Welcome to KALLER International Distributors Meeting June 14-16, 2011 Workshop 7 • Delayed return units

Controllable Gas Springs KF Delayed return units Lockable piston rod Controllable Gas Springs KF Flex FormTM Lockable piston rod Advantages for the user: All the benefits of a standard gas spring (e.g. even force distribution via link system, remote gas charging & discharging, high force ratings, long service lifetime) No hydraulics to fill and bleed with thick hydraulic hoses to fit and maintain. Adjustable Initial Forces from 1500 to 7500 daN. Adjustable (KF2-A) stroke lengths from 10 to 160 mm (+7/-8 mm).

Flex FormTM Flex Form TM Press Lockable piston rod Self Contained Option Flexible Orientation Controllable return speed PED approved High force hydraulic system Delayed return option Customized return force Low contact force No pressure increase

Flex FormTM No pressure increase Stroke Force Press Flex Form Cylinder Flex Form Force (blank holder force) Shows a working system (CC and HCP) in our press room. Note the movement of the hose, therefore hose clamps is recommended in dies. See also press diagram and the other movement curves in relation to each other.

Flex FormTM Hydraulic Fluid 7-100 bar Nitrogen System components Cylinder Flex Form CFF 1- 6 pcs Force Generator FFG Hydraulic Fluid 7-100 bar Nitrogen

Flex FormTM FFG CFF System components Flex Form Force Generator Cylinder Flex Form FFG Flex Form Force Generator One size Control up to six flex form cylinders Flow up to 300 l/min Pressure range 70-275 bar Max working temp. 93 °C CFF Cylinder Flex Form Stroke lengths 13-225 mm Four sizes Force CFF-1000 0.5 – 2 ton CFF-2400 1.3 – 4.8 ton CFF-4200 2.3 – 8.8 ton CFF-6600 3.6 – 12.5 ton

Flex FormTM Force Generator FFG Thermal Relay Accumulator Force generator pressure valve Safety Pressure Relief Valve Oil Bleed Plug Pressure Relief Overflow Hose Digital Pressure Gauge (24VDC) Return valve (24VDC) Return force control unit Foot Mount This shows one version of a complete FlexCam system including Power Unit HCP040-60 and Compact Cam CC040-49 for piercing operation.

Flex FormTM Cylinder Flex Form CFF Height Rod Diameter Cylinder Diameter Oil bleeder valve Bleeder Plug Base Width Base Height To the force generator This shows one version of a complete FlexCam system including Power Unit HCP040-60 and Compact Cam CC040-49 for piercing operation.

Flex FormTM Hydraulic Fluid 7-100 bar Nitrogen Function Cylinder Flex Form CFF 1- 6 pcs Force Generator FFG Force generator pressure valve pressure range 70-275 bar Hydraulic Fluid 7-100 bar Nitrogen Thermal Relay Return valve (24VDC) Digital pressure gauge (24VDC) Accumulator Return force control unit pressure 7-100 bar

Flex FormTM Requirements To obtain a complete system the following data is required: Number of pressure points (maximum six CFF to one FFG) • Needed tonnage for the system • Production rate parts/minute • Max high before stroked (L max) • Used stroke length • Max press velocity during stroke length (m/s) • Needed return force

Flex FormTM Possible solutions & benefits High Force Hydraulic System up to 12 ton with a single cylinder Low Contact and Return Force System provides a soft hit and very low reverse force to decrease press wear. Constant Force System has no pressure rise which provides constant force through entire stroke for better control of part quality. Flexible Orientation Flex Form system can be used in upper or lower applications. Delayed Return Option Cylinders can be delayed Applied stroke length optionally Self Contained Option The system can be provided fully filled, bled, and ready to be installed.

Delayed return units KF2 or TU CFF Energy Heat Energy Generates Heat Work cycle for standard gas springs Work cycle for delayed return systems KF2 or CFF Force TU Energy Heat Force Energy Stroke Energy = Force x Stroke Heat generation: It is important to note that energy is given to a gas spring from the press each time it is stroked. For a standard gas spring, this energy is given back to the press as the gas springs do work on the return stroke. For KF2 gas springs this is different, since the energy given to the gas spring on the downstroke of the press is locked into the gas spring. When the KF2 spring is released, the piston road is pushed up and the weight of tool it supports is lifted. However, the amount of energy the KF2 spring uses to do this is considerable less than when it was stroked. This difference in energy received and given by the KF2 spring results in heat build up in the KF2 spring itself.

Delayed return units System choice Dissipate 0.1 to 0.5 kW heat (depending of the spring size) Dissipate 2.3 kW heat Limited number of springs High force / area Not to high stroke length Large number of springs High stroke length & press velocity No place for hose connections Heat removal: Heat energy is conducted from the KF2 spring to the tool and radiated from its external surfaces. If the number of strokes a KF2 performs per minute reaches a predetermined maximum limit without additional cooling, then the KF2 will overheat, it’s seal will be damaged and this will lead to gas leakage. To prevent overheating there are two engineered solutions to help cool down the KF2 gas spring: Liquid cooling and Gas cooling.

Flex FormTM Summary Flex Form TM Press Lockable piston rod High force hydraulic system Delayed return option Customized return force Low contact force No pressure increase Self Contained Option Flexible Orientation Controllable return speed PED approved Available!