Hydraulic Intensifier: A Complete Guide to How It Works

Hydraulic intensifier are devices that are connected to hydraulic machines and increase the amount of pressure they can generate. Two pistons of roughly equal size operate the mechanism to add pressure to the internal fluid. The mechanism is propelled by the energy of a large volume of liquid at low pressure. Some hydraulic machines require high pressure to operate, which a pump cannot provide. Hydraulic machines include hydraulic rams, hydraulic presses, hydraulic lifts, and other similar devices. High pressure is required for these machines to function. Hydraulic intensifiers are typically installed on pumps and operating machines. There are two kinds of hydraulic intensifiers: single acting and double acting.

Hydraulic Intensifier in Details

A hydraulic intensifier is made up of three main parts that are connected in the correct order to increase the pressure of the input fluid. Among them are sliding cylinders, fixed rams, and fixed cylinders.

  • FIXED CYLINDER: The hydraulic intensifier’s outer body. Low-pressure liquid enters here from the main supply. The ram or sliding cylinder moves within the fixed cylinder.
  • The next and middle component of the hydraulic intensifier is the sliding cylinder or ram. It moves back and forth between the fixed cylinder and fixed ram. There is only one moving part in it, and that is the ram. The hydraulic force causes it to slide. The sliding cylinder is supplied with high pressure liquid by the fixed ram.
  • FIXED RAM: This is the hydraulic intensifier’s smallest and most interior component. It is surrounded by the sliding cylinder. This fixed ram is fed with high-pressure fluid.
  • VALVE: The hydraulic booster has four valves as well. For clarity, refer to them as A, B, C, and D. “A” and “D” allow liquid to flow from the power supply to the device at low pressure. The liquid enters the fixed cylinder via valve “D,” flows through valve “A,” and continues into the sliding cylinder. The valve reduces fatigue by allowing low pressure fluid to flow out of the stationary cylinder, allowing it to be evacuated for deflation. Valve “B” directs high-pressure fluid to the intensifier’s outlet, which is linked to the hydraulic engine.
  • Operation of a hydraulic booster
  • Hydraulic boosters, as we all know, are used to increase the intensity of fluid pressure. The hydraulic booster’s operation is dependent on the movement of the fluid within it. At high pressure, low pressure fluid enters and exits the outlet or engine.
  • Initially, the shift cylinder is stationary, or in its lowest position. The low-pressure liquid then enters the stationary cylinder via the “D” valve and properly fills it. Then, valves C, B, and D are closed. Only valve ‘A’ is open, which allows low-pressure fluid to enter the cylinder or slide cylinder. Then, valve ‘C’ opens, allowing low-pressure fluid to flow from the stationary cylinder and vent to the exhaust pipe. The slide moves after the low pressure exits the stationary cylinder.

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