Expt N0.

Aim: To study accumulators and intensifiers.

Key words: Accumulators, Intensifiers, Shock Absorber, Pressure boosters.
Definitions:
Accumulator:
A hydraulic accumulator is a device that stores the potential energy of an incompressible fluid
held under pressure by an external source against some dynamic force.
Intensifier: A pressure intensifier is a device used to increase the pressure in a hydraulic system
to a value above pump discharge pressure.
Theory:
Accumulators:
A hydraulic accumulator is a device that stores the potential energy of an incompressible fluid
held under pressure by an external source against some dynamic force. This dynamic force can
come from different sources. The stored potential energy in the accumulator is a quick secondary
source of fluid power capable of doing useful work.
There are three basic types of accumulators:

1. Weight-loaded or gravity accumulator

2. Spring-loaded accumulator:
3. Gas-loaded accumulator:
1. Weight-loaded or gravity accumulator:
Schematic diagram of weight loaded accumulator is shown in Fig. 1.1.It is a vertically
mounted cylinder with a large weight. When the hydraulic fluid is pumped into it, the weight
is raised. The weight applies a force on the piston that generates a pressure on the fluid side
of piston. The advantage of this type of accumulator over other types is that it applies a
constant pressure on the fluid throughout its range of motion. The main disadvantage is its
extremely large size and heavy weight. This makes it unsuitable for mobile application.

2. Spring-loaded accumulator: A spring-loaded accumulator stores energy in the form of a

compressed spring. A hydraulic fluid is pumped into the accumulator, causing the piston to move
up and compress the spring as shown in Fig. 1.2. The compressed spring then applies a force on
the piston that exerts a pressure on the hydraulic fluid.
This type of accumulator delivers only a small volume of oil at relatively low pressure.
Furthermore, the pressure exerted on the oil is not constant as in the dead-weight-type
accumulator. As the springs are compressed, the accumulator pressure reaches its peak, and as
the springs approaches their free lengths, the accumulator pressure drops to a minimum.

Gas-loaded accumulator: A gas-loaded accumulator is popularly used in industries. Here

the force is applied to the oil using compressed air. Schematic diagram of a gas loaded
accumulator is shown in Fig. 1.3.A gas accumulator can be very large and is often used with
water or high water-based fluids using air as a gas charge. Typical application is on water
turbines to absorb pressure surges owing to valve closure and on ram pumps to smooth out
the delivery flow.

There are two types of gas-loaded accumulators:

1. Non-separator-type accumulator: Here the oil and gas are not separated. Hence, they are
always placed vertically.
2. Separator-type accumulator: Here the oil and gas are separated by an element. Based on the
type of element used to separate the oil and gas, they are classified as follows:
a)Piston-type accumulator: Schematic diagram of a piston type accumulator is shown in Fig.
1.4.It consists of a cylinder with a freely floating piston with proper seals. Its operation begins by
charging the gas chamber with a gas (nitrogen) under a pre-determined pressure. This causes the
free sliding piston to move down. Once the accumulator is pre-charged, a hydraulic fluid can be
pumped into the hydraulic fluid port. As the fluid enters the accumulator, it causes the piston to
slide up, thereby compressing the gas that increases its pressure and this pressure is then applied
to the hydraulic fluid through the piston. Because the piston is free sliding, the pressure on the
gas and that on the hydraulic fluid are always equal.

(b) Diaphragm accumulator: In this type, the hydraulic fluid and nitrogen gas are separated by
a synthetic rubber diaphragm. Schematic diagram of diaphragm accumulator is shown in Fig.
1.5. The advantage of a diaphragm accumulator over a piston accumulator is that it has no sliding
surface that requires lubrication and can therefore be used with fluids having poor lubricating
qualities. It is less sensitive to contamination due to lack of any close-fitting components.

(c) Bladder accumulator: It functions in the same way as the other two accumulators.
Schematic diagram of bladder accumulator is shown in Fig. 1.6. Here the gas and the hydraulic
fluid are separated by a synthetic rubber bladder. The bladder is filled with nitrogen until the
designed pre-charge pressure is achieved. The hydraulic fluid is then pumped into the
accumulator, thereby compressing the gas and increasing the pressure in the accumulator. The
port cover is a small piece of metal that protects the bladder from damage as it expands and
contacts the fluid port.

Applications of Accumulators
There are four basic applications where accumulators are used in a hydraulic system:
1. An auxiliary power source
2. A leakage compensator
3. An emergency power source
4. A hydraulic shock absorber
1. Accumulator as an auxiliary power source: The purpose of accumulator in this application
is to store the oil delivered by the pump during a portion of the work cycle. The accumulator
then releases the stored oil on demand to complete the cycle, thereby serving as a secondary
power source.

Fig1.7: Accumulator as an auxiliary Power Source

The schematic diagram is shown in Fig. 1.7. When the four-way valve is manually activated, oil
flows from the accumulator to the blank end of the cylinder. This extends the piston until it
reaches the end of the stroke. When the cylinder is in its fully extended position, the accumulator
is being charged. The four-way valve is then deactivated for retraction of the cylinder oil flows
from both the pump and accumulator to retract the cylinder rapidly.
2. Accumulator as a leakage compensator: An accumulator can be used as a compensator for
internal and external leakage during an extended period in which the system is pressurized but
not in operation. The pump charges the accumulator and the system until the maximum pressure
sets the pressure switch ON. The schematic diagram is shown in Fig. 1.8. The contacts on the
pressure switch then open to automatically stop the electric motor that drives the pump. The
accumulator then supplies leakage oil to the system during a long period. Finally, when the
system pressure drops to the minimum pressure setting of the pressure switch, it closes the
electrical circuit of the motor until the system gets recharged. The check valve is placed between
the pump and accumulator so that the pump does not reverse when the motor is stopped and does
not permit all the accumulator charge to drain back into the power unit. With this circuit, the

only time the power unit operates is when the pressure drops to an unsafe operating level. This
saves electric power and reduces the heat in the system.

Fig1.8 Accumulator as a leakage compensator:

3.Accumulator as an emergency power source: In some hydraulic systems, safety dictates that
a cylinder be retracted even though the normal supply of oil pressure is lost due to a pump or
electrical power failures. The schematic diagram is shown in Fig. 1.9. In it, a solenoid activated
three-way valve is used along with the accumulator. When the three-way valve is energized, oil
flows to the blank end of the cylinder and also through the check valve into the accumulator and
the rod end of the cylinder. The accumulator charges as the cylinder extends.

Fig 1.9: Accumulator as an emergency power source:

If the pump fails due to an electric failure, the solenoid de-energizes, shifting the valve to its
spring offset mode. Then the oil stored under pressure is forced from the accumulator to the end
of the cylinder. This retracts the cylinder to its starting position.
4. Accumulator as a hydraulic shock absorber: One of the important applications of
accumulators is the elimination of hydraulic shock. The schematic diagram is shown in Fig. 1.10.
Hydraulic shock is caused by the sudden stoppage or declaration of a hydraulic fluid flowing at
relatively high velocity in a pipe line. Rapidly closing a valve creates a compression wave. This
compression wave travels at the speed of sound upstream to the end of the pipe and back again to
the closed valve, which causes an increase in pressure.

Fig 1.10 Accumulator as a hydraulic shock absorber:

The resulting rapid pressure pulsations or high-pressure surges may cause damage to the
hydraulic system components. If an accumulation is installed near the rapidly closing valve, the
pressure pulsations or high-pressure surges are suppressed.
Pressure Intensifiers:
A pressure intensifier is used to increase the pressure in a hydraulic system to a value above pump
discharge pressure. It accepts a high volume flow at relatively low pump pressure and converts the
portion of this flow to high pressure. Although a pump is a primary source for a hydraulic system,
intensifiers are frequently employed for special purposes.
Pressure Intensifier Circuit:
Fig 1.11 shows the circuit for a punch press application where a pressure intensifier is used to eliminate
the need for a high-pressure/low-flow pump. This circuit also includes a pilot check valve and sequence
valve. The operation is as follows.
When the pressure in the cylinder reaches the sequence valve pressure setting, the intensifier starts to
operate. The high pressure output of the intensifier closes the pilot check valve and pressurizes the blank
end of the cylinder to perform the punching operation. A pilot check valve is used instead of a regular
check valve to permit retraction of the cylinder. Very high pressure can be supplied by a pressure

intensifier operating on a low-pressure pump. The intensifier should be installed near the cylinder to keep
the hogh pressure line as short as possible.

Fig 1.11: Pressure Intensifier Circuit

Air-over-Oil Intensifier system:

In fig.1.12 we see an air-over-oil intensifier system circuit, which drives a cylinder over a large
distance at low pressure and then over a small distance at high pressure. Shop air can be used to
extend and retract the cylinder during the low-pressure portion of the cycle.The system operates
as follows.
Valve 1 extends and retract the cylinder using shop air at approximately 80 psi. Valve 2
applies air pressure to the top end of the hydraulic intensifier. This produces high hydraulic
pressure at the bottom end of the intensifier. Actuation of valve 1 directs air to approach tank.
This forces oil at 80 psi through the bottom of the intensifier to the blank end of the cylinder.
When the cylinder experiences its load (such as punching operation in and punch press), valve 2
is actuated which sends the shop air to the top end of the intensifier. The high-pressure oil cannot
return to the approach tank because this port is blocked off by the downword motion of the
intensifier piston. Thus, the cylinder receives high-pressure oil at the blank end to overcome the
load. When valve 2 is released, the shop air is blocked, and the top end of the intensifier is
vented to the atmosphere. This terminates the high-pressure portion of the cycle. When valve 1
released, the air in the approach tank is vented and shop air is directed to the return tank. This
delivers oil at shop pressure to the rod end of the cylinder, causing it to retract. Oil enters the
bottom end of the intensifier and flows back to the approach tank. This completes the entire
cycle. This type of intensifier is capable of producing output hydraulic pressure up to 3000 psi.

Fig 1.12: Air-over-Oil Intensifier system

Conclusion: To be written by you.