Hydraulic Intensifier: A Complete Guide to Its Operation, Benefits

As previously stated, a hydraulic intensifier is used to increase the intensity of fluid pressure. The hydraulic intensifier’s operation is dependent on fluid movement within it. The liquid enters at low pressure and exits at high pressure at the outlet or machine.

The sliding cylinder is at rest at the start, i.e. in the lowest position. The low-pressure liquid then enters the fixed cylinder through the valve ‘D’ and properly fills it. The valves C, B, and D are then closed. Only valve ‘A’ opens, allowing low-pressure liquid to enter the ram or sliding cylinder. The valve ‘C’ then opens, allowing low pressure liquid to flow from the fixed cylinder to be discharged to the discharge port.

Because of the supply from valve ‘A,’ the sliding cylinder moves upwards once the low pressure is released from the fixed cylinder. When the sliding cylinder reaches its highest point, it is filled with a low-pressure liquid. When the sliding cylinder completely fills with low pressure liquid, both ‘A’ and ‘C’ are closed. The ‘B’ and ‘D’ valves now open, and the low-pressure liquid flowing through valve ‘D’ enters the fixed cylinder, pushing the sliding cylinder downward.

In the fixed cylinder, high pressure liquid is produced, which is then supplied to the required output or to some hydraulic machinery. The high pressure liquid then exits through valve ‘B,’ and the cycle is repeated indefinitely until low pressure liquid exits.

Hydraulic Intensifier Applications

  • A hydraulic intensifier is used in situations where high-intensity pressure is required.
  • It is used when the pump alone cannot provide the required high intensity of pressure.
  • Hydraulic intensifiers are commonly used in hydraulic rams, hydraulic cranes, hydraulic presses, and hydraulic lifts, among other applications where a high intensity of 

Pros of Hydraulic Intensifier

  • The hydraulic intensifier body is compact and simple to operate and control.
  • It can be directly connected to hydraulic machines or devices wherever they are needed.
  • It saves a lot of energy when compared to other devices.
  • It is cost effective due to its simple and cost-effective operation. Simply put, it operates smoothly, safely, and efficiently.
  • Because it operates quickly, it can be started and stopped as needed.
  • Working becomes easier with the pump; thus, it can be attached between the pump and the hydraulic machinery.
  • It provides consistent force and pressure throughout the entire working process.

Cons of Hydraulic Intensifier

  • One of the most significant disadvantages of a hydraulic intensifier is fluid leakage, which is also common in other hydraulic devices.
  • The hydraulic fluid used may be corrosive, causing damage to the machinery’s body.
  • Because leaking fluids can catch fire, work should be done carefully and any minor leakage of fluids should be avoided.
  • Its upkeep is prohibitively expensive.

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