High pressure intensifier Hydraulic cylinders
Increase your fluid power
PRESSURE INTENSIFIERS Our pressure intensifiers are designed to reliably achieve a 700 bar working pressure on the bottom head of the hydraulic cylinder. In the case of an intensifier with a 1:4 ratio, a 175 bar inlet pressure is enough to generate a 700 bar pressure on the cylinder bottom head. Pressure intensifiers can be either fitted to the pipes or flanged directly on the cylinders. We can supply the hydraulic cylinders produced in our Icop Hydraulics plants, suitably sized to work at high pressures. As an alternative, our pressure intensifiers can be fitted on ISO 6020-1 cylinders having a rated pressure of 160 bar. In this way, the hydraulic system will have a general pressure of 40 bar (1:4 ratio). Benefits of ICOP Hydraulics intensifiers: Smaller size of the hydraulic cylinders which allows using more compact and lightweight machineries Use of standard gear pumps as an alternative to more expensive piston pumps Use of low pressure flexible hoses to reach the hydraulic cylinders Lower working pressures which ensure a longer system life
• • • •
Differences between ICOP Hydraulics intensifiers and standard commercial intensifiers: A higher flow rate (up to 100 l/min compared to 10 l/min of standard simple-acting in-line intensifiers) Possibility of installing a regenerative plate to increase the flow rate to 300 l/min. Possibility of decompressing the chamber without any aid from extra valves No leakage between intensifier and pressure chamber Oil pressure is automatically maintained even in case the actuator is consuming oil (as opposed to the need of restoring operating conditions to resume pressure in standard intensifiers, i.e. by dischargin the oil).
• • • • •
Demolition crusher cylinder
Press cylinder
Sheet shear cylinder
Mine driller cylinder
Picture 1 Marine crane arm lifting cylinder
2
Increase your fluid power
FIELDS OF APPLICATION Fields of application of ICOP Hydraulics intensifiers:
Demolition and pulverising Mining industry Drilling Cranes and lifting Earth moving machinery Plastic machines Presses Materials test
3
GENERAL CHARACTERISTICS Picture 2 Characteristic pressure intensifier section
Operating principle 1
2
3
4
5
6
Loadless rod extension. The hydraulic oil enters through inlet A and is sent to valve 1 (valve 2 is calibrated, therefore it is closed). The oil enters into the cylinder bottom head, causing the cylinder to extend. The cylinder rod extends until it comes across a resisting load; valve 2 opens, the oil goes through valve 7 and goes on into the Pp line of valve 6 which takes up the crossover position. The oil is then driven into Booster 5, where it is intensified according to the designed multiplication ratio (for example 1:4), and then to the cylinder bottom head (meanwhile, valve 1 closes due to the pressure difference). Once Booster 5 has reached its stroke limit, the feedback spool 7, which is mechanically linked to it, connects outlet Pp of valve 6 with T1, bringing it to the parallel position. This causes Booster 5 to retract and hence to be filled with oil. At this point, it is ready to resume its pressure intensifying stroke on the cylinder bottom head. Booster 5 stops intensifying the pressure until the cylinder has reached the stroke limit or the pressure value required by the load. The pressure remains stable at the reached value, provided that there is no leakage on the cylinder and that there are no load changes. To reduce pressure in the cylinder bottom head and to get the cylinder to retract, switch the inlet pressure delivered by the hydraulic system to inlet B. Valve 1, which features a pressure reducing device, depressurizes the cylinder bottom head and then opens, ensuring that the hydraulic cylinder resumes the standard pressure set in the main hydraulic system.
APPLICATION A B
Low pressure
High pressure
Picture 2 Pressure intensifier applied on a high pressure cylinder (low pressure at rod inlet, high pressure at rod outlet).
4
Increase your fluid power
A1
9
B1
CYLINDER
HYDRAULIC DIAGRAM
BOOSTER
P2 5
Mq
Mb
Mq
T2
Mq
S
T
6
Sequence valve
3
Check valve
4
Check valve
5
Booster
6
Reverse valve
7
Feedback spool
8
Main hydraulic system
9
Cylinder
7
P Pp
T1 3
T T2
2 2
2
T1
S S
Pilot operated check valve
INTENSIFIER REAR HEAD
4
1
1 3 T
A
B
INTENSIFIER FRONT HEAD
A
1
8
P1 5
CHARACTERISTIC CURVES Laboratory tests have evidenced the following operating characteristic curves in cylinders fitted with an intensifier:
Values achieved with a 36 cSt viscosity at 50째C 90/60 cylinder, 400 mm stroke with 1:3 intensifier
Pressure (bar)
Flow rate (lpm)
700
Opening of valve 2
175
100
33
(Equivalent mean flow rate)
Time (Sec.) Start
0
Loadless stroke
Pressure intensification P2 cylinder bottom head pressurization
Picture 3 Cylinders with intensifier for mining works
6
P2 = cylinder bottom head pressure P1 = hydraulic system pressure P2 = cylinder bottom head flow rate
Increase your fluid power
PERFORMANCE DATA Maximum operating pressure
bar 700
Maximum flow rate
l/min 100
Ambient temperature range
°C -20 / +70
Fluid temperature range
°C -20 / +80
Fluid viscosity range
cSt 10 ÷ 400
Degree of fluid contamination
ISO 4406:1999 Standard
Recommended viscosity
cSt 25
Masse
kg 35
class 20/18/15
140
INSTALLATION DIMENSIONS
SECTION C-C 1/2”
A
B
460 12
49
140
57 D19
140
140
1/2”
4
14 H8
29,5
30
Ø26H8
Ø18 Ø21,5 Ø33
2.9
D13
+0 -0,100
394
27,5
+/- 0,05
34
A 60 C
B
C
40 130
Picture 4 Cylinder with intensifier for shears (demolition)
7
DEMOLITION, PULVERISING
The field of demolition represents one of the main applications of pressure intensifiers. In this field, the weight of the cylinders linked to the demolition crusher, permits more extension of the operating machine arm they are connected to. The use of an intensifier allows reducing the cylinder diameter or employing crushers with a higher closing force. Icop Hydraulics intensifiers for the demolition field feature yet an additional exclusive function in that they generate a strong impact when the crusher hits the concrete structure. This causes the structure to collapse easily, thus increasing productivity. Picture 5
• Hydraulic cylinder with pressure intensifier for demolition-pulverising machines. • The pressure intensifier is flanged to the rod. • During the work phase, the cylinder body comes out, the demolition debris do not hit the chromed rod, thus maintaining its functionality. • Oil delivery lines are located inside the rod.
8
Increase your fluid power
MINING INDUSTRY In mining industry applications, Icop Hydraulics pressure intensifiers help optimise the digging and drilling works. When the tool hits a highly resistant rock, the pressure intensifier automatically generates a pressure head, which allows the tool to break through. Pressure and force on the cylinders remain the same until the rock layer bearing more resistance has been broken through. After that, the load on the cylinders decreases and the pressure intensifying effect stops, leaving on the cylinders the pressure set in the hydraulic system.
Picture 6 Hydraulic cylinder with pressure intensifier for mine drilling machines. The intensifier is flanged to the cylinder bottom head. The hydraulic connection to the front oil inlet for rod retraction is carried out inside the cylinder body through a deep hole.
• • •
• No more accidental impacts or disconnection of external piping fittings.
9
CRANES AND LIFTING In the past twenty years, the field of cranes has undergone an impressive transformation thanks to the introduction of electronic controls. Now, machines feature higher safety standards and operating precision, due to the tests carried on the hydraulic systems using gear or piston pumps with max. pressure limits of 350 bars. In specific situations, the use of pressure intensifiers ensures a considerable increase in power. For this field, Icop Hydraulics has developed a special intensifier with low pressure pulsations to prevent the arm from swinging. Limited weights and increased lifting power offer a major competitive advantage to the most innovative crane manufacturers.
Picture 7 Lifting arm cylinder
10
Increase your fluid power
PRESSES Icop Hydraulics pressure intensifiers can be fitted in hydraulic press control circuits. Two possible configurations, depending on the size of the press:
• Double acting with direct pump crossing • In a shunt with pressurization occurring after the downward stroke of the press and the closing of pre-filling valve. Hydraulic diagram of an intensifier applied in a shunt to a vertical gravity press with auxiliary cylinders.
Pp A B A1
Tank
X
A
B
Picture 8 Ferrous material press
11
INJECTION AND BLOWING plastics
The great innovations in the field of plastics injection and blowing machines have determined a massive introduction of electromechanical actuators in place of the conventional hydraulic drives. The use of Icop Hydraulics pressure intensifiers represents an efficient alternative, particularly in the mould closing function.
Characteristic diagram of a mould closing device for plastics injection machines (simplification: no need for toggle joint thanks to an increased thrust force):
Picture 9 Section of booster with electric connection
12
Increase your fluid power
The innovation brought about since the introduction of Icop Hydraulics intensifiers on the plastics injection machines has had two main effects: 1) simplification: no need for toggle joint thanks to an increased thrust force. 2) a reduction of the electric power of the hydraulic system, which allows reducing the diameter of the closing cylinder as well as the inlet flow rate Diagram 2 has a higher performance as it allows determining when to insert the booster in an extremely accurate and fast way. By installing the booster on the cylinder by means of a suitable sizing, the maximum pressure can be reached very fast by energizing valve 3 only once. This is because only the oil inside cylinder 1, side A1, is to be pressurized. Diagram 1
1
Diagram 2
1
7
7
A1
A1
B1
B1 6
3
2
6
2 5
8 B
A
8 B
A
Operating principle - diagram 1 • Cylinder 1 rod is extended, the mould closes.
Operating principle - diagram 2 • Cylinder 1 rod is extended, the mould closes.
• Pressure on A increases up to valve 5 setting value. • Valve 5 opens, booster 2 starts operating by intensifying
• Pressure on A increases up to maximum value of the
pressure on A1.
• The maximum value of A1 depends on the booster multiplication ratio and on the inlet pressure of the hydraulic system (for example, 800 bar on A1 with 200 bar system pressure on A and a 1:4 multiplication ratio).
hydraulic system.
• The booster starts working when solenoid valve 3 is energized; pressure on A1 is intensified.
• A1 maximum value depends on the booster multiplica-
tion ratio and on the inlet pressure of the hydraulic system (for example, 800 bar on A1 with 200 bar system pressure on A and a 1:4 multiplication ratio).
13
LINEAR ACTUATORS
Electromechanical, with a hydraulic booster in a closed circuit The most typical issue when introducing electromechanical actuators in machines (particularly in plastics processing machines) is the difficulty to reach high closing forces on linear drives. Our solution: • a linear actuator with ball recirculation screws • connection flange for a servo controlled DC brushless electric motor • coupling by means of hydraulic system in a closed circuit. A version with the following characteristics is currently produced: • a 1000 mm linear stroke • 2000 daN maximum power with electric actuation • 8000 daN maximum power (in the last 70 mm of the stroke) generated when connecting the hydraulic booster.
Fig. 10 Brushless power
14
Characteristic section of an electromechanical linear actuator with hydraulic booster in a closed circuit.
Increase your fluid power
COMPACT TEST BENCHES with very high pressure
Icop Hydrauics use self-manufactured pressure intensifiers on their high performance compact test benches. Our benches can be used for testing pipes, fittings, hydraulic components, moulds and containers under pressure. Our mobile benches are fitted with wheels and hence they can be easily transported.
USB
PRESSURE TRANSDUCER
COMPUTER
PRINTER
PICTURE 11 System diagram
TESTING CERTIFICATIONS
Performance:
• Maximum outlet pressure 1000 bar • Maximum pressure at intensifier inlet - 250 bar • 50 l tank • 9 l/min maximum outlet pressure • Electric motor, 4 Kw 4 poles 230-400V/50-60Hz • Filter on return - 10 µm (β10>100)-ISO 4406:1999 class 18/16/13 • Solenoid valve DN6, 4-ways, three positions, two 24DC solenoids with pressurization, pressure maintaining function and de-compression
• N° 1 press. gauge, scale 1000 bar + N° 1 pressure gauge, scale 400 bar Optional:
• N° 1 analogic pressure transducer. 1000 bar max pressure scale • N° 1 PC with pressure curve acquisition card • N° 1 Software for data management and configuration for printing
the certification of the tested product (sheet with customer’s logo) • N° 1 A4 inkjet printer • N° 1 burst-resistant hydraulic metal containment structure for the material to be tested (variable length in 1-metre multiples to be applied at the rear of the test bench) • N° 1 air-oil heat exchanger for extended use
460
420
890
1600
ALTA HIGH PRESSIONE PRESSURE
Picture 12 Very high pressure test benches for flexible hoses
15
COMPANY PROFILE
Icop Hydraulics is located in an area with a high density of universities. The company staff has a highlevel technical background and has gained experience in working with equipment, organisation and process controls from the automotive field.
Complete production range of hydraulic cylinders. Standard cylinders, compliant with the ISO 6022, ISO 6020-1, MIL norms. Special screwed, welded cylinders and cylinders for rugged environments. Cylinders with linear transducers and integrated valves.
Internal production of all the components: our machines cover the whole production cycle. At the heart of the system are modern Multi Tasking MAZAK machines of the latest generation, featuring a Wi-Fi connection with the project and production flow.
Innovative technology for measuring the manufactured parts, based on ZEISS WMM 850 threedimensional measuring machine. Quality management system compliant with the ISO 9001:2008 standard.
High product innovation skill, aiming at offering real competitive advantages to individual reference markets.
16
Increase your fluid power
Passion. Excellence. Trustworthiness. 17
QUALITY, RESEARCH, INNOVATION
The performance and the reliability of our products depend on the accuracy and on the technologies used for checking them. To us quality is an opportunity.
Not just a cylinder ... but the very heart of a machine! This is the reason why the technologies we employ for testing our hydraulic components are more advanced than the ones used by our competitors. We perform continuous scan dimensional controls and three-dimensional geometric controls. The centesimal grading tolerances on couplings and concentricity need to be strictly complied with to ensure performance above the standard.
Repeatability and precision
Our customers’ machines will not permit any mistakes!
High temperature ranges
Fatigue cycles
Increase your fluid power
Performance attainable through a well designed path!
Each procedure...
...with a strong background...
Our target: the excellence.
Passion. Excellence. Trustworthiness.
ICOP Oleodinamica e Automatismi S.r.l. Via Ballerini, 3 - 29122 PIACENZA (PC) ITALY Tel. +39-0523.593367 Fax +39-0523.593052 CF e P.Iva 01063050338 info@icophydraulics.com www.icophydraulics.com
Made in ITALY
Increase your fluid power