1. Flex Cam – Training
This shows one version of a complete FlexCam system including Power Unit HCP and Compact Cam CC for piercing operation.

2. 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

3. 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.

4. 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

5. 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

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

7. 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

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

9. 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).

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

11. Flex Cam – Component Selection1
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.

12. 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

13. 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

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

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

16. 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

17. 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

18. 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

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

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

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

28. 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

29. 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

30. 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

31. Flex Cam – Fill and Bleed
Fill and bleed, see ”Quick Start Guide” Necessary tools and equipment:
• Pump Unit
Hook Spanner (-015)
Hook Spanner ( )
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

32. 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

33. 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

34. 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

35. 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

36. 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

37. 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