System for improving the energy efficiency in hydraulic systems

A system for improving the energy recovery efficiency in hydraulic systems, comprising:

• a working cylinder operable as a consumer of hydraulic energy in a first operating state thereof and as a generator of hydraulic energy a second operating state thereof, said working cylinder having a piston movable therein;
• a hydraulic accumulator connected to and chargeable by said working cylinder for storing energy from said working cylinder in the second operating state and connected to said working cylinder for discharging and delivering energy to said working cylinder in the first operating state, said hydraulic accumulator being an adjustable hydropneumatic piston accumulator having a plurality of separate fluid pressure chambers formed therein on a fluid side thereof, said fluid pressure chambers adjoining effective surfaces of different sizes, said piston accumulator having a gas side, said piston accumulator having an accumulator piston guided for axial movement in an accumulator housing and separating said gas side from said fluid side in said accumulator housing, said accumulator piston being configured as a step piston with active surfaces of different sizes of said fluid side and arranged in order from a largest active surface to a smallest active surface, at least one of said active surfaces being annular and being disposed concentrically relative to a longitudinal axis of said accumulator piston, said smallest active surface being circular and innermost, the remaining ones of said active surfaces surrounding said smallest active surface, cylindrical surfaces extending between and axially spacing the respective active surfaces, said accumulator housing has stepped portions having a smallest housing surface and other annular housing surfaces corresponding to respective ones of said active surfaces of said step piston and having cylindrical surfaces, extending between and axially spacing the respective housing surfaces, said active surfaces, said housing surfaces and said cylindrical surfaces of said accumulator piston and said accumulator housing delimiting said fluid pressure chambers therebetween, one of said fluid pressure chambers being delimited by said smallest active surface, said smallest housing surface and the respective cylindrical surface of said accumulator piston, fluid ports in said accumulator housing being connected to said fluid pressure chambers;
• a gas filling port in said accumulator housing on said gas side;
• an adjustment assembly selectively connecting one or more of said fluid pressure chambers of said piston accumulator to said working cylinder depending on pressure levels prevailing on said gas side of said piston accumulator and at said working cylinder, said adjustment assembly having directional valves controlling fluid flow between said fluid pressure chambers of said piston accumulator and said working cylinder and having first and second pressure sensors and a position sensor, said first pressure sensor being directly coupled to said gas side and providing signals representative of pressure levels of said gas side of the piston accumulator, said second pressure sensor providing signals representative of pressure at said working cylinder, said position sensor providing signals representative of movement directions of said piston in said working cylinder;
• and
• a control logic unit connected to said adjustment assembly processing the signals received from said sensors and controlling said valves based on the signals via lines connecting said sensors to said control logic unit and connecting said control logic unit to said valves.