Basic Operation of a Hydraulic Intensifier

Do you know what hydraulic intensifier are? Yes, a hydraulic pressure intensifier (also known as a booster) is a mechanical device that uses a low-pressure hydraulic power source to generate a higher pressure. When the pump alone cannot produce the high pressure required for the application, this device is typically used. Presses, jacks, torque wrenches, work holding, die casting, hydraulic power packs, and other similar applications are examples. This article explains the basic operation of this hydraulic pressure intensifier.

What is the location of a hydraulic intensifier? A hydraulic intensifier is placed precisely between the pump and the working machine during system design. With this design, the pump’s hydraulic pressure can be increased and transferred to the working machine, 

A hydraulic architecture is built into the compact hydraulic pressure intensifier. The low pump pressure can be increased to 1000 psi, 6000 psi, or even between 20,000psi and 60,000psi using this device. Different types of intensifiers that can be easily integrated with any hydraulic circuit include in-line models, flange-on models, and cartridge types.

What are the essential elements of an intensifier? The compact intensifier design consists primarily of four elements, which are arranged in the following order: fixed cylinder, sliding cylinder/RAM, fixed RAM, and check valves. The fixed cylinder is the external body of the intensifier that receives low-pressure liquid from the main supply. The sliding cylinder/RAM is a movable part located inside the fixed cylinder that contains high-pressure liquid stored via the fixed ram.

So, how exactly does a hydraulic intensifier function? An intensifier, in essence, compresses the hydraulic system fluid to a value greater than the pump discharge pressure. When the sliding cylinder is in the bottom-most position, which is considered to be in the rest state, the intensifier operation begins. 

When the intensifier is turned on, the low-pressure fluid from the pump enters and fills the fixed cylinder through a valve (let’s call it ‘A’). During this process, other valves will be closed. Following that, another valve (let’s call it ‘B’) opens, allowing this low-pressure fluid to enter the ram or sliding cylinder. The low-pressure fluid is then diverted to the exhaust via another valve (let it be ‘C’) for discharge from the fixed cylinder.

 When the sliding cylinder is filled with low-pressure fluid and reaches the topmost position, the valves ‘D’ and ‘A’ are opened, allowing the low-pressure fluid to enter the fixed cylinder through valve ‘A’. This forces the sliding cylinder downward, resulting in high-pressure fluid in the cylinder. The high-pressure fluid produced exits through valve ‘D.’

What advantages do hydraulic intensifiers have? This small device can be easily attached to any hydraulic machine. Furthermore, this energy-saving and low-cost device will maintain constant force and pressure throughout the process. Aside from high performance and longer life, the ability to adapt the required intensification ratio is the most important benefit of a pressure intensifier. Furthermore, it provides consistent power and weight throughout the working process.

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