Whilst looking for a new and complex component to be installed in the centre console of its latest model, a well-known Electric Vehicle manufacturer based in the USA has worked closely with TR Fastenings to create a tailored spring and spool system, in collaboration with its global sales & engineering team.
Patrik Ringdahl, engineering manager at TR Fastenings who worked on this project, explains more: “The automotive industry has very high demands for precision, quality, and consistency. The EV manufacturer required bespoke spring and spool products for integration in the interior of the car. The challenge was to achieve precise and consistent movement of the centre console’s sliding mechanisms, with three variations developed for installation in the tray, cup holder and lid.”
The solution is a bespoke spring which is preassembled to a polymer spool. Patrik continues: “The customer struggled to find a partner capable of supplying the integrated spring and spool unit, and developing clear specifications for such a product was unfamiliar terrain for them – and at first, even for us. With the support from within our vast array of approved manufacturing sources, we were soon able to establish a technically feasible concept solution.”
In order to create a smooth and continuous motion, the spring performance was matched with a damper to ensure the consol travelled smoothly, even when subject to vibrations due to vehicle movement. The spool was manufactured from a specific polymer and designed to align with the geometry of the spring and mating carrier components – which enabled low friction when sliding the assembled parts without stick-slip, causing squeaking. Ultimately, the spring and spool assembly translates rotational torque into a linear sliding motion.
TR teams from the USA and Sweden worked alongside global manufacturers to solve this engineering challenge. “We did extensive research and had many interactions with experts in the manufacturing field. These relationships are so important. To have transparency around the challenges and capabilities – this open communication helps us find the right solution,” explains Patrik. Despite the initial challenge, TR was able to provide a full-service provision, offering extensive technical expertise from initial design and prototyping of the product to full serial production.
Patrik adds: “One of our greatest strengths is the breadth and diversity of our manufacturing capabilities. Thanks to our supplier relationships and our strong understanding of the manufacturing technologies – this helps us visualise how the product should be made.”
Through collaboration with its customers, as well as utilising its own global teams, TR has created a custom spring and spool system specially tailored to its customer’s requirements.
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