Designed for use in commercial landscaping equipment, this extension spring is an excellent example of how we can improve an OEM’s product while saving them money. The design for this spring is a bit unusual, as it calls for loops that are larger than the outside diameter of the spring’s body.
Prior to consulting with Master Spring, the customer had problems with the spring cracking. They were installing a second spring during product assembly to act as a backup if the first one cracked.
The new customer asked if we could redesign their extension spring to eliminate cracking.
In order to understand the spring’s space constraints and the assembly process, we visited the customer’s assembly line. We watched how the assembly line worker installed the extension springs. We listened to the product engineer’s details about the spring cracking.
Master Spring collaborated with the customer’s assembly line worker and product engineer to figure out how to easily assemble the spring. We used the product engineer’s input and our spring design software to design a spring with less stress and a longer cycle life. We manufactured 20 prototypes of the new design. Our advanced CNC wire forming equipment seamlessly coils and loops the spring. A touch probe keeps the loops positioned correctly with each other.
The customer’s assembly line worker tested installing them, and the customer’s product engineer ran them through a cycle test.
The spring cracking was eliminated which improved the customer’s product. The customer no longer needed a second spring as a backup. This eliminated the cost of the second spring per product unit and of installing it. The new design was also easier to install, so the assembler saved assembly time per spring. After the new design was tested and approved, the OEM customer placed a repeating annual blanket order of 55,000 extension springs.
At Master Spring and Wire Form, we have the capability to design and manufacture a wide variety of extension springs. We specialize in supplying OEMs their requirements of medium to high quantities of springs and wire forms. Browse our gallery of custom extension springs or review our extension springs product page to learn about our capabilities.
Contact us if you need a custom extension spring for your application at (800) 836-2243.