Flexible Separator Test Device with Push-Pull Actuation
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Solution Overview
Problem
Current methods for testing the reliability of flexible separators in hydraulic accumulators require complex and vulnerable hydraulic circuits, limiting the number of deformation cycles and duration of tests, often restricted to 2,000,000 cycles due to inertia and pressure losses, which is insufficient for applications requiring extended testing beyond this limit.
Innovation Solution
A test device with two similar rigid chambers and a 'push-pull' operation system that alternately varies the liquid volume in phase opposition, allowing for high-rate deformation cycles at reduced pressure, eliminating the need for complex hydraulic circuits and enabling tests to continue until separator rupture, with energy-efficient and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex hydraulic circuit with four-way valve is used to reverse liquid flow direction, then the separator can be deformed cyclically, but the system becomes vulnerable and limits the number of cycles to 2,000,000 due to inertia and pressure losses
Solution Approach 1:
The system is divided into two independent but coupled test chambers, each with its own separator. The chambers operate in parallel with push-pull synchronization, eliminating the need for complex flow reversal valves. Each chamber handles half the testing load, allowing extended cycles beyond 2,000,000 without hydraulic circuit vulnerabilities.
Solution Approach 2:
Instead of using a single chamber with flow reversal to achieve cyclic deformation, the invention uses two chambers deforming in opposite phases simultaneously. This inverted approach converts the flow reversal problem into a synchronized dual-chamber expansion-compression system, eliminating inertia and pressure loss limitations.
2Reliability
If hydraulic circuit with four-way valve is used, then separator deformation cycles can be achieved, but the inertia and pressure losses limit the cycle rate and extend test duration
Solution Approach 1:
While one chamber is in compression phase, the other is in expansion phase, and vice versa. This continuous alternating action ensures that the system is always in productive deformation cycle without idle time for flow reversal, achieving 4-6 Hz cycle rates and completing 10,000,000+ cycles in feasible test durations.
3Reliability
If high operating pressure (700+ bar) is maintained to simulate service conditions, then realistic separator testing is achieved, but the energy consumption and system requirements increase significantly
Solution Approach 1:
The invention changes the pressure parameter from high (700+ bar service pressure) to low (2-3 bar test pressure) while maintaining realistic deformation conditions. By using gas pre-charged at service pressure inside the separator and low-pressure liquid outside, the system achieves authentic separator behavior without high-energy hydraulic infrastructure, reducing energy consumption and system complexity.
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
This approach allows for accelerated cycle rates (4 to 6 Hertz) and significantly shorter test durations, enabling reliable evaluation of separator longevity until failure while meeting industrial constraints, with reduced energy consumption and pressure, allowing tests to continue beyond 10,000,000 cycles.
Implementation Method 1
The two gas capacitors communicate continuously during the test and the interaction between the two gas capacitors, causing a driving reaction force due to the flow of gas entering alternately into one then the other of the capacitors
Implementation Method 2
means causing the volume of liquid in each of them to vary alternately and in phase opposition by the same quantity
Implementation Method 3
each liquid capacity communicates directly with a deformable chamber, and in that said deformable chambers are of the same volume and coupled to actuating means imparting to them similar deformations in opposition to phase
Data Source
AI summary
A method and device for reliability testing of flexible separators under conditions that accelerate the cycle rate are described. According to the invention, two separators (10) are enclosed in rigid chambers (12a, 12b) defining a liquid capacity (51) and a gas capacity (52). The two gas capacities (52) are connected, and each of the liquid capacities is connected by means that alternately vary the volume in each of them.