Air Spring Assembly
INDUSTRY CHALLENGES
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01Strict flatness requirements for the air spring inner support ring, with tolerances of ±1 mm and first-pass yield below 70%.
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02
Tight roundness requirements for crimped components, with dimensional deviation limited to 0.2 mm.
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03
Gap inspection has a false-call rate of around 8%, while roundness inspection accuracy remains challenging.
INDUSTRY SOLUTION
TZTEK provides high-precision, intelligent air spring assembly solutions covering assembly, crimping, and in-line inspection. A pneumatic assembly process combined with precision tooling and proprietary control algorithms minimizes relative movement between components, achieving assembly deviation of ≤1.2 mm and first-pass yield of up to 85%. A proprietary secondary correction mechanism further raises single-station yield to over 90%.
The crimping process uses a 12-segment synchronous crimping machine with precision force and displacement closed-loop control, achieving crimping deviation below 0.2 mm for consistent forming quality.
For inspection, proprietary AI deep-learning algorithms reduce gap-inspection false calls to below 2%. AI-based 3D modeling and metrology enable high-precision roundness inspection while maintaining production throughput and stability. The flexible line supports multiple air spring configurations for scalable production.
KEY ADVANTAGES
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Expertise in Inner Support Ring Assembly: Proven processes, proprietary development, and high-volume production experience.
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Crimping Expertise: Advanced forming processes and precision control backed by proven large-scale production deployment.
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Inspection Algorithms: Proprietary AI algorithms for accurate, stable inspection and continuous optimization.
