Explore the crucial role of custom spring fabrication in ensuring the optimal performance of reciprocating compressors. We delve into the key considerations for selecting and designing custom springs, and highlight the benefits of working with an experienced spring manufacturer.
Springs are mechanical devices designed to push, pull, support, wind, protect, or lift. They are mostly used in mechanical assemblies to provide tensile, compression, or torsion forces wherever they can be used to open die sets, lift engine valves, or secure batteries, to name some examples.
Springs are usually wound from wire but can be stamped from steel, machined from solid steel, formed as bags, or assembled with other springs.
Ordinary wire springs naturally exhibit a force whose size or magnitude increases in a linear fashion as the spring is twisted, pulled, or pushed. This behavior, with respect to distance displacement, is referred to as Hooke’s law of Motion.
Types of Springs
Different types of springs are available these days, and thanks to advanced technology, many spring-makers have successfully fine-tuned the art of manufacturing springs for nearly a century.
Some of the common types of springs available today include:
- Extension springs
- Garter springs
- Compression springs
- Torsion springs
- Drawbar springs
- Wave springs
- Constant force springs
- Volute springs
- Flat springs
- Gas springs
- Disc springs, etc.
Other spring types include those assembled into components for particular applications and are known as spring assemblies. Protective coil springs are springs that help protect hydraulic lines.
Hydraulic springs make use of special hydraulic fluid in very short-stroke applications found in die springs. Box springs are usually utilized as support for bed mattresses.
The Importance of Custom Spring Fabrication
Spring manufacturers produce a vast selection or wide range of wire forms and springs, including many not found in standard catalogs. However, when it comes to custom spring fabrication, it’s all about meeting the specific needs of clients who may often require only a small quantity of springs.
Sometimes, the clients may need just one customized spring to replace a malfunctioning component or even a product prototype.
Design and Its Importance in Spring Fabrication
Manufacturing springs is not really feasible without design. Spring-makers consider several elements while ensuring every measurement is exactly right, especially when fabricating a custom spring for a reciprocating compressor. For instance, a bespoke spring fabrication must consider factors such as load and movement, type, etc.
Any slight change to any of these factors can significantly affect the overall performance of the spring. For example, if a spring maker chooses and uses a different material for a particular spring, it will change its capabilities even if its dimensions have not been altered.
If a spring’s outer diameter is modified, it will make a substantial difference. It does not matter if the change is minimal; this implies that measurements have to be 100 percent precise.
Other vital considerations spring makers make when designing springs for reciprocating compressors include the following:
- The number of coils, which is determined by the particular application of the spring
- The free length of the spring, which is also referred to as the overall length of the spring when no force or load is applied to it.
- How much force the spring can comfortably withstand
- The solid height of the spring is also known as the ‘maximum solid.’
- The spring’s inner diameter
- The ends of the spring
Other crucial considerations spring makers must bear in mind when fabricating customized springs include the following:
- The tension of the spring
- The wire diameter and the coil diameter of the spring, which will determine the spring constant. This metric is highly crucial for designing customized springs for reciprocating compressors.
- The wind direction, which determines whether or not a left- or right-hand spring, is required.
- The shape of the wire. You can decide to choose between round or rectangular options.
Therefore, spring makers need to manufacture custom springs that their clients require. This is only possible when the clients supply the ideal specifications they need their custom springs to meet.
Moreover, considering spring fabrication, especially before finishing other crucial components of the clients’ product, is important. Some custom springs may not be safe to use or perform as desired if their design is not considered.
A carefully thought-out custom spring fabrication will result in the fabrication of springs with long life spans since the environment within which the spring will function, including material considerations, has already been considered from the beginning.
The custom spring will also be of the highest possible quality, thanks to the careful selection of the manufacturing process and spring materials. The spring will also be highly compatible with the product, such as a reciprocating compressor. This is because every dimension has been carefully measured with 100 percent precision and readily accounted for.
Stock Springs vs. Customized Springs
There are a few differences between customized springs and stock springs. Let’s take a look at them:
Stock springs are immensely beneficial for product makers in the prototyping phase of a specific design or require several replacements. Moreover, they are great economical options for those in need of only a small quantity of this class of springs.
Purchasing more than a few components of stock springs is always cost-effective. Clients will be able to efficiently calculate and figure out precisely what they need.
- Customized Springs
On the other hand, customized springs are ideal for going into the production of spring-operated devices or applications. Furthermore, the cost or price of large production quantities of this class of springs is much lower than stock springs.
In addition, precise dimensions are made available when a client orders customized springs. But stock springs do not require precise dimensions.
Conclusion
The role of spring fabrication of custom spring designs for reciprocating compressors cannot be overstated. The right custom spring design ensures you don’t exceed your budget.
A poorly designed custom spring will not be reliable and can delay the production or launch of your product. Your expenses may also increase because you will require another batch of custom springs.
But by ensuring the correct custom spring design from the beginning, the springs will have the ideal dimensions and be functional. There will be no need to repeat the order or fix anything.
If you’re looking for reliable and high-quality custom springs for your reciprocating compressor, look no further than KB Delta. Contact us today to learn more about our custom spring fabrication capabilities and how we can help optimize the performance of your compressor.