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Gas springs main assembly line

Gas springs main assembly line

Robotic main assembly line for gas springs with different diameter of the piston rod and the outer diameter of the cylinder. The line also includes gas filling and a functional test.

Main features

Parameter Value
Personnel 1 operator
Dimensions 14,5 x 10 x 2,5 m
PLC 2xPLC MELSEC iQ-R (Mitsubishi)
Assignment Main assembly of gas springs
Piston rod diameter range: 6-14 mm
Cylinder outer diameter range: 15-28 mm

Initial assumptions

The aim of the project was to develop and build a main assembly line for gas springs with all the necessary functionalities for gassing and functional testing. The assumptions were made that the line was to occupy as little space as possible and involve minimal service. Our advantage in this case was our experience in the automation and robotization of processes related to the production of shock absorbers and gas springs.

Robotization of the gas springs assembly

Limiting the space occupied by the line and reducing the service, but at the same time ensuring the desired OEE value, we decided to solve by robotizing the entire process. Two types of robots have been proposed – SCARA – for fast component feeding and 6-axis robots for operating in the area of ​​the gas filling, testing and unloading module. A number of manipulation axes were also designed, enabling the correct course of the process in the number of 34. The whole was linked by a fast CC Link IE Field (1 Gbps) network.

Modular line structure

  • 1. Module 1 – loading the piston rods
  • 2. Module 2 – loading cylinders
  • 3. Module 3 – piston rod assembly
  • 4. Module 4 – spring assembly
  • 5. Module 5 – gassing and spring test
  • 6. Module 5 – unloading


Work on the implementation of this project is a great example of good cooperation with global suppliers of solutions in the field of automation and robotization. In this particular case, it was Mitsubishi Electric. It was decided for full hardware compatibility and large configuration possibilities, especially when it comes to servo drives. The assumed properties of the line were achieved, including the reduction of the occupied space by approx. 40% in relation to typical solutions. Thanks to robotization, the necessary line maintenance has been reduced from 5 to 1 operator.

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