Hydro-Pneumatic Accumulator Nitrogen Precharge Regeneration
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Solution Overview
Problem
Hydro-pneumatic accumulators experience continuous pressure loss due to gas leakage through bladders and seals, requiring periodic servicing to maintain gas pre-charge levels for proper operation.
Innovation Solution
A device and method that monitors gas pre-charge levels in hydro-pneumatic accumulators using sensors to measure pressure, temperature, volume, and weight, automatically replenishing the gas when levels fall below a threshold by generating nitrogen gas from ambient air and introducing it into the accumulator using a controller and nitrogen gas generator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If gas pre-charge is stored in the accumulator, then energy storage capability is improved, but gas leakage through bladders and seals causes continuous pressure loss
Solution Approach 1:
The system performs preliminary action by automatically detecting gas pre-charge levels and replenishing them before pressure loss affects accumulator performance. Sensors continuously monitor pressure and trigger gas replenishment when thresholds are approached, preventing energy loss rather than reacting after degradation occurs.
Solution Approach 2:
The system implements feedback through sensors that continuously monitor pressure, temperature, volume, and weight parameters of the gas pre-charge. This feedback loop enables the controller to detect when gas levels fall below thresholds and automatically activate the gas generator to replenish the pre-charge, creating a closed-loop system that maintains optimal energy storage capability.
2Reliability
If periodic servicing is performed to replenish gas, then pressure levels are restored, but system downtime and maintenance frequency increase
Solution Approach 1:
The system applies self-service by automatically monitoring its own gas pre-charge levels and replenishing them without external intervention. The integrated sensors, controller, and gas generator work together to detect when gas levels are low and automatically generate and introduce new gas, eliminating the need for periodic manual servicing and reducing system downtime.
Solution Approach 2:
The system performs preliminary action by continuously monitoring gas levels and replenishing them before pressure loss degrades performance. This proactive approach prevents the need for reactive servicing, keeping the accumulator in optimal condition without requiring system shutdown or manual intervention.
3Extent of automation
If sensors and control systems are added to monitor gas levels, then automated replenishment is achieved, but device complexity increases
Solution Approach 1:
The system applies multi-functionality by using a single integrated controller that manages multiple functions: receiving signals from various sensors (pressure, temperature, volume, weight), calculating gas mass, comparing against thresholds, and controlling the gas generator. This consolidates what could be multiple separate control systems into one universal controller, reducing overall complexity while achieving comprehensive automation.
Solution Approach 2:
The system replaces manual mechanical servicing with automated electronic monitoring and control. Sensors electronically detect gas levels, and an electronic controller automatically triggers the gas generator, eliminating the need for manual pressure checks, valve operations, and gas replenishment procedures that would require complex mechanical interfaces and human intervention.
4Stability of the object's composition
If gas mass is continuously monitored and maintained, then performance consistency is improved, but measurement and control requirements increase
Solution Approach 1:
The system uses an intermediary approach by employing multiple sensors (pressure, temperature, volume, weight) that indirectly measure gas mass rather than requiring direct mass measurement. The controller integrates data from these intermediary measurements and calculates gas mass using the ideal gas law or other thermodynamic relationships, achieving accurate monitoring without complex direct mass measurement equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Automated gas replenishment maintains optimal pressure levels, reducing the need for frequent servicing and ensuring consistent performance of hydro-pneumatic systems by continuously monitoring and maintaining the gas pre-charge within predetermined thresholds.
Implementation Method 1
a nitrogen gas generator or the like, to scrub gas (e.g., nitrogen) from the air (e.g., ambient air, pressurized air or other air source)
Implementation Method 2
The gas then is processed through a pump/intensifier and introduced into the accumulator
Implementation Method 3
one or more sensors measure a pressure, temperature, volume, flow, and/or weight of a gas in the gas-side of the accumulator
Implementation Method 4
one or more sensors measure a pressure, temperature, volume, flow, and/or weight of a gas in the gas-side of the accumulator
Data Source
AI summary
A pressure accumulator includes an accumulator housing having first and second ports for receiving first and second pressure mediums, respectively, a movable separating element subdividing an interior of the accumulator housing into at least first and second working spaces, the first working space accommodating the first pressure medium and the second working space accommodating the second pressure medium, wherein the first port is in fluid communication with the first working space and the second port in fluid communication with the second working space. At least one sensor is operatively coupled to the first working space for measuring at least one characteristic of the first working space, and a gas generator is operative to generate a gas from ambient air, the gas generator including an outlet for outputting the generated gas, the outlet in fluid communication with the first port. A controller is operatively coupled to the at least one sensor and the gas generator, the controller configured to calculate an amount of gas in the first working space based on the at least one characteristic and upon the calculated amount of gas in the first working space being below a first threshold level, generate a command to introduce gas from the gas generator into the first working space.