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Fluid
Intensifiers
Brendan Casey
Marian Tumarkin
FLUID INTENSIFIERS
Intensifiers can be used to create hyper-high hydraulic pressure above 1000
bar (15,000 psi). Other advantages of using intensifiers are:
An intensifier can develop and maintain high pressure for long periods of
time without using power or generating heat in the hydraulic system.
Therefore, it can be used in many applications, where constant fluid flow
is not required (clamping, pressing, static testing, etc)
PRINCIPLE OF OPERATION
Intensifiers increase fluid pressure using ratio-of-areas principle in a linear
actuator - Figure 2.12. Lower pressure fluid in the chamber (1), acting on the
piston (2), exerts a force that is transferred mechanically to the rod (4), which
displaces a smaller volume of fluid in the chamber (5), but at a higher pressure.
Seals around the rod (4) separate
the chambers (3) and (5). Check
valves (6) and (7) enable inlet
and outlet of high pressure fluid.
p1 A1 = p 2 A 2
Low Pressure
Fluid
p1 A1
A2
p2
High Pressure
Fluid
p 2 A1
=
p1 A 2
Ratio
4 :1
160 :1
p 2 = p1
A1
A2
Single-stroke intensifier
Double-stroke intensifier
Reciprocating intensifier (pump) - can be single-stroke or double-stroke
a) General symbol
b) 2 types of fluid
SINGLE-STOKE INTENSIFIER
The single-stoke intensifier usually
3
3
delivers a volume of up to 50 cm (3 in )
of HP fluid. This type of intensifier can
operate without check valves (Fig. 2.14)
and with solenoid DCV (6). Such a
configuration optimizes intensifier
efficiency and reliability.
To fill the HP chamber, bleeding solenoid
valve (7) should be installed on the test
component (actuator). Given the limited
capacity of the intensifier, proper bleeding
is essential.
To simplify design, the solenoid
DCV (6) in Fig. 2.14 can be
replaced by installing a special seal
(8) Fig. 2.15. In this configuration,
the effective stroke does not begin
until the rod enters the seal.
Drain port (9) prevents mixing of
the different fluids.
HIGH PRESSURE
FLUID
BLEEDING
TEST
COMPONENT
LOW PRESSURE
FLUID
HP FLUID IN
HP FLUID OUT
9
LP FLUID
EXAMPLE 2.1.
Test Rig creates high water pressure proportional to input electrical signal. It
uses an Air-Water Intensifier Fig. 2.16.
AIR
CONTROL SIGNAL
WATER
BLEEDING
DRAIN
Main parameters:
Ratio 204 : 1
3
3
Displacement 25 cm (1.5 in )
EXAMPLE 2.2.
Test Rig creates brake fluid pressure proportional to input electrical signal. It
uses an Oil-Brake Fluid Intensifier Fig. 2.17.
BRAKE FLUID
Main parameters:
Ratio 2 : 1
3
3
Displacement 15 cm (1 in )
DRAIN
CONTROL SIGNAL
OIL
DOUBLE-STROKE INTENSIFIER
LP Fluid
HP Fluid
EXAMPLE 2.3.
Pump intensification ratio could be up to 200 : 1. This means that air pressure of
5 bar (70 psi) can create hydraulic pressure of up to 1000 bar (15,000 psi).
1 Hydraulic plunger
4 Air piston
5 Upper limit switch
8 Air cycling valve
9 Oil out check valve
10 Lower limit switch
12 Oil in check valve
7
8
1
Air
With position of the cycling valve (8)
shown in Fig. 2.19, air is supplied to
upper chamber (3) and forces the
Oil IN
Oil OUT
piston (4) to move down on the
compression stroke. The oil plunger
9
12
11
10
(1) intensifies pressure in chamber
(11). Check valve (12) is closed, check
Fig. 2.19. Air driven oil pump
valve (9) is open, and HP oil flows into
the hydraulic system. When piston (4)
reaches the lower position, it actuates limit switch (10) and opens connection of
the line (7) to the air supply. Spool (8) moves to the right and connects air
chamber (2) with air supply, and chamber (3) with exhaust. Air piston (4) starts
moving up, drawing oil into chamber (11) through check valve (12).
Copyright 2006 www.HydraulicSupermarket.com
INTENSIFIER CIRCUITS
Intensifier LP fluid is controlled by standard hydraulic/pneumatic system. For
example, pneumatic system for Air Driven Oil Pump shown in Fig. 2.20. Here air
pressure regulator (5) is used to control oil high pressure.
5
6
Oil OUT
2
1
AIR
CONTROL SIGNAL
3
Oil IN
WATER
Displacement transducer
FURTHER READING
Advanced Hydraulic Control by Brendan Casey & Marian Tumarkin
Available second half of 2007: http://www.HydraulicSupermarket.com/books