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Springs can be found in a multitude of technologies we use in our every day lives. Although the vehicles we depend on for our day-to-day transportation needs would not be possible without motor spring technology, the use of springs in the automotive manufacture has changed significantly over the years.

Here, we take a deeper look into the types of springs that have been used in car manufacture throughout the years, and the differences between these.

Leaf Springs

The use of leaf springs in automobiles had been common practice for many years; they were most commonly used in suspension to ensure a smoother ride for vehicles carrying heavier loads. Whilst you will still find this type of spring in some older vehicles (especially in lorries or vans), they have made way for updated materials and components that are more durable and efficient.

The first use of leaf springs in vehicles goes back as far as the early 19^th century, with the first spring-suspension vehicle designed and patented by British inventor Obadiah Elliot. The vehicle consisted of two steel leaf springs on each side of a carriage on both axles to ensure a smoother, more stable ride for carriages carrying heavy loads.

The effect of adding the leaf springs to carriages was so profound that within the next decade most British horse carriages were equipped with them. Although most carriages utilised leaf springs in the form of those invented by Elliot, wooden versions of the springs were also used to cut costs and avoid taxation for carriages carrying lighter loads.

Whilst the use of leaf springs is slowly being phased out by vehicle manufacturers now, these springs have played a vital role in the development of vehicles over the past two century’s. Without the use of leaf springs within automotive design, the smooth ride we experience in our cars today would not have been possible.

In their latest iteration, leaf springs work with the topmost and longest strip of steel, known as the ‘master leaf.’ Being curled at each end to resemble something like an eye, this is then connected to the frame of the suspension. Each leaf spring below the ‘master leaf’ are progressively shorter and less curved to allow the spring to absorb the shock from travelling over a bump or pothole in the road.

Coil Springs

More commonly used in vehicle suspension today, coil springs (also known as helical springs), help to support the weight of the car and allow the vehicle to remain stable, even in extremely rough driving conditions. This type of spring is ideally suited for vehicle suspension, as it can store energy and release it later when needed. It also absorbs shock and maintains force between two contacting surfaces.

When your vehicle goes over a pothole or bump in the road, the coil spring will compress and absorb the impact of the bump. Once the road becomes even again, the spring releases the energy stored and returns to its original state. Due to the shock-absorbing purpose this spring brings, they are built to last and are often coated with a vinyl coating to ensure they are resistant to corrosion.

Coilover Springs

Finally, the most advanced type of spring used in the suspension of vehicles are coilover springs. These springs are only used in the most advanced new vehicles on the market and offer the user of the vehicle the smoothest journey available today.

You’ll find coilover springs at the front and back of a car, offering a consistently smooth ride throughout the vehicle. They also provide exceptionally good performance, which is why you’ll find this type of spring used in all manner of performance and racing cars.

Audi’s Innovative Suspension Springs

With the goal of refining the sphere of lightweight automobiles, Audi released a new type of suspension spring back in 2014.

These springs are unusual in a variety of subtle ways:

The Audi suspension springs were manufactured from glass fibre-reinforced polymer (GRP) in a light green colouration.
The strand of these springs is thicker than the norm and has a larger diameter at the expense of more coils.
The GRP springs are approximately 40% lighter than the springs previously used by Audi, allowing springs of a similar performance to be made according to incredibly lightweight specifications.

The result of utilising these springs has led to more precise driving experience with reduced vibration. The springs also won’t corrode, suffer chemical damage and require less energy to be produced than the more commonly produced suspension springs.

As spring manufacturers, we know the importance of ensuring that all springs we produce are fit for purpose. All of our springs are extremely durable and are made with the care and precision needed to guarantee that we only produce springs of the highest quality.

As one of the UK’s leading spring and pressing manufacturers, European Springs & Pressings has recently doubled the size of its Cornwall operation with the purchase of a new 2000 square metre site.

With factories in Redruth, Cornwall and Beckenham near London, European Springs & Pressings has multiplied the size of its South West operation to over 4000 square metres with the purchase of new premises in Penryn, Cornwall.

Michael Gibbs, Managing Director of European Springs & Pressings in Cornwall says: “Purchasing the new Penryn based factory is a really exciting new chapter for everyone in European Springs & Pressings and a fantastic achievement in our 70^th year. This significant investment allows for continual growth across our industrial and automotive product divisions and affords new opportunities for expansion across the sites in Redruth and Penryn.”

The new site will specialise in the industrial element of the business, supplying springs across multiple sectors ranging from aerospace to rail to the food and drink sector.

Gibbs concludes: “In the last year turnover in Cornwall has increased by 40% and we’ve grown from a team of 43 to over 60. Five years ago we relocated to a larger site in Redruth from Indian Queens – we then extended that factory to meet demand, and have been rapidly outgrowing our current premises ever since. This year we’ve invested over £3m in new infrastructure, machinery and technologies, which is a strong indicator of the strength of manufacturing in the region and we’re delighted to be further investing in, and supporting, the South West’s £14bn manufacturing industry.”

Over 20 staff will be based at the new site which is planned to be fully operational from Q4 2018.

Springs have been at the heart of engineering since before the Industrial Revolution and now they are set to be a key part of today’s Robotic Revolution.

European Springs & Pressings in Redruth, Cornwall has been working with the French based Robot Studio, an internationally recognised specialist supplier of biomimetic robot hardware, evolving the next level of robot interaction.

Rob Knight, founder of The Robot Studio, says: “At the moment there are a lot of single purpose robots, particularly in factories, and they are powerful and expensive. Domestic robots, thus far, are limited to light tasks like vacuum cleaning and all attempts to move industrial technology across have failed simply because factory robots rely on precision. They are stiff and heavy and can only operate in a completely controlled environment.

The Robot Studio, having achieved exceptional success at mastering robotic builds, copying the biomechanical features of the human body, is now looking at how to properly control a system as complex as the human body through Deep Learning.

Knight continues: “Our robots originate from a completely different aim which is to build a body capable of shedding some light on the problem of human consciousness. Phenomenological consciousness, the sensation of existing, is a notoriously difficult area to study – it is like the light in a fridge – it is always there when you look.”

The European Springs & Pressings springs feature in a number of new mechanics, running on Nvidia’s GPU (the brain of computers and robots), developing an open source system, using blockchain, that facilitates the enormous transfer of human knowledge, economically fairly, to robot systems – achieving robots who are able to perceive and understand the world.

Knight concludes: “Our ambition is to develop a meaningful robot labour system that benefits all of humankind – well, you’ve got to aim high, haven’t you?”

Michael Gibbs, Managing Director of European Springs & Pressings: “The diversity of the industries our bespoke products support is extraordinary and to be a very small part of what is destined to be a huge global phenomenon, is bionic.”

This year’s Engineering Design Show is an exciting time for European Springs, as we have our very own stand. The event will be taking place from the 17^th to the 18^th October 2018 at the Ricoh Arena in Coventry. The Engineering Design show brings together the entire engineering sector for two days of ideas, inspiration, networking and innovation. The event is a great opportunity both for companies interested in showcasing their products and services and for attendees looking for engineering expertise and design solutions.

Here we’re going to take a look at what the Engineering Design Show is, why companies should be exhibiting there and where you can find European Springs at this year’s event.

What is the Engineering Design Show?

The Engineering Design Show is the UK’s only event entirely dedicated to engineering, electronics and embedded design. With more than twenty-five conference speakers, a wide-range of free-to-attend workshops, exciting feature zones and over 220 exhibitors (ourselves included) who will be showcasing their products and services, it is the only event to cater to all aspects of engineering that can be found under one roof in one dynamic, exciting environment.

Entry to the design show is free, and visitors will have unrivalled access to expert speakers exploring best practice, new design techniques and industry issues. The event sees the return of the Innovation Zone, a feature area focused on introducing visitors to ground-breaking technology, plus new additions including EDS TV – all designed to offer visitors a fully immersive experience of innovation, inspiration, interaction and insight.

This year there is features a fantastic line up of speakers from all across the industry, such as Nigel Barrow, the technical manager at EMS-GRIVORY who has forty years of experience in the plastics industry; John Reilly, the Senior Partner Manager for Northern Europe at Arm, who has over fifteen years’ experience in technical sales; and Gary Hinde, a Product Engineering Architect with Cadence Design Systems with over 25 years of experience in technical roles.

There will also be a range of conferences taking place on topics such as energy efficiency, legislation, advanced manufacturing techniques, sustainable design, mechatronics and design for aerospace and many more.

Why Exhibit at the Engineering Design Show?

Exhibiting at the Engineering Design Show is the most effective way for a company to maximise its exposure to the design engineering community. With over 4,000 visitors from the design engineering community expected to attend, and an estimated 72% of those attendees specifically looking to source suppliers (39% of which are looking to find a solution to a specific design problem), companies can’t afford to miss this amazing opportunity for exposure to potential clients.

Where Can You Find Us There?

This year, European Springs will be attending, and you can find us at stand number G85. As spring manufacturers with exceptional engineering expertise in the spring coiling, wire forms, as well as bespoke pressings and bespoke stampings, we will be showcasing some of our fantastic products during the design show to show prospective clients what it is we do best.

With recent reports of the number of apprenticeships falling by 30% in the last 12 months, European Springs & Pressings are amongst a number of manufacturers determined to enhance apprenticeships social mobility, addressing the UK’s productivity gap.

Kick starting their engineering careers with a spring in their step, five new apprentices launched their learning at European Springs & Pressings in Beckenham this month.

This next generation of engineers are studying a BTEC level 3 in engineering operations and maintenance, with an accompanying NVQ in mechanical manufacturing engineering which follows the nationally recognised mechanical manufacturing apprenticeship framework.

Stuart McSheehy, Managing Director of the Beckenham manufacturing plant says: “The value of apprenticeships can never be undervalued. Training a new generation of manufacturing practitioners, offering them the opportunity to gain experience and qualifications in the workplace, establishes a secure foundation for their future and it’s a part of our work we’re especially proud of.”

McSheehy concludes: “We recognise that apprenticeships are particularly beneficial to a broad section of our youth society. However, they are also hugely beneficial to us as well, as they diversify the workplace, bring different talents and backgrounds to the business and create a dynamic workforce. We welcome the new faces and look forward to seeing their progression as they are given the opportunities to shine.”

All the apprentices, aged from 16-19 will be on day release to Mid Kent College, starting next week.

Despite the big-name, high-profile infrastructure projects – Hinkley Point C nuclear power station and High Speed 2 rail link to name just two – and the news that the engineering sector generates around a quarter of the nation’s GDP, equating to approximately £420.5 billion, the issue of a skills shortage facing the industry does not appear to be going away any time soon.

Some years ago – five to be precise – we wrote an article about the gap in the labour market, yet since then not much seems to have changed in terms of either the numbers of engineers coming through the system or those still needed to meet future demand.

That almost three-quarters of businesses stated they were not confident there would be enough people with the skills to fill their high-skilled job vacancies should come as no surprise. The evidence gathered by Engineering UK in their 2018 publication, The State of Engineering, highlights that the vacancy ratio has remained at 2.6 vacancies for every 100 jobs filled.

In order for the UK to remain competitive and equipped to deal with the pace of technological and socio-economic change, this is an issue that needs to be urgently addressed, particularly if we want to see the kinds of infrastructure investment and progression that a modern-day economy needs. Just to deliver the proposed upgrades to the rail network, for example, a further 7,200 technical and engineering workers will be required by 2020.

As spring manufacturers, we continually keep a close eye on issues affecting the wider engineering sector. Here, we detail some of the key things that need to be addressed in the coming years.

Engineering for the Future

It is clear that to continue as we are and hope that the ingenuity of engineering will solve its own problems is not only unrealistic but also unlikely. The fact that we wrote on this subject half a decade ago and are in the same position today underlines this point.

The continued lack of certainty around a post-Brexit Britain doesn’t help matters; however, it is not sufficient to use that as a reason for not taking any action at all. Intervention is needed, and there are a number of steps that can be and, indeed, are being taken.

Surely a quick win would be for engineering as a discipline to tap into non-traditional sectors of the labour market and diversify its workforce. In 2016, women accounted for 46.9% of the overall working population in the UK, yet they represent less than a fifth of the engineering industry in general, and even less (12%) of the core and related-engineering roles.

Diversity Still an Issue in Engineering

When the figures are examined, it shows that the number of women entering the field decreases at various stages; at secondary school level, the number of boys taking STEM subjects is almost twice that of girls, whilst even fewer women are making it through technical education. In England between 2015 and 2016, only 7.5% of engineering-related apprenticeships were completed by women.

This lack of diversity is not just restricted to gender: an even lower proportion of apprenticeships – 6.8% – in the field of engineering were completed by candidates of black or mixed ethnicity, despite this demographic making up 12% of the UK workforce. Work, therefore, needs to be done to understand what barriers are preventing significant diversity in the field of engineering.

The demand for skilled engineering labour has had a positive influence on remuneration; Engineering UK found that whilst the average salary in the UK in 2016 was £28,195, the median salaries of full-time employees working in engineering in 2016 range between £32,987 and £47,394. So from that perspective, it shouldn’t be that difficult to persuade those already of working age but not engaged in the labour market to make a transition into engineering, with the right support.

Young People and Engineering

Steps are being taken to increase the number of young people entering the educational pipeline towards engineering. The Technical and Further Education Act from 2017 aims to address this specific issue by looking at the perceived low value of many apprenticeship schemes, reducing or removing some of the complexities within the system itself and also compelling schools to improve the access for their students to Higher Education providers.

There is ongoing monitoring of the government-proposed framework for fifteen technical education routes for both employment-based and college-based training, an element of which includes the introduction of T-Levels. Delivered as part of the Post-16 Skills Plan, these proposed reforms will also include the creation of new apprenticeship standards and degree apprenticeships, the latter to assuage employers’ concerns that degree-led education does not place sufficient emphasis on practical or problem-solving skills.

Additional measures are also being taken to encourage young people to consider a career in engineering; the diversity of the profession, the comparatively higher average salaries, along with emerging new technologies and practices are all positive drivers.

Until the UK has fully agreed withdrawal terms from the EU, there will be continued uncertainty; however, it is becoming clearer by the day that engineering will not be able to rely on migrant labour to apply a temporary fix to the skills shortage. Therefore, a coherent and decisive plan must be put into place to ensure that an industry, which contributed £1.23 trillion of the £5.3 trillion total turnover generated by the UK in the financial year 2015-2016, not only survives but evolves.

Category: News & Updates