From Concept to Production: The Journey of Developing a New Coil Compression Spring

Introduction:

The development of a new coil compression spring requires a blend of creativity and precision spring engineering. This journey from concept to production encapsulates a series of meticulous steps, incorporating the latest technological advancements to address specific needs within automotive, aerospace, industrial, and consumer product applications. The goal of this article is to demystify this process for makers, manufacturers, inventors, innovators, and industry enthusiasts, providing insights into the challenges and solutions encountered along the way.

1. Conceptualization:

Every great product starts with an idea. In the realm of coil springs, this could emerge from the quest for improved vehicle suspension systems, the need for better vibration control in industrial equipment, or innovative uses in consumer electronics. A notable example includes Tesla's initiative to enhance the coil compression springs in their Model S vehicles, aiming to elevate ride comfort while maintaining high performance standards. This phase is crucial, as it sets the stage for all subsequent design and manufacturing decisions.

Case Study: Tesla's Coil Spring Redesign

Challenge: Balancing enhanced comfort with high vehicle performance.
Solution: Development of coil springs with better spring rates and advanced spring materials.
Outcome: A notable improvement in ride comfort coupled with enhanced vehicle handling and performance.

2. Design and Simulation:

The design phase transitions an idea into a tangible blueprint. Here, engineers determine the spring's critical dimensions, such as wire diameter, outer diameter, and uncompressed length (Free Length), ensuring it meets the specific requirements of its application. Leveraging rapid 3D Spring CAD builder software is indispensable in this phase for precision modeling and simulation. Acxess Spring’s 3D CAD, for instance, allows for the intricate design and real-time modification of spring parameters, providing immediate feedback on how changes affect the spring's performance.

3. Material Selection:

Selecting the appropriate spring material is paramount for ensuring the spring's performance and longevity. This decision is influenced by factors such as environmental conditions, required load-bearing capabilities, and cost constraints.

4. Spring Index:

The main culprit in all spring design problems and what nobody ever talks about is “Spring Index”

Spring Index is the heart and soul of a spring design. What is Spring Index? Spring index is the correlation between the mean diameter of a spring and the wire diameter of a spring. This proportion will determine the strength of the spring, the stress induced on the spring, and the manufacturability of the spring.

Formula For Calculating Spring Index

Index = Mean Diameter (D) / Wire Diameter (d)

Mean Diameter (D) = Outer Diameter (OD) - Wire Diameter (d)

What this means is that the Index of a great spring design should be from 6 to 12 to 1 index. This range of index usually gives the user the ability to use all the spring travel or deflection and get all the load force possible from their spring design.

If your spring index ranges from 4.1 to 5.9 Meaning your spring is too tightly wound. Your spring is highly stressed, meaning you will get a limited amount of travel and force load from this type of spring design. Your spring may be manufacturable, but at a higher cost due to the complications it implies.
If your spring index ranges from 6 to 12, your spring has an ideal index and is not stressed and can probably travel or deflect all the way down to solid height as well as get all the force from this type of spring design. Your spring can be manufactured at a normal cost.
If your spring index ranges from 12.1 to 15, your spring has a higher index and a difficulty grade that makes it a bit harder to manufacture, but it’s not excessively complicated.
If your spring index ranges from 15.1 to 25 it may still be manufacturable but at a higher cost.
A spring index above 25 is very complicated and not likely to be manufacturable.

Case Study: Springs for a Powder Coating Production Plant

Challenge: Crafting springs inside their assembly line apparatus that holds product while being powder coated and capable of enduring the extreme conditions of 500 degree fahrenheit heat at extended periods of time.
Solution: Incorporating 17-7 PH ASTM A 313 Stainless Steel Spring Wire. Known for its high strength and thermal ability to withstand the proposed 500 F. heat.
Outcome: Springs that significantly contribute to the reliability and repeatability of the assembly line apparatus. Thus saving the company from re-purchasing replacement springs continually. Spring performance under harsh operational conditions was achieved.

5. Prototyping and Testing:

Prototyping is the bridge between design and full-scale production, providing a tangible product to evaluate form, fit, and function. It's during this stage that the spring design faces its first real-world challenges. Acxess Spring's Online Spring Force Tester, for instance, can play a crucial role by allowing engineers to measure and verify the force exerted by the spring at different lengths, ensuring it meets design specifications before moving to mass production.

Example: Development of a specialized coil compression spring for new mountain bike suspensions.

Challenge: Achieving the desired durability and performance under varied terrain conditions.
Solution: Iterative prototyping and rigorous testing to refine the spring design.
Outcome: A spring that enhances rider comfort and bike performance across diverse conditions.

6. Manufacturing Process:

The transition from a prototype to mass production is a significant step that involves selecting the most appropriate and efficient manufacturing processes. Modern manufacturing techniques like CNC coiling allow for high precision and flexibility in producing complex spring shapes and sizes, catering to the unique demands of each application.

Case Study: BMW’s adoption of CNC coiling technology

Challenge: Streamlining production to meet high-quality standards and reduce waste.
Solution: Integration of advanced CNC coiling technology into the manufacturing line.
Outcome: Enhanced production efficiency, consistency in spring quality, and a reduction in material waste.

7. Quality Control and Assurance: ISO 9001:2015 Certified:

Quality control is essential in maintaining the integrity of the production process and ensuring that each spring meets or exceeds the established performance criteria. This involves a series of inspections and tests, from the raw material stage through to the final product, to identify and rectify any defects or deviations from the design specifications. Acxess spring’s quality management system is ISO 9001:2015 Certified

Example: Adoption of automated quality control systems in the manufacturing of industrial springs.

Challenge: Ensuring each spring meets stringent quality standards.
Solution: Implementing advanced automated sensors for inspection and sorting systems as well as inspection cameras.
Outcome: High-quality springs that consistently meet or exceed performance expectations.

8. Implementation and Market Introduction:

The final phase involves integrating the new helical compression spring into its intended application and launching it to the market. This stage is critical for assessing the spring's performance in real-world conditions and gathering feedback for potential improvements. Successful market introduction is supported by comprehensive testing, effective marketing strategies, and responsive customer service.

Case Study: Launch of a new automotive suspension spring

Challenge: Gaining acceptance in a competitive market.
Solution: Extensive testing and a targeted marketing campaign highlighting the spring's benefits.
Outcome: Adoption by leading automotive manufacturers and positive reception from consumers.

9. Innovations and Future Directions:

The coil compression spring industry is continually evolving, driven by advancements in spring materials science, manufacturing CNC technology, and spring design methodologies. Embracing innovative tools like Acxess Spring's Spring Creator with 3D Spring Blueprints and online spring force testing services can empower designers and engineers to push the boundaries of traditional spring design and functionality.

Conclusion:

Developing a new helical coil spring from concept to production is an intricate yet rewarding process that merges creativity with technical rigor. By embracing the latest technological tools and methodologies, such as those offered by Acxess Spring, companies can streamline this process, fostering innovation and ensuring the production of high-quality, effective springs that meet the evolving needs of diverse industries.