Automatic Gas Spring Filling Station

Automatic Gas Spring Filling Station – Custom-Designed Filling Solution for Maximum Precision

The Automatic Gas Spring Filling Station developed by BIBUS Kft. is a fully customized automation solution designed for accurate, repeatable and efficient filling and quality verification of gas springs. Every system is engineered according to the customer's production requirements, ensuring seamless integration into existing manufacturing processes while maximizing productivity, process reliability and product consistency.

Unlike standard filling equipment, every BIBUS gas spring filling station is developed through a collaborative engineering process. Our specialists work closely with customers from the first concept through design, manufacturing, commissioning and operator training to create a system perfectly matching the production environment and quality expectations.

The station automates the complete filling process, including positioning, filling, pressure regulation, force measurement, quality evaluation, labeling and production data management. PLC-based control eliminates operator-dependent adjustments, ensuring repeatable results while significantly reducing production time and minimizing human errors.

Using servo-controlled high-pressure proportional valves, force measurement technology and intelligent software algorithms, the system automatically compensates for process variables such as temperature, enabling exceptionally accurate gas spring filling with force tolerances as low as ±10–20 N under suitable operating conditions.

The integrated recipe management allows different gas spring types to be stored and recalled instantly, reducing setup times and simplifying production changeovers. The station supports barcode or serial number generation, automatic label printing, ERP connectivity and multilingual HMI interfaces, making it suitable for both local production facilities and international manufacturing environments.

Designed according to modern industrial safety standards, the machine incorporates safety light curtains, emergency stop functions, pressure monitoring and mechanical overpressure protection to ensure safe operation for personnel and equipment.

Because every production process is different, BIBUS develops each filling station individually. Mechanical design, electrical engineering, PLC software, HMI visualization and automation functions can all be adapted to customer-specific requirements, allowing future expansion and functional upgrades whenever production needs evolve.

Key Benefits

• Fully customized engineering according to customer requirements
• High-speed automatic gas spring filling
• Excellent filling accuracy and repeatability
• Automatic force measurement and quality evaluation
• PLC-controlled filling process independent of operator experience
• Intelligent temperature compensation
• Recipe management for multiple gas spring types
• Automatic label printing and serial number generation
• ERP and production data integration
• Remote diagnostics and software support
• High operator safety
• Easy maintenance
• Expandable modular architecture

Main Features

• Servo-controlled high-pressure proportional valve
• High-precision force measurement cell
• Servo-driven linear positioning system
• Ball screw linear actuator
• Programmable PLC control
• 12-inch HMI touchscreen
• EtherCAT communication
• Integrated pressure monitoring
• Automatic OK / NOK evaluation
• Zebra printer compatibility
• CSV recipe import/export
• Multilingual software
• Remote maintenance capability

Operating Principle

The operator inserts the gas spring into the filling station and selects the appropriate product recipe. The automated system positions the filling head, performs the filling sequence under PLC control and continuously monitors pressure and force values throughout the process.

After filling, the system measures the resulting force and automatically determines whether the gas spring meets the specified quality criteria. Approved products can immediately receive a printed identification label, while production data can be transferred to higher-level manufacturing systems. This automated workflow ensures consistent quality, minimizes operator influence and significantly improves production efficiency.

Engineering Process

Every Automatic Gas Spring Filling Station is developed through a structured engineering process carried out jointly by the customer and the BIBUS engineering team.

The project begins with analysing production requirements, product variants, cycle time expectations and integration possibilities. Based on this information, our engineers design the complete mechanical structure, electrical architecture and automation concept. Software development, HMI design and safety functions are individually configured for each application.

Following assembly, the system undergoes extensive testing before installation and commissioning at the customer's facility. BIBUS also provides comprehensive operator and maintenance training, ensuring that production personnel can safely and efficiently operate the equipment from day one. Ongoing technical support, remote diagnostics and future software enhancements are available whenever required.

Applications

• Gas spring manufacturing
• Automotive industry
• Industrial component production
• Mechanical engineering
• OEM manufacturing
• High-volume production
• Quality control applications
• Automated assembly lines

Why BIBUS? + Related Technologies

BIBUS Kft. delivers complete engineering solutions rather than standard machines. Every filling station is designed around the customer's production objectives using a system engineering approach that combines mechanical engineering, industrial automation and intelligent software development.

Our multidisciplinary expertise covers mechanical design, pneumatics, hydraulics, electric drives, motion control, industrial communication, PLC programming, HMI development and machine safety. This enables us to deliver reliable, future-proof production systems tailored to individual manufacturing requirements.

Beyond system delivery, BIBUS supports customers throughout the entire lifecycle of the equipment with commissioning, operator training, technical consulting, software updates, remote diagnostics and long-term service support.