and is the largest production facility within the Group, employing around 400 staff.

Precision and Efficiency with the S41

Jaromir Hornych, an operator of the new Studer S41, recently machined a pinion gear for a railway shaft. He remarked, “The precision and surface finish are exceptional, achieved in remarkably short machining times.”

The S41’s innovative C.O.R.E. hardware and software architecture ensures modern, user-friendly operation. Efficiency, precision, flexibility, and long-term viability through proven quality were crucial factors in Wikov’s choice of the S41. Dominik Sádlo, head of technology at Wikov, stated, “With the S41, we can significantly speed up the grinding process—sometimes by over 60% per component. Many machining tasks can now be completed in a single setup.”

With a center distance of 1,000/1,600mm and a maximum workpiece weight of 250kg, the S41 ranks among the largest machines in the Studer portfolio. However, Wikov employs it for smaller gearbox components. Mr. Sádlo explained, “Our order volume has increased significantly, so we needed a more flexible and productive grinding solution for smaller components in large quantities. The S41 was the best choice due to its flexibility and quick setup times.”

Advancements in Grinding Technology

The advantages of the S41 are the result of Studer’s extensive expertise. Like Wikov, the Swiss manufacturer has evolved over its 111-year history while maintaining traditional values. Many components of the S41 are developed and optimized in-house, including the wear-resistant StuderGuide system and the Granitan mineral cast machine bed.

Studer is a leader in grinding innovation, offering technologies for more efficient production. The S41 features SmartJet cooling, which can reduce energy and water consumption by up to 50%, and the WireDress process for economical dressing of grinding wheels.

Automation is a key focus for Studer. Mr. Sádlo noted, “Automation capability is increasingly important as we face a shortage of skilled workers. Intelligent automation is essential for maintaining production levels without compromising quality.” Studer’s easyLoad system provides a cost-effective automation solution, allowing for easy handling of components without requiring robot programming expertise.

Commitment to Customer Support

Pavel Branda, Studer area sales manager for the Czech Republic, Slovakia, and Hungary, emphasized the importance of personalized support. He provided expert guidance during Wikov’s purchase of the S41 and continues to assist them. “The ability to communicate in the local language is a significant advantage during technology implementation,” he noted.

Mr. Sádlo highlighted that Studer’s knowledgeable team helped them optimize the S41 for their specific needs, stating, “Cylindrical grinding at Wikov has reached a new level.”

Training was a vital part of the process, with Mr. Hornych traveling to Studer’s training center in Thun, Switzerland, followed by further training at Wikov’s facility.

Mr. Sádlo concluded, “We were impressed by how quickly our team learned to operate the S41 and achieve high-quality results. The S41 and our collaboration with Studer have elevated our production capabilities significantly, contributing to our ongoing success.”