Basic Principles of Hydraulic Intensifiers

Are you familiar with hydraulic intensifiers? In a hydraulic pressure intensifier (also called a booster), a low-pressure hydraulic power source is used to generate a higher pressure. The device is mostly used when the pump alone cannot meet the application's high pressure requirements. Presses, jacks, torque wrenches, work holding, die casting, hydraulic power packs, and more are some of the applications. A hydraulic pressure intensifier is explained in the article below

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What is the position of a hydraulic intensifier?

During system design, a hydraulic intensifier is positioned precisely between the pump and the working machine. By using this design, the hydraulic pressure produced by the pump can be intensified and transmitted to the working machine for clamping, holding, punching, lifting, etc.

Hydraulic architectures are included in compact hydraulic pressure intensifiers. Using this device, low pump pressure can be increased to 1000 psi or 6000 psi, or even 20,000 psi to 60,000 psi. There are several types of intensifiers that can be integrated into hydraulic circuits, including in-line models, flange-on models, and cartridge models.

What are the important components of a hydraulic intensifier?

A compact intensifier consists of four elements: a fixed cylinder, a sliding cylinder/RAM, a fixed RAM, and check valves. Low-pressure liquid is supplied to the fixed cylinder from the main supply via the exterior body of the intensifier. Within the fixed cylinder, the sliding cylinder/RAM contains high-pressure liquid stored via the fixed ram. The cylinder is surrounded by a sliding mechanism. 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 The intensifier compresses hydraulic system fluid above the pump's discharge pressure. The intensifier begins to function when the sliding cylinder is in the bottom-most position, which is considered to be in rest. A valve (let's call it 'A') will allow low-pressure fluid from the pump to enter and fill the fixed cylinder. Other valves will be closed during this process. A second valve (say 'B') allows this low-pressure fluid to enter the ram or sliding cylinder. Once the low-pressure fluid is diverted to the exhaust, another valve (let's call it valve 'C') discharges it from the fixed cylinder. When low-pressure fluid moves out of the fixed cylinder, the sliding cylinder will move upward due to fluid supply from 'B'. The valves 'D' and 'A' are opened after the sliding cylinder has filled with low-pressure fluid, allowing the fluid to enter the fixed cylinder through valve 'A'. When the sliding cylinder is pushed downward, high-pressure fluid is generated. A high-pressure fluid is discharged through valve 'D'.