Scanwill Pressure Intensifier

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Jonathon Burnside

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Aug 3, 2024, 5:10:46 PM8/3/24

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In large systems there can be problems maintaining the pressure for all functions, or a higher pressure is required for one function. The Scanwill intensifiers can be inserted where needed ensuring sufficient pressure for all functions.

ScanWill Fluid Power designs and manufactures hydraulic pressure intensifiers, used to boost a hydraulic inlet pressure to a higher end pressure. End pressures up to 2,000 Bar / 29,000 psi are possible. Typical applications include workholding, presses and hydraulic tools.

Today the Scanwill pressure solutions are distributed through partners all over the world, like IC-Fluid Power, and are used every day by hydraulic engineers as a common solution to achieve greater hydraulic power.

Pressure Intensifiers are used to generate a higher pressure power source. They can be used for a variety of applications, for example, to create a power pack or HPU. We offer a wide range of reliable Pressure Intensifiers. Do you need help in finding the best solution? We will gladly help you make the right decision.

At AHydraulics, we try to give you the best option for every department. Pressure Intensifiers are key in increasing higher pressure. From all-round in-line intensifiers to custom made intensifiers. We offer the best intensifiers possible for your company. Do you need help finding the best solution? Our experts will gladly help you make the right decision.

Hydraulic pressure intensifiers, sometimes referred to as hydraulic pressure boosters, generate a higher pressure from a low-pressure hydraulic power source. They always work powered by a pump, which is operating at a set pressure and from this the intensifier simply generates a higher output pressure. They are most commonly used in hydraulic power packs but originally had their beginnings in the workholding industry for use with CNC machines.

How the reciprocating intensifiers work
These devices are based on a differential piston principle, where a larger diameter piston pushes a smaller diameter piston, thus increasing the pressure to a factor equal to the ratio: Larger diameter area divided by smaller diameter area. The outlet pressure will always be proportional to the supplied pressure. The movement of the intensifier pistons is controlled by internal valves, and the piston speed can be as high as 20 Hz when increasing the pressure. At this point the intensifier continuously delivers flow to the high-pressure side. When the end pressure is reached, the piston movement stops. In case of a pressure drop on the high-pressure side, the intensifier will automatically start working to maintain the pressure.

The design of the intensifiers is very compact, and they are very easy to install. They are offered as in-line models, which fit standard pipe clamps used throughout the industry, as flange-on models, as cetop models and as cartridge type intensifiers. Despite the compact design, the intensifiers have all the required high-pressure check valves integrated.
Depending on the intensifier model, they can be used for flows starting at 0.3 gpm and up to 21 gpm. If built into a bypass, they can be used in very high flow systems. Most commonly, they are used in systems to generate end pressures between 1,000 and 7,300 psi. Some models go up to end pressures between 20,000 and 60,000 psi

An important point to remember is that when using intensifiers, you will initially have the full pump flow supplied to the high pressure side, e.g. to move a cylinder rod in position. After pump pressure has been reached, the intensifier automatically kicks in and increases the pressure in the cylinder to the higher pressure required.

In a typical application, for example, when operating a clamping cylinder, the intensifier is positioned between a directional valve and the cylinder. Connecting the P-port of the intensifier to the pump and the T-port to tank allows the full pump flow to go straight through the integrated check valves in the intensifier, and the cylinder rod will move into position at pump speed. When the cylinder has moved into position and pump pressure has been established inside the cylinder, the intensifier automatically increases the pressure to the required end pressure. As the cylinder now is filled with oil, the pressure increase is done swiftly, typically within a few seconds. In this situation, the intensifier will automatically maintain the pressure. To revert the cylinder rod, the directional valve on the pump side is activated, connecting pump pressure to the intensifier T-port and the P-port is connected to tank. This prompts a pilot signal to an integrated pilot-operated check valve (dump valve or POV), which opens, and creates a direct passage from the cylinder through the intensifier and back to tank.

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It is observed in lot of applications especially in special purpose metal cutting machines that the main hydraulic system works at very low pressure mainly the indexing and machining slides. However in most of these systems the job is clamped with Clampets which are very compact cylinders. These are used mainly to accommodate them in a very small space available on the machine. Since these are compact cylinders, the piston area is also small.

Normally it is observed that the bore sizes available for these clampets is not more than 50 mm. To achieve a force of say 3T one needs this cylinder to operate at 200 bar ! Invariably there is separate clamping power pack or else there is a separate pump motor assembly may be with a radial piston or some other high pressure pump installed on the same low pressure power pack. So you have an additional electric motor, bell housing assembly, suction strainer, separate relief valve etc. To get rid of the hassles one should think of using an Oil to Oil pressure intensifier. The typically most of the valves used in the metal cutting SPMs are CETOP 3 ( NG 06 ) mounting.

Scanwill Fluid Power has launched a new series of MP-2000 XP pressure solutions that are designed with an additional side outlet port, so that the oil from the high-pressure side is returned directly to tank. This ensures the intensifier and the cylinder are always supplied with cool and filtrated oil.

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Denmark ScanWill hydraulic pressure intensifiers

ScanWill pressure intensifiers can be applied to a host of diverse applications such as hydraulic workholding, pressure die casting, static and impulse testing equipment, hydraulic power packs, intensifier panels for subsea ROV's, hydraulic operated tools.

Scanwill - The Clever Way to get high Pressure
The Scanwill Pressure Boosters offer an easy, safe and cost efficient way to get high pressure from low pressure hydraulic power sources.

With experience dating back to 1991 our staff can guide you in deciding the right product as well as how to incorporate the Scanwill intensifiers in existing as well as new hydraulic systems.

Denmark ScanWill

ScanWill's range of hydraulic pressure intensifiers covers most fluids and includes solutions for low, medium and high-pressure ranges and variable flows. The intensifiers are available in cast iron, steel and stainless steel, and are always in stock for day-to-day shipment.

ScanWill intensifiers are used to generate a higher pressure from a low-pressure hydraulic power source. The intensifier is based on a piston principle, where a larger diameter piston pushes a smaller diameter piston, thus increasing the pressure to a factor equal to the ratio: Larger diameter area divided by smaller diameter area. The outlet pressure will always be proportionate to the supplied pressure. The hydraulic system controlling the piston movement allows this to be up to 20 Hz during pressure build up, during which the intensifier delivers continuous flow. When the end pressure is reached, the piston movement stops. In case of a pressure drop on the high pressure side, the intensifier will automatically start working to maintain the pressure. The compact ScanWill intensifiers all have high-pressure valves integrated.

The drawing shows the basic principle of the ScanWill intensifiers, consisting of a piston arrangement, a Piston Control Valve PCV, Check Valves CV1 & CV2 and the Pilot Operated check Valve POV.

By receiving low-pressure hydraulic input and amplifying it, the hydraulic intensifier generates high-pressure output. This amplification process involves mechanisms such as movable pistons or plungers to boost hydraulic pressure. Notable advantages of hydraulic intensifiers include their compact size, efficient pressure enhancement, and precise control, leading to minimized energy losses within the system.

Hydraulic intensifiers find applications across diverse fields including industrial machinery, construction equipment, aircraft, and automobiles. For instance, in aircraft hydraulic systems, where high-pressure hydraulic power is vital for tasks like landing gear operation and flight control, hydraulic intensifiers play a pivotal role in delivering the required high pressure from low-pressure systems.