Automotive

WIRE BENDING PARTS

WIRE BENDING PARTS ARE PRODUCED IN NEARLY ALL TYPES ACCORDING TO CUSTOMER REQUIREMENTS AND DRAWINGS

Function:

Mechan­i­cal reset to the ini­ti­tal posi­tion after activation

Description:

Improved oper­at­ing com­fort through spring load assis­tance for mechan­i­cal adjust­ment of seats, back­rests, hatch­es and locks.

ADVANTAGES

  • High pow­er and torque trans­mis­sion in a small instal­la­tion space
  • Geom­e­try can be flex­i­bly adapt­ed to the instal­la­tion space

INNOVATION

  • Cal­cu­la­tion of torques even with com­plex geometry
  • Increase of life­time thanks to spe­cial pro­duc­tion processes

PRODUCTION

  • CNC con­trolled bend­ing head machines
  • mul­ti-slide machines with per­ma­nent tools
  • pro­cess­ing of round wire and shaped wire
  • sur­face coat­ing accord­ing to cus­tomer requirement

Automotive

TORSION SPRING

Tor­sion springs are coiled or wound wire springs.

Function:

Tor­sion springs are used as ener­gy stor­age like oth­er springs. They are often used for camshaft adjuster sys­tems or for reset­ting hatches. 

Description:

Tor­sion springs can be loaded in open­ing as well as in clos­ing direc­tion. In case of clos­ing load hooks or legs are nec­es­sary to intro­duce the torque into the spring. In case of open­ing load there is no need of legs because the torque intro­duc­tion takes place via the cut­ting edge of the spring wire.

ADVANTAGES

  • High reli­a­bil­i­ty under sta­t­ic and dynam­ic loads
  • Large range of vari­ants and dimen­sions available
  • Cost-effec­tive manufacturing
  • High appli­ca­tion knowl­edge that can be trans­ferred to spring design

INNOVATION

  • Devel­op­ment of a cut­ting method for the pro­duc­tion of a plane cut­ting edge which is per­pen­dic­u­lar to the wire axis (EOS process)
  • Devel­op­ment of a stress-opti­mized pro­duc­tion for springs loaded in open­ing direc­tion which allows a mate­r­i­al sav­ing of up to 30% com­pared to stan­dard springs.
  • Devel­op­ment of an exten­sive cal­cu­la­tion pro­gram for dynam­ic design of tor­sion springs, includ­ing assem­bly sim­u­la­tion (SpringDe­sign­er)

PRODUCTION

  • In-house machine con­struc­tion sup­ports in case of auto­mat­ed pro­duc­tion process­es and pro­duces spe­cial solu­tions to increase the per­for­mance of tor­sion springs
  • In-house pro­to­type shop
  • Fatigue-strength tests
  • In-house process development

Automotive

COMPRESSION SPRING

COMPRESSION SPRINGS ARE CHARACTERIZED BY A COMBINATION OF MATERIAL, PRODUCTION DEPTH AS WELL AS THE ABILITY TO MANAGE EXTREME REQUIREMENTS

Function:

Com­pres­sion springs are ver­sa­tile spring ele­ments used in numer­ous appli­ca­tions as an ener­gy stor­age or reset func­tion. The spring ele­ment have a high ener­gy uti­liza­tion ratio.

Description:

Com­pres­sion springs are used in the fol­low­ing appli­ca­tions: Injec­tion sys­tems (pumps and injec­tors), tor­sion­al damper sys­tems (DMF, clutch and con­vert­er damp­ing springs), shock absorbers, brake sys­tems (ABS, ESP, brake actu­a­tors), trans­mis­sion con­trol, belt and chain ten­sion­ing sys­tems, oil pumps.

ADVANTAGES

  • High ener­gy efficiency
  • Cost effec­tive manufacturing
  • Wide range of vari­ants and dimen­sions can be produced
  • Use of spe­cial treat­ments (e.g. heat treat­ments and coatings)
  • High lev­el of appli­ca­tion knowl­edge that can be trans­ferred to spring design

INNOVATION

  • Devel­op­ment of stress-opti­mized man­u­fac­tur­ing (SOF)
  • Devel­op­ment of nitrid­ing treat­ments for wear pro­tec­tion and life­time enhancement
  • Devel­op­ment of springs opti­mized in terms of trans­verse force
  • DMC laser coding
  • Devel­op­ment of a com­pre­hen­sive cal­cu­la­tion pro­gram for the dynam­ic design of com­pres­sion springs (SpringDe­sign­er).

PRODUCTION

  • In-house mechan­i­cal engi­neer­ing sup­ports auto­mat­ed pro­duc­tion process­es and man­u­fac­tures spe­cial solu­tions for increas­ing the per­for­mance of com­pres­sion springs
  • In-house pro­to­type construction
  • In-house process and development

Automotive INDUSTRY

HOSE CLAMPS

Hose clamps are assem­bled in ser­vo sys­tems, fuel sys­tems and intake air systems.

Function:

Hose clamps are used in vehi­cles to con­nect hoses and noz­zles in air con­di­tion­ing sys­tems, ser­vo sys­tems and injec­tion systems.

Description:

Hose clamps are self-adjust­ing fix­ing ele­ments. Espe­cial­ly in the auto­mo­bile there are many tech­ni­cal arrange­ments which are con­nect­ed to each oth­er by hose and sock­et. These con­nec­tions must com­ply with the high require­ments of the OEMs.

ADVANTAGES

  • Uni­form sur­face pres­sure due to per­fect roundness
  • Self-adjust­ing effect

INNOVATION

  • Opti­mum cor­ro­sion pro­tec­tion due to coating
  • Pre­loaded hose clamp with var­i­ous lock­ing systems

PRODUCTION

  • Dynam­ic simulation
  • In-house pro­to­type shop

Automotive

PISTON RING EXPANDER

IN THE PRODUCTION OF PISTON RING EXPANDERS SCHERDEL IS A TECHNOLOGICAL PIONEER AND GLOBAL MARKET LEADER

Function:

In the engine, the pis­ton ring spring, togeth­er with the oil scraper ring, seals the cylin­der against hot com­bus­tion gas­es in the crankcase and from too much oil in the com­bus­tion cham­ber, and thus reg­u­lates the oil bal­ance, fuel con­sump­tion, exhaust gas bal­ance and, in part, the life­time of the engine.

Description

The pis­ton ring expanders are long com­pres­sion springs with very small out­er diam­e­ter and option­al­ly dif­fer­ent coil dis­tances. The spring is closed with a latch pin to get its round shape. It is prefer­ably used in diesel engines but also applied in gaso­line engines.

ADVANTAGES

  • Many years of expe­ri­ence in pro­duc­tion and design
  • Inter­na­tion­al structures
  • Very small spring index
  • Relax­ation resistance
  • Diam­e­ter of 45–1000mm
  • Wear pro­tec­tion options

INNOVATION

  • Gas-nitrid­ed, hard sur­face for stain­less steel
  • Par­tial nitrating
  • Small diam­e­ters with high loads

PRODUCTION

  • Indi­vid­ual design and development
  • Almost all options can be pro­duced in-house
  • Wear test
  • Relax­ation test
  • Spe­cial machines devel­oped in-house

Automotive

CONSTANT FORCE AND POWER SPRINGS

SPIRALLY COILED METAL STRIP

Function:

Return springs in the field of door lock­ing systems

Description:

Pow­er springs serve among oth­er things to reset elec­tric motors in electro­mechan­i­cal­ly oper­at­ed locks of car side doors

ADVANTAGES

  • Var­i­ous mechan­i­cal com­po­nents in the sys­tem can be omitted
  • Pow­er springs cre­ate a flat torque characteristic
  • Triebfed­ern haben einen großen Arbeitsbereich
  • Use as main­te­nance-free sys­tem possible

INNOVATION

  • Mate­r­i­al edge pro­cess­ing which is manda­to­ry for the func­tion of the lock­ing sys­tem could be devel­oped togeth­er with the mate­r­i­al supplier
  • Poduc­tion of dif­fi­cult spring geome­tries with­out the use of an induc­tive anneal­ing process in cer­tain areas of the pow­er spring

PRODUCTION

  • Cross-curved pro­duc­tion process is applied
  • Com­pli­ance with very strict tol­er­ance frames dur­ing production
  • Use of robot han­dling systems
  • 100% cam­era mea­sure­ment of indi­vid­ual char­ac­ter­is­tics dur­ing assembly
  • Assem­bly of indi­vid­ual components

Automotive

SPIRAL SPRINGS

SPIRAL SPRINGS FOR CAM SHAFT ADJUSTER WERE ACCOMPANIED FROM PRODUCTION TO MARKET MATURITY

Function:

Return springs in the area of cam shaft adjustment.

Description:

Return springs increas­es the cam shaft adjust­ment speed and puts the cam shaft adjuster in an opti­mal posi­tion for the engine start­ing process. Spi­ral springs are exposed to high dynam­ic loads in the appli­ca­tion and must there­fore be opti­mal­ly designed and man­u­fac­tured in close tolerances.

ADVANTAGES

  • Increase of the adjust­ment speed in NWV systems
  • Flex­i­ble pro­duc­tion pos­si­ble with regard to geometry

INNOVATION

  • A sep­a­rate devel­op­ment direc­tive for spi­ral springs has been cre­at­ed for design purposes
  • Prepa­ra­tion of exact fric­tion mod­els for sim­u­la­tion (FEM calculation)
  • Dynam­ic design is pos­si­ble with the high­est accuracy

PRODUCTION

  • Com­bined pro­duc­tion process­es such as form­ing and shot peening
  • 100% cam­era mea­sure­ment of indi­vid­ual characteristics
  • Use of induc­tive anneal­ing process in spe­cif­ic areas of the spring
  • Pro­duc­tion loca­tions in Europe, USA, China

Automotive

DISC SPRING

DISC SPRING ARE SPRING ELEMENTS WITH BIG LOAD-DEFLECTION RATIO

Function:

Spring ele­ment with big force-deflec­tion ratio

Description:

Disc springs make it pos­si­ble to com­pen­sate large loads with a small trav­el dis­tance for exam­ple as play com­pen­sa­tion in trans­mis­sion appli­ca­tions. By stack­ing disc springs in the same direc­tion, the loads can be summed up. As stack­ing in oppo­site direc­tions, a large deflec­tion is summed up by stack­ing them with a con­stant load. Geo­met­ri­cal adjust­ments to the instal­la­tion space can be made by inter­nal and exter­nal interlocking.

ADVANTAGES

  • Small adjust­ing trav­el, high load
  • Mate­r­i­al selec­tion adjust­ed to the requirements
  • Degres­sive to load-decreas­ing char­ac­ter­is­tic curve

INNOVATION

  • Bainitic hard­en­ing
  • Fine-blank­ing process for disc production
  • Tem­per­ing of indi­vid­ual parts

PRODUCTION

  • Form­ing simulation
  • In-house pro­to­type shop
  • Fatigue strength tests
  • Relax­ation tests

Automotive

VALVE SPRING

VALVE SPRINGS ARE HELICAL COMPRESSION SPRINGS FOR DYNAMIC STRESS UNDER INCREASED TEMPERATURE

Function:

Con­trol of valve move­ment in the valve train of an inter­nal com­bus­tion engine

Description:

Valve springs are high­ly loaded com­po­nents and there­fore pre­mi­um prod­ucts spe­cial­ly designed to meet the cus­tomer require­ments. An opti­mum devel­op­ment includes the indi­vid­ual kine­mat­ic analy­sis of the valve train, the sta­t­ic design of the spring tak­ing into account the wire pro­file, mate­r­i­al, spring shape, etc., as well as the dynam­ic pre­cal­cu­la­tion or mea­sure­ment of the valve train dynamics.

ADVANTAGES

  • Many years of experience
  • Large mar­ket share 

INNOVATION

  • SOF process
  • DMC laser coding

PRODUCTION

  • Dynam­ic simulation
  • In-house pro­to­type shop
  • Fatigue strength tests
  • Relax­ation tests

Automotive

WAVE SPRING

WAVE SPRINGS ARE COILED OR STAMPED ELASTIC PARTS

Function:

Wave springs can almost always replace heli­cal com­pres­sion springs. They are often used in sys­tems where a small axi­al spring length is required.

Description:

Wave springs are used very often for length com­pen­sa­tion and and pre­ten­sion­ing of bear­ings. The sim­plest form is a sin­gle lay­er wave spring ring which can have an open and a closed end. Main­ly flat wire is used, espe­cial­ly for mul­ti-lay­er wave springs. Sin­gle lay­er wave spring rings weld­ed at the end are used in clutches.

ADVANTAGES

  • Very small axi­al assem­bly space (up to 50% less com­pared with heli­cal com­pres­sion springs)
  • Var­i­ous design options
  • High appli­ca­tion knowl­edge which can be trans­ferred into the spring design.

INNOVATION

  • Devel­op­ment of a com­plex cal­cu­la­tion pro­gram for the design of non- lin­ear wave spring sys­tems (SpringDe­sign­er)
  • High­ly effi­cient weld­ing of wave spring rings by means of laser

PRODUCTION

  • In-house machin­ery divi­sion sup­ports auto­mat­ed pro­duc­tion process­es and pro­vides spe­cial solu­tions for the pro­duc­tion of wave springs
  • In-house process development

Automotive

Tension Springs

TENSION SPRINGS ARE COIL SPRINGS WHICH COUNTERACT THE AXIAL FORCE DIRECTED AT THE EXTENSION OF THE SPRING

Function:

Ten­sion springs belong to the group of coil springs, with the dif­fer­ence that the real­iza­tion of an “Inner pre­load F0” is possible.

Description:

Ten­sion springs are used in var­i­ous areas of the vehi­cle. They can be found, for exam­ple, in access sys­tems but also in brak­ing and inte­ri­or areas. Besides the actu­al spring design, the devel­op­ment com­pe­tence for some appli­ca­tions also includes con­sid­er­a­tion of the asso­ci­at­ed kinematics.

ADVANTAGES

  • Very high ini­tial ten­sion FO
  • Defined set­ting loss­es in the function
  • 100% load con­trol with­in the pro­duc­tion process

INNOVATION

  • Real­ized as an assem­bly includ­ing all asso­ci­at­ed exten­sion parts
  • Stress-opti­mized production

PRODUCTION

  • Pro­duc­tion of pro­to­types on series machines
  • Wide range of mate­r­i­al dimen­sions and qualities

The SCHERDELGroup: Mechan­i­cal Engineering