Advanced cutting tool for EV market

An advanced cutting tool can increase the number of operations in a die and perform high-precision, controlled piercing and stamping by using highly accurate guiding elements without side deflections.

The market for Electric Vehicles (EVs) has grown exponentially since 2013, and is expected to continue growing at a fast rate. According to the International Energy Agency (IEA), the number of EVs in use in the world has grown from about 380 000 vehicles in 2013 to nearly ten times as much in 2017, with over three million EVs on the roads (see report).

The latest developments in the underlying technology, and the attractiveness of government in-centives like subsidies and exemptions from parking fees in some countries, adds to the popu-larity of EVs. Several vehicle manufacturers are by now developing and releasing an offering of EVs and/or hybrids alongside combustion engine vehicle models to answer to market demand.

Adding EV charge ports to vehicle production

An EV that is plugged into a power source to charge the batteries frequently requires an addition to the manufacturing process of the vehicle body. For vehicle manufacturers this means that new requirements, in the form of e.g. fender variants for a vehicle body, need to be handled in the production process and the design of tools and die.

For a new vehicle model, manufacturers can set up the new production process to include an EV charge port for EV models but eliminate the port for other models – all in the same die. Using advanced, cost-effective cutting tools that can be positioned at a 360° angle and perform multiple operations in a die, a vehicle manufacturer can reduce the amount of steps and tools required for producing a fender with, or without, an EV charge port.
The tool handles fender variants, stamping out a charge port for EVs that require it, and removing the charge port operation for other models. The two fender variants can be produced in the same die, eliminating the need for a specialized die for stamping out a charge port for EV models.

 

Benefits of using advanced, cost-effective cutting tools

An EV that is plugged into a power source to charge the batteries frequently requires an addition to the manufacturing process of the vehicle body.
For vehicle manufacturers this means that new requirements, in the form of e.g. fender variants for a vehicle body, need to be handled in the production process and the design of tools and die.


For a new vehicle model, manufacturers can set up the new production process to include an EV charge port for EV models but eliminate the port for other models – all in the same die. Using advanced, cost-effective cutting tools that can be positioned at a 360° angle and perform multiple operations in a die, a vehicle manufacturer can reduce the amount of steps and tools required for producing a fender with, or without, an EV charge port.

Using advanced, cost-effective cutting tools

KALLER Flex Cam simplifies cutting tools by increasing the number of operations in a die on a production line. The KALLER Flex Cam can perform high-precision, controlled piercing and stamping by using highly accurate guiding elements without side deflections.

Adding KALLER Flex Cam to your vehicle production line has several benefits:

  • Simplifies process engineering, die design and tool manufacturing
  • Enables positioning of KALLER Flex Cam at any angle, with 360° application area
  • Punches even upwards at negative angles
  • Adds operations and flexible solutions to new dies
  • Uses space efficiently
  • Reduces total number of dies and tools with multi-functionality and durability
  • Protects against tool damage and over-pressure with controlled force and safety features

Using KALLER Flex Cam enables vehicle manufacturers to:

  • Reduce production cost per part
  • Increase production rate and efficiency
  • Reduce tooling costs with less tool and die investments
  • Be more environmentally sustainable with less tools

About KALLER Flex Cam

The KALLER Flex Cam has become a standard component for many vehicle manufacturers, and is often included in different vehicle manufacturing tool standards globally. 

The KALLER Flex Cam system has, with a proper set-up, performed more than two million cy-cles without any servicing required.

KALLER Flex Cam Components for this solution:

  1. Compact Cam CC 090-049
  2. Power Unit HCP 090-060
  3. Custom made HCP Actuator, moved by an air cylinder or manually

For more information on the KALLER Flex Cam, please contact your distributor >>.

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