Forward Engineered Nitrogen Gas Manifolds
The SuperBrute® Nitrogen Manifold Systems by Forward revolutionizes press operations by offering seamless die transitions, constant force, adjustable pressure, and simplified maintenance. It eliminates the need for preloading, saving space and setup time. This game-changing system sets new standards for efficiency and precision in the manufacturing industry.
SuperBrute® Manifold by Forward
Discover the precision and versatility of Nitrogen Manifold Systems in die manufacturing with SuperBrute® manifolds. These systems replace conventional coil springs, offering adjustable force for enhanced precision. From inverted draws to strip punches and combined operations, they redefine die functionality, saving time and money. Experience precise control and eliminate balancing issues, even in high-speed productions.
Advantages of Manifold Systems
- Constant force throughout the stroke
- Easier die transitions
- Adjustable pressure/ force
- Simplified maintenance
- No need for preloading saving space & setup time
- Enhanced precision
- Minimum leak points
Get Started!
We will gladly help you get you get started with your new manifold based off of your needs and productivity goals. View our full catalog below for detailed information on your various options.
For a time-efficient development, get in touch with us by filling out the contact form below to be quickly connected with a KALLER representative and get your manifold started today!
Manifold Design
We offer two types of manifold systems: the standard 1500 psi manifold and the high-pressure 2000 psi manifold. You can choose to design the system yourself or have our engineers design a system for you. We work with a wide variety of 2D and 3D CAD files and can promptly provide you with a design and quotation.
A typical manifold system consists of a metal plate with cavities into which cylinders are threaded. The cavities are connected by passages or reservoir holes drilled into the plate, through which nitrogen gas is forced. The size of these passages depends on the amount of pressure required to perform the stamping or forming operation. All cylinders are designed for leak-free mounting.
The most compact system uses the manifold plate as a die shoe. However, when more space is available, the system can be designed with the manifold plate separate from the die shoe. Having a separate manifold allows independent servicing of either the die or the cylinders.
Design Factors
There are seven basic factors to consider in order to design an efficient manifold system:
- Force
- Force distribution
- Stroke
- Cylinder model
- Reservoir holes
- Pressure control
- Safety
Note: This information is for designing a 1500 psi manifold. For 2000 psi manifolds, please contact us.
For more details, download the Catalog:
Applications
High Speed
Nitrogen cylinders react quickly and precisely, making them ideal for high speed production runs.
Conventional Draw
The adjustable force of the nitrogen system allows precise pressure not available using conventional springs.
Inverted Draw
A common use of nitrogen manifold cylinders is in upper die applications, often in transfer or progressive dies.
Strip Punches
Nitrogen systems deliver high force on contact without preload to hold the strip securely. Punches can be stripped without breaking.
Form Up and Down
Forming in two directions is simple with a nitrogen system but difficult with conventional springs. The nitrogen cylinders provide precise control and the balance needed to produce quality parts consistently.
Combined Operations
Nitrogen systems allow two or more operations to be performed in one press stroke to save both time and money. High force on contact pre-forms the part and embossing, piercing or another operation can be performed at the bottom of the stroke.
Close Station Centers
In a nitrogen system, each cylinder has the same pressure because they are interconnected. Each system, whether upper or lower application, maintains its own pressure setting for precise control that conventional springs cannot offer.
No Balancing Problems
While air cushions can experience balancing problems when pressure is required in off-center stations, this is not an issue with nitrogen systems where cylinders of different tonnages can be used and still maintain precise control.