Compact Spring and End Cap Assembly Machine Case Study

Brief

Small component assembly may appear simple, but repetitive manual operation can easily cause 

inconsistent positioning, unstable assembly force and low production efficiency.

For this project, TIMEAST developed a compact semi-automatic machine for assembling a spring

with an end cap. The equipment combines a customized positioning fixture, AirTac pneumatic 

cylinders, a Leadshine motor, push-button control and safety light curtain protection.

With a footprint of only 58 x 40 x 39 cm, the machine can be installed directly beside an existing 

production line or used as an independent assembly workstation.The completed equipment achieves

an approximate production capacity of 500–600 pieces per hour while maintaining a simple operating 

process and compact machine structure.

Machine Operation Video

The following video shows the actual operating process of the compact semi-automatic spring and

end cap assembly machine, including manual component loading, button activation and the automatic

assembly cycle.

The operator manually loads the spring and end cap into the customized fixture. After the cycle is 

activated, the machine completes the controlled assembly movement and automatically returns to

its initial position.

Customer Requirements

The customer needed a small custom machine to improve the assembly of a spring and end cap.

The original process depended heavily on manual handling. Because the spring is small and can

move during installation, the position and assembly result may vary between operators.

The customer did not require a large fully automatic production line. Instead, the main 

requirements were:

• Compact machine dimensions

• Simple manual loading and unloading

• Stable spring and end cap positioning

• Repeatable assembly movement

• Easy push-button operation

• Suitable safety protection

• Production capacity of approximately 500–600 pieces per hour

• Short manufacturing and delivery time

Based on the customer’s product and production requirements, TIMEAST designed a compact 

semi-automatic assembly workstation.

Project Challenges

Positioning Small Components

The spring and end cap must be positioned correctly before the assembly movement begins. If either

component moves inside the fixture, the final assembly may become unstable.A product-specific 

fixture was therefore required to support the components and keep them aligned during operation.

Controlling the Assembly Movement

Manual assembly force may vary from one operator to another. Excessive force can damage the 

component, while insufficient force may result in incomplete assembly.The machine needed a

controlled and repeatable motion system to reduce dependence on manual force.

Maintaining a Compact Footprint

The customer wanted a machine that could be placed on a workbench or installed beside existing 

production equipment.The mechanical structure, pneumatic components, motor and control system 

therefore had to be integrated into a machine measuring only 58 x 40 x 39 cm.

Operator Safety

Because the operator loads and unloads the components manually, the working area must be protected 

during the automatic assembly cycle.A safety light curtain was installed in front of the working area 

to help prevent the equipment from operating when the protected area is interrupted.

TIMEAST Custom Solution

TIMEAST developed a compact semi-automatic spring and end cap assembly machine based on

the customer’s sample parts and production process.The machine uses a customized fixture to position

the spring and end cap before assembly. AirTac pneumatic

cylinders provide reliable pneumatic movement, while a Leadshine motor is used for controlled 

mechanical motion.The operator completes loading and unloading manually and starts the assembly

cycle through the machine buttons. Once activated, the equipment performs the programmed assembly

movement and then automatically returns to its original position.

This design offers a practical balance between manual operation and automation. It improves consistency 

without requiring the cost, floor space or complexity of a fully automatic production line.

Machine Working Process

Step 1: Manual Loading

The operator places the spring and end cap into the customized positioning fixture.

Step 2: Component Positioning

The fixture supports and aligns the components in the required assembly position.

Step 3: Cycle Activation

After confirming that the components are correctly loaded, the operator starts the assembly cycle using 

the control buttons.

Step 4: Automatic Assembly

The AirTac cylinders and Leadshine motor perform the programmed assembly movement.

Step 5: Mechanism Return

After the assembly operation is completed, the moving mechanism automatically returns to its 

initial position.

Step 6: Manual Unloading

The operator removes the assembled product and loads the next set of components.

This straightforward process makes the machine easy to operate and suitable for repetitive 

small-part assembly.

Main Equipment Features

Customized Product Fixture

The fixture is designed according to the shape and dimensions of the customer’s spring and 

end cap. It helps keep both components stable during the assembly cycle.

Compact Machine Design

The complete machine measures approximately 58 x 40 x 39 cm and weighs about 30 kg.

Its compact structure makes it suitable for:

• Workbench installation

• Small production areas

• Independent assembly stations

• Installation beside an existing production line

• Pilot production and medium-volume manufacturing

AirTac Pneumatic Components

AirTac cylinders are used for the pneumatic movements of the machine.

The recommended compressed air pressure is 0.5–0.7 MPa.

Leadshine Motor

A Leadshine motor provides controlled motion for the assembly mechanism, supporting stable

and repeatable operation.

Push-Button Control

The machine uses a simple button-based control method. Operators can start and control the 

production cycle without a complicated operating interface.

Safety Light Curtain

A safety light curtain, also known as a safety raster, protects the loading and assembly area.

When the protected light beam is interrupted, the machine control system prevents or interrupts 

the assembly movement to improve operator safety.

Standard Electrical Supply

The machine operates with an AC 220 V, 50 Hz power supply, making it suitable for installation

in many standard industrial production environments.

Technical Specifications

Actual production capacity may vary depending on the component structure, operator loading

speed and final assembly requirements.

Project Results

The completed machine provided the customer with a compact and practical solution for 

spring and end cap assembly.The main results included:

• Approximate production capacity of 500–600 pieces per hour

• More consistent component positioning

• Reduced dependence on manual assembly force

• Simple loading and unloading process

• Improved operator safety through light curtain protection

• Compact installation without requiring a large production area

• Easy integration into an existing production process

• Completed with a lead time of 10 working days

The project demonstrates that an effective automation solution does not always need to be

large or highly complex.

For many small-part assembly applications, a compact semi-automatic workstation can 

provide the required production capacity, consistency and safety while keeping the equipment

investment and factory space under control.

Suitable Applications

This type of customized assembly machine can be adapted for other small-component applications,

 including:

• Spring insertion

• End cap installation

• Plastic component press fitting

• Pin insertion

• Small metal and plastic part assembly

• Connector component assembly

• Product positioning and pressing

• Semi-automatic component installation

The fixture, assembly mechanism, cylinder stroke, motor movement and control sequence can all be

customized according to the customer’s product.

Why Choose a Compact Semi-Automatic Workstation?

A fully automatic production line is not always the most economical solution.

For products with moderate production volumes or processes that still require flexible manual 

loading, a compact semi-automatic machine can offer several advantages:

• Lower equipment investment

• Shorter project lead time

• Smaller machine footprint

• Easier operation and maintenance

• Faster product changeover

• Better consistency than completely manual assembly

• Easier integration into an existing workshop

This project was completed within 10 working days, demonstrating TIMEAST’s ability to 

provide fast and practical custom automation solutions for clearly defined assembly processes.

Custom Small-Part Assembly Solutions

TIMEAST designs custom assembly machines ranging from compact semi-automatic workstations

 to multi-station fully automatic production lines.

Our engineering team can develop the machine structure, product fixture, pneumatic system, motion

 control and safety system according to your product and production requirements.

Need a custom machine for spring insertion, end cap installation, press fitting or small-component assembly?

Send us your product drawings, sample parts, required production capacity and assembly process. 

TIMEAST will evaluate the application and recommend a suitable automation solution.