When manual finishing of thick sheet metal reaches its economic and quality limits, automated systems help ensure consistent edge quality, reliable processes, and efficient production in accordance with DB requirements.
Deutsche Bahn’s (DB) quality standards for the finishing of sheet metal parts can now hardly be reliably met by manual methods alone. Among other things, the required edge quality, reproducibility, and process reliability often exceed the economic feasibility of manual processing. It therefore quickly became clear to Salzgitter Mannesmann Stahlhandel that without automation, these requirements would no longer be sustainable—and, above all, economically manageable—in the future. That is why those in charge began to address the question of suitable automation solutions.
High volumes, the highest quality standards
Using four oxy-fuel and plasma cutting systems, Salzgitter Mannesmann Stahlhandel manufactures sheet metal parts with thicknesses ranging from 5 to 250 mm. A significant portion of these components is intended for applications with particularly high quality requirements, including bridge structures built to DB standards. This standard requires slag-free cut edges, defined edge radii, and a reproducible machining quality that in some cases exceeds the requirements of DIN EN 1090. At the same time, the components vary greatly in geometry, quantity, and machining complexity.
Two systems for different component requirements
This combination of high production volumes and strict quality requirements made a one-size-fits-all solution impossible. After some research, the decision was made to go with the supplier Teqram, and specifically, the choice was deliberately made to use two complementary automation solutions: the EasyDebur for cost-effective series production and the EasyGrinder for complex, quality-critical parts. This ensures a reliable process and the necessary quality level, thereby ensuring compliance with DB standards.
Automated deburring and edge rounding
With the introduction of the Teqram EasyDebur solution, Salzgitter Mannesmann Stahlhandel has further advanced the automation of its existing Lissmac systems. The EasyDebur offers a cost-effective and reliable solution for automated feeding, particularly for series production. In addition, manual effort is significantly reduced, which has a direct impact on cost structure, throughput times, and working conditions. The two existing machines are used for automatic slag removal on both sides and edge rounding. The key advantage of the complete solution: consistently high and reproducible quality, regardless of shift or operator.
Robotic grinding for maximum quality
For particularly demanding parts, Salzgitter has opted for the Teqram EasyGrinder. The EasyGrinder is used when the flash needs to be removed, oxide needs to be removed from the narrow sides, the hardened layer needs to be removed, or a more pronounced edge rounding is required.
“The robotic grinding system handles all these tasks reliably and with consistently high quality—tasks that are not only time-consuming when done manually, but also difficult to reproduce,” emphasizes Andreas Medzich, Site Manager in Hanover. “With the EasyGrinder grinding robot, it is possible to achieve a surface finish that is virtually impossible to achieve manually. In addition, one EasyGrinder replaces up to three employees and increases process reliability.”
When combined with the EasyDebur system, this creates a seamless, automated post-processing workflow that is ideally suited for both standard and high-end components.
Quick to install, ready for the future
“The installation was carried out very professionally and surprisingly quickly,” reports Medzich. “After just one week, both systems were already running in regular production.” In the long term, the EasyGrinder offers additional potential: In the future, chamfering and stamping are also to be automated—a logical step toward even greater process reliability and efficiency.
Background:
Salzgitter Mannesmann Stahlhandel GmbH is a flexible system partner and service provider that offers a comprehensive range of steel products at various stages of processing, extending far beyond the field of cut-to-length products. As a leading, mill-affiliated steel trading company, the firm ensures nationwide availability and short delivery times through its stocking locations throughout Germany. The company handles all services for its customers—from technical consulting and procurement to warehousing, processing, manufacturing, and distribution.
Teqram develops and implements automation solutions for the metalworking industry. Systems such as EasyGrinder and EasyDebur help automate manual processes.
Web:
www.salzgitter-mannesmann-stahlhandel.de
www.teqram.com
