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HDP - Heavy Duty Protection

Heavy Duty Protection covers are designed to significantly prolong the lifetime of the gas springs in dirty or contaminated application environments.

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How to Save, Optimize Performance in Dirty Environments

In contaminating conditions, such as Hot Stamping, dust and debris can impair Gas Spring performance and longevity. This can lead to costly production downtime, frequent maintenance, repairs, and unnecessary replacements.

Fortunately, there is a simple solution: the KALLER HDP Covers.

What are HDP Covers?

They are a protective canvas that fit seamlessly over the Gas Spring piston rod to protect it from contamination and corrosive materials.

HDP Ordering Brochure
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HDP Features

  • Significantly increases the lifetime of Gas Springs in extremely dirty environments
  • Reduces costs from production downtime, maintenance, and replacements from damaged Gas Springs
  • Maximizes production throughput and reliability
  • The first piston rod cover in the world without open breathing holes
  • Fits most mounting options
  • For Gas Springs with upper flange, a Flange Adapter (HDPF) can easily be used
  • Adds 10 mm additional length
  • Available for Gas Springs with a threaded piston rod and with cylinder sizes Ø45 mm, Ø50 mm, Ø63 mm, Ø75 mm, Ø95 mm, Ø120 mm, Ø150 mm, and Ø195 mm

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Want to know more? Just fill out the form right here. Thank you for your interest!

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Cylinder Size Ø45

Cylinder Size Ø50

Cylinder Size Ø63

Cylinder Size Ø75

Cylinder Size Ø95

Cylinder Size Ø120

Cylinder Size Ø150

Cylinder Size Ø195

Flange adapter HDPF

Adapter needed if the gas spring is flange assembled.

How to Order

You can find the corresponding gas spring for each HDP model in the tables below. For full ordering  instructions, please refer to our HDP Order Guide Brochure.

If you would like additional help, feel free to Contact Us with any questions!

 

*Please Note: 

  • The HDP adds an additional 10mm to the top of the piston rod of the gas spring.
  • If the gas spring is flange mounted, a Flange Adapter (HDPF) must be used. See ordering information in the table below or the HDP Order Guide Brochure.
HDP Order Guide Brochure

Find the Right HDP for your Gas Spring

Cylinder Size (mm) Stroke Length (mm) Gas Spring Models Order Number:
Ø45 10-250

X 750

TX 750

XG 750

XF 750

HDP-1-45
Ø50 10-250

TU 750

LCF 750

HDP-1-50
10-250

X 1000

TX 1000

XG 1000

XF 1000

HDP-2-50
Ø63 10-250

X 1500

TX 1500

XG 1500

XF 1500

HDP-1-63
Ø75 10-250

TU 1500

LCF 1500

HDP-1-75
10-250 TX 2400 HDP-2-75
10-250

X 2400

XG 2400

XF 2400

HDP-3-75
Ø95 10-250

TU 3000

LCF 3000

KF2/KF2-A 1500

HDP-1-95
10-250

X 4200

TX 4200

XG 4200

HDP-2-95
Ø120 10-250

TU 5000

LCF 5000

KF2/KF2-A 3000

HDP-1-120
10-250

X 6600

TX 6600

XG 6600

HDP-2-120
Ø150 10-250

TU 7500

LCF 7500

HDP-1-150
10-250

TX 9500

X 9500

HDP-2-150
10-250 KF2/KF2-A 5000 HDP-3-150
Ø195 10-250

TU 10000

KF2/KF2-A 7500

HDP-1-195
10-250

X 20000

TX 20000

HDP-2-195

 

Flange Adapter Order Information

For Cylinder Size For Mounting Flange Order Number
Ø 45 FCS 500 HDPF-45
Ø 50 FCS 750 HDPF-50
Ø 63 FCSX 1500 HDPF-63
Ø 75 FCS 1500 HDPF-75
Ø 95 FCS 3000 HDPF-95
Ø 120 FCS 5000 HDPF-120
Ø 150 FCS 7500 HDPF-150
Ø 195 FCS 10000 HDPF-195

Assembly & User Manual

For full instructions on how to apply HPD to your gas springs, you can find them in the HDP User Manual.

HDP User Manual

Application Example: Hot Stamping

Optimizing Hot Stamping Operations

Hot stamping, a transformative process revolutionized the fabrication of lightweight, high-strength components crucial for safety, lightweighting, and fuel efficiency in the automotive industry. This method, also known as press hardening or hot press forming, involves stamping and metallurgical heat-treating sheet metal, especially high-strength steel like Boron steel (22MnB5). To enhance the efficiency of hot stamping operations, KALLER introduces a groundbreaking solution – hot stamping with Gas Springs, fortified by Heavy Duty Protection (HDP) Covers.

 

The Hot Stamping Landscape Overview

Hot stamping's evolution, primarily focused on low-carbon manganese Boron alloyed steel, has expanded to higher carbon grades with advanced coatings. The process demands specialized equipment, including roller hearth furnaces, die cooling systems, etc. Its advantages, such as superior strength, reduced defects, and the ability to tailor material properties, make hot stamping indispensable for producing components like A-pillars, B-pillars, bumper beams, and more.

 

Challenges in Hot Stamping Operations

However, the hot stamping environment poses challenges, particularly in maintaining the longevity of Gas Springs because of contaminants like scale, dust, and debris. This is where KALLER's hot stamping with Gas Springs solution comes into play.

KALLER®'s Hot Stamping with Gas Springs Solution

Protection Against Contaminants: HDP Covers

Heavy Duty Protection (HDP) Covers offer robust protection against the harsh conditions found in hot stamping operations. These covers protect Gas Springs from a variety of contaminants such as dirt, dust, and even corrosive scale. The unique design of the HDP Covers ensures complete protection in hot stamping operations, including the quenching process.

 

Longer Lifespan, Consistent Performance

The HDP Covers shield Gas Springs from contaminations and contribute to significantly increasing their lifespan in extremely dirty environments such as hot stamping. This increased durability ensures the reliable performance of Gas Springs, reducing downtime and maintenance costs.

 

Designing a Cost-effective Hot Stamping Tool

HDPs are designed for seamless integration into hot stamping setups. The HDP Covers fit without needing modifications to the Gas Spring, and an upper Flange adapter can be easily added. The solution is versatile, compatible with various mounting options, and adds 10 mm to the length of the Gas Spring. Hot stamping operations equipped with the HDP - Gas Springs combination are more reliable and consistent, contributing to savings on replacement and maintenance costs.

 

Ensure Optimal Performance and Longevity

In the ever-evolving landscape of automotive manufacturing, hot stamping is a cornerstone for producing high-strength, lightweight components. Hot stamping with Gas Springs, fortified by the innovative HDP Covers, addresses the challenges of the harsh hot stamping environment. By ensuring the longevity and optimal performance of Gas Springs, KALLER contributes to the seamless and efficient operation of hot stamping processes, furthering the industry's pursuit of lightweighting, safety, cost-effectiveness, and sustainability.

 

Want to learn more? Contact us for more information or request for a quote!