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