In the scope of this paper, a novel efficiency optimized supply pressure adaptive concept of pneumatic pressure boosters is presented. It is deduced from a profound analysis of state of the art components. The working cycle of the pump chambers can be divided into a filling, compression, pumping and decompression phase. A promising solution for efficiency improvements, which is further analyzed in the scope of this paper, is to adapt the required force of the compression chambers by nonlinear mechanics. Thus, a smaller force at the end of the stroke is required and a reduced air consumption of the driving chamber occurs. As the force demand of the compression chamber and therewith the load distribution over the stroke changes with the operational pressures, an adaptive concept needs to be implemented.
The novel device and its parameterization are deduced by means of an analytical description of state of the art pressure boosters. Subsequently, it is investigated by one-dimensional simulation in DSHplus. The results show broad applicability of the method in relevant applications and huge energy saving potentials compared to state of the art products.