Article in the magazine "Betriebstechnik & Instandhaltung"
Fitting our blog entry you can find an article in the february edition called "Pressure accumulators
safely in view"
Why the right preload pressure is crucial
Hydraulic accumulators are indispensable components in hydraulic systems. They stabilise the pressure in the system, compensate for load peaks and secure the supply in an emergency. For these functions to work reliably, one key figure is crucial: the correct nitrogen pre-charge pressure.
Even small deviations can have serious consequences:
Pressure too low: less storage capacity, more pump starts, higher wear, risk of downtime
Excessive pressure: Reduced oil clearance, undamped pressure peaks, possible damage to machinery
Incorrect pressure conditions: risk of diaphragm or bladder damage up to total failure
Whether mobile hydraulics, wind energy or stationary systems - continuous and reliable testing is essential for all hydraulic systems.
Challenges of traditional testing methods
Traditional tests are time-consuming and interfere with memory. Each measurement causes a small but relevant pressure loss. As a result, operators test less frequently - or do not test at all. This increases the risk of failures and unplanned downtimes.
The big change: contactless pressure monitoring
STAUFF relies on a new concept:
Mount once - monitor permanently.
The system consists of:
Storage tank adapter: Permanent installation on the gas connection, filling valve remains usable
RFID pressure sensor: Compact, without cable or battery, permanently assigned with serial number
Reader: Activates the sensor via electromagnetic field, data transmission without pressure loss
Digital advantages:
Automatic storage of gas pressure, temperature, date & time
Up to 15,000 data records for trend analyses and audits
No error-prone manual documentation
Practical benefits for operators
There are clear advantages, especially for many hydraulic accumulators - e.g. in steelworks, test benches or wind turbines:
No pressure losses due to measurements
Shorter test times per store
Reduced downtimes
High process reliability thanks to clear measuring points
Basis for condition-based maintenance
Early detection of critical memory
The result: more system availability, less effort, better verification.
A small sensor with a big effect
What used to be a time-consuming routine can now be carried out contactlessly, precisely and without interfering with the system. This technology makes hydraulic accumulators safer and creates the basis for data-based maintenance concepts - a smart step forward for operators with high efficiency requirements.
FAQs
How does contactless pressure monitoring work with hydraulic accumulators?
RFID technology enables contactless measurement of the nitrogen pre-charge pressure. A reader activates the sensor via an electromagnetic field and transmits the data without pressure loss - ideal for condition-based maintenance.
What advantages does RFID sensor technology offer for the maintenance of hydraulic accumulators?
No pressure loss during measurement
Shorter test times
Digital documentation for audits and trend analyses
Basis for data-based maintenance concepts
What data is saved with each query?
Gas pressure, temperature, date, time and the unique sensor ID. This data can be used for analyses, audits and predictive maintenance.
Can the system be integrated into existing hydraulic systems?
Yes, the Adaptors are suitable for bladder and diaphragm accumulators and allow the standard filling valve to be used unchanged. This makes retrofitting simple and safe.
For which sectors is the solution particularly interesting?
The technology is suitable for operators with many hydraulic accumulators, e.g. in steelworks, test benches, presses, wind turbines and mobile hydraulics.
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