Basic Principles of Hydraulic Intensifiers

Basic Principles of Hydraulic Intensifiers

Do you know anything about hydraulic intensifiers? A hydraulic pressure intensifier (also called a booster) uses a low-pressure hydraulic power source to generate a higher pressure. The device is mostly used when the pump alone doesn't produce the high pressure required for the application. Some of the applications include presses, jacks, torque wrenches, work holding, die casting, hydraulic power packs, and more. The article below explains the workings of a hydraulic pressure intensifier

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What is the position of a hydraulic intensifier?

A hydraulic intensifier is positioned precisely between the pump and the working machine during system design. Using this design, the hydraulic pressure produced by the pump can be intensified and transferred to the working machine for clamping, holding, punching, lifting, etc.

Compact hydraulic pressure intensifiers include hydraulic architectures. By using this device, the low pump pressure can be increased to 1000 psi or 6000 psi, or even 20,000 psi to 60,000 psi. Different types of intensifiers can be integrated into any hydraulic circuit, including in-line models, flange-on models, and cartridge types.

What are the important components of a hydraulic intensifier?

In a compact intensifier, four elements are arranged in a proper sequence: fixed cylinder, sliding cylinder/RAM, fixed RAM, and check valves. The fixed cylinder is the exterior body of the intensifier that receives low-pressure liquid from the main supply. Located inside the fixed cylinder, the sliding cylinder/RAM contains high-pressure liquid stored via the fixed ram. It is surrounded by a sliding cylinder. In addition, the design includes four valves for supplying and draining hydraulic pressure, which will be explained soon.

How does a hydraulic intensifier work?

An intensifier compresses hydraulic system fluid above pump discharge pressure. Intensifier operation begins when the sliding cylinder is in the bottom-most position, which is considered to be in rest. The low-pressure fluid from the pump will enter and fill the fixed cylinder through a valve (let's call it 'A'). During this process, other valves will be closed. This low-pressure fluid is then allowed to enter the ram or sliding cylinder through another valve (say 'B'). After the low-pressure fluid is diverted to the exhaust, it is discharged from the fixed cylinder through another valve (let it be valve 'C'). Due to fluid supply from 'B', the sliding cylinder will move upwards when the low-pressure fluid moves out of the fixed cylinder. After the sliding cylinder has filled with low-pressure fluid, the valves 'D' and 'A' are opened, allowing the low-pressure fluid to enter the fixed cylinder through valve 'A'. High-pressure fluid is generated in the sliding cylinder as a result of the sliding cylinder being pushed downwards. Through valve 'D', high-pressure fluid is discharged.

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