As Brimotech was already involved in another project for this client, we were approached to solve this problem. With shading systems, reliability is crucial, especially when it comes to large and complex installations such as conservatory awnings with a projection of up to 5 metres and an area of 30m². When one of our customers heard unexpected noises when operating their shading systems, we knew a solution was needed that would operate both quietly and efficiently. This success story shows how Brimotech rose to the challenge and designed an improved gas spring that met all requirements.

Customer problem statement

Our client produces high-quality sun protection systems that are unique because of their large dimensions and complex applications. The first series of these systems was equipped with gas springs from a fellow company from Germany, and initially everything worked satisfactorily. However, over time, the systems started making strange snapping noises, especially after extended periods of downtime. This noise was a source of concern for our customer, who feared possible damage or loss of performance of the blinds.

Since Brimotech was already involved in another project for this client, we were approached to solve this problem. The challenge lay in the fact that the gas springs had a long stroke length of 800mm, combined with a piston rod diameter of only 10mm and forces of up to 1200N. These specifications required very precise guidance to avoid buckling and the associated noise.

Approach from Brimotech

Our team analysed the existing gas springs and found that the noise was caused by the piston rod being able to clamp when sliding in, causing a snapping noise. This problem was due to the way the piston rod behaved under load, almost like spaghetti that can kink. We decided to modify our standard steel guide bushing by fitting it with a special Igus® bearing, which significantly improved the sliding characteristics.

Although this modification reduced noise, it had not completely disappeared. Therefore, we also introduced an oil chamber and a specially extended guide in the gas spring. This combination completely eliminated noise and made the system more stable and reliable.

Results

These modifications allowed our customer to offer a very stable and reliable shading system, without the annoying noises that previously occurred. In addition, we ensured that the long 1750mm gas springs were delivered in special wooden crates, introducing a deposit system to reuse the crates, which also contributes to environmental friendliness. Our client has now become one of the biggest players in Europe in this type of awning.

Conclusion

Brimotech’s modifications to the gas springs not only solved the noise problem, but also contributed to the overall reliability and durability of the awning systems. This project shows our commitment to providing customised solutions that meet the highest standards and contribute to our customers’ success.