Challenge:
KUKA, a global leader in industrial robotics, was facing repeated mechanical issues in their high-precision robotic arms. The problem stemmed from the tension springs used in their robotic joints. These springs, provided by some other supplier, consistently failed before reaching the required fatigue cycles, leading to frequent breakdowns and costly downtime. Given the nature of KUKA’s operations, reliability and precision were critical, and the failures were negatively affecting production schedules and increasing maintenance costs.

Solution:
KUKA turned to EASON SPRING to provide a more durable and reliable solution. After detailed consultations with their engineering team, we conducted an in-depth analysis of the operational conditions, stress loads, and fatigue requirements for their robotic arms. Our team recommended custom-designed torsion springs made from high tensile strength steel, specifically engineered to handle the extreme stress these robotic arms encountered during operation.

In addition to using high-quality materials, we implemented a specialized heat treatment process to further improve the springs’ fatigue resistance. This ensured that the tension springs could endure a significantly higher number of operational cycles without failure, even under the constant, repetitive motions typical in robotic applications.

Results:
The custom tension springs we provided resulted in a 30% increase in the operational lifespan of KUKA’s robotic arms. The new springs not only exceeded the expected fatigue cycle requirements but also reduced the frequency of breakdowns, minimizing downtime and allowing for smoother, uninterrupted operations. This improvement led to reduced maintenance costs and enhanced productivity on KUKA’s production lines.