Industrial Fluid Power (11-3) Hydraulic System Components

The load characteristic of a spring are such that the energy storage depends on the force
required to compress the spring. The uncompressed length of spring represents zero energy
storage. As the spring is compressed to the maximum installed length, the minimum
pressure value of fluid in the cylinder is established. As fluid under pressure enters the
cylinder, tl:.espring is further compressed, thereby increasing the spring force at that instant
and hence pressure increases. Similarly as the fluid under pressure leaves the cylinder, the
spring decompresses.
The instantaneous spring force reduces thereby reducing the fluid pressure. Thus the
pressure is not constant
.
Instantaneous spring Spring constant k (N/m) ...(11.3)
Force F (N) = x compressed distance (m)

Spring

Piston
Packing

,;:;_~ii;;:~i;i~;:j!iiii:ii;iiiI1i1i~~i;;:i.

Fluid

Fig 11.3 Spring loaded accumulator

The output pressure available from the spring loaded accumulator at any instant
2 Spring-Force F (N)
Pressure p (N/m ) = cis Area A (m2) I ...(11.4)

Thus the pressure generated by this type depends on the size and pre-loading of the
spring. Also, seen the pressure exerted on the fluid is not constant.
The spring loaded accumulators can mounted in any position. However, they deliver'a
relative small volume of oil at low pressures. Hence, where large quantities of fluid are
required at high pressure, the forces involved make the spring sizes impractical. They are
also not used for applications requiring high cycle rates because the spring will fatigue and
lose its elasticity.
 III
Industrial Fluid Power (11-4) Hvdraulic System Components

11.4 GAS-CHARGED ACCUMULATOR

They are also frequently called as hydro-pneumatic accumulators. They are much morE
practical than the weight type and spring loaded type and hence are the most frequentl)
used accumulators.
Hydraulic fluids are nearly incompressible and hence for a large increase in oil pressure
there is a very small decrease in its volume. However, gases are compressible is nature and
hence for a large increase in gas pressure there is a significantly large decrease in its volume

(p CJ.~ ). This property of the gas to be compressed is made use of the storage of potential
energy in a gas charged accumulator.
A gas charged accumulator consists of a constant volume chamber which is pre-charged
with a compressible gas when the hydraulic fluid enters the chamber, the gas get
compre§>sed thereby storing potentjal energy. On reduction of the system pressure, the gas
expands and this potential energy forces the hydraulic fluid out of the accumulator.
The hydraulic pressure developed and the volume of fluid available to the system are
dependent on the pre-charge pressure and expansion characteristic of gas. Gas charged
accumulators operate in accordance with Boyle's law of gases, according to which
,.. (11.5)

Where (p) and (v) represent the absolute pressure and volume of gas, and the subscripts
represent different pressures and volumes of gases.
When a gas is compressed and expanded quickly, and the gas is insulated, then the
conditi::ms can be approximated to be adiabatic and the gas law followed is
P1Vl1.4 = P2V21.4 = P3vlAI ..,(11.6)
In most circumstances the performance of the gas is neither isothermal nor adiabatic,
hut somewhere in between Le. polytropic. Hence gas law followed is
.r 1.25 1.25 1.25
Pp 1 = pzV2 = P3V 3 ... (11.7)

Gas charged accumulators are of two types

(1) Non-separator type ; (2) Separator type
11.4.1 Non-separator type Gas Charged Accumulator
The non separator type consists of a fully enclosed cylinder
containing an oil port in the bottom and a gas charging valve on
the top (Fig 11.4). The gas is confined in the top and the' oil at
the bottom of the shell. There is no physical separator between
Free Surface
the gas and the oil and thus the gas pushes directly on the oil.
When pil starts getting pumped into the accumulator, the gas
above dle oil gets compressed and storGS potential energy. This
... Fluid
energy is then released as per the system requirements.
Fig 11.4 : Non-sepaJ:'&tor type
gas charged accumulator
Indu!'~~ial Fluid Power (11-5) Hydraulic System Components

Advantage:
(i) Due to the lack of physical separator, the gas can be absorbed in the oiL This makes
the oil compressible, resulting in spongy separation of the hydraulic actuator.
(ii) It must always be insta11ed vertica11y to keep the gas confined at the top of the
cylinder.
(iii) It should not be used with high speed pumps, since the entrapped gas in the oil can
cause cavitation and damage to'.'.;~e pump.

11.4.2 Separator type Gas-charged Accumulator

The separator type gas-charged accumulator is the most commonly accepted design. In
this type there is a physical barrier (in the form of piston, diaphragm or bladder) between
the gas and the oiL This physical barrier effectively uses the draw backs of the non-
separator type. The three main types of the separator type are
(1) Piston type accumulator
(2) Diaphragm type accumulator
(3) Bladder type accumulator
(1) Piston type accumulator : The piston type accumulator consists of a cylinder
containing a freely floating piston with proper seals as seen in Fig 11.5 (a). The piston
serves as a barrier between the gas and oiL The piston is under gas pressure on one side
and constantly tries to force the oil out on the opposite side. Here, too the pressure is a
function of the cOlnpression and various with the volume of oil in the chamber.
Gas Chamber Fluid Chamber

Gas Valve

'-'-"Oil Port

I
Piston'Seal Piston

Fig 11.5 : Piston type accumulator

The floating piston design is balanced so that the gas and fluid pressure acting on it are
equal in magnitude. This minimizes the leakage and also reduces the accumulator wa11
loading and the stresses oq.the floating piston.
This type can be mounted in any position, but it is preferable to mount it vertically with
gas connection on top.
Advantages:
(1) It can handle very high or low tem.?erature system fluids through the utilization of
compatible o-seals.
Industrial Fluid Power (11-6) Hydraulic System Component

Disadvantages:
(1) Expensive to manufacture and have practical size limitations.
(2) With use over a long period of time, piston packing gets worn off, thereby increasin,
leakage and requiring frequent pre-charging.
(3) They should not be used as pressure pulsation dampers or shock absorbers becaus
of inertia ofpiston and friction of seals.
(2) Diaphragm type Accumulator:
Screw plug
Seal ring

Shut off button

Fig. 11.6 : Diaphragm type accumulator

A typical diaphragm type accumulator is as shown in Fig 11.6. It consists of a flexible

rubber diaphragm, secured in a steel shell. The diaphragm acts as an elastic barrie]
between the oil and gas. A shut off button, which is secured t.o the diaphragm base, cover!
the inlet of the line connection when the diaphragm is fully stretched. This iJrevents thE
diaphragm from being pressed into the vpening during pre-charge period. On ~he gas side
the screw plug allows the charging of the accumulator by means of a charging device.
Fig 11.7 illustrates the operation of a diaphragm type accumulator. The hydraulic pumI
delivers oil into the accumulator and deforms the diaphragm. As the system pressurE
increases, the gas gets compressed thus storing potential energy. Now, when the systen
pressure decreases and an additional oil is required to be pumped into the system, thi!
stored potential energy in the accumulator forces the additional required oil into the system.
Industrial Fluid Power (11-7) Hydraulic System Components

Advantages:
(1) It has a small weight to volume ratio. Hence, it is exclusively used for airborne
applications. (2) The inertia of the device is very small since there are no piston, ram or
spring.

Fig 11.7 : Operation of a diaphra~ type accumulator

.
(3) Bladder type accumulator: 'Fig 11.8 Gas Valve
shows a bladder type accllmulator which consist
of a elastic bladder which provides the barrier
between the fluid al~d gas. The bladder is
integrally molded with a gas valve. Which is ..:.:.:.:.:.:.:..
::::::::::;::::::::::=:
fitted in the accumulator. The bladder along Shell
'::~I~~::
...................

with gas valve can be installed or removed

through the shell opening at the poppet valve.
This poppet valve ~loses the inlet when the Bladder
accumul&tor bladder from being pressed into the
opening. Thus it prevents the bladder from
damage and rupture and increases the
volumetric efficiency. An drain plug is provided oppet Valve
near the poppet valve to bleed the air from the
system.
Drain Plug
Fig 11.9 illustrates the operation of bladder
type accumulator. The l.ydraulie pump delivers
oil into the accumulator and deforms the
Oil Port
bladder. As the system pressure increases, the Fig 11.8 : Bladder type accumulator
Industrial Fluid Power (11-8) Hydraulic System Components

gas gets ~ompressed thus storing hydraulic energy. When the pressure in the external circuit
falls below that in the accumulator the gas. expands and force the fluid into the circuit.

(a) with out (b) with ni.trag';:l: (c) inlet oftluid

nitrogen charge charged to pre-charge for storage
pressure PI

(d) charged to (e) discharge (1) discharged to

maximum operating of tluid minimum operating
pressure P3 pressure p 2

Fig 11.9 Operation of a bladder type accumulator

Advantages:
(1) It provides a positive sealing between the gas and oil chamb~rs.
(2) It has a small weight to volume ratio
(3) it has a small inertia and hence provides a quick plessure response for pressure
regulating, pump pulsation and shock dampening applications.

11.5 ACCUMULATORAPPLICATION I FUNCTION CIRCUITS

Since hydraulic accumulators store pressurized fluid for system use on demand, they can
be used to serve a variety of system functions. Typical of these functions are maintain
system pressure, absorbing hydraulic shocks, supplementing pump delivery, providing an
emergency source of power, balancing loads and acting as a barrier between dissimilar
fluids.
Some of these functions are discussed in detail in the following articles:
Industrial Fluid Power (11-9) Hydraulic System Components

11.5.1 Accumulator as an auxiliary power source:

Accumulator are used as an auxiliary power source in a system where intermittent
operations are performed. These accumulators store the oil delivered by the pump during a
portion of work cycle, and then release this stored oil on demand, thereby serving as a
secondary power source to assist the pump. Thus, the accumulator reduces the input horse-
power by storing energy during idle times of the machine and also facilitates the use of a
smaller sized pump.

Fig 11.10 : Accumulator as an auxiliary power source.

This application is depicted in Fig 11.10 in which a 4/2 manually operated, spring
return D.C valve is used in conjunction with an accumulator.
When the 4/2 D.C valve is manually actuated to position I, oil flows from the
accumulator to the blank end of the cylinder. This extends the piston unit it reaches the end
of its stroke. When the desired operation is occurring (when the cylinder is in fully extended
position), the accumulator is being charged by the pump. When the accumulator is fully
charged, the pump. When the accumulate>r is fully charged, the pilot operated relief or
unloading valve opens and allows the pump delivery to return to the reservoir at very low
pressure. The accumulator maintains its charge since it is isolated by check valve.
When the 4/2 way D.C valve is deactivated, the position II is attained. The oil from both
the pump as well as the accumulator flows into the rod end of the cylinder. The added
volume available from the accumulator speeds. The accumulator size is selected to suVply
adequate oil during the retraction stroke.
This circuit is basical~y used in presses for the fast retraction of the ram.

11.5.2 Accumulator as ar. emergency power source

Whenever there is an failure of wither electric power supply or that of the pump, the oil
pressure is the system is lost. In some critical hydraulic circuits, it is necessary that during
Industrial Fluid Power (11-10) Hydraulic System Components

such times, the cylinder be retracted. Such an application requires the use of an accumulator
as an emergency power source, as depicted in Fig 11.11.

I
---__I

Fig 11.11 : Accumulator as an emergency pow~r source

In this circuit, a solenoid actuated 3/2 D.C valve is utilized in conjunction with the
accumulator.
When the 3/2 way valve is energized, position I is obtained and oil flows from the pump
into the blank end of cylinder and also through the check valve into the accumulator and rod-
end of cylinder. The accumulator gets charged. Now, as the oil in the rod end of cylinder has
been directed through a check valve its pressure is much less than that on the black end oi
cylinder. Hence the piston extenqs to the right.
When the solenoid is de-energized either during circuit operation or due to electriclL
power supply failure, the 3/2 way valve is returned to position II by the return spring. Here
the oil stored under pressure is forced from the accumulator to the rod end of the cylinder
This retracts the cylinder to its starting position.

11.5.3 Accumulator as a Pressure Maintaining Circuit / Leakage compensator

In holding and clamping operations, when the pump is shut off the accumulator acts liE
a leakage compensator to maintain the bJstem pressure. This applic&tion is as shown in Fig
11.12. In this circuit a 4/2 solenoid operated D.C valve is used in conjunction with thE:
accumulator.

When the solenoid is energized, the 4/2 way D.C. valve is in position (II) The oil flo~
from pump into both the accumulator charging it and into the black end of cylinder, causin;;
the piston to extend. In the maximum extended position, the vice jaws are in clamping:
mode. During clamping, the pressure builds up. When the maximum pressure setting on thE
pressure switch is obtained, it automatically stops the electric motor that drives the pUIDJ:
Industrial Fluid Power (11-11) Hydraulic System Components

In this high pressure state any leakage past the piston packing in the cylinder is
compensated for by the volume from the accumulator. Thus the accumulator maintains the
high system pressure required for clamping operation.

Pressure ~
Switch ~I
I

----_I
I

Fig 11.12 : Accumulator as a leakage compensator

When the clamping process is completed, the solenoid de-energizes and the 4/2 way
valve is returned to position. (l) The system pressure drops to the minimum pressure setting
of the pressure switch, which is turn starts the pump motor. This pump along with the
accumulator then pumps the oil into the rod-end of cylinder causing a rapid retract. The
pump is on till the accumulator is fully charged for next cycle.
The use of an accumulator as a leakage compensator not only maintains the system
pressure but also saves electrical power and reduces head in th,e system.

11.5.4 Accumulator as a Hydraulic Shock c:ibsorber

One of the most important functions of accumulations is the elimination or reduction of
high pressure pulsation or hydraulic shocks (i.e. water hammer). Hydraulic shocks are
caused due to sudden reversal of a hydraulic fluid flowirig[\at relatively high velocity in a
pipeline. These hydraulic shocks can cause the hydraulic lines to burst or leak, damage the
valves, cause pumps to fail and create excessive noise levels.
Hydraulic shock load can be reduced considerably by reducing the deceleration time of
the flowing fluid mass. This is achieved by installing the accumulator as close to the shock
source as pos~ible as shows in Fig 11.13.
Industrial Fluid Power (11-12) Hydraulic System Components

I
I
L__I

Fig 11.13 : Accumulator as a hydraulic shock absorber

Problems on Accumulator Sizing

Problem 11.1 :
A ballast type accumulator with a cross section diameter of 0.25m, generates a constant
pressure of 100 bars. Determine the weight of the ballast used. Also what must be the
stroke length to have a capacity of 200 litres.
Solution :
(1) Weight of ballast used in weight loaded accumulator
The output pressure available from weighted accumulator is given by,
2 _ Weight F (N)
Paccumulator(N/m ) - Area A (m2)
F
.. 100 X 105 =
~ (0.25)2
.. weight F = 490873.85 N
.. weight F = 500~.!'kg = 50.038 tons I
...Ans.

(II) Stroke length of accumulator:

The accumulator capacity is given by,
3, 2'
QaccliIDulator (m J = Area A (m )x stroke S(m)
Industrial Fluid Power (11-13) Hydraulic System Components

..
200 x 10-3 =j (0.25)2x S
.. I Stroke S = 4.074ml ...Ans.
Problem 11.2 :

P2 = 200 bar guage

v,_
V3 Usable Oil
P3 = 150 bar guage

VI Oil at less tham

150 bar PI = 100 bar guage

Fig.
An gas charged accumulator supplies a hydraulic system with 20 litres of oil within the
pressure range 150-200 bar gauge, if the accumulator has a pre-charge pressure of 100 bars
gauge. Size the accumulator for (i))) Isothermal expansion (ii) Adiabatic Expansion of gas
Note : Absolute pressures must be used when one is working with gas
(I) Isothermal Expansion and contraction of gas:
Let VI = capacity of accumulator
Now V3 - V2 = 20 lit. = 20 x 10-3 m3
.. V3 = V2 + (20 x 10-3) m3

For isothermal condition, we can write

P2 V2 = P3V3

.. V = P3 V. = (150 + 1.013) x 105 (V (20 x 10-3)

2 P2 x 3 (200 + 1.013) x 105 x 2 +
.. V2 = 0.7513 V2 + 0.015025
.. V2 = 0.060415 m3 ...(1)
Now PIVI =P2V2

.. V = PI x V = (200 + 1.013) x 105 0 060415

I ?1 2 (100 + 1.013) x 105 x .
.. Capacity VI = 0.120 m3 = 120 litre I
...Ans.

(n) Adiabatic Contraction and expansion of gas:

Industrial FluidPower (11-14) Hydraulic System Components

For adiabatic expansion, we can write

IA IA
P2V2 = P3V2.
.. P3}..!.
V2 = (I>;Y.4
.. Capacity VI = 0.14423 m3 = Alls.
144.231
We find that for adiabatic conditions, the accumulator capacity increases. The %
increase is given by
. 144.23 - 120
% mcrease = 144.23 = 100
% increase in accumulator size for adiabatic condition = 16.8% ...Ans.

Exercise
Problem: What size accumulator is necessary to supply 17 litres wi:h an allowable pressure
drop from 180 bars to 160 bars. The per-charge. is 120 bars.
All pressures given are absolute
Isothermal : Capacity V = 204 litres
Adiabatic: Capacity V = 258.75 litres
11.6 PRESSUREINTENSIFIERS
A pressure intensifier is a device that is used to increase the pressure in a hydraulic
system to a value several times above the pump disccarge pressure. It accepts a high
volume flow at relatively low pressure and converts a portion of this flow to required value of
high pressure. Due to this pressure boosting capacity, it is also known as pressure booster.
Intensifiers are basically used in applications such as hydraulic presses, riveting machines,
spot welding machines etc. where a great force is required to perform work through a relative
short distance.

11.6.1 Single Acting Intensifier

Low Pressure Piston
Low Press'ure cy linder

Fig 11.14 : Sir.['le Acting Pressure Intensifiers

Industrial Fluid Power (11-15)

A single acting pressure intensifier is shown in Fig 11.14. The intensifier unit has a low
pressure piston with an effectively larger area. The direction control v'mve directs the low
pressure fluid into the left hand side of larger piston. The low pressure acting on the larger
piston generates a force F. Now, when this force is transmitted to the high pressure ram, it
generates a considerably high pressure on the fluid located on the right side of smaller
piston. Although high pressure fluid is available to do work, it should be noted that the
volume of fluid discharged at the high pressure end will be proportionately less than that on
a larger end.
The increase in pressure is directly proportion to the ratio of the larger piston area and
the smaller piston area. While the volume output is inversely proportional to this ratio.
11.6.2 Double Acting-Intensifiers
A double acting intensifier is as shown in Fig 11.15 (a). It consists of a reciprocating
large piston that has two small rod ends. The piston has its large area exposed to the low
pressure oil. The force of this low pressure oil moves the piston and causes the small area of
piston rod to force the oil out at intensified high pressure. This device is symmetrical about a
vertical center line. Thus, as the large piston reciprocates each other during each stroke of
the unit duplicate each other during each stroke of the large piston. Thus in effect the double
acting intensifier stimulates the operation of two single acting intensifiers.
Lowpressurepiston-, ~ Lowpressurecylinder
High pressure rams
Booster cylinder II

(II) Simplitied Double Acting Intensifier

(III) Asa Symbol

Fig 1l.15(a) : Double Acting Pressure Intensifiers

Double acting intensifiers are used for applications needing longer work strokes or for
maintaining high pressures for a longer period of time.
Industrial Fluid Power (11-16) Hydraulic System Components

The working of a double acting intensifier is as shown in Fig. The D.A. intensifier is
actuated by a 4/2 solenoid operated D.C. valve. Valve E check valves A and B are installed
an either side on the high pressure outlet line, while check valves C and D are installed on
the low pressure outlet lines.
When valve E is actuated and position I is attained then the low pressure oil from the
pump is directed to the left intensifier cylinder. It pushes the main piston to the right
discharging fluid from the right side of cylinder to the tank. As the ram moves to the right,
fluid is intensified in Booster II. This intensified fluid closes the check valve D and check
valve A. Thus, the high pressure is delivered to outlet through check valve B. While the
piston is moving to the right, the low pressure fluid also passes through the check valve C
into the Booster cylinder I for intensification in next cycle. When the main piston reaches the
end of its stroke to the right, the solenoid gets energized in the opposite direction and valve
E now attains position II. The main piston starts moving towards left. The fluid in the
Booster cylinder I gets intensified. This high pressure fluid closes check valves Band C and
high pressure oil is then delivered to the output through check valve A.

H.P. output

A Check B

Valve E

L.P. input

Fig 11.15 b: Working of a Double Acting Intensifier

A double actihg intensifier delivers high pressure fluid by continuous reciprocation of
major piston. Common ratios of pressure intensification available with manufa~tures is 5 :
1, 7 : 1, 10 : 1, '7.5: 1, 50 : 1, etc.....
Industrial Fluid Power (11-17) Hydraulic System Components

11.6.3 Air Oil Intensifier

In an air oil intensifier, there are two
cylinders. The air cylinder with large t Air
piston and -.the booster
... hydraulic cylinder Air
with a small piston. Both the piston are Cylinder
connected by a piston rod. Air is directed
into the top end of intensifier (i.e. the
head end of air cylinder>. This forces the
hydraulic piston (ram) through the lower
Air
seal and into the lower booster cylinder.
In the bottom end of the intensifier (i.e.
the head end of booster cylinder), the
hydraulic fluid gets trapped by- the
retreating hydraulic piston and Booster
generates high pressure. The degree if Cylinder
the pressure boost is determined by the
area ratios of the air piston to the
hydraulic ram. FIUidt
. EIiJt .11.16.: Air oil intensifier
F 19-J.-r.ru;: Air-on IntenSltIer

,EXH
,,

:'-

.EXH AirOil
6 ba1 Rerum
II,' Tank

ValveB

Approach
Tank
Air
Cylinder ~.F1oad

Oil Cylinder--+-
Booster
Cylinder

Intensitier

Fig. 11.17 :Airoveroil intensifier circuit