Another challenge taken up by our team of hydraulic experts! The project was the study, the design and the realization of a battery of hydropneumatics accumulators with high capacity and performances.
Study of th client’s request and objectives
First, our team studies the state of the battery market: the existing, the differences, the evolutions and innovations present on the market.
The accumulator is considered as the most dangerous component in hydraulics. Industrialists use hydraulic accumulators for various problems: pulsation damping, suspensions, thermal expansions, power accumulation, emergency energy reserve, leakage compensation…
Indeed, the storage and the restitution of a volume of fluid are achievable by compressing a gas (usually nitrogen) in a part of a tank in a controlled time. Therefore, the behavior of the compressed gas plays an important role, which implies a particular care for the dimensioning calculation of the device.
If the very low compressibility of fluids makes it difficult to store their energy in small volumes, it allows them to transmit important forces. The high compressibility rate of gases makes it possible to store considerable energy in a small volume.
There are three main technologies for hydraulic accumulators: bladders, diaphragms and pistons.
Many manufacturers of accumulators are present on the market. On the other hand, the project initiated by AMACH aims to develop a real battery of hydraulic accumulators that can store a large quantity of energy and fluid. The objective is to be able to store up to 800 L of fluid with a gas pressure of 150 bars. The device to be developed must be modular to offer different ranges.
At the beginning of the project, we did not identify an equivalent or scalable solution that could store a large amount of energy by piston accumulator. We had to innovate to find a solution to the client’s request. We did not find an equivalent in the field.
The objective of this project is to design a prototype of batteries with hydraulic piston accumulators. The system must meet technical performances such as the storage of a large quantity of energy and fluid, but also in terms of ergonomics with an increased modularity and an ease of management. Furthermore, we make sure that the final product meets the PED 2014/68/EU standard. This standard specifies the way in which pressure vessels must be produced, manufactured, stored or used
Design and implementation of work carried out
Our team has therefore produced diagrams representing the hydraulic circuit of the system with 4 piston accumulators with a capacity of 200L. This first part of development consists in the prototyping of the device. We carried out a dimensioning study for the design of elements such as the accumulators, pumps of supply of the hydraulic circuits and other elements of safety. This spatial modeling of the different circuits of the installation allows the customer to visualize the project before realization.
After the client’s validation of the schematics, the manufacturing was launched. To make sure that the device works properly, a modularity and testing phase was carried out at the end of the manufacturing process.
The management of the different accumulators was carried out via a control box as well as the specific display of physical information (pressure, volume, temperature…).
All elements were tested in different configurations in our workshop. Numerous situations were simulated to ensure the efficiency of the system.
Finally, we installed the batteries at our customer’s site and carried out the commissioning and testing at our customer’s site.
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