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Approximately 1,500
different components
made of a wide
variety of materials
and with a variety of
thicknesses that are
used for security
vehicles are
manufactured in
Georgsmarienhütte.
New grinding technology ensures quality and efficiency in the production of special protection modules for security vehicles
Efficiency in production and quality are important parameters in sheet metal processing.
That also includes, in particular, removing burrs from laser-cut parts before further
processing or installation. In light of this, one manufacturer of security vehicles has
invested in new, customised system technology.
Text: Annedore Bose-Munde
At Farmingtons Automotive GmbH in Georgsmarienhütte, special protection solutions
are manufactured for the automotive industry. For more than 40 years, the WELP Group,
to which the company belongs, has acted as a specialist for the supply of safety
productions to UN organisations (NGOs), authorities, VIPs, police, courts, banks and
safety service providers throughout the world. The requirements and standards applied to
the production and processing technology used for the components are accordingly high.
Now the company has invested in a deburring brush line from LISSMAC Maschinenbau
GmbH in Bad Wurznach.
Achieve higher quality and faster processes
“Due to the WELP Group’s new strategy alignment, it was also necessary to focus more
on process efficiency and thus, process capacities, at the Georgsmarienhütte site.
Another item is the increased alignment toward the OEM target group and the related
quality requirements,” says Torsten Rieger, CEO of Farmingtons Automotive GmbH. For
this reason, various challenges had to be overcome. For instance, with respect to
corrosion protection, the coating quality should be increased to achieve further cost
efficiency through faster processes. And work safety and working conditions should be
improved. Therefore, the hunt for the right system technology was undertaken.
Gerold Hilger is responsible for production control at the company and, together with
Leonid Muilar, was responsible for the project and the related new procurement. He
brings complex expertise in the field of laser and brushing systems from previous
activities. Thus, the idea of using a brushing machine arose.
“Farmingtons Automotive uses oxygen for laser cutting. This results in an oxide layer on
the cutting edges where the coating can spall again. The sharp edges also pose an injury
hazard. And, last but not least, the scale has to be removed from the armour steel
processed in the special vehicles in Georgsmarienhütte,” Hilger summarises the
situation. If possible, all three technical problems should be solved with the new system
technology.
Processing the sharp laser edges
The initial contact with the machinery manufacturer, LISSMAC, was made in 2018.
Together, the situation was analysed. The results were presented in a qualified manner
after performing tests with components. On the basis of these basic parameters and the
specifications from Farmingtons Automotive, LISSMAC developed a suitable machinery
concept.
“The objective was to cover the highest possible degree of component diversity of the
parts with the system technology. After all, approximately 1,500 different components
made of a wide variety of materials and with a variety of thicknesses are manufactured in
Georgsmarienhütte. In addition, the machine needed to remove the oxide layer in only
one work step and round the edges on both the top and bottom,” says Gerold Hilger.
The LISSMAC SBM-M-B2
steel brushing machine is
located directly behind the
SBM-L-G1S2 grinding
machine which are linked
both mechanically and with
respect to their control
technology. Together with the
grinding machine, it
constitutes a technological
unit and is activated directly
by the grinding machine.
“But, at that time, Farmingtons Automotive was already considering procuring a fibre
laser. Fibre lasers in particular create cutting burrs. So, once again, comprehensive tests
with sample parts were conducted and the results were evaluated. And, once again,
various system concepts were created with a view to procuring the fibre laser,” Dirk
Schürstedt, Regional Sales Manager for Metal Processing at LISSMAC Maschinenbau
GmbH describes the decision-making process.
New system meets all requirements
In the middle of 2019, the decision was made to invest in LISSMAC technology. The
LISSMAC SBM-M 1500 B2 steel brushing machine is located directly behind the SBM-L-
G1S2 grinding machine which are linked both mechanically and with respect to their
control technology.
With the grinding and deburring machine, which work with a dry process, both sides of
parts made of steel and stainless steel can be processed, in alternating operation, in only
one work step. It is designed for debrruing and evenly rounding the workpiece edges on
the exterior and interior contours. The steel brushing machine also works with a dry
process. Four brush belt units with two tilted brushes each on the top and bottom,
working in opposite directions, ensure optimal cutting edge processing. The sheet metal
parts to be processed automatically run through the machine. The four brush belt units
An intuitive user interface
allows for the part and
processing data to be set
without complications.
brush off the oxide layers on all interior and exterior edges. Thus, in only one work step,
edges and surfaces that are suitable for coating are created on both sides. In addition,
process safety is ensured by means of an automatic thickness measurement.
The new system also scores points with respect to working conditions. The dry dust
extractor allows for the exhaust air to be recirculated into the room with a degree of purity
of 99.9 percent.
Significant savings potential achieved
Farmingtons Automotive is very satisfied with the results achieved with the LISSMAC
machines. Today, parts from one to fifteen millimetres and materials from construction
steel to armour steel are processed with the new system technology.
“Almost 80 percent of the components can now be processed with the new system
technology. Thus with respect to the processed spectrum of parts, only nine grinding
hours per week are required in comparison with the thirty hours required to date,” says
Peter Schulte. In this context, the personnel costs for the process were significantly
reduced. Since the machine also removes the scale, the costs for cleaning are also
saved.
And employee satisfaction has also increased. Due to the new system, it is no longer
necessary to work in the grinding cabin or wear hearing protection and a mask. The
employees are now better protected due to the dust filters in the system.
With the grinder, which works with a dry process, both sides of small parts made of steel, stainless steel and aluminium can be processed, in alternating operation, in only one work step
The company has now also become more flexible with respect to the production of new
company. Now, both large and small components can be processed as can various
thicknesses and materials. This is a great basis for being prepared for future trends and
requirements.
Last but not least, the important topic of quality is covered. The components
manufactured in Georgsmarienhütte are primarily considered special protection modules
for all-terrain vehicles, pick-ups and vans and are screwed into the vehicles later.
Depending on the customer’s wishes with respect to equipment and on the specific
vehicle, that amounts to between 40 and 70 components per vehicle. These so-called
component kits are safety certified and therefore have to meet the highest quality
requirements and, accordingly, have to be precisely manufactured. Service life
documentation is indispensable for these types of vehicles because, ultimately, they are
used to protect human life.
The production area in Georgsmarienhütte was expanded by 6,000 m² at the end of
2020. However, Peter Schulte is already thinking about the next efficiency topic in this
context: “The long-term plan is to introduce an automation system between the laser and
the deburring brush machine.” The potential addition of a system for barrel finishing the
smaller parts is also being discussed. So, Farmingtons Automotive is very well-prepared
for the future.
The sheet metal parts to
be processed
automatically run through
the machine. The four
brush belt units brush off
the oxide layers on all
interior and exterior
edges.
.
The WELP Group
The corporate group, which generated turnover of more than 90 million euros in 2020,
consists of Farmingtons Automotive GmbH with sites in Georgsmarienhütte and
Wolfsburg, Indikar Individual Karosseriebau GmbH in Wilkau-Haßlau and Kranzberg b.
München, the WELP Group UK in Birmingham, Dressel + Höfner Automotive GmbH in
Neustadt bei Coburg and S.C. Dressel + Höfner International S.R.L in Medias in Romania.
With a total of more than 730 employees, the companies in the WELP Group develop and
manufacture customised solutions for industry and the automotive industry. The premium
supplier for numerous passenger and utility vehicle manufacturers considers itself a full-
service partner in this context. Its range of services includes development services, the
production of prototypes and models as well as complex injection moulding tools for
prototype, small series and serial production, serial production of plastic parts and their
assembly into complex modules as well as paintwork. In addition to this automative range
of services, the companies possess comprehensive expertise in the development and
production of specially protected vehicles and modules as well as special and customised
vehicles.
Contact: Farmingtons Automotive GmbH
Beekebreite 18 - 20
49124 Georgsmarienhütte
www.welp-group.com
LISSMAC Maschinenbau GmbH
Dirk Schürstedt
Lanzstraße 4
D-88410 Bad Wurzach
www.lissmac.com
Text Author: Annedore Bose-Munde, specialist journalist for technology and business in Erfurt,
www.bose-munde.de
All images: WELP Holding GmbH