Innovative guiding technology ensures productivity in press tools

As the metal stamping industry evolves, it requires tools that can keep up with it. These days, production demands have increased in terms of managing new sheet metal materials and time efficiency, which has made the already challenging forming operation even harder to perform than before. When stamping sheet metal, lateral movements appear in the press tool. Because of those, tool guiding elements are also required, to save the gas springs from breaking. Due to these new production demands, the gas spring guiding technology also needed to improve.

Lightweight materials – all steps towards more sustainable future

It all started back in 2001 with an increased demand for lightweight cars. The market required smaller engines, less fuel consumption, and lightweight materials
– all steps towards more sustainable automotive production. Hence, the industry moved to use new materials for car parts - which caused a need for more powerful press tools. The consumption speed also had leveled up, along with the expectations on production rate, or parts produced per hour, that increased fast - even though the budget did not. This caused a lot of unforeseen issues with the press tools. Issues that resulted in inability to produce in desired speed and extent.

 

Lateral movements – a concern

When forming sheet metal, it’s important that every piece looks the same. Quality is of upmost importance to achieve a flawless end-product.
Every press tool consists of an upper and a lower die, placed in a press that moves up and down to perform the sheet metal stamping.

 

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During the stamping operation lateral movements appear in the tool – which increases with production speed and applied force. The movement puts a lot of strain on the gas spring piston rod, and therefore there’s always some guiding elements installed in the tool to minimize it. The lateral movement remaining creates friction inside the gas spring, and when the resulting temperature gets too high, it causes damages to the gas sealing elements.
With production rate increasing along with the increased force needed to form stronger materials, existing guiding elements in the spring were no longer effective. From either scaring or over-heating, the gas springs got worn out fast - and the production rate suffered.

 

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Conventional guide

 

 

 

 

 

KALLER – new gas spring guiding technology

To solve this, KALLER launched the Flex Guide solution. The Flex Guide is a unique guiding technology that’s been developed for years - with the purpose to lower damages and increase gas spring service life. The Flex Guide is best described as an added layer of protection for the gas spring when the forming tool moves up and down in the press. Instead of fighting those strong lateral movements that appears, it adjusts to it and absorbs them – while keeping the piston rod safely in place.


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By reducing the friction to a minimum, Flex Guide saves the gas spring from wearing out.

 

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With the piston rod running smooth, the solution allows more strokes per minute, which means that the press can operate at a higher SPM -stroke per minute, without putting the gas springs at risk.

 

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FlexGuide Technology

 

 

 

 

Long-lasting gas springs – excellent results

Since 2002 the Flex Guide solution has been up and running to save gas springs, not only in the car part industry. When the solution entered the market, it was the first technology of its kind – and has proven to increase gas spring endurance and improve production quality in several productions. Using Flex Guide in your gas springs means a reduced need for gas spring servicing, safer long-term production, fewer production stops, and higher production rate. And with
long-lasting gas springs and less need for servicing, the environmental footprint gets smaller. In conclusion, the Flex Guide is an efficient solution that will streamline your production.

 

Lateral movement

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To the left a gas spring with a generic guide, to the right a KALLER gas spring with Flex Guide Technology.

 

By allowing the piston rod to follow the lateral movement of the press the Flex Guide™ system reduces the load onto the tube, flange and screws.

About KALLER Flex Guide

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The KALLER Flex Guide™ system has been up and running since 2002. When introduced on the market, it was the first technology of its kind – and has since proven to increase gas spring endurance and improve production quality in several applications, not only in the car part industry.

Using Flex Guide in your gas springs means a reduced need for gas spring servicing, safer long-term production, fewer production stops, and higher production rate. And with long-lasting gas springs and less need for servicing, the environmental footprint gets smaller. In conclusion, the Flex Guide is an efficient solution that will streamline your production.

The Flex Guide™ system is a part of the KALLER safety and reliability program, and the majority of our products are equipped with it. It has been proven to prolonge the lifetime of gas springs used in metal sheet stamping, but lateral movement happens in almost every tool – and we believe there are several businesses that could benefit from it.

We are proud to announce that our existing customers have regarded us as a safer choice on the market. Compared to a non-flexible guiding solution, you can feel safe with Flex Guide giving a more secure installation and ensuring a safer working environment.

 

We offer products that will help you solve technical problems with creative solutions, with the purpose to optimize your production and slim your costs. What is your challenge? Get in touch and let us know what we can solve for you!

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

 

 

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