Objectives

Explain the four basic functions of accumulators in hydraulic systems. Describe the design of weight-, spring-, and gas-loaded accumulators. Compare the basic operating principles of weight-, spring-, and gas-loaded accumulators. Compare the construction and performance of piston-, diaphragm-, and bladder-type gasloaded accumulators.
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Objectives
List and describe the typical uses of accumulators in hydraulic systems. Select the proper type and size of an accumulator for a circuit. List the safety factors that must be considered when working with accumulators.

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Basic Functions of an Accumulator

Accumulators allow a hydraulic system to use the noncompressible nature of liquids while still being able to absorb and store energy in the system Accumulators are also used to absorb sudden pressure increases in the system to prevent damage to system components

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Basic Functions of an Accumulator

Accumulators installed on a machine

MTS Systems Corporation 8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Basic Functions of an Accumulator

Energy is stored in an accumulator by:
Lifting a weight Compressing a spring Compressing a gas

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Basic Functions of an Accumulator

Energy stored in an accumulator can be used to:
Maintain system pressure Produce fluid flow to expand pump output Power the circuit when the pump is not operating

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Weight-loaded accumulators are generally used in large, stationary hydraulic systems
Vertically mounted units with heavy weights mounted on the cylinder rod Gravity acts on the weight to pressurize the hydraulic system fluid, thus storing energy Seldom used in current hydraulic system designs

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Conceptual weightloaded accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Spring-loaded accumulators store energy by compressing a spring Spring tension maintains pressure on system fluid
Allowing storing of energy Absorbs any sudden pressure increases in the fluid

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Typical spring-loaded accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Gas-charged accumulators are the most common type of accumulator They use a piston, bladder, or diaphragm to separate the liquid and gas This separation prevents the gas from being absorbed by the liquid or entering the system liquid lines

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Piston-type accumulators are basically a cylinder with a free-sliding piston that separates the cylinder into a gas chamber and a liquid chamber These units are available in sizes from under 10 cubic inches to over 100 gallons

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Piston-type accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Bladder-type accumulators use a flexible bladder fitted into a metal shell The gas is stored in the bladder, while the hydraulic fluid is held in the space between the shell and the bladder This accumulator design is available in sizes ranging from a few cubic inches to a maximum of approximately 40 gallons
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Bladder-type accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Poppet prevents bladder from being forced into the system line

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Diaphragm-type accumulators are constructed of two metal hemispheres separated by a flexible diaphragm Hydraulic fluid fills one of the hemispheres while the second holds the gas

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Diaphragm-type accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Gas valve is used to precharge the accumulator to the proper pressure

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

During operation, pressurized hydraulic fluid fills the liquid-side of the accumulator
Creates force against one of the surfaces of the piston, bladder, or diaphragm This force moves these parts, reducing the volume of the gas chamber The gas is compressed, which stores energy When the hydraulic system pressure drops, the gas expands to release energy
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

The gas in a gas-charged accumulator responds to pressure, temperature, and volume changes following the ideal gas laws A basic understanding of these laws is essential to understanding the operation of an accumulator The ideal gas laws are discussed in Chapter 3

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Isothermal and adiabatic are terms that need to be understood to fully explain the operation of an accumulator
An isothermal process is one in which temperature remains constant An adiabatic process results in an increase or decrease in temperature Gas accumulators typically perform between these two operating conditions
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Accumulator Design and Operation

Comparison of isothermal and adiabatic

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

The four basic functions of accumulators are
Providing a means to store energy Controlling pressure and flow variations Maintaining system pressure Supplementing pump output flow

Energy is being stored any time an accumulator is being filled

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

Rapid pressure increases or fluctuations in flow can cause hydraulic component damage Control of these problems requires careful accumulator sizing, precharging, and placement in a hydraulic circuit

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

Circuit that stores energy when the pump is not operating

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

Accumulators work well to hold system pressure without continuous operation of the power unit The power unit may be shut off or unloaded while the accumulator holds the required system pressure

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

Ambient temperature may effect system pressure during a holding cycle. An accumulator can:
Absorb the hydraulic fluid volume increase caused by expansion due to temperature increase Resupply fluid when the volume decreases as the temperature drops

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Functions of Accumulator Circuits

Circuit that holds pressure

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Accumulators are available in a wide range of sizes

HYDAC Technology Corporation 8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Rated capacity of an accumulator is based on the gas volume when all liquid has been expelled Actual volume that can be stored is well below the rated capacity Ratio of rated capacity to actual volume varies somewhat between manufacturers

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Pressure rating is based on the maximum safe operating pressure of the accumulator, as determined by the manufacturer
Pressure ratings range from 2000 psi to as high as 10,000 psi Rated pressures are maximum system operating pressures, not accumulator precharge pressures

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Usable accumulator volume indicates the amount of hydraulic fluid the unit can supply in a specific system application

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Three pressures are involved in calculating the usable operating volume of an accumulator
Maximum operating pressure Minimum operating pressure Precharge pressure of the accumulator

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Precharge pressure is the pressure on the gas side of the accumulator after the pressure on the hydraulic fluid side has been reduced to 0 psi

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Selecting and Sizing Accumulators

Precharge pressure varies with the application of the accumulator in the circuit Common recommended precharge pressures are:
100 psi below minimum operating pressure for maintaining system pressure or supplementing pump output 100 psi above relief valve setting for smoothing flow pulsation or reducing effects of shock pressures
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Weight-loaded accumulators must be vertically mounted Ideally, spring- and gas-loaded accumulators should be mounted in a vertical orientation
Horizontal installation is allowable May shorten the service life of accumulator bladders and piston seals Debris may collect in the accumulator
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Vertically mounted accumulators

MTS Systems Corporation

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Gas precharge pressure should be checked on a regular basis Incorrect pressure can produce inefficient system operation and may cause damage to bladders, diaphragms, and piston seals

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Precharging/gauging equipment is available from accumulator manufacturers Manufacturer-recommended procedures must be closely followed when completing these procedures

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Precharge equipment connects a nitrogen supply to the gas valve

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Precharging equipment

HYDAC Technology Corporation 8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.

Setup and Maintenance of Accumulators

Several critical safety rules and procedures must be followed when working with accumulators Specific training is required to assure personal safety and safe system operation when working with accumulators

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
An accumulator permits _____ to be absorbed and stored in a hydraulic system.

energy

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
In bladder-type gas-charged accumulators, what is the purpose of the poppet valve?

To prevent damage to the bladder, which may occur if it is forced into the system line through the system port.

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
List the three designs of gas-charged accumulators used in hydraulic systems.

A. Piston, B. bladder, and C. diaphragm.

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
Air or _____ should never be used in gascharged accumulators. pure oxygen

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
Which accumulator design must be mounted in a vertical position?

Weight-loaded accumulator.

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
The volume of fluid available from an accumulator is greatest if the unit is charged and discharged as a(n) _____ process. isothermal

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
List three reasons why air cannot be used as a precharge gas.
A. Risk of explosion as the oxygen it contains is compressed; B. moisture in the air can condense and rust system components and reduce fluid life; and C. oxygen in the air causes oxidation of the hydraulic fluid.

8/13/2012

V.R.S.C.E.T, Dept. of Mech. Engg.

Review Question
List four safety factors that must be followed when working with accumulators.
1. Special training is needed before working with accumulators and accumulator circuits.

2. Use only inert gas as charging gas.

3. Never exceed recommended precharge pressure. 4. Always remove accumulator-related pressure from hydraulic system oil before considering a system shut-down. (Other answers are also suitable for discussion)
8/13/2012 V.R.S.C.E.T, Dept. of Mech. Engg.