Accumulator

Abstract

An apparatus including an accumulator and a drive mechanism. The accumulator includes an energy storage apparatus with a first piston face configured to reversibly compress an energy storage medium and a second piston face forming at least part of an inner surface of a corresponding second fluid chamber reversibly expandable by movement of the second piston face. A third piston face forms at least part of an inner surface of a corresponding third fluid chamber reversibly expandable by the third piston face. The first, second and third piston faces are coupled together.

Claims

1. An apparatus including: an accumulator, and a drive mechanism including a hydraulic drive motor; the accumulator including: an energy storage apparatus with a movable first piston face configured to reversibly compress an energy storage medium; a movable second piston face forming at least part of an inner surface of a corresponding second fluid chamber reversibly expandable by the second piston face; a movable third piston face forming at least part of an inner surface of a corresponding third fluid chamber reversibly expandable by the third piston face; the first, second and third piston faces being coupled together, wherein the apparatus further includes hydraulic fluid lines and hydraulic fluid interconnections, the hydraulic fluid lines including: at least one pressure line from a prime mover to; the drive motor; accumulator second fluid chamber; accumulator third fluid chamber; at least one drain line input to the prime mover from; the drive motor; accumulator second fluid chamber; at least one pressure line from the accumulator third fluid chamber to; the drive motor; the apparatus configured to concurrently; input hydraulic fluid to the second fluid chamber and output hydraulic fluid from the third fluid chamber to the hydraulic drive motor, during an expansion of the energy storage medium.

2. An apparatus as claimed in claim 1, wherein the second and third fluid chambers are located within a common piston sleeve and separated by a second piston having the second and third piston faces.

3. An apparatus as claimed in claim 1, wherein the piston faces include at least one of the group comprising: movable sealing faces of pistons configured to slide within co-operating cylinder sleeves; mountings for connecting an elastic medium to the second fluid chamber; mountings for connecting an elastic medium to the third fluid chamber.

4. An apparatus as claimed in claim 1, wherein the energy storage apparatus includes a first fluid chamber reversibly expandable by the movable first piston face forming at least part of an inner surface of the first fluid chamber.

5. An apparatus as claimed in claim 4, wherein the first, second and third fluid chambers are coupled such that the first and third fluid chambers operate antagonistically and the first and second fluid chambers operate co-operatively.

6. An apparatus as claimed in claim 4, wherein the fluid chambers are coupled to include at least one of the group comprising: an expansion of the first fluid chamber creates an expansion of the second fluid chamber and a contraction of the third fluid chamber; a contraction of the first fluid chamber creates a contraction of the second fluid chamber and an expansion of the third fluid chamber; an expansion of the third fluid chamber creates a contraction of the first and second fluid chambers; an expansion of the second fluid chamber creates a contraction of the third fluid chamber and an expansion of the first fluid chamber.

7. An apparatus as claimed in claim 4, wherein the first, second and third piston faces are coupled such that; expansion of the third fluid chamber by movement of the third piston face causes a contraction of the second fluid chamber and a contraction of the first fluid chamber, by movement of the second and first piston faces respectively, and expansion of the first fluid chamber by movement of the first piston face causes an expansion of the second fluid chamber and a contraction of the third fluid chamber, by movement of the second and third piston faces respectively.

8. An apparatus as claimed in claim 4, wherein the first and second piston faces are connected together for common movement.

9. An apparatus as claimed in claim 4, wherein the first fluid chamber is located within the second fluid chamber or the second fluid chamber is located within the first fluid chamber.

10. An apparatus as claimed in claim 4, wherein the first and second fluid chambers are concentric.

11. An apparatus as claimed in claim 10, wherein the first and second fluid chambers are: substantially coaxial; or have parallel central axes aligned substantially parallel with the direction of the common movement of the first and second piston faces.

12. An apparatus as claimed in claim 4, formed with a double-ended piston assembly located within first and second piston sleeves and wherein: the first piston and the second piston are movable within the first piston and second piston sleeves respectively, to form the first fluid chamber and third fluid chamber respectively, the first piston and the second piston have piston faces within the first chamber and the third chamber, respectively defining the first piston and the third piston face, the first piston and the second piston are coupled together by a connector and configured such that expansion or contraction of the first fluid chamber by movement of the first piston face on the first piston causes a reciprocal contraction or expansion of the third fluid chamber by movement of the third piston face of the second piston; at least one intermediary partition separates the first piston sleeve and the second piston sleeve, the first piston and the second piston being respectively located in the first piston sleeve and the second piston sleeve and the intermediary partition allowing reversibly movable passage therethrough of the connector; the second fluid chamber is formed from: the intermediary partition, a portion of an inner surface of the second piston sleeve and the second piston face, formed on the second piston on an opposing side to the third piston face.

13. An apparatus as claimed in claim 12, including a signalling mechanism including a signal port incorporated into a fourth fluid chamber formed in the first piston sleeve between a movable fourth piston face located on the opposing side to the first piston face on the first piston and the intermediary partition surface spans the first piston sleeve.

14. An apparatus as claimed in claim 12, wherein the first and second pistons are coupled via a pivotal linkage configuration.

15. An apparatus as claimed in claim 4, including: a hammer weight with at least one drive-engagement surface; a drive projection configured to engage with the drive-engagement surface, and a drive mechanism capable of moving the drive projection reciprocally between two opposed directions, and wherein the energy storage medium is pressurised accumulator working gas.

16. An apparatus as claimed in claim 15, wherein the drive mechanism includes a ram drive.

17. An apparatus as claimed in claim 15, wherein at least one drive projection is attached to the drive mechanism being formed from a rotating endless loop passing about two rotational members, at least one said rotational member being driven by the drive motor.

18. An apparatus as claimed in claim 4, including a signalling mechanism including a pressure sensor monitoring the pressure in the first fluid chamber.

19. An apparatus as claimed in claim 1, further including at least one of the group comprising: fluid conduits, valves and connections, configured to allow hydraulic fluid to be concurrently input to the third fluid chamber and output from the second fluid chamber.

20. An apparatus as claimed in claim 1, wherein the hydraulic drive motor translates the hydraulic fluid flow into mechanical movement, including driving a drive sprocket.

21. An apparatus as claimed in claim 1, wherein the hydraulic drive motor translates the hydraulic fluid flow into mechanical movement, including linear movement in a ram-drive.

22. An apparatus as claimed in claim 1, wherein the energy storage medium includes an elastic medium, capable of moving the first piston face coupled to the elastic medium upon input or release of energy to the medium.

23. A method of operating an apparatus including: an accumulator; a hammer weight with at least one drive-engagement surface; a drive projection configured to engage with the at least one drive-engagement surface on the hammer weight, and a drive mechanism including a hydraulic drive motor, the drive mechanism capable of moving the drive projection reciprocally between two opposed directions, the accumulator including: an energy storage apparatus with a movable first piston face configured to reversibly compress an energy storage medium; a movable second piston face forming at least part of an inner surface of a corresponding second fluid chamber reversibly expandable by the second piston face; a movable third piston face forming at least part of an inner surface of a corresponding third fluid chamber reversibly expandable by the third piston face; the first, second and third piston faces being coupled together; wherein the apparatus further includes hydraulic fluid lines and hydraulic fluid interconnections, the hydraulic fluid lines including: at least one pressure line from a prime mover to; the drive motor; accumulator second fluid chamber; accumulator third fluid chamber; at least one drain line input to the prime mover from; the drive motor; accumulator second fluid chamber; at least one pressure line from the accumulator third fluid chamber to; the drive motor; configured to concurrently; input hydraulic fluid to the second fluid chamber and output hydraulic fluid from the third fluid chamber to the hydraulic drive motor during an expansion of the energy storage medium, wherein in the method, the drive mechanism is cyclically operable through a cycle including the stages of an up stroke, upper stroke transition, down stroke and lower stroke transition, wherein during the: up stroke, the drive projection engages with the drive-engagement surface to raise the hammer weight upwards; upper stroke transition, the hammer weight disengages from the drive projection as the hammer weight reaches its maximum extent of the up stroke and the hammer weight starts to travel downwards under the force of gravity; down stroke, the drive projection re-engages with the hammer weight via another drive-engagement surface as the hammer weight moves downwards, thereby adding additional impetus to the gravitational force driving downwards; lower stroke transition, the drive projection detaches from the drive-engagement surface allowing the hammer weight to strike an impact surface.

24. The method of claim 23, wherein the accumulator is cyclically operable through the stages of a charging stroke and a power stroke performed contemporaneously with the up stroke and the down stroke stages respectively, whereby during the: up stroke and charging stroke stage; the energy storage medium of the accumulator is compressed by high pressure fluid flow from the prime mover into the accumulator third fluid chamber, and the hammer weight is lifted by activation of the drive motor by high pressure flow from the prime mover, upper stroke transition stage; the hammer weight reaches an upwards travel limit and the drive mechanism either stops upwards movement or disengages from the hammer weight, down stroke and power stroke stage; the energy storage medium expands and moves the first piston face, the third fluid chamber contracts, outputting hydraulic fluid at high pressure to the drive motor, high pressure hydraulic fluid from the prime mover is input to the second fluid chamber applying pressure on the second piston face, thereby causing the second fluid chamber to expand, as the second fluid chamber expands co-operatively with the energy storage medium, force on the second piston face compounds with force on the first piston face to expel fluid from the third fluid chamber, lower stroke transition stage; the hammer weight reaches limit of downwards travel and the drive mechanism either stops downwards travel or disengages from the hammer weight.

25. The method of claim 24, wherein during the lower stroke transition stage, hydraulic fluid from the drive motor is temporarily directed to the third fluid chamber, before hydraulic fluid output from the prime mover is directed to the drive motor.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) Further aspects and advantages of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which:

(2) FIG. 1a) shows a longitudinal cross-section of an accumulator according to a first embodiment of the present invention;

(3) FIG. 1b) shows a longitudinal cross-section of the accumulator of FIG. 1a with a signaling port;

(4) FIG. 2 shows an end view and partial longitudinal cross-section of the accumulator of FIG. 1a;

(5) FIG. 3 shows a side elevation of a powered drop hammer and carrier with the powered drop hammer shown in partial section to show interior componentry;

(6) FIG. 4a) shows a schematic representation of the first stage of a cyclic operation of the accumulator of FIG. 1a operating with the powered drop hammer of FIG. 3;

(7) FIG. 4b) shows a schematic representation of the second and third stages of a cyclic operation of the accumulator of FIG. 1a operating with the powered drop hammer of FIG. 3;

(8) FIG. 4c) shows a schematic representation of the fourth stage of a cyclic operation of the accumulator of FIG. 1a operating with the powered drop hammer of FIG. 3;

(9) FIG. 4d) shows a schematic representation of an alternative fourth stage to that shown in FIG. 4c) wherein the accumulator of FIG. 1b) is utilised;

(10) FIGS. 5a)-d) respectively show the accumulator of FIG. 1a), in longitudinal cross-section, in the first, second, third and fourth stages of the operational cycle of FIGS. 4a-c);

(11) FIGS. 6a)-d) respectively show a second embodiment of an accumulator, in longitudinal cross-section, in the first, second, third and fourth stages of the operational cycle of FIGS. 4a-c);

(12) FIG. 7 shows a longitudinal cross-section of an accumulator according to a third embodiment of the present invention;

(13) FIG. 8 shows a longitudinal cross-section of an accumulator according to a fourth embodiment of the present invention;

(14) FIG. 9 shows a schematic representation of the accumulator of FIG. 1a) operating with a compactor ram;

(15) FIG. 10 shows a longitudinal cross-section of an accumulator according to a fifth embodiment of the present invention;

(16) FIG. 11a) shows a longitudinal cross-section of an accumulator according to a sixth embodiment of the present invention;

(17) FIG. 11b) shows a longitudinal cross-section of the accumulator of FIG. 11a with a signaling port;

(18) FIG. 12 shows a seventh embodiment of an accumulator, in longitudinal cross-section,

(19) FIG. 13a) shows a schematic representation of the first stage of a cyclic operation of the accumulator of FIG. 11a operating with the powered drop hammer of FIG. 3;

(20) FIG. 13b) shows a schematic representation of the second and third stages of a cyclic operation of the accumulator of FIG. 11a operating with the powered drop hammer of FIG. 3;

(21) FIG. 13c) shows a schematic representation of the fourth stage of a cyclic operation of the accumulator of FIG. 11a operating with the powered drop hammer of FIG. 3;

(22) FIG. 13d) shows a schematic representation of an alternative fourth stage to that shown in FIG. 13c) wherein the accumulator of FIG. 11b) is utilised;

(23) FIG. 14 shows a longitudinal cross-section of an accumulator according to an eighth embodiment of the present invention;

(24) FIG. 15a) shows a longitudinal cross-section of an accumulator according to a ninth embodiment of the present invention;

(25) FIG. 15b) shows a longitudinal cross-section of the accumulator of FIG. 15a with a signaling port;

(26) FIG. 16 shows a tenth embodiment of an accumulator, in longitudinal cross-section,

(27) FIG. 17a) shows a schematic representation of the first stage of a cyclic operation of the accumulator of FIG. 15a operating with the powered drop hammer of FIG. 3;

(28) FIG. 17b) shows a schematic representation of the second and third stages of a cyclic operation of the accumulator of FIG. 15a operating with the powered drop hammer of FIG. 3;

(29) FIG. 17c) shows a schematic representation of the fourth stage of a cyclic operation of the accumulator of FIG. 15a operating with the powered drop hammer of FIG. 3;

(30) FIG. 17d) shows a schematic representation of an alternative fourth stage to that shown in FIG. 17c) wherein the accumulator of FIG. 15b) is utilised;

(31) FIG. 18 shows a longitudinal cross-section of an accumulator according to an eleventh embodiment of the present invention;

(32) FIG. 19a) shows a longitudinal cross-section of an accumulator according to a twelfth embodiment of the present invention;

(33) FIG. 19b) shows a longitudinal cross-section of the accumulator of FIG. 19a with a signaling port;

(34) FIG. 20 shows a thirteenth embodiment of an accumulator, in longitudinal cross-section,

(35) FIG. 21a) shows a schematic representation of the first stage of a cyclic operation of the accumulator of FIG. 19a operating with the powered drop hammer of FIG. 3;

(36) FIG. 21b) shows a schematic representation of the second and third stages of a cyclic operation of the accumulator of FIG. 19a operating with the powered drop hammer of FIG. 3;

(37) FIG. 21c) shows a schematic representation of the fourth stage of a cyclic operation of the accumulator of FIG. 19a operating with the powered drop hammer of FIG. 3;

(38) FIG. 21d) shows a schematic representation of an alternative fourth stage to that shown in

(39) FIG. 21c) wherein the accumulator of FIG. 19b) is utilised;

(40) FIG. 22 shows a longitudinal cross-section of an accumulator according to a fourteenth embodiment of the present invention;

(41) FIG. 23a shows a longitudinal cross-section of an accumulator according to a sixth embodiment of the present invention; and

(42) FIG. 23b shows a longitudinal cross-section of an accumulator according to a seventh embodiment of the present invention.

BEST MODES FOR CARRYING OUT THE INVENTION

(43) Reference numerals for FIGS. 1-10.

(44) TABLE-US-00001 (1) accumulator (2) piston assembly (3) first piston sleeve (4) second piston sleeve (5) first piston (6) second piston (7) connector (8) first fluid chamber (9) first piston face (10) second fluid chamber (11) third fluid chamber (12) second piston face (13) third piston face (14) longitudinal axis (15) longitudinal bolts (16) endplate (17) endplate (18) intermediary partition (19) fourth fluid chamber (20) fourth piston face (21) valved port (22) second fluid chamber port (23) third fluid chamber port (24) hydraulic connectors (25) hydraulic connectors (26) prime mover (27) hammer assembly (28) hammer weight (29) housing (30) lifting surface projection (31) drive down surface projection (32) a drive projection (33) endless drive chain (34) upper sprocket (35) lower sprocket (36) hydraulic drive motor (37) pressure line from prime mover (26) to drive motor (36) (38) pressure line from prime mover (26) to accumulator second fluid chamber (10) (39) pressure line from prime mover (26) to accumulator third fluid chamber (11) (40) drain lines to prime mover (26) from drive motor (36) (41) drain lines to prime mover (26) from accumulator second fluid chamber (10) (42) pressure line between accumulator third fluid chamber (11) and drive motor (36) (43) signalling port (44) signalling piston (45) first piston seal (46) second piston seal (47) piston assembly bearing (48) piston assembly bearing (49) rod seal (50) spring (51) buffer system (200) accumulator (300) accumulator (303) first piston sleeve (304) second piston sleeve (305) first piston (308) first fluid chamber (309) first piston face (310) second fluid chamber (311) third fluid chamber (312) second piston face (313) third piston face (314) relief valve (316) endplate (322) second fluid chamber port (323) third fluid chamber port (324) recess (400) accumulator (403) first piston sleeve (405) a first piston (408) first fluid chamber (409) first piston face (410) second fluid chamber (411) third fluid chamber (413) third piston face (416) endplate (417) endplate (422) second fluid chamber port (423) third fluid chamber port (445) spring (500) compactor (550) compactor ram (551) input (552) hydraulic logic control (553) piston (554) compaction housing (600) accumulator (603) first piston sleeve (604) second piston sleeve (605) first piston (606) second piston (607) connector linkage (608) first fluid chamber (609) first piston face (610) second fluid chamber (611) third fluid chamber (612) second piston face (613) third piston face (614) con rod (615) con rod (616) lever (617) pivot connection (618) pivot connection) (619) fulcrum (622) second fluid chamber port (623) third fluid chamber port

(45) The figures show various embodiments of the present invention in the form of an accumulator and a powered drop hammer incorporating an accumulator.

(46) FIGS. 1a) and 1b) respectively show preferred schematic embodiments of the present invention in the form of a non-signalling and a signalling accumulator. Both embodiments are substantially similar and like parts are numbered with the same reference numerals.

(47) The accumulator (1) in FIG. 1a) includes a piston assembly (2) located in first (3) and second (4) piston sleeves. The piston assembly (2) consists of a double-ended piston comprised of a first piston (5) located inside the first piston sleeve (3) and a second piston (6) located in the second piston sleeve (4), coupled together by a connector (7).

(48) An energy storage apparatus is provided in the form of a first fluid chamber (8) configured to receive and contain an energy storage medium provided in the form of a compressible fluid such as a gas. The first fluid chamber (8) is formed between an end plate (16), the inner surface of the first piston sleeve (3) and a first piston face (9) located on said first piston (5). The second piston (6) forms part of both a second fluid chamber (10) and a third fluid chamber (11) located inside the second piston sleeve (4). A second piston face (12) and a third piston face (13) located on opposing sides of the second piston (6) provide movable sealing surfaces for the second (10) and third (11) fluid chambers respectively.

(49) In the embodiments shown in FIG. 1 and FIG. 2, the piston sleeves (3, 4) are configured as cylinders assembled together and orientated about a common longitudinal axis (14). The piston sleeves (3, 4) are secured by longitudinal bolts (15) through respective endplates (16, 17) opposing said first and third piston faces (9, 12), thus delimiting the distal ends of the first and third fluid chambers (8, 11) respectively. Alternative embodiments may use welds, screws or other means for fixing the endplates (16, 17) to the sleeves (3, 4). The first and second pistons (5, 6) are coupled together by a connector (7) in the form of a rigid, linear rod, permitting both pistons (5, 6) to move freely and reversibly together along said longitudinal axis (14) within the piston sleeves (3, 4). Thus, it can be seen that the first, second and third piston faces (9, 12 and 13) are coupled together. Movement of the piston assembly (2), comprised of the first and second pistons (5, 6) and connector (7), causes the first and third fluid chambers (8, 11) to expand and contract antagonistically to each other and the first and second fluid chambers (8, 10) to expand and contract cooperatively.

(50) The connector (7) also passes through an intermediary partition (18) separating the first and second piston sleeves (3, 4). The partition (18) provides a fixed surface forming part of both the second fluid chamber (10) in the second piston sleeve (4) and a fourth fluid chamber (19) located in the first piston sleeve (3). The piston assembly thus effectively provides a double-ended, double sided piston assembly with four reversibly contractible/expandable fluid chambers (8, 10, 11, 19).

(51) The second fluid chamber (10) is defined by the inner surfaces of the second piston sleeve (4), the partition (18) and the second piston face (12) formed on the opposing side of the second piston (4) to the third piston face (13). The fourth fluid chamber (19) is located on the opposing side of the partition (18) and is defined by the inner surfaces of the first piston sleeve (3), the partition (18) and a fourth piston face (20) formed on the opposing side of the first piston (5) to the first piston face (9).

(52) It will be thus readily understood that the fluid chambers (8, 10, 11, 19) are coupled such that said first and third fluid chambers (8, 11) operate antagonistically and said first and second fluid chambers (8, 10) operate co-operatively. Thus an expansion in the first chamber (8) respectively creates an expansion in the second fluid chamber (10) and a contraction in the third and fourth fluid chambers (11, 19) and vice versa. Equally, a contraction in the first chamber (8) respectively creates a contraction in the second fluid chamber (10) and an expansion in the third and fourth fluid chambers (11, 19) and vice versa.

(53) In use, the first fluid chamber (8) is initially filled with a fixed volume of compressible inert gas such as nitrogen via a valved port (21) (shown only in FIG. 1) while the fourth fluid chamber (19) is filled with air at atmospheric pressure or close thereto. The second and third fluid chambers (10, 11) are both configured to receive and expel an incompressible hydraulic fluid via respective ports (22, 23). FIG. 2 shows standard hydraulic connectors (24, 25) fitted to the second and third fluid chamber ports (22, 23) in a variety of cyclic applications where excess motive power capacity is available during parts of the operation cycle and it is desirable to utilise additional power at other parts of the cycle. The accumulator (1) is particularly suited to usage in a powered drop hammer embodiment. FIG. 3 shows a further embodiment of the present invention in the form of a powered drop hammer (100) attached to a prime mover (26) in the form of a tracked carrier. The prime mover (26) is the source of power to operate the drop hammer (100), and is typically provided by the carrier's auxiliary hydraulic pump (not shown individually), connected to the drop hammer (100) via hydraulic fluid lines (not shown in FIG. 3) in known manner. It will be appreciated that the prime mover may take a variety of forms and the usage of a tracked carrier powering an auxiliary hydraulic pump (as shown in FIG. 3) is purely exemplary.

(54) FIGS. 4 a-c) respectively show schematic representations of the powered drop hammer (100) incorporating the accumulator (1) operating through four stages of a cyclic operating cycle.

(55) The elements of the powered drop hammer (100) and accumulator (1) apparatus is identical in each of FIGS. 4 a)-c) and reference numerals, particularly those denoting hydraulic fluid lines, are thus not repeated unless necessary for clarity. The powered drop hammer (100) collectively includes: the accumulator (1) as described herein, together with a hammer assembly (27) including: a housing (29) (shown only in FIG. 3); a hammer weight (28), with two drive-engagement surfaces in the form of a lifting surface projection (30) and a drive down surface projection (31); a drive projection (32) configured to engage with either of the drive-engagement surfaces (30, 31) on the hammer weight (28), and a drive mechanism in the form of an endless drive chain (33), driven about an upper (34) and lower (35) sprocket by a hydraulic motor (36).

(56) In an application such as a powered drop hammer (100) as described herein, there are intrinsic limitations on the speed at which the hammer weight (28) can be raised as the hammer weight (28) needs to be brought to rest before being driven downwards into the impact surface. The greater the velocity the hammer weight (28) is raised at, the greater height needed for the hammer weight (28) to decelerate unaided, i.e. due to gravity, and/or the stronger the impact shock to be absorbed by a buffer system (51) incorporated into the powered drop hammer system (100). In contrast, it is highly desirable to force the hammer weight (28) downwards at the highest attainable velocity to provide the maximum impact force.

(57) As the drive mechanism operates, the hydraulic motor (36) drives the upper sprocket (34) to rotate the drive chain (33). The drive projection (32) attached to the chain (33) thus moves around the travel path of the chain (33) between the sprockets (34, 35) in two substantially opposing directions. It will be understood that while the drop hammer (100) may operate at a range of angular orientations, the vertical case is considered herein for simplicity and is shown in FIGS. 4a-c). Thus, the path of drive chain (33) and drive projection (32) travels between the sprockets (34, 35) on a vertically upwards and then downwards path, herein referred to as the up stroke and down stroke respectively.

(58) The four stages of the operating cycle (shown in FIGS. 4 a)-c) are: FIG. 4 a. up strokefrom W to X: As the drive chain (33) is rotated at the start of the up stroke, the drive projection (32) engages with the lifting surface projection (30) and the hammer weight (28) is raised upwards. FIG. 4 b. upper stroke transitionfrom X to Y: As the hammer weight (28) reaches the top of the up stroke, the drive projection (32) rotates around the upper sprocket (34) and the hammer weight (28) disengages from the drive projection (32). The upward movement of the hammer weight (28) momentarily ceases, whereupon the hammer weight (28) then starts to travel downwards under the force of gravity. In preferred embodiments the drop hammer (100) includes an arresting spring (not shown) at the upper portion of the housing (29) to arrest the hammer weight (28) upward movement. The hammer weight (28) acts on the arresting spring against its spring bias until coming to a momentary pause and then the spring releases the energy as an additional driving force to the hammer's downward movement. FIG. 4 b. down strokefrom Y to Z: As the hammer weight (28) moves downwards at the start of the down stroke, the drive projection (32) engages with the drive down surface projection (31) on the hammer weight (28) adding additional impetus to the gravitational force driving downwards. FIG. 4 c. lower stroke transitionfrom Z to W: Towards the lower portion of the down stroke, the drive projection (32) detaches from the drive down surface (31) before passing around the lower sprocket (35) and the hammer weight (28) continues downward to strike the impact surface (not shown). After passing around the lower sprocket (35), the drive projection (32) then re-engages with the lifting surface projection (30) on the hammer weight (28) and the cycle sequence is repeated.

(59) The operation of the accumulator (1) integrates into the above-described cyclic operation of the hammer, whereby: the charging stroke refers to the storing of energy in the accumulator (1) by compressing the accumulator's working gas in the first fluid chamber (8). The charging stroke is performed during lifting of the hammer weight (28) on the hammer up stroke (W-X) shown in FIG. 4a; the power stroke refers to the discharge of the energy stored in the accumulator first fluid chamber (8) to increase hydraulic fluid flow applied to the hydraulic drive motor (36) during the descent of the hammer weight (28) on the hammer down stroke (Y-Z) shown in FIG. 4b.

(60) FIGS. 4 a-c) also show the hydraulic fluid interconnections between the prime mover (26) (represented symbolically as a hydraulic pump and hydraulic oil reservoir), drive motor (36) and the accumulator second and third fluid chambers (10, 11), said interconnections including: pressure lines (37, 38, 39) respectively from the prime mover (26) to; the drive motor (36); accumulator second fluid chamber (10); accumulator third fluid chamber (11); drain lines (40, 41) respectively to the prime mover (26) from; the drive motor (36); accumulator second fluid chamber (10); pressure line (42) between the accumulator third fluid chamber (11) and the drive motor (36).

(61) The accumulator (1) is integrated into the operating cycle of the powered drop hammer (100) shown in FIG. 4a-c) as follows:

(62) Considering the initiation of the hammer weight up stroke with the hammer at its lowest point, (i.e. the impact point with the working surface) as the starting reference point of the cycle (as shown in FIG. 4a), the powered drop hammer (100) performs the following steps according to the passage of the drive projection (32) between the positional reference markers W, X, Y, Z shown in FIGS. 4 a-c). Step I. hammer weight up stroke and accumulator charging stroke, (FIG. 4a, W-X): The accumulator (1) is charged by high pressure flow (39) from the prime mover (26) into the accumulator third fluid chamber (11). Pressurising the third fluid chamber (11) causes a contraction of the coupled first fluid chamber (8) and therefore a pressurisation of the accumulator working gas therein. The hammer weight (28) is raised by activation of the drive motor (36) by high pressure flow (37) from the prime mover (26). Step II. upper stroke transition, (FIG. 4b, X-Y); The hammer weight (28) reaches the limit of its upwards travel and the drive projection (32) disengages from the lifting surface projection (30) on the hammer weight (28). The accumulator working gas in the first fluid chamber (8) is compressed to its maximum pressure in the operating cycle. Step Ill. hammer weight down stroke and accumulator power stroke (FIG. 4 b, Y-Z): The accumulator (1) discharges as the high pressure accumulator working gas moves the first piston face (9) to expand the first fluid chamber (8). The third fluid chamber (11), coupled to said first fluid chamber (8) therefore contracts, forcing out hydraulic fluid through outlet (23) through high pressure line (42) to the drive motor (36). Simultaneously, high pressure hydraulic fluid in pressure line (38) from the prime mover (26) is input to the second fluid chamber (10) applying pressure on the second piston face (12), thereby causing the second fluid chamber (10) to expand and the coupled third fluid chamber (11) to contract.

(63) As the second fluid chamber (10) expands co-operatively with the first fluid chamber (8), the force on the second piston face (12) compounds with the force on the first piston face (9) to expel the fluid from the third fluid chamber (11). The drive mechanism thus drives the hammer weight (28) downwards with the combined power of the compressed accumulator working gas in the first fluid chamber (8) plus the power of the prime mover (26) via the second piston face (12) of the second fluid chamber (10).

(64) Step IV. lower stroke transition (FIG. 4c, Z-VV): The drive projection (32) disengages from the drive down surface projection (31) on the hammer weight (28) which travels downward until impacting the working surface (not shown). The accumulator working gas in the first fluid chamber (8) is at its minimum pressure in the operating cycle. The fluid flow from the prime mover (26) is diverted from the second fluid chamber (10) to the drive motor (36) at low or negligible pressure until the drive projection (32) passes around the lower sprocket (35) and re-engages with the hammer weight (28) to repeat the cycle.

(65) FIG. 4 d) relates to a variant of the above described operating cycle and uses the accumulator embodiment shown in FIG. 1 b) which incorporates a signalling mechanism located in the fourth fluid chamber (19). The signalling mechanism is comprised of a signalling port (43) incorporating a signalling piston (44) (or in alternative embodiments a small valve (not shown)) configured to be tripped by movement of the fourth piston face (20) causing either direct contact between the signalling piston (44) and said fourth piston face (20), or the compression of a gas or liquid in the fourth fluid chamber (19) to exceed a threshold level. The signalling mechanism can be used to trigger a regeneration step in the above operating cycle during the lower stroke transition in step IV, as follows: Step IV. lower stroke transition and accumulator regeneration (FIG. 4 d, Z-VV): The drive projection (32) disengages from the drive down surface projection (31) on the hammer weight (28) which travels downward until impacting the working surface (not shown). The accumulator working gas in the first fluid chamber (8) is at its minimum pressure in the operating cycle. The drive mechanism including the drive motor (36), drive chain (33), drive projection (32) and sprockets (34, 35) still possess appreciable kinetic energy and momentum after being disengaged from the hammer weight (28). The residual drive mechanism kinetic energy is transferred to the accumulator (1) by briefly directing hydraulic fluid from the drive motor (36) back into the third fluid chamber (11) via hydraulic line (42a). This temporary diversion of hydraulic fluid from drive motor (36) into the third fluid chamber (11) assists in pre-charging the accumulator working gas in the first fluid chamber (8) and reduces the time required for the drive mechanism to slow to the appropriate rate for the up stroke/charging stroke. Once the speed of the drive motor (36) has dropped sufficiently to match the initial flow rate required to lift the hammer weight (28), the prime mover (26) hydraulic output is directed to the drive motor (36) via hydraulic line (37) and the operational cycle from Step I repeats.

(66) It will be appreciated that the triggering for the accumulator (1) regeneration stage provided by the signalling mechanism may be provided by alternative means, e.g. electronically monitoring the pressure drop in the accumulator first fluid chamber (8) for example.

(67) FIGS. 5 a)-d) show an enlarged view of the accumulator (1) during the operational cycle Steps I-IV described above. FIG. 5a corresponds to the start of step I (Z-W) where the accumulator (1) is fully discharged, the working gas in the first fluid chamber (8) is at a minimum (i.e. the pre-charge pressure) and all the hydraulic fluid has been expelled from the third fluid chamber (11).

(68) In FIG. 5 b), corresponding to a midpoint in between step I (Z-VV), the accumulator is partially charged, with the first fluid chamber (8) partially compressed and the third fluid chamber (11) partially filled with hydraulic fluid.

(69) FIG. 5 c) shows the accumulator (1) in a charged configuration corresponding to step II, where the first fluid chamber (8) is fully compressed with the working gas at maximum pressure and the third fluid chamber (11) at maximum expansion (X-Y).

(70) In FIG. 5 d), the accumulator (1) corresponds to step III, with the first fluid chamber (8) partially discharged and the third fluid chamber (11) partially contracted (Y-Z).

(71) In the following embodiments, parts which are identical or equivalent to like parts in the above embodiments are like numbered.

(72) FIGS. 6 a-d) show an alternative embodiment of the present invention in the form of an accumulator (200), identical to the accumulator embodiment (1) shown in FIGS. 5 a-d) with the exception of the accumulator working gas in the first fluid chamber (8) being replaced by an elastic media in the form of a compression spring (50). The accumulator shown in each of FIGS. 5a-d) operates in an identical manner to the accumulator (1) embodiment in FIGS. 1-5, with each individual figure of FIGS. 6 a-d) corresponding to the same stage in the operational cycle as the accumulator (1) described with respect to each of FIGS. 5 a-d) respectively. The operation of the spring (50) is equivalent to the working gas in the first fluid chamber (8) of FIGS. 1-5, i.e. compression of the spring (50) is equivalent to compression of the working gas.

(73) FIG. 7 shows a further embodiment of the present invention in the form of an accumulator (300) configured with a first fluid chamber (308) and a second fluid chamber (310) with respective first and second piston faces (309, 312). The first fluid chamber (308) is located inside the first piston sleeve (303), which is itself located co-axially and concentrically within a second piston sleeve (304) forming the outer surface of the second fluid chamber (310). The inner surface of the second fluid chamber (310) is formed by the outer surface of the first piston sleeve (303). The first fluid chamber (308) is filled with accumulator working gas via relief valve (321) as per the previous embodiments. However, instead of the second fluid chamber (310) being coupled to the first fluid chamber (308) via a connector passing through an intermediate partition to a separate piston, the first fluid chamber (308) is located within the second fluid chamber (310). The first and second piston faces (309, 312) are located on the same side of a common first piston (305). The opposing side of the first piston (305) provides the third piston face (313) forming part of a third fluid chamber (311) with a hydraulic fluid outlet (323).

(74) The first and second fluid chambers (308, 310) are sealed from each other by a first piston sleeve (303) attached to the first piston face (309) to prevent fluid transfer therebetween. As the first piston (305) travels within a second piston sleeve (304), the first piston sleeve (303) slides into an annular recess (324) within the endplate (316) to maintain the fluid/gas separation between the first and second fluid chambers (308, 310). In all other operational and functional aspects, the accumulator (300) is identical or equivalent as the accumulator (1) in the embodiments shown in FIGS. 1-5.

(75) FIG. 8 shows a further embodiment of the present invention in the form of an accumulator (400) configured with a first piston (405) inside a first piston sleeve (403). Instead of an accumulator working gas, the accumulator (400) includes an energy storage medium in the form of an elastic media. Although the elastic media may take several forms, the embodiment represented in FIG. 8 incorporates an elastic media in the form of spring (450) located inside the first piston sleeve (403) in a fluid chamber (410) bound by a fixed endplate (416) and the first piston face provided in the form of spring mounting (409) on the first piston (405). Hydraulic fluid from the prime mover (not shown) may also be pumped into the same fluid chamber (410) via inlet (422). It can thus be seen that the spring (450) and second fluid chamber (410) operate respectively as the functional equivalents of the separate physical first and second fluid chambers (8, 10) in the embodiments shown in FIGS. 1-5. The spring (450) and fluid chamber (410) are both formed in this embodiment by the same physical chamber (410) bounded by the first piston sleeve (403), a fixed endplate (416) and the first piston face (409). The third fluid chamber (411) (with third piston face (413), fluid outlet (423) and endplate (417)), is equivalent to the third fluid chamber (11) in the previous embodiments of FIGS. 1-5.

(76) As previously discussed, it can be seen that the present invention is implementable in a variety of forms and applications incorporating cyclically and/or reciprocating machinery including powered drop hammers, compactors feeders, sawmills, wood splitters, compaction equipment, plastic moulding equipment, agricultural hay balers, concrete breakers, slewing mechanisms in excavators and cranes

(77) FIG. 9 shows a further exemplary embodiment of the present invention in the form of a compactor (500) including an accumulator (1) as previously described. The compactor (500) includes a compactor ram (550) with a high pressure input (551) supplying hydraulic fluid from the prime mover (26) at high pressure, via a hydraulic logic control (552) to drive a piston (553) in the compactor ram (550). FIG. 9 shows the ram (550) driving into a compaction housing (554) to compact any material therein, e.g., waste material, landfill refuse, cars or the like. The compactor ram (550) receives additional hydraulic fluid flow from the accumulator (1) during the extension of the ram (550) to assist in crushing the material in the compaction housing (554). On the return stroke of the ram (550), less power is required and thus unutilised capacity may be stored in the accumulator (1), as previously described, until being released on the next compacting step.

(78) It should be appreciated that the embodiments illustrated in FIGS. 1-9 are symbolic and not necessarily to scale.

(79) FIG. 10 shows an alternative embodiment of the accumulator (1) where the first and second piston sleeves (3, 4) are different diameters. Consequently, this results in a different surface area for the first piston face (9) compared to the second and third piston faces (12, 13). This difference in piston face surface area is desirable in order to balance the different performance characteristics of the gas side (first fluid chamber (8)) and the oil side (second and third fluid chamber (10, 11)). The accumulator working gas in the first fluid chamber (8) is preferably maintained at the minimum pressure practicable (e.g. 70 bar) to reduce gas leakage over time. However, the hydraulic oil side ideally operates at a much higher pressure, e.g., four times higher (280 bar). FIG. 10 shows a first piston face (9) with four times the surface area of the second and third piston faces (12, 13), thus giving an ideal gas/oil side pressure ratio. The accumulator gas side/oil side configuration may be adjusted by varying at least one of; the gas-side parameters of: area of first piston face (9); first piston (5) stroke length; working gas pressure in the first fluid chamber (8); the volume of the spring (50);
and/or the oil-side parameters of: area of second piston face (12); area of third piston face (13); second piston (6) stroke length.

(80) Table 1 below illustrates the effects of changes in the aforementioned parameters on the accumulator (1) performance according to different system requirements.

(81) TABLE-US-00002 TABLE 1 Accumulator performance variables System Requirements Accumulator configuration comment Very low pressure gain of Large volume of accumulator Provides most constant accumulator working gas in relative to working volume power output first fluid chamber (8) High pressure systems Area of third piston face (13) is Volume of first fluid smaller than area of first piston chamber (8) needs to be face (9) large Low pressure systems Area of third piston face (13) is similar to area of first piston face (9) Long period to charge Large working gas volume in Typical reciprocating accumulator with unutilised first fluid chamber (8) can be cylinder application where capacity (i.e. long scavenge at low pressure or excess can return speeds need to be period) be dumped constrained - produces maximum power gain Short period to charge Small working gas volume in Typical regeneration circuit accumulator with unutilised first fluid chamber (8) at high for an excavator or the like capacity (i.e. short scavenge pressure period) Large difference between Large working volume, can be Maximum power gain scavenge pressure and pump at low pressure or excess can pressure be dumped I Small additional power Second piston face (12) can Accumulator is small and requirement be small relative to third piston economical face (13) with a short stroke Large additional power Third fluid chamber (11) must Large power gain - high requirement be large, scavenge time must benefit from accumulator be long with low pressure requirement, area of second piston face (12) small relative to area of third piston face (13) Power delivered mainly as A large third fluid chamber Needs long scavenge time extra hydraulic fluid flow (11) and a small second piston face (12) area relative to area of third piston face (13) Power delivered mainly as Area of second and third extra pressure piston face as large as possible

(82) It can be thus seen the accumulator may be configured to accommodate a wide range of differing system requirements. As previously discussed typical prime movers exhibit particular characteristics e.g., high flow/low pressure from a large excavator or low flow/high pressure from a smaller excavator. While such characteristics are inherent to the particular configuration of the individual excavator and cannot be changed, the accumulator may be easily configured to suit the prime mover's characteristics. The operator is thus able to inexpensively optimize the accumulator to match the prime mover (as illustrated in table 1), rather than incurring the high cost of purchasing a new prime mover or incurring the operational inefficiencies of using mismatched characteristics.

(83) As previously discussed herein, the designation of the respective fluid chambers (8, 10, 11, 19) relates to their function and interconnection as part of the apparatus and is not necessarily restricted to their mutual physical positioning. Consequently, it will be well apparent to one skilled in the art that the physical layout of the first, second, third and fourth fluid chambers (8, 10, 11, 19) show in the first embodiment (FIG. 1-5), second embodiment (FIGS. 6a,b), third embodiment (FIG. 7), fourth embodiment (FIG. 8), and fifth embodiment (FIG. 10), are exemplary only.

(84) Moreover, it will be further apparent that different physical permutations and combinations of the four fluid chambers (8, 10, 11, 19) includes, but is not limited to: Interchanging the first and second fluid chamber (8, 10), and/or Interchanging the third and fourth fluid chamber (11, 19, and/or Interchanging the elastic medium (spring 50) and the compressible fluid (accumulator working gas), and/or Combining the elastic medium (spring 50) with first or second fluid chamber (8, 10).

(85) These different embodiments are visualised schematically in FIGS. 11-22 as described more fully below. It will be noted the respective reference numerals in FIGS. 11-22 are identical to those in the corresponding FIGS. 1-10 as the fluid chambers (8, 9, 11, 19) and associated components and interconnections are still functionally identical.

(86) FIGS. 11a and 11b show a sixth embodiment of the present invention (differing only in the inclusion of a signaling port in FIG. 11b). This sixth embodiment corresponds to the first embodiment shown in FIGS. 1a and 1b, with the physical position of the first and second fluid chambers (8, 10) interchanged.

(87) FIG. 12 shows a seventh embodiment of the present invention corresponding to the second embodiment as shown in FIGS. 6a-6d, with the physical position of the first and second fluid chambers (8, 10) interchanged.

(88) FIGS. 13a-13c respectively show the sixth embodiment operating through the first, second, third and fourth stages of a cyclic operation of the accumulator of FIG. 11a operating with the powered drop hammer of FIG. 3.

(89) FIG. 13d shows the sixth embodiment operating an alternative fourth stage to that shown in FIG. 13c) wherein the accumulator of FIG. 11b) is utilised.

(90) FIG. 14 shows an eighth embodiment of the present invention corresponding to the fifth embodiment shown in FIG. 10, with the physical position of the first and second fluid chambers (8, 10) interchanged.

(91) FIGS. 15a and 15b show a ninth embodiment of the present invention (differing only in the inclusion of a signaling port in FIG. 15b). This ninth embodiment corresponds to the first embodiment shown in FIGS. 1a and 1b, with the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(92) FIG. 16 shows a tenth embodiment of the present invention corresponding to the second embodiment as shown in FIGS. 6a-6d, with the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(93) FIGS. 17a-17c respectively show the ninth embodiment operating through the first, second, third and fourth stages of a cyclic operation of the accumulator of FIG. 15a operating with the powered drop hammer of FIG. 3.

(94) FIG. 17d shows the ninth embodiment operating an alternative fourth stage to that shown in FIG. 17c) wherein the accumulator of FIG. 15b) is utilised.

(95) FIG. 18 shows an tenth embodiment of the present invention corresponding to the fifth embodiment shown in FIG. 10, with the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(96) FIGS. 19a and 19b show a sixth embodiment of the present invention (differing only in the inclusion of a signaling port in FIG. 19b). This sixth embodiment corresponds to the first embodiment shown in FIGS. 1a and 1b, with both the physical position of the first and second fluid chambers (8, 10) interchanged and the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(97) FIG. 20 shows a seventh embodiment of the present invention corresponding to the second embodiment as shown in FIGS. 6a-6d, with both the physical position of the first and second fluid chambers (8, 10) interchanged and the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(98) FIGS. 21a-21c respectively show the sixth embodiment operating through the first, second, third and fourth stages of a cyclic operation of the accumulator of FIG. 19a operating with the powered drop hammer of FIG. 3.

(99) FIG. 21d shows the sixth embodiment operating an alternative fourth stage to that shown in FIG. 21c) wherein the accumulator of FIG. 19b) is utilised.

(100) FIG. 22 shows an eighth embodiment of the present invention corresponding to the fifth embodiment shown in FIG. 10, with the physical position of the first and second fluid chambers (8, 10) interchanged and the physical position of the third and fourth fluid chambers (11, 19) interchanged.

(101) FIGS. 23a, 23b show a further embodiment of the present invention in the form of an accumulator (600) configured with a first piston (605) inside a first piston sleeve (603) and a second piston (606) inside a second piston sleeve (604). The first and second piston sleeves (603, 604) are not rigidly connected together as per the embodiments of FIGS. 1-10, but are instead connected together via connector linkage (607) in the form of first and second con-rods (614, 615) (respectively attached to the first and second pistons (605, 606)) pivotally connected to a lever (616) at non-identical positions (617, 618) respectively.

(102) The lever (616) is itself pivotal about a fulcrum (619) which is separated from the con-rod pivot connection (617, 618) by distances XX, YY respectively. It will be readily appreciated that by varying the relative lengths of XX and YY, the power ratio between the first and second pistons (605, 606) may be varied commensurately. FIG. 11a shows the fulcrum (619) positioned closer to the second piston (606) (i.e. XX>YY), while FIG. 11b shows the converse arrangement with the fulcrum (619) positioned closer to the first piston (605), i.e. XX<YY. The configuration shown in FIG. 11a would be applicable to a situation where it is desirable to retrieve very high pressure but less flow from the oil side, i.e., the second piston sleeve/second piston (604, 606) assembly. Conversely, FIG. 11b illustrates the situation where it is desirable to retrieve high flow from the oil side but at less relative pressure and thus the fulcrum (619) is positioned closer to the first piston sleeve/first piston (603, 605) assembly. It will be readily appreciated by one skilled in the art that numerous alterative connector linkage arrangements may be utilised and as such fall within the scope of the invention.

(103) Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.