ASYMMETRIC RAM PISTON FOR INTENSIFIER

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of Provisional Application No. 63/739,261, filed Dec. 27, 2024, the disclosure of which is hereby incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to systems that pressurize fluids for use in industrial and/or commercial purposes. More particularly the disclosure relates to an intensifier and components thereof such as a ram piston that reciprocates a plunger within a high pressure cylinder of an intensifier pump utilized to pressurize fluids.

BACKGROUND

Precision cutting for industrial and commercial purposes is often accomplished through the use of a fluid jet system that directs a high speed stream of fluid at a material surface to be cut. Fluid jet systems pressurize a fluid (e.g., water) to 15,000 psi or greater to generate a fluid jet traveling at speeds in excess of Mach 2. This high velocity fluid jet, often mixed with an abrasive, is capable of slicing through hard materials such as metal and granite with thicknesses of more than a foot.

Intensifier pumps typically include bi-directional and uni-directional systems. Known bi-directional intensifier pumps include two plungers supported by a single piston resulting in movement of the piston in both directions being a “working” or power stroke that pressurizes fluid. Known uni-directional intensifier pumps include a single plunger on only one side of the piston resulting in movement in one direction (e.g., the direction that the plunger faces) being a working or power stroke that pressurizes fluid, and movement in the other direction (e.g., the direction facing away from the plunger) being a “recovery” stroke during which fluid is not pressurized. Typically, fluid is drawn into a high pressure chamber as the plunger withdraws from the high pressure chamber during the recovery stroke. To maintain a steady supply of pressurized fluid, some known pressurization systems include multiple intensifier pumps that are “phased” such that the respective working stroke of each of the intensifier pumps are offset in time.

Referring to FIG. 1, the load on a known ram piston 20 is relatively high during a power stroke (when a plunger 22 advances into a high pressure cylinder 24 pressurizing and discharging fluid located within the high pressure cylinder 24). During a recovery stroke (when the plunger 22 withdraws from the high pressure cylinder and fluid is drawn into the high pressure cylinder to be pressurized), the load on the ram piston 20 is relatively low (compared to the power stroke). Because of the reduced load, the recovery stroke typically occurs at a higher rate of speed than the power stroke.

In multi-intensifier systems the faster recovery stroke enables the plunger 22 to reach its “home” position (end of recovery stroke and beginning of power stroke) in time to begin a pre-charge portion of the power stroke before another of the intensifiers/ram pistons 20 that is “on stroke” (i.e., performing a power stroke) completes its power stroke. This overlap of working strokes allows the intensifier/ram piston 20 that is in the pre-charge portion of its power stroke to reach the required discharge pressure at the same time as the intensifier/ram piston 20 that is completing its discharge stroke. Properly overlapping working strokes eliminates pressure drop normally associated with a reciprocating intensifier.

As shown, the known ram piston 20 has the same effective area on both sides of the piston (referred to herein as a symmetric ram piston). The known symmetric ram piston 20 displaces the same volume of hydraulic oil during the power and recovery strokes. The instantaneous hydraulic power required to operate the known asymmetric ram piston 20 of a single intensifier is the product of the pressure of the hydraulic fluid acting on the ram piston 20 and a flow rate of the hydraulic fluid being supplied to a hydraulic cylinder enclosing the ram piston 20.

Because the retraction speed of the known ram piston 20 is higher (and the recovery stroke takes less time) than the extension speed (i.e., the power stroke) of the known ram piston 20, a higher flow rate of hydraulic fluid/oil is needed. This results in increased hydraulic fluid consumption and power consumption during the retraction/recovery phase compared to the extension/power phase. These higher hydraulic fluid consumption rates limit the operational envelope for known intensifier pumps. Accordingly, higher capacity hydraulic pumps are often installed to achieve incremental increases in the discharge capacity of the known intensifier pump.

BRIEF SUMMARY

Some embodiments described herein provide a high pressure system that pressurizes a working fluid (e.g., water, oil, air) for use in the treatment of workpieces. According to one example, the working fluid is pressurized to between about 15,000 psi and about 200,000 psi for use in a fluid jet cutting head where the pressurized working fluid is forced through an orifice to generate a fluid jet that may be used to process (e.g., treat the surface of, cut through) a workpiece. The high pressure system may include an intensifier pump with a ram piston positioned within a hydraulic drive chamber. A plunger is carried by/secured to the ram piston such that the plunger extends away from the ram piston and into a pressurization chamber. The pressurization chamber contains a volume of working fluid that is pressurized as the ram piston advances towards the pressurization chamber and the plunger advances into the pressurization chamber.

In some cases, embodiments described herein provide a high pressure system that pressurizes a process fluid (e.g., peroxide catalyst) for use in the production of materials (e.g., low density polyethylene). According to one example, the process fluid is pressurized (e.g., up to about 50,000 psi) and placed in a reaction vessel (e.g., along with ethylene gas) where a polymerization process occurs. The high pressure system may include an intensifier pump (e.g., a McCartney Intensifier Unit) with a ram piston positioned within a hydraulic drive chamber. A plunger is carried by/secured to the ram piston such that the plunger extends away from the ram piston and into a pressurization chamber. The pressurization chamber contains a volume of process fluid that is pressurized as the ram piston advances towards the pressurization chamber and the plunger advances into the pressurization chamber.

Embodiments of an asymmetric ram piston described herein may reduce the volume of hydraulic fluid “consumed” by the hydraulic drive chamber during a recovery stroke (during which the asymmetric ram piston and the plunger retreat from the pressurization chamber) and may similarly reduce the hydraulic power used to retract/retreat the asymmetric ram piston. The asymmetric ram piston includes a smaller effective area (e.g., a surface exposed to/in contact with the hydraulic fluid) on one side (i.e., the retraction/recovery side that faces toward the pressurization chamber) and a larger effective area on another side (i.e., the extension/power side that faces away from the pressurization chamber). Some embodiments of the asymmetric ram piston and/or the hydraulic drive chamber are constructed such that up to an entirety of the extension side/surface is exposed to/in contact with the hydraulic fluid during a power stroke and therefore is part of the effective area.

The asymmetric ram piston reduces the flow rate of hydraulic fluid used during the recovery/retraction stroke which in turn reduces the hydraulic power required by the intensifier pump during the recovery/retraction stroke. Thus, the disclosed high pressure system with an asymmetric ram piston (e.g., as part of an intensifier pump) enables installation of motors with less power to achieve existing performance levels and increases in pressurized fluid discharge rate can be realized without upsizing the capacity of the hydraulic pump or the motor power.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, identical reference numbers identify similar elements or acts. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements and may have been solely selected for ease of recognition in the drawings. The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

FIG. 1 is a cross-sectional, side view of a known high pressure system including an intensifier pump with a symmetric ram piston.

FIG. 2 is a cross-sectional, side view of a high pressure system according to an embodiment, including an intensifier assembly with an asymmetric ram piston in a first position.

FIG. 3 is a cross-sectional, side view of the high pressure system illustrated in FIG. 2, with the asymmetric ram piston in a second position.

FIG. 4 is a front isometric view of the asymmetric ram piston illustrated in FIGS. 2 and 3, according to an embodiment, showing a power stroke working surface.

FIG. 5 is a rear isometric view of the asymmetric ram piston illustrated in FIG. 4, showing a recovery stroke working surface.

FIG. 6 is an exploded view of the asymmetric ram piston illustrated in FIG. 4, showing the power stroke working surface.

FIG. 7 is an exploded view of the asymmetric ram piston illustrated in FIG. 5, showing the recovery stroke working surface.

FIG. 8 is a side elevation view of the asymmetric ram piston illustrated in FIG. 4.

FIG. 9 is a cross-sectional, side view of the asymmetric ram piston along line 9-9 illustrated in FIG. 8, according to an embodiment.

FIG. 10 is a rear elevation view of the asymmetric ram piston illustrated in FIG. 4, showing the recovery stroke working surface.

FIG. 11 is a front elevation view of the asymmetric ram piston illustrated in FIG. 4, showing the power stroke working surface.

DETAILED DESCRIPTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc.

Unless the context requires otherwise, throughout the specification and claims which follow, the word “comprise” and variations thereof, such as, “comprises” and “comprising” are to be construed in an open, inclusive sense, that is as “including, but not limited to.”

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

Reference herein to two elements “facing” or “facing toward” each other indicates that a straight line can be drawn from one of the elements to the other of the elements without contacting an intervening solid structure. The term “aligned” as used herein in reference to two elements along a direction means a straight line that passes through one of the elements and that is parallel to the direction will also pass through the other of the two elements. The term “between” as used herein in reference to a first element being between a second element and a third element with respect to a direction means that the first element is closer to the second element as measured along the direction than the third element is to the second element as measured along the direction. The term “between” includes, but does not require that the first, second, and third elements be aligned along the direction.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range including the stated ends of the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context.

The headings and Abstract of the Disclosure provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

Referring to FIGS. 2 and 3, a high pressure system 100 may include an intensifier assembly 102 that receives a fluid 104 (e.g., from a source 105 such as a reservoir) as an input, increases the pressure of the fluid 104 to form a pressurized fluid 106, and then outputs the pressurized fluid 106. The fluid 104 may be a working fluid that, when pressurized, is delivered to a tool 108 (e.g., a fluid jet cutting head) that uses the pressurized fluid 106 to complete a task (e.g., processing/cutting a workpiece). In some embodiments the fluid 104 is a process fluid that, when pressurized, is delivered to the tool 108 (e.g., a reaction chamber) that uses the pressurized fluid 106 to produce a material (e.g., undergo a chemical reaction). Thus, the fluid 104 and the pressurized fluid 106 as used herein includes working fluids, process fluids, and other fluids used for industrial purposes.

The intensifier assembly 102 may include a pressure vessel 110 having a body 112 and a bore 114 extending through the pressure vessel 110 (e.g., along a length of the pressure vessel 110 parallel to an axis 117 of the intensifier assembly 102). The intensifier assembly 102 may include a plunger 116 that extends into the bore 114 through a proximal end 118 of the pressure vessel 110. Some embodiments of the intensifier assembly 102 may include a check valve assembly 123 that delivers the fluid 104 through a distal end 121 of the pressure vessel 110, opposite the proximal end 118 along a length of the bore 114. The plunger 116 reciprocates within the bore 114 of the pressure vessel 110 to increase the pressure (i.e., pressurize) the fluid 104. The plunger 116 may reciprocate along a direction D1, which is parallel to the length (e.g., along the axis 117). The plunger 116 may be driven by an asymmetric ram piston 160, as described in detail below.

Unpressurized/low pressure fluid 104 may enter the pressure vessel 110, specifically the bore 114, during a recovery stroke (i.e., a retraction stroke, or an intake stroke) of the plunger 116 (i.e., while the plunger 116 moves proximally). The fluid 104 may enter the bore 114 via passage through the check valve assembly 123. The pressurized fluid 106 may exit the pressure vessel 110 via passage through the check valve assembly 123 during a power stroke (i.e., extension stroke) of the plunger 116 during which the plunger 116 moves distally (i.e., toward the distal end 121). The intensifier assembly 102 may include an end flange 124 that secures the pressure vessel 110 in position relative to the cylinder housing 126. Similarly, the intensifier assembly 102 may include a cylinder housing (standoff) 126 securable relative to the pressure vessel 110 opposite the check valve assembly 123 and the end flange 124 along the length.

The check valve assembly 123 may be positioned outside the pressure vessel 110. The check valve assembly 123 may be a double ball check valve assembly that provides passage for the fluid 104 into the pressure vessel 110 during the extension stroke, and also provides passage for the pressurized fluid 106 out of the pressure vessel 110 during the power stroke.

The intensifier assembly 102 may include seals between adjacent components to prevent fluid leaking from the pressure vessel 110. For example, the intensifier assembly 102 may include one or more dynamic seals 128 that form a liquid impermeable barrier between components that move relative to one another (e.g., the plunger 116 and the body 112 of the pressure vessel 110). The intensifier assembly 102 may include one or more static seals 130 that form a liquid impermeable barrier between stationary components (e.g., the body 112 of the pressure vessel 110 and the seal head 120). The intensifier assembly 102 may include a sleeve 132 adjacent an inner wall of the pressure vessel 110. The sleeve 132 may be positioned so as to occupy a portion of the volume within the pressure vessel 110 thereby improving the pumping efficiency of the pressure vessel 110.

As shown, the intensifier assembly 102 may include a hydraulic pressure chamber 140. The hydraulic pressure chamber 140 may include a chamber body 142 and a chamber bore 144 extending through the chamber body 142. As shown, the chamber bore 144 may extend through the chamber body 142 along a length of the hydraulic pressure chamber 140. The length of the hydraulic pressure chamber 140 may be parallel to the length of the pressure vessel 110 (i.e., parallel to the first direction D1) when the hydraulic pressure chamber 140 is secured to the pressure vessel 110. An inner surface 146 of the hydraulic pressure chamber 140 may face toward and thereby define the chamber bore 144 at least partially enclosing an interior volume 148 of the hydraulic pressure chamber 140.

The hydraulic pressure chamber 140 may include a first port 150 that provides passage for a hydraulic fluid 152 (e.g., hydraulic oil) to enter interior volume 148. As shown in FIGS. 2 and 3, an amount of the hydraulic fluid 152 may enter (e.g., be pumped into) the interior volume 148 in the direction indicated by arrow 154 during a power stroke and in the direction indicated by arrow 156 during a recovery stroke. As the amount of the hydraulic fluid 152 that enters the interior volume 148 increases, the asymmetric ram piston 160 may be forced to move (e.g., translate within the interior volume 148 along the first direction D1).

During a power stroke, the hydraulic fluid 152 may enter the first port 150, which may be positioned to one side (e.g., proximally as illustrated) of the asymmetric ram piston 160. As the hydraulic fluid 152 enters the first port 150, the hydraulic fluid 152 exerts a force on a first effective area 158 of the asymmetric ram piston 160.

The first effective area 158 may include one or more surfaces (e.g., a ring-shaped surface 162 perpendicular to the first direction D1 facing proximally). The first effective area 158 may further include a second (e.g., circular/ring-shaped surface 164 concentric with the ring-shaped surface 162). The surfaces of the first effective area 158 may be offset along the first direction D1 (e.g., such that the circular/ring-shaped surface 164 is proximal of the ring-shaped surface 162, or vice versa).

During a recovery stroke, the hydraulic fluid 152 may enter a second port 166, which may be positioned on an opposite side (e.g., distally as illustrated) of the asymmetric ram piston 160 as the first port 150. As the hydraulic fluid 152 enters the second port 166, the hydraulic fluid 152 exerts a force on a second effective area 168 of the asymmetric ram piston 160. The second effective area 168 may be different than (e.g., smaller than) the first effective area 158. As described above, the different sizes of the first effective area 158 and the second effective area 168 may result in a reduced flow rate for the hydraulic fluid 152 into the interior volume 148 during either the power stroke or the recovery stroke (when the smaller of the first effective area 158 and the second effective area 168 is being “pushed” by the hydraulic fluid 152). The second effective area 168 may include one or more surfaces (e.g., a ring-shaped surface 170 perpendicular to the first direction D1 facing distally).

Because less force is needed during the recovery stroke (during which the fluid 104 is not being pressurized), the size of the second effective area 168 upon which the hydraulic fluid 152 exerts a force may be smaller than the first effective area 158. The reduced size of the second effective area 168 results in a reduced change in volume of the interior volume 148 on the recovery side (e.g., distal side) of the asymmetric ram piston 160 as the asymmetric ram piston 160 moves proximally. Thus, the asymmetric ram piston 160 can be moved distally faster than the asymmetric ram piston 160 moves proximally (during a power stroke) without increasing the power consumed by the intensifier assembly 102 or the flow rate of the hydraulic fluid 152.

According to tests conducted by Applicant, using the asymmetric ram piston 160 may reduce average hydraulic power consumption by up to 25% of a high pressure system compared to that same system using a known, non-symmetric ram piston (e.g., the known ram piston 20). Similarly, substituting the asymmetric ram piston 160 for a known ram piston may reduce peak hydraulic power requirement of the high pressure system by up to 38%. According to testing, the average hydraulic flow rate may be reduced by up to 25% when the asymmetric ram piston 160 is substituted for a known ram piston in a high pressure system. Further, testing shows up to a 25% reduction in the cooling used to maintain a desired operating temperature for the hydraulic oil of a high pressure system when substituting the asymmetric ram piston 160 for a known ram piston.

The asymmetric ram piston 160 may define a boundary between two portions of the interior volume 148 of the hydraulic pressure chamber 140. As shown, the interior volume 148 may include an extension portion 172, positioned proximally of the asymmetric ram piston 160, into which the hydraulic fluid 152 flows during a power stroke. The interior volume 148 may further include a retraction portion 174, positioned distally of the asymmetric ram piston 160, into which the hydraulic fluid 152 flows during a recovery stroke. As the asymmetric ram piston 160 moves proximally (e.g., during a recovery stroke) the extension portion 172 shrinks (as the retraction portion 174 enlarges) and the hydraulic fluid 152 within the extension portion 172 is moved out of the interior volume 148. Similarly, as the asymmetric ram piston 160 moves distally (e.g., during a power stroke) the retraction portion 174 shrinks (as the extension portion 172 enlarges) and the hydraulic fluid 152 within the retraction portion 174 is moved out of the interior volume 148.

The plunger 116 may be carried by the asymmetric ram piston 160 such that movement of the asymmetric ram piston 160 results in corresponding movement of the plunger 116. As shown, a portion of the plunger 116 may pass through the proximal end 118 of the pressure vessel 110 and into the bore 114. As the asymmetric ram piston 160 moves distally, the plunger 116 advances within the bore 114 toward the seal head 120 and the distal end 121, pressurizing the fluid 104 (e.g., water) within the bore 114. The pressurized fluid 106 then exits the pressure vessel 110 via the check valve assembly 120. The pressurized fluid 106 may then exit the intensifier assembly 102 (e.g., as indicated by arrow 176) and be delivered to the tool 108 (e.g., a fluid jet cutting head, a reaction chamber) for use (e.g., to process/cut a work piece, to undergo a chemical reaction).

The intensifier assembly 102 may include one or more sensors that detect the asymmetric ram piston 160 as the asymmetric ram piston 160 approaches the end of a stroke (e.g., the power stroke or the recovery stroke). According to one embodiment, when a proximity sensor detects the arrival of the asymmetric ram piston 160, the intensifier assembly 102 changes (e.g., reverses) the direction of movement of the asymmetric ram piston 160. According to one embodiment, the intensifier assembly 102 includes a direction control valve 178 that changes the direction of flow of the hydraulic fluid 152 (e.g., from arrow 154 to arrow 156, or vice versa).

Some embodiments of the intensifier assembly 102 may be devoid of the proximity sensors. For example, the high pressure system 100 may include digital feedback control of the asymmetric ram piston 160 (e.g., to achieve phased control of multiple intensifier assemblies 102). The digital feedback control may include a motion controller PLC, position sensors 179, and servo valves for each of the intensifier assemblies 102.

For example, during the power stroke the hydraulic fluid 152 may enter the first port 150 (e.g., into the extension portion 172 of the interior volume 148 that is “behind” the asymmetric ram piston 160 with respect to the direction of movement of the asymmetric ram piston 160). As the asymmetric ram piston 160 approaches the end of the power stroke, one or more of the proximity sensors may detect the asymmetric ram piston 160 and trigger the direction control valve 178 to change the direction of flow of the hydraulic fluid 152 (e.g., to enter via the second port 166 into the retraction portion 174 of the interior volume 148 that is “in front of” the asymmetric ram piston 160 with respect to the direction of movement of the asymmetric ram piston 160 during the power stroke).

Although shown in use with a particular style of intensifier pump, the asymmetric ram piston 160 idea is not limited to use with that particular pump. Rather, the asymmetric ram piston 160 is applicable to any embodiment of high-pressure cylinder and check valve arrangement.

Referring to FIGS. 2 to 11, the asymmetric ram piston 160 may include a head 180 that includes at least a portion of the first effective area 158 and at least a portion of the second effective area 168. As shown, the head 180 may include a first surface 182 that faces/defines the extension portion 172 (e.g., the ring-shaped surface 162) and a second surface 184 that faces/defines the retraction portion 174 (e.g., the ring-shaped surface 170).

The first surface 182 may define a first outer perimeter 183 within a plane perpendicular to the first direction D1 and the axis 117. Similarly, the second surface 184 may define a second outer perimeter 185 within a plane perpendicular to the first direction D1 and the axis 117. The first outer perimeter 183 and the second outer perimeter 185 may match (i.e., have the same size and shape). As shown, the first outer perimeter 183 and the second outer perimeter 185 are both circular with a center intersected by the axis 117. The head 180 may define a first cross-sectional dimension measured perpendicular to the axis 117. The head 180 may be cylindrical, or some other shape that corresponds to (i.e., matches) the chamber bore 144 of the hydraulic pressure chamber 140.

As shown, the head 180 may include a radial sidewall 186 that extends between the first surface 182 and the second surface 184 (e.g., from the first surface 182 to the second surface 184). The head 180 may include one or more grooves 188 (e.g., formed in the radial sidewall 186) that receive respective seals (e.g., o-rings) that form a liquid impermeable barrier with the inner surface 146 of the hydraulic pressure chamber 140. As shown, the head 180 may define a diameter J1 measured through the radial sidewall 186 along a direction D2 perpendicular to the radial sidewall 186 and perpendicular to the direction D1.

The asymmetric ram piston 160 may further include a first shaft 190 extending out and away from the first surface 182 and a second shaft 192 extending out and away from the second surface 184. The first shaft 190 may define a third outer perimeter 191 within a plane perpendicular to the first direction D1 and the axis 117. Similarly, the second shaft 192 may define a fourth outer perimeter 193 within a plane perpendicular to the first direction D1 and the axis 117.

As shown, the first shaft 190 may be positioned so as to reduce an area of the first surface 182 that is exposed to the interior volume 148/the extension portion 172. For example, the first shaft 190 may be cylindrical having a diameter J2 that is smaller than the diameter J1 of the head 180. The first shaft 190 may terminate at a proximal end surface 194 (e.g., the circular/ring-shaped surface 164) that forms a portion of the first effective area 158 during at least a portion of the power stroke. Some embodiments of the asymmetric ram piston 160 may be devoid of the first shaft 190, and the first surface 182 may be a circular surface that forms an entirety of the first effective area 158.

The second shaft 192 may be positioned so as to reduce an area of the second surface 184 that is exposed to the interior volume 148/the retraction portion 174. For example, the second shaft 192 may be cylindrical having a diameter J3 that is smaller than the diameter J1 of the head 180 and larger than the diameter J2 of the first shaft 190. The second shaft 192 may terminate at a distal end surface 196 that is positioned outside the retraction portion 174 so as to not form a portion of the second effective area 168. The second shaft 192 (e.g., the distal end surface 196) may receive the plunger 116 (e.g., within a pocket 198 of the asymmetric ram piston 160 that extends into the second shaft 192 through the distal end surface 196). The plunger 116 may be securable within the pocket 198 (e.g., by one or more fasteners, such as a snap ring). Other means of securing the plunger 116 are also disclosed herein, including threaded engagement, magnets, adhesive, clamps, etc.

Some embodiments of the second shaft 192 may include a sleeve 200 that encloses a hollow interior 202 (and optionally a solid inner core 204). The hollow interior 202 reduces the mass of the second shaft 192 and accordingly the asymmetric ram piston 160 resulting in less energy being used to move, stop, and reverse direction of the asymmetric ram piston 160. Alternatively, the second shaft 192 may be solid (i.e., devoid of a hollow interior or interior voids). As shown, the sleeve 200 and the solid inner core 204 may cooperatively form the distal end surface 196. According to some embodiments, the pocket 198 may extend into and be formed by the solid inner core 204. Some embodiments of the asymmetric ram piston 160 may be devoid of pockets (e.g., a plunger receiving pocket) extending into one or both ends of the asymmetric ram piston 160.

Some embodiments of the first shaft 190 may include a pocket 199 that extends into the first shaft 190. The pocket 199 of the first shaft 190 may receive the position sensor 179 and may extend into and through the head 180 and into the solid inner core 204 of the second shaft 192.

A method of assembling the asymmetric ram piston 160 may include coupling the sleeve 200 to the solid inner core 204. According to an embodiment, the sleeve 200 and the solid inner core 204 may each include corresponding threads 208, such that coupling the sleeve 200 to the solid inner core 204 includes threadedly engaging the corresponding threads 208. The method may include forming a seal between the sleeve 200 and the head 180. For example, forming the seal between the sleeve 200 and the head 180 may include compressing a seal member 210 (e.g., an o-ring) between the sleeve 200 and head 180.

The method may include enclosing the hollow interior 202 between the sleeve 200 and the solid inner core 204. The hollow interior 202 may include a single ring-shaped/tubular void (e.g., pocket of air, gas, or vacuum). The method may further include securing the plunger 116 to the asymmetric ram piston 160. According to some embodiments, the plunger 116 may be secured to the asymmetric ram piston 160 via one or more snap rings. The one or more snap rings may be opened to release/accept the plunger 116 and biased to a closed configuration in which the plunger 116 is secured to the asymmetric ram piston 160.

Operating the high pressure system 100 or components thereof (e.g., the intensifier assembly 102) may include a method of pressurizing a fluid (e.g., the fluid 104). The method of pressurizing the fluid 104 may include pumping the hydraulic fluid 152 into the extension portion 172 of the interior volume 148 of the hydraulic pressure chamber 140 (e.g., via the first port 150). The method may further include exerting a force on at least a portion of the first effective area 158 of the head 180 to move the asymmetric ram piston 160 in a distal direction. The method may further include moving the asymmetric ram piston 160 in the distal direction toward the pressure vessel 110. While moving the asymmetric ram piston 160 in the distal direction, the method may include simultaneously advancing the plunger 116, which is secured to the asymmetric ram piston 160, into the bore 114 of the pressure vessel 110.

The method may include increasing a pressure of the fluid 104 (e.g., from less than 200 psi to a pressure between about 15,000 psi and about 200,000 psi) to generate the pressurized fluid 106. Increasing the pressure of the fluid 104 may include advancing the plunger 116 distally into the bore 114 of the pressure vessel 110 while the fluid 104 is present within the bore 114. When the fluid 104 has been pressurized within a desired pressure range (e.g., between about 15,000 psi and about 200,000 psi) the pressurized fluid 106 may exit the intensifier assembly 102 (e.g., via the check valve assembly 123). After exiting the intensifier assembly 102, the pressurized fluid 106 may be delivered to a tool 108 (e.g., a fluid jet cutting head, a reaction chamber) for use (e.g., to process/cut a workpiece, to undergo a chemical reaction).

The method may further include pumping the hydraulic fluid 152 into the retraction portion 174 of the interior volume 148 of the hydraulic pressure chamber 140 (e.g., via the second port 166). The method may further include exerting a force on at least a portion of the second effective area 168 of the head 180 to move the asymmetric ram piston 160 in a proximal direction. According to some embodiments, the second effective area 168 contacted by/having a force exerted upon by the hydraulic fluid 152 is smaller than the first effective area 158 that was contacted by the hydraulic fluid 152 during the distal movement of the asymmetric ram piston 160. The method may further include moving the asymmetric ram piston 160 in the proximal direction away from the pressure vessel 110. While moving the asymmetric ram piston 160 in the proximal direction, the method may include simultaneously retreating the plunger 116, which is secured to the asymmetric ram piston 160, from the bore 114 of the pressure vessel 110.

The method may include moving the fluid 104 into the bore 114 of the pressure vessel 110. Moving the fluid 104 may include drawing the fluid 104 into the bore 114 via the withdrawal of the plunger 116 from the bore 114. Alternatively, or in addition to the withdrawal of the plunger 116, the method may include pumping the fluid 104 into the bore 114 of the pressure vessel 110 (e.g., via the check valve assembly 123). As the hydraulic fluid 152 enters the retraction portion 174 of the interior volume 148 hydraulic fluid 152 exits the extension portion 172 of the interior volume 148 (e.g., via the first port 150).

The above description of illustrated embodiments, including what is described in the Abstract, is not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Although specific embodiments of and examples are described herein for illustrative purposes, various equivalent modifications can be made without departing from the spirit and scope of the disclosure, as will be recognized by those skilled in the relevant art. The various embodiments described above can be combined to provide further embodiments.

Many of the methods described herein can be performed with variations. For example, many of the methods may include additional acts, omit some acts, and/or perform acts in a different order than as illustrated or described.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.