and preloading bearings for optimal performance. Spirolox retaining rings provide 360° retention across multiple internal and external applications, whilst Hoopsters are particularly well suited to tubular frames due to the shallow groove requirements. Design engineers are moving away from
stamped springs and retaining rings, and towards ones made via edgewinding. This method involves coiling wire on edge to create springs or retaining rings to precise specifications. The process gives more flexibility to manufacturers in terms of bespoke sizing and allows wider material choices to be considered. In addition, the circular grain metallurgy
increases the strength and stability of the material – cold rolling causes metal grains to elongate and lock together, which improves mechanical properties. Since the grain follows the direction of the coil, it provides better mechanical properties than if it were to be stamped from sheet material where grain flow is in just one direction.
One example of a component made by edgewinding is a Crest to Crest wave spring, an alternative to the traditional coil spring. Crest to Crest Wave springs are flat-wire compression springs offering the same spring force as a traditional wire round spring, but at 50% of the operating height. Single turn wave springs are perfect for
preloading bearings while, for applications with higher forces, designersmay prefer nested wave springs composed of multiple layers nested together to provide a compact high force solution. The potential for a 50% saving in space
benefits the work of design engineers working on electric drive designs for e-bikes, which must be compact so that they can easily be integrated into different bicycle frames. The space-saving opens up new design possibilities, in particular reducing material usage and making bikes lighter – a significant efficiency advantage. In e-bike drivetrain technology, retaining rings are used for securing bearings on shafts, and
SimonWard
as retaining elements in gear assemblies. Here too, designers are opting of flat-wire spirals due to their improved performance. Compared with traditional stamped circlips (DIN 471/472), they have no protruding lugs and, depending on the variant, no gap in the circumference. Even in situations with limited radial space
or where rotating components require minimal imbalance, flat wire retaining rings are the preferred choice of many e-bike designers. The edgewinding process creates
components with many technical benefits. From space saving to easy installation, wave springs and retaining rings can help UK e-bike manufacturers produce appealing products to support this growing industry.
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