Hydraulic pressure intensifiers provide standard intensification ratios of up to 16 and yield maximum outlet pressures of 58,000 psi / 4,000 bar.
Reciprocating Type — Pressure Intensifiers
A pressure intensifier boosts hydraulic pressure generating a small quantity of high-pressure fluid from a large quantity of low-pressure fluid. A pressure intensifier may also be called a pressure multiplier or a pressure booster. This can be done in new or existing systems to increase the available pressure. In new systems, you can design a hydraulic power unit for low standard pressures and add the intensifier to handle the high-pressure situations.
In refit applications, the intensifier can be installed as an in-line model towards the area where the pressure is increased. This option does not require expensive replacement to the power pack. A common misconception is that intensifiers are only used to generate high pressure, and in this case, high pressure means 10,000 psi/630 bar. In fact, pressure intensifiers can be used to boost pressure in lower pressure ranges from 1,500 psi /103 bar to 3,000 bar psi/206 bar for example.
Check out these videos on how intensifiers work:
How to select the right pressure intensifier for your application:
The following videos show the ScanWill Intensifier in the action and give a brief overview into how they function.
The following videos show the ScanWill Intensifier in an Application with a Double-Acting, Single-Acting, and Single-Acting Cylinder respectively.
How do Pressure Intensifiers Work?
Pressure intensifiers are powered by a pump, which is operating at a set pressure. The hydraulic intensifier consistently delivers flow until the output pressure has been reached. The flow from the pump enters the intensifier, where two pistons of different size (respective to the intensification ratio) pump the fluid thereby intensifying it. In the process, waste flow is returned to tank.
How are Pressure Intensifiers Used?
Hydraulic intensifiers were first seen in CNC machines in the workholding industry. Today, hydraulic intensifiers are frequently used in hydraulic power packs as a cost-efficient way to generate high pressure, without having to purchase a high-pressure system.
In What Applications are Pressure Intensifiers Used?
A hydraulic pressure intensifier can be used for many applications, such as rupture tests on hoses, pipes, and containers; hydroforming; bolt tensioning; presses; proportioning precisely defined volumes; demolition tools including stone crushing tools and hydraulic construction tools; hydraulic power packs; and workholding cylinders.
What are the Benefits of a Pressure Intensifier?
Hydraulic intensifiers are a fast and cost-effective solution to increasing pressure in comparison to other alternatives, such as replacing and buying a new hydraulic power pack or HPU. Its compact design features a built-in bypass valve and POV and allows for a simple and quick installation.
Pressure intensifiers are offered in a range of options, such as in-line models that are designed to fit standard industry pipe clamps. Intensifiers can also come in flange-on models, cetop models, and as cartridge-type intensifiers.
What is the Flow and Pressure Rate of Hydraulic Pressure Intensifiers?
Pressure intensifiers are selected by choosing the intensification ratio (the multiplication factor from your input pressure to your required output pressure), flow rate, pressure, and mounting requirements for your applications. Hydraulic intensifiers can have a flow rate starting at 0.3 gpm/1.1 lpm and up to 21 gpm/79.4 lpm depending on the model. In terms of pressure, hydraulic intensifiers typically produce between 1,000 to 7,300 psi. Some models have the capacity to generate between 20,000 to 60,000 psi.
The Function: The MP-Series of hydraulic pressure intensifiers are reciprocating, and will automatically increase a supplied pressure to a higher end pressure. Fig. 1 shows the basic principle of the intensifiers, consisting of a piston arrangement and a Piston Control Valve, PCV. The position of the pistons will, at the end of every stroke, prompt a signal “S” to the PCV, which makes this change position and ensuring the pistons are moving in the opposite direction. This cycle will continue until the end pressure has been reached. At this point the pistons stop, and will now only move to maintain the end pressure.
The Cycle When a hydraulic fluid is supplied to the P-connection of the intensifier and the T-connection is connected to tank, the oil will be directed through the check valves CV1 and CV2 to the high pressure connection HP. If the internal pilot operated check valve POV is incorporated the oil will go straight to the HP connection. In this situation all the flow supplied goes to the high pressure side ensuring a fast filling of the system. When pump pressure has been reached, the intensifier pistons will deliver the flow to the high pressure side, and continue to do so until the required end pressure has been reached. The pistons then stop, and will only move to make up for a pressure loss due to leakage or consumption. A general flow-pressure curve for the intensifier is shown in Fig.2.
For evacuating the high pressure side the internal POV is used. This valve is opened by directing the supplied pressure to the T-port and connecting the P-port to tank. This allows the oil from the high pressure side to flow directly back to tank.
In some applications it is necessary to shut off the pump either to preserve energy to prevent heat build up or because the application is moved (e.g. pallets for machine tools). In these situations, it is advisable to insert a leak proof pilot operated check valve after the intensifier, as the integrated check valves in the intensifiers are not designed to be leak proof in these situations. See figure 5 to the right.
General Data: Material: Cast Iron and steel (also available in stainless steel) Surface coating: Chromit blue finish Fluids: Recognized hydraulic fluids and water glycol (water and other fluids are possible) Filtration: 10μ nominal, maximum 19/16 according to ISO 4406 Hydraulic reciprocating pressure intensifiers are compact and suitable for most applications where pressure intensification is required, as:
The table below lists the various models and their capabilities. For more detailed information, please consult the catalog or contact IC-Fluid Power.
|Intensifier Model||Predominant Feature||Mounting||Min. Inlet Flow||Max. Inlet flow||Min. Inlet Pressure||Max. Supply Pressure||Max. Output pressure||Weight|
|(GPM / LPM)||(GPM / LPM)||(psi / bar)||(psi / bar)||(psi / bar)||(lbs / KG)|
|MP-S||Most compact||In-Line||0.5 / 2||2.0 / 8||218 / 15||3,000 / 200||11,600 / 800||1.54 / 0.7|
|MP-T||All-Purpose, Most Common||In-Line||0.5 / 2||4.0 / 15||218 / 15||3,000 / 200||11,600 / 800||2.86 / 1.3|
|MP-T-XP||Small Power Packs||In-Line||0.5 / 2||4.0 / 15||218 / 15||3,000 / 200||11,600 / 800||2.86 / 1.3|
|MP-C||Stacking System||Cetop / NG6||0.5 / 2||4.0 / 15||218 / 15||3,000 / 200||7,250 / 500||5.94 / 2.7|
|MP-CT||Stacking System with Separate Pressure Out||Cetop / NG6||0.5 / 2||4.0 / 15||218 / 15||3,000 / 200||11,600 / 800||5.28 / 2.4|
|MP-F||Flange-Mount||Flange||0.5 / 2||4.0 / 15||218 / 15||3,000 / 200||10,150 / 700||3.08 / 1.4|
|MP-M||Medium Pressure and Medium-High Flow Rate||In-Line||1.9 / 7||9.3 / 35||218 / 15||3,000 / 200||11,600 / 800||7.7 / 3.5|
|MP-L||Highest Flow Rate||In-Line||15 / 4||21.2 / 80||218 / 15||3,000 / 200||11,600 / 800||19.8 / 9|
|MP-2000||Medium-High Pressure & Medium Flow Rate||In-Line||0.5 / 2||3.4 / 13||218 / 15||3,000 / 200||43,500 / 3,000||5.94 / 2.7|
|MP-2000-XP||Small Power Packs||In-Line||0.5 / 2||3.4 / 13||218 / 15||3,000 / 200||37,700 / 2,600||5.94 / 2.7|
|MPL-1400||High Flow & High Pressure||In-Line||4 / 15||13.2 / 50||218 / 15||3,000 / 200||20,300 / 1,400||19.8 / 9|
|MPL-2000||Second-to-Highest Pressure||In-Line||4 / 15||7.9 / 30||218 / 15||3,000 / 200||40,600 / 2,800||19.8 / 9|
|MPL-4000||Highest Pressure||In-Line||4 / 15||7.9 / 30||218 / 15||3,000 / 200||58,000 / 4,000||19.8 / 9|