Spring assembly and method

1. A method of assembling a spring assembly; the method comprising:

providing a coil spring having first and second opposite spring ends and an axis;

providing a tube having an interior space and a first retaining structure at a first end of the tube such that the coil spring transmits force to the tube upon insertion of the coil spring into a second end of the tube;

providing an elongated rod having first and second rod ends;

positioning the rod in the tube with the first rod end toward the first tube end and the second rod end toward the second tube end;

positioning the spring in the tube with the first end of the coil spring engaging the first retaining structure;

providing a second retaining structure;

attaching the second retaining structure to the second end of the rod such that the second retaining structure moves with the rod, and wherein the coil spring is positioned at least partially inside the tube between the first and second retaining structures;

axially compressing the coil spring;

measuring an axial force acting on the coil spring as the coil spring is axially compressed utilizing an assembly tool having a force sensor;

followed by fixing a stop on the second end of the tube such that the stop retains the second retaining structure at a position wherein the magnitude of the measured axial force acting on the coil spring is at a predefined magnitude or is within a predefined range;

removing the spring assembly from the assembly tool whereby the force sensor of the assembly tool is no longer capable of measuring an axial force acting on the coil spring.

2. The method of claim 1 , including:

placing the tube in a fixture;

placing the elongated rod in a fixture; wherein the elongated rod has an annular surface;

positioning the second retaining structure on the rod in contact with the annular surface; and

deforming a portion of the elongated rod to fix the second retaining structure on the elongated rod such that a position of the second retaining structure on the elongated rod cannot be adjusted.

3. A method of assembling a spring assembly; the method comprising:

providing a coil spring having first and second opposite spring ends and an axis;

providing a tube having an interior space and a first retaining structure at a first end of the tube such that the coil spring transmits force to the tube upon insertion of the coil spring into a second end of the tube;

providing an elongated rod having first and second rod ends;

positioning the rod in the tube with the first rod end toward the first tube end and the second rod end toward the second tube end;

positioning the spring in the tube with the first end of the coil spring engaging the first retaining structure;

providing a second retaining structure;

attaching the second retaining structure to the second end of the rod such that the second retaining structure moves with the rod, and wherein the coil spring is positioned at least partially inside the tube between the first and second retaining structures;

axially compressing the coil spring;

measuring an axial force acting on the coil spring as the coil spring is axially compressed utilizing an assembly tool having a force sensor;

followed by fixing a stop on the second end of the tube such that the stop retains the second retaining structure at a position wherein the magnitude of the measured axial force acting on the coil spring is at a predefined magnitude or is within a predefined range;

removing the spring assembly from the assembly tool whereby the force sensor of the assembly tool is no longer capable of measuring an axial force acting on the coil spring;

the tube defines an axis;

the stop comprises an integral flange that extends inwardly in a direction that is transverse to the axis of the tube, wherein the flange is formed at the second end of the tube.

4. The method of claim 3 , wherein:

the annular flange is formed on the second end of the tube by bending portions of the tube after the second retaining structure is attached to the elongated rod.

5. The method of claim 4 , wherein:

the tube includes an inwardly-extending flange at the first end defining the first retaining structure at the time the tube is placed in the fixture;

the rod includes a ring structure having a transverse opening therethrough at the first end of the rod; and

positioning the rod in the tube includes positioning the ring structure outside of the first end of the tube adjacent the inwardly-extending flange.

6. The method of claim 5 , including:

positioning an inner portion of an end plug inside the tube before forming the annular flange, whereby an outer portion of the end plug having a transverse opening therethrough is positioned outside the tube after forming the annular flange and the inner portion bears against the annular flange.

7. The method of claim 6 , wherein:

the coil spring is deformed utilizing a linear powered actuator.

8. The method of claim 6 , wherein:

the second end of the tube is deformed to form the stop while the coil spring is compressed to thereby retain a portion of the end plug inside the tube.

9. The method of claim 8 , wherein:

the stop comprises a flange formed by a forming tool.