Hydraulic Pressure Calibrator with Intensifier
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Solution Overview
Problem
Current hydraulic pressure calibrators are unable to handle pressures of up to 4 or 5 kilobars, making it cumbersome and time-consuming to calibrate high-pressure sensors and devices, especially in industries like automotive and petroleum extraction.
Innovation Solution
A hydraulic pressure calibrator design that incorporates a piping system with a compressible fluid, a pressure transducer, and a fluid pump, along with an intensifier to amplify the fluid pressure, allowing for pressures up to 5 kilobars to be achieved using a relatively weak pressure pump, ensuring stability and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a relatively weak pressure pump is used, then the pump can be more stable and fast, but the maximum pressure it can directly realize is limited
Solution Approach 1:
An intensifier is introduced as an intermediary device between the pressure pump and the hydraulic fluid. The intensifier receives low-pressure fluid from the pump and mechanically amplifies it to high pressure, allowing the pump to operate in its stable, fast-response range while still achieving the required high pressure output
Solution Approach 2:
The direct mechanical connection between pump and high-pressure fluid is replaced with a two-stage system: first the pump delivers low-pressure fluid, then the intensifier's mechanical mechanism (pistons with different areas) converts this to high pressure, substituting the direct high-pressure mechanical system with a controlled transformation process
2Stress or pressure
If available hydraulic pressure calibrators are used for high pressure applications, then they can handle pressures up to 2 kilobar, but they are not capable of handling pressures of about 4 or 5 kilobar
Solution Approach 1:
The pressure generation function is segmented into two independent stages: a pressure pump for generating low pressure and an intensifier for amplifying to high pressure. This segmentation allows each component to be optimized for its specific pressure range, enabling the system to achieve pressures of 4-5 kilobar while maintaining the stability characteristics of lower-pressure components
3Stress or pressure
If high pressure is realized directly by the pressure pump, then the pressure can be increased, but the pump becomes less stable and operates at or near maximum capacity
Solution Approach 1:
The intensifier serves as a mediator that decouples the pump's operating conditions from the required high pressure output. The pump operates at moderate, stable pressures while the intensifier handles the pressure amplification, preventing the pump from operating in its unstable high-pressure regime
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
Enables the realization of high hydraulic fluid pressures in a controlled and stable manner, facilitating efficient calibration of high-pressure devices and sensors, even at pressures exceeding 200 N/mm2, with precise control and reproducibility.
Implementation Method 1
an intensifier for intensifying fluid pressure provided by the pressure pump
Implementation Method 2
a pressure transducer for sensing the pressure of hydraulic fluid inside the piping
Data Source
AI summary
The invention relates to a hydraulic pressure calibrator. The hydraulic pressure calibrator is a device for manipulating pressure of a hydraulic fluid in a controlled manner and can be used for calibration of pressure devices, such as hydraulic calibration and/or test applications. The calibrator comprises piping for accommodating a compressible hydraulic fluid to be pressurized. The piping has a connector for enabling a fluid connection to a device to be calibrated, such as a pressure standard. The calibrator further comprises a pressure transducer for sensing the pressure of hydraulic fluid inside the piping and a fluid pump for increasing pressure of hydraulic fluid inside the piping. Furthermore, the calibrator comprises an intensifier for intensifying fluid pressure provided by the pressure pump. In embodiments, the intensifier can have a piston assembly and the calibrator may further comprise a displacement transducer for sensing a change in position of said piston assembly.