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Precision Springs at Their Best
The expertise of our specialists is reflected in every one of our products. We support our customers from spring design throughout to the finished component. Whether compression springs, tension springs, leg springs, wire-formed parts, or spring-related assemblies - high-quality and cost-effective processing is given utmost priority right from the project planning stage. With Hans Ziller GmbH as your partner, you gain far more than just a spring supplier. We see ourselves as specialists and service providers in all matters related to springs.
Winding
The winding of the spring body is the first step in the spring manufacturing process and lays the foundation for the final product. In our spring coiling machines, the raw material undergoes a cold forming process without material removal, transforming it into a spring blank. We keep our machinery up to date with the latest technology to ensure optimum conditions for producing springs with wire diameters ranging from 0.1 to 18 millimetres. Using camera or laser-based measuring systems, we closely monitor the process to ensure precision in the production of spring blanks.
Grinding
Grinding is an important and costly step in the manufacturing process of compression springs. At Hans Ziller GmbH, both through-feed and plunge grinding techniques are used. State-of-the-art feeding systems automatically load the grinding machines for large-scale production. With 30 machines in operation, we ensure that the spring blanks are ground to the highest standards of parallelism and concentricity.
Heat Treatment
In order to eliminate unwanted internal stresses that could adversely affect the spring's properties, the springs undergo a heat treatment process after being coiled. Depending on the material, this step takes place at temperatures between 240 and 650 degrees Celsius. At Hans Ziller GmbH, heat treatment is carried out either in chamber furnaces or in a continuous process using tunnel furnaces.
Shot Peening
During the shot peening process, the surface of the spring is hardened and compacted. We increase the fatigue strength of highly dynamically loaded components by introducing compressive residual stresses into the material. In our modern trough belt systems, we use shot media with diameters of 0.4 and 0.6 millimeters. This ensures high-quality results in terms of fatigue strength that significantly exceed common industry standards.
Pre-setting
To prevent plastic deformation of the spring during its service life, Hans Ziller GmbH pre-sets the springs to customer specifications. This process involves applying a deliberate load that exceeds the elastic limit of the material, anticipating future loss of force and length. Using a variety of machines, we subject the springs to either a hot or cold pre-setting process to ensure that they withstand the specific demands of the customer's intended use.
Custom Packaging
Special packaging plays a crucial role in many processes in the world of technical springs. It is used to protect the springs and improve part handling. As springs can easily become entangled or caught, custom packaging solutions help to prevent this.
– Packaging in VCI bags
– Packaging in bags or small load carriers (KLTs)
– Other customer-supplied packaging
– Application on adhesive foil
– Application on magnetic plate
– Insertion into tubes or pipes
– Separation into blister packs
– Separation into trays or combs