Answer
In high-volume automotive production, such as planetary gear sets, wave springs are often installed using automated 'pick and place' systems. The primary challenge is 'tangling' or nesting, where springs interlock during bulk storage or vibratory bowl feeding. To prevent this, 'tangle-resistant' designs with overlapping ends or continuous coiling are used. Another challenge is ensuring correct orientation; while most wave springs are symmetrical, those with 'shim ends' must be oriented so the flat surface faces the critical mating part. Automated systems use optical sensors to verify the presence of the spring and laser displacement sensors to confirm that the spring is seated flat and has not been 'cocked' or tilted during insertion, which would lead to non-uniform pressure.
