Reell Spring Technologies has developed a proven and patented process that redefines quality and consistency for spring, coil and precision wire form manufacturing. Reell ST is a quality driven organization with strict attention given to every detail throughout design, production and packaging.
Custom Precision Springs
Our patented technology enables us to produce complex springs with tolerances previously unknown to the industry. Using our state-of-the-art computer-controlled equipment, we can achieve high levels of quality and performance. Our customers have experienced an order of magnitude (10x improvement) tighter tolerances than industry standards in Reell ST’s products. Reell ST’s process can produce springs with tighter tolerances than the tolerances of the wire.
Capabilities
Spring consistency from part to part and from lot to lot is affected by normal tool wear and by variations in wire properties. Reell ST’s spring winding process monitors the performance of the winding machines and adjusts the position of the tool to achieve much tighter tolerances in spring diameter, spring pitch and spring toe position.
- Control diameter tolerances to 0.0005” (0.0127 mm)
- Precise and consistent control of coil pitch and spring toe position
- Precise and consistent control of spring force
- Recognized leader in manufacturing precision springs for the wrap-spring clutch industry
- Specializing in coiling custom shaped wire
- Custom built torque-testing equipment to simulate application conditions
Manufacturing Process
Here is how the spring manufacturing process works at Reell. Wire is passed through a set of feed rollers and is pushed through a quill or wire guide. As the wire leaves the quill, the coiling tool bends the wire to create the helical shape. The diameter of the coil is controlled by measuring it as it is being formed, electronically adjusting the coiling tool distance from the quill at a rate of 400 times per second. This is accomplished using a linear variable displacement transducer (LVDT) that contacts the coil and sends a signal to a computer controlling the process. The computer compares this measurement reading with the programmed value using a proportional integral derivative (PID) loop in its software, and sends out a correction signal. This signal is sent to a piezo-electric device embedded in the coiling tool, causing it to move closer to or farther away from the quill by as much as 0.003 inch. The micro-positioning action removes most of the variability from the spring forming process. In some applications, Reell has achieved tighter tolerances by an order of magnitude (10x improvement) better than industry standards.
Reell also employs a variety statistical process control (SPC) measurements that ensure we can identify and correct variations in our manufacturing process before our products are out of specification. This eliminates the need for final inspections. As a result, we have been able to provide millions of springs per year defect free to our customers.