Flex Cam – Training This shows one version of a complete FlexCam system including Power Unit HCP040-60 and Compact Cam CC040-49 for piercing operation.

Flex Cam – Training Training… Is about safety and to… • Understand the concept • Find the information • Select Components • Install the system • Fill & bleed Get production running The Product Presentation with all applications, this Training Presentation, Flex Cam catalogue, Quick Start Guide and User´s Guide to be used – from process engineers, purchase dep., die designers, die makers to end users include maintenance Catalogue page

Flex Cam – Cost Saving Step 1 Forming + ? Step 2 Piercing Flanging + ? • Add functionality • Increase production rate Reduce production costs • Reduce tooling costs Step 1 Forming + ? Step 2 Piercing Flanging + ? Step 3 Trimming + ? The FlexCam system helps the end user to reduce production costs, also the costs for design and manufacturing the tools by reduce quantities and simplify design.

Flex Cam – The Concept Page 9.3/2 1 Initial pressure This video describe the function of the system and the internal oil-flow and nitrogen pressures. Also the internal gas springs for the cam return with the nitrogen pressure. In case a jam happens it also show that the accumulator can take all of the oil without any over-pressure or damage in the system or the tool. This is a very important safety function. Page 9.3/2 1 Initial pressure 2 Oil pressure increase during stroke 3 Oil pressure when piercing 4 Oil and gas pressure accumulator 5 Oil and gas pressure accumulator when the cam is blocked

Flex Cam – The Concept Non-parallel motion, for example piercing Parallel motion, for wide flanging or forming steels Different press-cam ratio, stroke and force Page 9.3/2 - 3

Flex Cam – The Concept Page 9.4/1 – 4 See also the Product Presentation for more applications

Flex Cam – Component Selection Required Force Note: Piercing an open hole or cutting an edge creates side load. Consider the use of guiding element or Flange Cam CCF 040. Page 9.6/1

Flex Cam – Component Selection Size of Cam Unit/ Force Cylinder Page 9.6/2 Make sure to select big enough Cam Unit /Force Cylinder

Flex Cam – Component Selection Stroke of Cam Unit/ Force Cylinder Page 9.6/2 When a shorter stroke length is needed, arrange a mechanical stop in the die (contact your distributor for further support depending on your needs).

Flex Cam – Component Selection Order number for the Cam Unit / Force Cylinder Page 9.6/3

Flex Cam – Component Selection 1 Size and Stroke of Power Unit Used stroke 2 No No 3a 3b 3c It is also possible to made oil volume calculations for special combinations, see catalogue page 9.6/6. Page 9.6/4 Three Power Unit options (a, b, c) different used stroke (110, 50 and 35) and ratio (0.5, 1.2, 2.0). Avoid the grey area, the ratio between press and cam unit is very high.

Flex Cam – Component Selection Hose size selection Note: It is always the size of Power Unit and press velocity that determines the size of hose in the system. For other values please contact your distributor. Page 9.6/7

Flex Cam – Component Selection Capacity and Performace Normal gas filling pressures Note: Other values may be accepted under special conditions, contact your distributor Page 9.7/1

Flex Cam – Component Selection Accumulator pressure Note: Min accumulator pressure 50 bar, max 180 bar. Normal pressure is 150 bar. Page 9.7/2

Flex Cam – Component Dimensions Note: See www.kaller.com for your 3D models. All is available including the hose system. Page 9.8/1 – 47

Flex Cam – Component Selection Designing your Hose System Hose size, check Power Unit size. See table 1 below. The hose has always straight ends. Select adapters depending on connection threads and hose size. If possible, use straight adapters into the Power Units or Cam Units. If space problems, an Adjustable Locknut Elbow is available. See picture below. Always use Hose Clamps when possible to avoid steel – hose contact especially sharp edges. Page 9.8/37 – 49

Flex Cam – Component Selection Hose System for Control Units and external bleeding Always use separate Control Units to the Cam Unit / Force Cylinder and the Accumulator. In case it is difficult to bleed the cam inside the die – use the external bleeding outside Page 9.8/50

Flex Cam – Component Selection Hose System for Control Units and external bleeding Only one control block can be used for both Cam Units – getting the same return force But the external bleeding should be one for each Cam Unit – easier to bleed Page 9.8/51

Flex Cam – Component Selection Hose System for Control Units and external bleeding Only one control block can be used for both Cam Units – and another to the Accumulators getting the same return force – and working force But the external bleeding should be one for each Cam Unit – easier to bleed Page 9.8/52

Flex Cam – Component Selection Hose System for Control Units and external bleeding Only one control block can be used for all Force Cylinders – and another to the Accumulators getting the same return force – and working force But the external bleeding should be one for each Force Cylinder – easier to bleed Page 9.8/53

Flex Cam – Installing the System System installation • Use well educated personnel • A clean working place to avoid contamination in system • Functional equipment and tools • Proper eye and skin protection • Keep protection plugs on hoses, remove only when connect Handle nitrogen products with care (see gas spring guides) See recommended torque settings for screws (12.9 grade) Page 9.9/1 – 2

Flex Cam – Installing the System Power Unit installation • A driver (1) is used to push the Piston Rod of Power Unit The Power Unit can be installed up-side down In case no room for standard HCP, use the HCP-S with separate accumulator The Accumulator should always be used in the system Make sure to avoid side-load and over-stroke, see below or Page 9.10/1

Flex Cam – Installing the System Compact Cam installation • Use dowel pins and key to locate the unit Punch plate (1) can be removed for machining by remove screws (2). Note the Gas Spring (4). Force generated from punch should be within a specified area (3), see catalogue for additional info. Minimize the angle on top of punch to avoid side-load (above 5-7 degrees there is a risk of punch sliding onto the panel surface). The Pump Unit can be used for final punch adjustments by moving the cam forward and back. Check the punch and die clearance. Page 9.10/2

Flex Cam – Installing the System Compact Cam installation • Same punch length, force within the ØA in case two punches are used Reduced stroke by two external mechanical stops ØA Page 9.10/2

Flex Cam – Installing the System Compact Cam installation 3 1 ØA 2 Different punch length to minimize cam size Use always the specified force location “ØA” on the Compact Cam Page 9.10/2

Flex Cam – Installing the System Page 9.10/2 Source: International conference Tool & die Volvo Oct. 5-6, 2004

Flex Cam – Installing the System Page 9.10/2 Source: International conference Tool & die Volvo Oct. 5-6, 2004

Flex Cam – Installing the System Flange Cam installation • This unit can handle side-load Can be used for flanging, open cut etc. A top-mount kit is available if needed A customized tool (1) should be installed in a specific area, see also force directions and location (2), more info in catalogue Page 9.10/2

Flex Cam – Installing the System Force Cylinder installation • To be used to push guided tool parts To return the tool part, separate gas springs is recommended if possible (even if the rod has threaded holes in case this is needed) Flange, foot or base mount is available Make sure no side load on the rod Use mechanical return stops in the tool to avoid heavy load (weight) on the actual cylinder For flange mount, use max 0.5 mm clearance as the picture. All three C-grooves can be used for the flange. See also the Key support for foot mount Page 9.10/3

Flex Cam – Installing the System Hose installation • The hoses are washed and plugged, keep the plugs on as long as possible Make sure no contact hose – sharp edges by using hose clamps (3). Hoses move a little when running Adjustable adapters has an o-ring (3) and a steel support ring (4) to be used Do not twist the hose or use a too short hose Tighten the hose and adapters until you feel a firmly stop Page 9.10/3

Flex Cam – Fill and Bleed Fill and bleed, see ”Quick Start Guide” Necessary tools and equipment: • Pump Unit 3017075 Hook Spanner (-015) 503417 Hook Spanner (-040-150) 503418 Allen Key 6 mm Open-ended or ring spanner 11 mm Open-ended or ring spanner 14 mm 18 litres of oil ISO VG 32 (see 9.7/1) Page 9.11/1-5

Flex Cam – Fill and Bleed Fill and bleed, see ”Quick Start Guide” • Make sure there is room enough for accumulator in die Apply Nitrogen Gas / Initial Charge Settings below using the same equipments as for gas springs In case self-contained gas springs are used for a Compact Cam – no need to fill gas Accumulator must be filled later with higher pressure Page 9.11/1-5

Flex Cam – Fill and Bleed Fill oil in the pump (max 18 litres) and connect the pump unit as shown above Page 9.11/2

Flex Cam – Fill and Bleed Run Pump Knob C (operates check valve in position) Manometer Valve/ Hose A Valve/ Hose B Check tool clearance before moving the cam unit Check punch alignment etc. when moving the cam unit Page 9.11/4

Flex Cam – Production running • Keep the system protected against damage During any tool service, check hoses Before starting production, check level of piston rod. In case piston rod is more than 3-5 mm lower, check any oil leak and add oil using the pump. Check nitrogen pressure every 200,000 strokes Change oil every 500,000 strokes, see following instructions Almost equal high, piston rod and accumulator Page 9.10/3

Flex Cam – Production running • Change oil after 500,000 strokes Open valve A, pump oil until clean oil comes out Close valve A, dispose of waste oil appropriately Make sure oil pressure is 0 bar Ready to use again Page 9.11/5

Flex Cam – Training Training… Is about safety and to… • Understand the concept • Find the information • Select Components • Install the system • Fill & bleed Get the production running The Product Presentation with all applications, this Training Presentation, FlexCam catalogue, Quick Start Guide and User´s Guide to be used – from process engineers, purchase dep., die designers, die makers to end users include maintenance Catalogue page