Hydraulic Intensifier – A Complete Guide and It’s Working

Hydraulic intensifiers are devices connected to hydraulic machines that increase the amount of pressure they can produce. For adding pressure to the internal fluid, two pistons generally of the same size operate the mechanism. The mechanism is powered by the large volume of liquid’s energy at low pressure. Some hydraulic machines can only operate under high pressure, which a pump cannot provide. Hydraulic machines include hydraulic rams, hydraulic presses, hydraulic lifts, etc. For these machines to work, high pressure is required. Pumps and operating machines are usually equipped with hydraulic intensifiers. Hydraulic intensifiers come in two types – single acting and double acting.

Hydraulic Intensifier in Details

To increase the input fluid’s pressure, a hydraulic intensifier is composed of three main parts attached in a correct sequence. Sliding cylinders, fixed rams, and fixed cylinders are among them.

• FIXED CYLINDER: This is the outer body of the hydraulic intensifier. From the main supply, low-pressure liquid enters here. Within the fixed cylinder, the ram or sliding cylinder slides.
•  Sliding cylinder or ram is the next and middle part of the hydraulic intensifier. It slides between the fixed cylinder and fixed ram. There is only one moving part in it, the ram. It slides due to the hydraulic force. The fixed ram supplies high pressure liquid to the sliding cylinder.
• FIXED RAM: This is the smallest and most interior part of the hydraulic intensifier. The sliding cylinder surrounds it. High pressure fluid is fed through this fixed ram.
• VALVE: The hydraulic booster also consists of four valves. Call them A, B, C, and D for better understanding. “A” and “D” allow low pressure liquid to flow from the power supply to the device. The liquid entering from valve “D” enters the fixed cylinder and flows through valve “A” and continues into the sliding cylinder. The valve helps with fatigue ie. allows low pressure fluid to flow out of the stationary cylinder to be evacuated for deflation. Valve “B” supplies high pressure fluid to the outlet of the intensifier which is connected to the hydraulic engine.
• Hydraulic booster operation
• As we know, hydraulic boosters are used to increase the intensity of fluid pressure. The operation of the hydraulic booster depends on the movement of the fluid in it. Low pressure fluid enters and leaves the outlet or engine at high pressure.
• The shift cylinder is initially stationary, that is, at its lowest position. The low-pressure liquid then enters the stationary cylinder through the “D” valve and fills it properly. Valves C, B and D are then closed. Only valve ‘A’ is open allowing low pressure fluid to enter the cylinder or slide cylinder. Valve ‘C’ then opens allowing low pressure fluid to flow from the stationary cylinder to be vented to the exhaust pipe. After the low pressure leaves the stationary cylinder, the slide cylinder moves up due to the supply from valve ‘A’. After the boost cylinder has reached the top position, the cylinder is filled with liquid under low pressure. Both ‘A’ and ‘C’ are closed when the slide cylinder is completely filled with low pressure liquid. Valves “B” and “D” are now open and the low pressure fluid flowing through valve “D” enters the fixed cylinder and forces the sliding cylinder to move downwards.
• The high pressure liquid is created in a solid cylinder which is fed to the required outlet or some hydraulic machine. The high pressure fluid then exits valve “B” and the cycle repeats continuously and the low pressure fluid exits at high pressure.
• Hydraulic booster app
• Hydraulic boosters are used when intense high pressure is required.
• It is used when the pump alone cannot provide the required high pressure intensity.
• You will find use of hydraulic boosters usually in hydraulic hoists, hydraulic winches, hydraulic presses and hydraulic elevators, etc. where high pressure intensity is required to lift the load.