Category: Engineering

Here at European Springs Ireland, we’re committed to providing our customers with a smooth journey while working with us to ensure they get everything they need. From initial conversations to providing repairs and maintenance long after handing over their orders, we’re here for our customers. One of the ways we assist is through our design support, which we’re exploring in today’s blog post.

We’re taking a look at the design support you should expect to receive when working with our team and what this entails, including our processes and how we handle each order, from mass productions to one-offs.

What Is Design Support?

Design support is part of our spring manufacturing process. It refers to the assistance provided to customers in designing custom springs, pressings, and wireforms that meet their specific needs and requirements. This support can include a range of services, such as consultation on material selection, wire diameter, spring rate, and other design parameters. For example, design support aims to help customers create a spring optimised for their application, considering load capacity, deflection, frequency, and durability factors. This can lead to improved performance, longer service life, and reduced costs for the customer over the long term. In addition, our conversations help bring our customers’ products to life, allowing them to visualise what they’re ordering and understand how it will function. This also allows our customers to voice any necessary adjustments to the design before production begins.

Our Design Support Process

As leading spring manufacturers in Ireland with over 70 years of industry experience, we are proud of our design support process and believe we have perfected this service.

Our expert team of engineers assist you in making decisions on the design of your product, whether you have a bulk order of compression springs or a single pressing. No matter the size of your order, we can help you decide on the design, material, and surface treatment of your chosen pressings, stampings, or springs. We do this to ensure customers get the most suitable products for their application and are completely satisfied with the final result.

Each order goes through our rigorous process, which involves the following:

• Selecting the material and considering technical requirements, price, and availability
• Manufacturing method
• Capital investment for tooling
• Finishing requirements, such as heat treatment
• Assembly requirements, including automation
• Repeatability

These requirements are essential in manufacturing the perfect product for our customers. They help us pinpoint exactly what our customers require, so they leave us satisfied and confident in our services. It also ensures that everyone involved in the manufacturing process is clear on the goals and that there aren’t any confusions or backtracking that could cost us and our customers time, money, and other resources.

Custom Spring, Pressing, and Wireform Manufacturing and Your Valuable Input

Our customers’ input is crucial when it comes to bespoke spring design for several reasons, such as:

• Ensuring we meet their specific requirements. Each custom product has unique requirements, such as dimensions, materials, and load-bearing capacities, so it’s vital that everyone involved in the manufacture understands this.
• Customisation. We pride ourselves on our bespoke services, meaning our spring design team can provide truly unique and specifically tailored products, and our client’s input on these details is essential.

• Building trust. Taking the clients’ input into account can also help build trust between the manufacturer and the client. By working collaboratively and considering the client’s needs, manufacturers can demonstrate their commitment to providing high-quality, customised products that meet their needs.

Design Support for Bulk and One-Off Orders

As mentioned, we offer design support for all orders, no matter how big or small. However, there are slight differences between the process if you want a bulk order or a one-off product.

Of course, the main difference between bulk and one-off orders is the number of products produced. This means more materials, time, and other resources will be used during the production of bulk orders, making it absolutely vital that everyone is satisfied with the final design before production begins. However, if a customer requests a single product, although the design is still important, it won’t have a catastrophic effect if slight changes are needed to the product after its production.

Following this, although some may believe that the design process may be lengthier for bulk orders, this isn’t always true. Although they require a lot of detail from the customer to ensure complete satisfaction before production begins, customers will bulk order our standard products, such as our tension springs, for example. In contrast, one-off orders may have unique and incredibly specific requirements that aren’t included in our Spring Catalogue.

Whatever your order, our design support team needs your input to ensure we provide you with the right product. So please get in touch today to begin those all-important conversations with our spring design experts.

As technology creeps further into every aspect of the manufacturing industry, European Springs Ireland is excited to be at the forefront of technological developments. We’re fascinated by the successes of these innovations and are always looking for ways we can implement new technology into our practices to provide better services for our clients.

One technological advancement that has proved it is here to stay is automation. In recent years, we have seen incredible automation developments in manufacturing and have been fascinated by how it is assisting manufacturers and engineers worldwide.

So, today, we’re exploring everything you need to know about automation in manufacturing. We’re taking you on an insightful look behind the curtain as we delve into what it is, how it has been implemented into the industry, and what the pros and cons are of this revolutionary technology; read on to learn more.

What Is Automation?

Automation is a term for any technology or computerised machine that, in order for it to work, requires little human input. While automation isn’t new, the different types of automated technology available today are constantly updated with the latest software.

There are different types of automation available, for example:

• AI. Artificial intelligence is used in many manufacturing companies across the world. For example, in spring manufacturing, it can be used in the replacement of the testing process to minimise resource waste.
• Process automation. This involves the use of apps or other software used to streamline business processes that were previously completed by humans either on a computer or through paperwork.
• Robotics. Also known as integration automation, robots have been used to mimic the actions of a human and can complete physical tasks such as packing.

There are also other, much more basic examples of automation that aren’t just found within the manufacturing industry. For example, using an online chat room for employees is considered a part of automation, as it replaces physical human interactions, which has been implemented in almost all industries.

How Has Automation Been Implemented Into Manufacturing?

As mentioned, automation has been implemented in the manufacturing industry in a wide variety of ways, such as through:

• Robotic assembly lines
• Computer-controlled tools
• Automated material handling
• Automated inspection systems

These are just a few examples of the many different areas of automated manufacturing, and we believe it will only get bigger and better. Whilst we would never expect automation to take over the creative minds of our spring design team, for example, we do believe it can be beneficial in other areas of our business. For instance, when it comes to producing custom bulk orders for our clients, implementing automotive technology may increase the springs’ accuracy and speed up the process.

Automation and Analytics

Analytics are used throughout manufacturing and has been a major part of Industry 4.0 in terms of machine data. As this often involves a lot of technical skill and, more often than not, advanced experience, automation has been tested to take over this area of manufacturing.

The two work together by providing automated data on production processes and machines. The automation systems are able to collect data from machines before feeding it into analytics software for review. During the review, the collected data can be used to identify patterns, which then allows manufacturers to make informed decisions about improving productivity and efficiency, for example. In addition, automation systems can also use this data to predict problems with the machines and prevent them from occurring.

Advantages of Automation in Manufacturing

There are plenty of advantages of automation in manufacturing; let’s take a look:

• Increased efficiency. Automation reduces production time significantly and works to streamline processes.
• Reduces human error. It can eliminate mistakes made by humans and produce more consistent products.
• Cost-effective in the long-term. By increasing production rates and reducing labour costs, automation can help manufacturing companies cut costs in the long run.
• Increased safety. By eliminating human error, injuries are reduced. In addition, as mentioned, automation processes can predict when a machine may have a problem, improving the safety of the technology humans work with.

Disadvantages of Automation in Manufacturing

Of course, many people will have doubts about automation, which is completely understandable. While it is impressive technology, it also comes with some drawbacks.

• Potential job losses. As mentioned, we don’t believe automation could take over humans in all aspects of manufacturing. Still, some areas may see some workforce cuts due to the overwhelming advantages of automation.
• High initial investment. Automation is cost-effective in the long term, but it must be mentioned that the initial investments can be high. Machinery, software, and other equipment are expensive.
• Technical issues. Like all technology, automation may run into some technical issues or malfunctions, which can cause delays in productivity.

Whatever your feeling about automation area, there is no denying that it is making its way into manufacturing in a variety of forms. If you work in the sector, you probably already noticed an increase in automation; if not, you certainly will now.

As mentioned, we’re excited about these digital transformations here at European Springs Ireland and actively seek opportunities to implement them into our spring manufacturing processes.

If you’re as excited as us by digital change and think that the fascinating world of spring design and manufacturing is a place you would thrive, we would like to hear from you. Get in touch to find out about our latest vacancies and start your new career at this exciting time of automation transformation.

At European Springs, we are proud of our role in manufacturing high-quality springs and pressings for a broad range of applications. We strive to develop new innovative processes and methods to maintain our status as one of the UK’s top manufacturers. Part of our work is to understand the causes of spring failure and prevent any such losses from occurring in our products with superior techniques.

Spring Design Considerations

With so many applications that require some spring to function, spring failure at any time will be at best a hindrance and, at worst disastrous. As spring manufacturers in Ireland, we understand that spring failure is not an option. However, we believe that by understanding why a spring fails, you can work toward avoiding it for yourself.

Spring Stress is a primary cause of spring failure. Overstessing your spring by applying stress or force that exceeds its specifications indicates a breakdown in the design process. For example, an extension spring will not have much elasticity if designed for strength, so by overextending this spring, you will put it under extreme stress, and it will most likely break.

Wrong Material Choice is also a common cause of spring failure. With so many materials available for your spring manufacture, you need to be sure that you select the best material for the function it needs to perform adequately. For example, Stainless steel is a good choice for clock springs but may not be for other spring types such as valve springs.

Shock loading and other misuses of your spring will lead to spring failure. Shock loading is when the weight of the load increases suddenly or speeds up. Dropping your spring from a significant height is an example of accidental shock loading. The more times the spring is shock loaded, the higher the risk of failure. You can mitigate this with friction devices such as vibration dampening devices or internal damper coils.

The key to our spring manufacturing process is to source specific high-quality materials to meet even the most exacting of production standards. Combined with our in-house contemporary CAD and CAM software and systems, we can help realise a comprehensive range of prototype ideas so you can be sure your specification will work in your required application.

Preserving Your Springs

Even with the best materials, manufacture and design, no spring will last forever; fortunately, as experienced gas spring manufacturers, we know of ways you can increase your spring’s life and prolong replacing it for as long as possible.

Several factors can shorten your spring’s lifetime, but you can ensure your product lasts longer than you expect with careful planning and a reputable manufacturer.

Friction – A spring touching the sides of a shaft (for example, a compression spring inside a gas spring), with repeated friction, will cause increasing damage to both components until one fails.

Environment – A spring that doesn’t have the correct finish will be less likely to function. It will continue to degrade until it fails. In addition, heat or extreme humidity will negatively affect an untreated spring and potentially cause spring relaxation. By keeping these springs cool, you can prolong the life of your spring and reduce the chance of spring relaxation

Stress – This is linked to the overstressing mentioned above. Applying too much pressure to your spring is unlikely to compress as far as it is designed. This will lead to overstressing and breaks. We recommend choosing a larger wire diameter to reduce the chance of spring stress. Additionally, lowering the final load and allowing more room for the spring will enhance longevity.

Prestressing to Prevent Spring Failure

Prestressing is the process where the spring is loaded to the point where the wire is under controlled stress. A spring designed to be prestressed will benefit from withstanding higher pressures and increasing its load-carrying ability while lighter than its equivalents. When spring is prestressed, the changes will increase its lifetime and provide you with a better product.

Shot Peening Improving Operating Life

Shot peening is a method where the surface of the spring is hit with small spheres. It is used on clutch springs, coil springs and compression springs. These impacts will create small indentations, which will overlap as they are repeatedly struck. As a result, the whole exterior of your spring will have a layer of metal in a state of increased residual compressive density. Shot peening essentially increases the tensile strength of your material and makes it far harder for fatigue cracks to start to form. Shot peening is beneficial for:

• Preventing corrosion
• Cracks and fatigue
• Hydrogen embrittlement

High-Quality Bespoke Spring and Pressings from European Springs

By choosing a world-renowned gas spring manufacturer such as European Springs, you can be confident that your required springs will be the highest quality choice with high durability and customised for whatever you need them for.

If you’re interested in any springs, pressings or wireforms, then please browse our stock catalogue to see what we have readily available.

Throughout our decades of experience manufacturing high-quality pressings and stampings, we have developed our processes to create an expert service that is constantly in high demand from our clients worldwide.

Our team of engineers have earned a wealth of knowledge in this field, covering manual, semi and fully automatic production to suit the requirements of the customer’s needs. One thing that became evident very early on is that no one type of press applies to every product. An important lesson is that adaptability is vital when conducting the bespoke pressings and stampings operations we offer. Therefore, our engineers must have a working knowledge of various press machines.

How Do Machine Presses Work?

Initially, pressings had to be created by hand. Before the machine press was invented, workers used tools such as hammers to change the shape of the metal. This was not only an agonisingly slow and physically draining process, but it would also be less effective on harder metals. So, this was replaced with the steam hammer around the mid-1800s. The steam hammer (or drop hammer) is the earliest known machine that led to modern pressings.

In modern manufacturing, the machines have replaced their steam with hydraulics. Every device will have its own unique designs, but all pressing machines share specific processes and features. Most pressing machines operate in a straightforward manner by pressing the workpiece plate or die onto the workpiece materials or into it for a more dramatic result. This process is controlled through multiple tool setters that ensure the position of the workpiece. This is when the hydraulics come in; the press pushes the plate or the die against each other using hydraulic pressure. This enables the desired change.

Machine presses rely on high pressure to create the intended results. Most machine presses use around 1 to 30 tons of pressure, which enables them to reshape a broad range of materials such as steel, beryllium copper, and stainless steel alloy. As experienced spring manufacturers, we have used carbon spring steel in our pressing operations with impressive results.

Punch Press

A punch press is the most well-known design of a press machine, and as the name suggests, this press deforms the material by punching holes into it. First, a portal frame with a centred ram or a C frame with a hydraulic ram. Punch presses can be operated manually, but with advances in CNC machining, computer-run punch presses are significantly more popular as they vastly increase production quotas.

Stamping Press

A stamping press is another well-known press design we use at European Springs a lot. While these are similar to punch presses, there are significant differences. They both use a pressurised tool to change the materials workpiece, but stamping does not create clear, clean holes like a punch press.

In this case, the material is pressed into the die to take the same shape, and the material is secured with a bolster plate between the die and a press tool. The tool in the stamping press is pushed into the material, forcing it to deform into the shape of the underlying die.

Lid Press

A Lid press is quite different to the previous examples. Whereas the previous focus was on changing the form of the material, this press is designed to apply a cover to an existing object. As a result, you’ll find lid press machines most used mainly for sealing storage containers such as buckets or cans.

Press Brake

A press brake is exclusively used for metal manufacturing. The role of this press is to bend and deform metal workpieces such as sheet metals. These are sandwiched by a tool and die, similar to other operations, especially stamping presses, with the exception that this machine only works with metal pressings.

Screw Press

As the name suggests, the defining feature of a screw press is the screw-driven ram installed. This updated design has been around for centuries but is now usually controlled through CNC machining to twist and turn the ram and force the tool down onto the workpiece to get the desired shape.

European Springs Pressings and Stampings

At European Springs, we can provide our clients with a broad range of materials to choose from, such as:

• Aluminium
• Beryllium copper
• Brass
• Carbon spring steel
• Copper
• Phosphor bronze
• Stainless steel
• super alloy

We can work these materials into your desired components from our high-quality strip material. This can include flattened wire for manufacturing flat springs and non-metallic materials if our clients prefer it.

Once you’ve worked with our design team to refine the idea, our engineers are able to decide the most effective method of creating your components in mass quantities using our fully equipped equipment room. They can create the perfect tool suitable for either manual semi or fully automatic production of your pieces.

Our facility has 24 progression power and multi-slide presses, with also nearly 40 single-stroke presses. This impressive collection of equipment allows us to create pressings efficiently, whether it’s a single prototype or full production.

You can learn more about our acclaimed pressings and stamping process online, including how we can help you with your next application. We are not just limited to our high-quality pressings; we also diversify into manufacturing springs and wireforms, all of which are made by our expert engineers and available for order online.