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Troubleshooting Accumulator Failures While in Use: Effective Solutions

When encountering accumulator failures during use, the following effective solutions can be taken:

  1. * * Check compression ratio * *: If the accumulator’s bag or diaphragm is excessively deformed under maximum system pressure, the lifespan of the bag or diaphragm will be greatly reduced. The compression ratio is calculated by dividing the maximum pressure (P2) of the system or subsystem installed in the accumulator by its gas pre charge pressure (P0). For example, if P2=9 bar and P0=6 bar, the applied compression ratio is P2/P0=9/6=1.5. For bag accumulators, the allowable compression ratio is usually 4 to 1, and for diaphragm accumulators it is 6 to 1. If the compression ratio is within an acceptable range, then the compression ratio issue can be ruled out.
  2. * * Check the actual gas pre charge pressure * *: Depending on the application of the accumulator, the pre charge pressure (P0) is usually 0.6 to 0.9 times the minimum pressure (P1) of the system or subsystem. If P0 is less than P1, the accumulator will never completely empty the fluid during normal operation. If all fluids are discharged from the accumulator at the minimum system pressure (P1), the bag or diaphragm may be damaged due to the anti compression device. Therefore, if the minimum system pressure (P1) changes for any reason, the pre charge pressure (P0) must also change accordingly.
  3. * * Consider operating temperature * *: The bag/diaphragm of the accumulator is made of polymer, and the lifespan of all polymer materials will be exponentially reduced due to operating temperatures exceeding 80 ° C. If the fluid operating temperature during testing is unknown, but considering that the automatic transmission test bench and automatic transmission can reach a peak temperature of 150 ° C (300 ° F), which is much higher than the typical or ideal temperature of traditional hydraulic systems. Therefore, excessively high operating oil temperature may be a factor leading to diaphragm failure.
  4. * * Slow inflation * *: When inflating the gas end of the bag or diaphragm accumulator, nitrogen should enter very slowly. If high-pressure nitrogen gas is allowed to rapidly expand upon entering the bag, it can cool the polymer material of the bag to the point of immediate brittle fracture. Rapid pre charging may also cause damage to the bag or diaphragm due to anti compression devices.
  5. * * Check the pressure relief valve * *: If the pressure relief valve fails to open or is not adjusted properly, it may accumulate too much pressure in the accumulator system, which may cause system damage or even accumulator rupture.
  6. * * Solving Bag Accumulator Problems * *: Bag accumulator problems can be resolved by replacing damaged bags, adjusting pre charge pressure, repairing any leaks, and ensuring proper system maintenance and operation.

In summary, the key to solving accumulator failures lies in ensuring correct operating parameters, appropriate maintenance, and monitoring system performance. Through these measures, it is possible to effectively prevent and solve the problem of accumulator malfunctions during use.

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