for Passenger Cars and Commercial Vehicles

Steering Pumps

Powerful.

The power plant called steering pump and what's behind it. With its continuously ongoing development, modern automobile and commercial vehicle manufacturing makes highest demands on the overall concept and on systems and single components of the vehicle. ZF Lenksysteme GmbH, a joint venture of Robert Bosch GmbH and ZF Friedrichshafen AG, equips vehicles of renowned manufacturers with both highquality single components and complete steering systems. Early cooperation by simultaneous engineering offers the advantage that our single components or systems can be matched to new vehicle concepts in a way that saves time and costs. Among the important single components have been for decades the steering pumps from ZF Lenksysteme, which are necessary for operating hydraulic power steering systems, because they decisively influence capability, energy consumption and noise level of the steering system. Their design features are the achievement of maximum flow rate and high efficiency with a compact design and low weight.

Contents

Page

Design and Function of ZF Vane Pumps . . . . . . . 4 ZF Vane Pump CP 14 . . . . . . . . . . . . . . . . . . . . . . . 6 ZF Vane Pump CP 1 . . . . . . . . . . . . . . . . . . . . . . . . 7 ZF Vane Pump FP 2 . . . . . . . . . . . . . . . . . . . . . . . . 8 ZF Vane Pump FP 4 . . . . . . . . . . . . . . . . . . . . . . . . 9 ZF Vane Pump FP 6 . . . . . . . . . . . . . . . . . . . . . . .10 Energy Saving by ZF Vane Pumps . . . . . . . . . . . 11 Variable Displacement Pump VARIOSERV . . . . 13 ZF Vane Pump FN 4 . . . . . . . . . . . . . . . . . . . . . . . 15 ZF Vane Pumps FN 31/ FN 32 . . . . . . . . . . . . . . . 16 ZF Radial Piston Pump RN . . . . . . . . . . . . . . . . . 17 ZF Tandem Pumps . . . . . . . . . . . . . . . . . . . . . . . .18 Technical Summary . . . . . . . . . . . . . . . . . . . . 19/20 Steering Pumps for Passenger Cars and Commercial Vehicles . . . . . . . . . . . . . . . . . . . . . . 21

Installation schematic of an engine-driven ZF vane pump with ZF Servotronic 2, electronic control unit, steering column, oil reservoir as well as pressure, suction and return lines.

Powerful.

A wide production program comprises different pump designs and model ranges. Apart from the millions of proven vane pumps, which are driven either directly by a combustion engine or by a compressor depending on the kind of vehicle, tandem pumps with two separate oil flows for a very wide range of applications are also used. Our energy saving solutions are gaining more and more importance. For both the energy saving pump in the form of the controlled constant displacement pump (ECO) and the variable displacement pump VARIOSERV have convincing saving potential.

Development trends Reduction of fuel/CO2 emission noise weight size cost Increase in safety comfort performance Improvement of ruggedness recycling capability Owing to an extensive pump production network, we are able to supply our global customers worldwide from local production plants and to assist them on site with technical competence. And everywhere the innovative products and modern manufacturing technologies contribute to reduce the environmental load by saving of material and decrease in consumption.

VARIOSERV is a registered trademark of ZF Lenksysteme GmbH.

Installation schematic of a compressordriven ZF vane pump with ZF Servocom, oil reservoir, height and tilt adjustable steering column and ball-track relay shaft.

Powerful.

Design and Function of ZF Vane Pumps

10

Design The construction principle of the ZF vane pumps is based on a pumping element which is usually in a light-alloy housing (1) and consists basically of a shaft (2), the rotor (3), ten vanes (4), a cam ring (5) and the pressure plate (6). Depending on the model range, a second pressure plate or control plate is used. The axial end is formed by a cover (9) which is also made of light alloy. The shaft is guided in the housing by a ball bearing or plain bearing system depending on the type of drive and connected free of play with the rotor (3) seated on it. The vanes (4) are located in the ten radially arranged slots of the rotor. The cam ring (5), which is fixed in the housing or cover against rotation, surrounds the rotor together with the lateral pressure/control plate or cover, respectively. The two crescent-shaped pump chambers are situated between the cylindrical circumferential surface of the rotor and the ellipsoidal bore in the cam ring. The volume of the chambers results from the largest possible

Functional scheme of ZF vane pump FP 4.

1 2 3 4 5

Housing Shaft Rotor Vane Cam ring

6 7 8 9 10

Pressure plate Suction chamber Pressure chamber Cover Pressure relief and flow limiting valve

Design and Function

crescent segment between two vanes and the width of the rotor or vanes, respectively. Due to the design, the oil flow generated in the crescent-shaped pressure chambers is directed to the valves for pressure relief and flow limitation (10) positioned longitudinally or transverse to the shaft, limited to the values set and passed on to the hydraulic power steering via a hose connected to it. The performance ranges of the vane pump model ranges as well as the different equipment variants in respect of mounting, type of drive, energy saving and attachment of an oil reservoir can be seen from the Technical Summary on page 19/20. Function Rotation of the input shaft (2) and, with it, the rotor (3) results in the vanes (4) located in the rotor being forced radially by centrifugal force on to the track of the fixed cam ring (5). This movement is assisted by the pressurized oil which flows from the pressure chamber (8) via connections to the internal faces of the vanes. Between the ten vanes, ten self-contained pump

cells are formed which draw oil into the two crescent-shaped pump chambers when the volume is increasing and expel it into the pressure chamber when the volume is decreasing. Since the shape of the cam ring means that two suction zones and two pressure zones always lie opposite each other, each of the ten pump cells delivers twice its own volume with every rotation of the input shaft. In addition, owing to this double-action arrangement of the suction and pressure zones, the hydraulic radial forces acting upon the rotor cancel each other out. Flow rate control For individual matching with the steering system, the control characteristic of the ZF vane pumps can optionally be set at a flow rate which is constant, falling or falling in steps. In the pump design offering a constant flow rate (see figure below; variant A) an almost constant oil flow is fed to the power steering gear throughout the speed range of the vehicle engine. The ZF vane pump with falling control characteristic (variant B) is designed such that the required flow rate is achieved

at a determined speed, e.g. 1000 rpm, and that from this point the flow rate continuously falls while the speed continues to rise. The reduced flow rate remains, however, sufficient to allow for the maximum hydraulic assistance to be built up at any time. This characteristic is influenced by a control system in the pressure region specifically developed by ZFLS, which results in a reduction of hydraulic assistance in the steering gear at higher speeds and, thus, in a distinct improvement of the contact between the steering wheel and the road surface. For special applications, it is alternatively possible to provide the pumps with a control characteristic falling in steps (variant C). In this design, the flow rate is reduced in a pronounced transition area already in the medium speed range. This shorter phase of transition from maximum to minimum flow rate can be adjusted individually by a special valve system.

Flow rate

[dm3/min]

Figure at top: ZF Vane pump FN 4. Figure at bottom: Basic diagram of control characteristics with constant and falling flow rate as well as flow rate falling in steps.

Pump speed

[rpm]

Design and Function

ZF Vane Pump CP 14

Design On this pump type, the pressure relief and flow limiting valve is installed transverse to the input shaft. The mounting is standardized and meets the specifications of the Association of the German Motor Industry (VDA). This allows easy exchange of competitors' products. As a rule, the ZF vane pump CP 14 on passenger cars is driven from the vehicle engine via a pulley. Flow rate control For individual matching with the steering system, the control characteristic of this vane pump can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable energy saving improvements can be achieved in this model range by using the ECO (Electronically Controlled Orifice) valve described on pages 11/12.

ZF Vane pump CP 14 with pressed-in suction connector.

ZF Vane Pump CP 14

ZF Vane Pump CP 1

Design The CP 1 model range with its modular design system allows mounting in many ways, thus ensuring optimum adaptation of the pump to the vehicle conditions. In addition to the specific CP 1 mounting longitudinally to the input shaft, it is also possible to make use of transverse bolt connection directly to the combustion engine. Also, it is possible to redesign the pump cover to allow individual variants of mounting, e.g. as a multifunctional bracket, besides the standard design. Again, this pump is usually driven by belt from the vehicle engine.

Flow rate control For individual matching with the steering system, the control characteristic of the vane pump CP 1 can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5).

Figure at bottom: ZF Vane pump CP 1 with a multi-functional bracket connected with the cover.

Figure at top: ZF Vane pump CP 1 with pressed-in suction connector.

ZF Vane Pump CP 1

ZF Vane Pump FP 2

Design The pump type FP 2 was designed specifically for the pressure oil supply of hydraulic power steering gears on small passenger cars of the Asian market. Both the compact design with the pressure port moved towards to the center and the reduction of hydraulic capacity and belt pull are adapted to match on a high degree the requirements of these subcompact cars. An optionally fitted pressure switch, tuned to the electronics of the engine management, prevents stopping the vehicle engine at low speed. The ZF vane pump FP 2 is provided with the standardized mounting according to the specifications of the Association of the German Motor Industry (VDA). Depending on the application, other possibilities of attachment are feasible. The pump is belt driven from the vehicle engine. Flow rate control For individual matching with the steering system, the control characteristic of this vane pump can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5).

ZF Vane pump FP 2 with pressed-in suction connector.

ZF Vane Pump FP 2

ZF Vane Pump FP 4

Design As a result of the standardized mounting which meets the specifications of the Association of the German Motor Industry (VDA), this proven pump type, of which millions have been made, ensures easy exchange of competitors products. Also, it allows to mount the oil reservoir directly on top of the pump. This saves a hose line and assembly costs. Drive is preferably by belt driven from the vehicle engine. Flow rate control For individual matching with the steering system, the control characteristic of the vane pump FP 4 can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable improvements for energy saving can be achieved in this model range too by adapting the ECO (Electronically Controlled Orifice) valve described on pages 11/12.

ZF Vane pump FP 4 with pressed-in suction connector.

ZF Vane Pump FP 4

ZF Vane Pump FP 6

Design The development of the FP 6 model range achieves in particular the new target, set by the automotive industry, of steering pumps of higher hydraulic capacity, for its performance

potential comprises a controlled flow rate up to 15 dm3/min. and a maximum pressure of 150 bar. The function of the pumping element and the external dimensions of this pump are for the most part identical to the vane pump FP 4. Again, the mounting is standardized and meets the specifications of the Association of the German Motor Industry (VDA). This allows easy exchange of competitors' products. If required, a plastic oil reservoir can be mounted in order to save a hose line and thus assembly costs. Flow rate control For individual matching with the steering system, the control characteristic of the vane pump FP 6 can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable improvements for energy saving can be achieved in this model range, too by using the ECO (Electronically Controlled Orifice) valve described on pages 11/12.

ZF Vane pump FP 6 with oil reservoir mounted on top.

10

ZF Vane Pump FP 6

Energy Saving by ZF Vane Pumps

6 5
Advantages:

4 1

8 2

12 3 11 10

Fuel reduction by 20 to 40 % on average 15 to 20 C decrease in temperature approx. 35 % less power input reduction of neutral pressure drop by about 4 to 6 bar (Values depend on duty cycles and system design)

9
800 700 600

Energy saving by ECO Another important step towards energy saving is the adaption of an ECO valve (4) (ECO = Electronically Controlled Orifice) on the vane pump (1). Due to control dependent on steering wheel turning rate and vehicle speed, this hydraulic control unit generates a flow rate as needed for the hydraulic steering system, thus extending significantly the functionality of the base pump. The oil flow not needed by the pump system is controlled chiefly during straight ahead driving.

The necessary electronic control can be integrated into the existing vehicle electronics. Power input [W]

Driving cycle

500 400 300 200 100

Figure at bottom: Pump comparison for average power input in the driving and ECE cycles (test method for measuring pollutant emissions).

Standard vane pump Vane pump with ECO

Figure at top: Schematic representation of a hydraulic steering system with a ZF vane pump with ECO valve. 1 2 3 4 5 6 ZF vane pump Steering gear (basic unit) Steering valve ECO valve Oil cooler (if required) Oil reservoir 7 8 9 10 11 12 Electronic control unit Anti-vibration hose CAN Battery Speed sensor Steering wheel turning rate sensor

Energy Saving

ECE cycle

11

6 7 8 9

3 1 5

4 2

Schematic representation of a ZF steering pump with ECO together with a ZF Active Steering on the basis of a ZF Servotronic 2.

1 2 3 4 5

ZF Vane pump FP 6 with ECO ZF Servotronic 2 (basic unit) Servotronic 2 rotary valve Electric motor Superposition gear system

6 7 8 9

Oil reservoir with fine filter Electronic control unit Hoses, anti-vibration hose Cables to power supply, CAN, ignition, vehicle sensors

Servotronic is a registered trademark of ZF Lenksysteme GmbH.

12

Energy Saving

Variable Displacement Pump VARIOSERV

The development goal for this pump type consists in assisting the automotive industry in achieving the target it has set, i.e. achievement of the CO2 and fuel consumption limits, particularly on upper mid-size and luxury cars. Further improvement is possible by reducing the steering oil temperature and protecting the pump against possible overload. Design Unlike the double-stroke rotor set of the standard ZF vane pumps, the cam ring (5, see fig. on page 14) of the single-stroke rotor set of the VARIOSERV is variable and can generate, due to varying eccentricity, a control-

lable theoretical displacement. The cam ring is varied as a function of speed against the prevailing differential pressure between the left-hand (12) and right-hand

chamber (13). A control valve (11) with integrated pressure relief, which is fitted transverse to the shaft (2), decisively determines the functional performance.

800 700 600

Power input [W]

Driving cycle

500 400 300 200 100

ECE cycle

Standard vane pump VARIOSERV

Left-hand figure: Pump comparison for average power input in the driving and ECE cycles (test method for measuring pollutant emissions). Right-hand figure: Variable displacement pump VARIOSERV.

Variable Displacement Pump VARIOSERV

13

10

11

12

13

operation prevents excessive generation of pressurized oil and, due to the reduced power input, this results at higher pump speeds in significantly lower energy consumption. This makes it possible to simplify cooling measures in the steering system. When the vehicle engine speed decreases, the differential pressure between the left-hand and right-hand chamber again increases eccentricity between the rotor and cam ring. The result is that the theoretical displacement continuously in creases again.

Function After the pump speed at engine idle has been reached, the pump delivers a constant oil flow to the hydraulic power steering gear. A further increase in speed causes the internally increasing pump

pressure to open the control valve, pressurize the cam ring and reduce eccentricity with respect to the rotor (3). The result is that the pump chambers which become smaller merely produce a reduced theoretical displacement. This limited pump

Functional scheme of the variable displacement pump VARIOSERV.

1 2 3 4 5 6 7

Housing Shaft Rotor Vane Cam ring Pressure plate Suction chamber

8 9 10 11

Pressure chamber Cover Outer ring Control valve with integrated pressure relief 12 Left-hand chamber 13 Right-hand chamber

14

Variable Displacement Pump VARIOSERV

ZF Vane Pump FN 4

Design The design of the vane pump FN 4 has primarily been conceived for connection to the air compressor of commercial vehicles by means of a crossslotted disk for torque transmission free from radial load. If radial drive loads occur, as for instance due to a gear drive, it is possible to fit the FN 4 with a shaft running in ball bearings. If relief of the type-specific maximum pressure of the pump (165 or 185 bar respectively) is not carried out within the steering gear as is recommended, this can in particular instances be done by means of a pressure relief valve integrated in the flow limiting valve. The function as well as the use of light-alloy components is as described on pages 4/5. Also, it is possible to mount the oil reservoir directly on top of the pump. This saves a hose line and thus assembly costs at the vehicle manufacturer.

Figure at bottom: ZF Vane pump FN 4 with oil reservoir mounted on top of it.

Figure at top: ZF Vane pump FN 4. Pressure relief and flow limiting valve fitted longitudinally.

ZF Vane Pump FN 4

15

ZF Vane Pumps FN 31/ FN 32

ZF Vane pump FN 31 The basis for the modular-design pump is the short-length lightalloy cover. It includes a pumping element which features two

pressure plates and is equal in its principle of hydraulic operation to the vane pump FN 4 described above. The cover also incorporates the flow limiting valve (if required, with integrated pressure relief), arranged at right angles to the drive shaft, and the suction and pressure ports. The pressure port is optionally feasible on the right or left. The symmetrical flange bolt pattern of housing and cover allows fitting in any one of 4x90 positions. The variable use of this pump is also based on the rugged shaft bearing system in the lightalloy housing. The pump is perfectly suitable to safely absorb the axial and radial drive loads if a clutch disc, V-belt pulley or gear is used. In a gear drive, the drive-side antifriction bearing can be lubricated by engine oil. ZF Vane pump FN 32 This pump, which is for the most part identical with the FN 31 model range, is used for applications with high displacements up to 32 cm3/rev.

ZF Vane pump FN 31. With gear drive and transversely fitted flow limiting valve.

16

ZF Vane Pumps FN 31/ FN 32

ZF Radial Piston Pump RN

ZF Radial piston pump RN The same direction of delivery of the radial piston pump for both clockwise and counterclockwise direction of drive is the reason for its principal application as a wheel-driven emergency steering pump on commercial vehicles. Besides the high pressure level of 200 bar maximum, the suction control is of particular importance. It ensures that the output flow remains the same in spite of varying pump speed and only that amount of oil is sucked in which is necessary for steering. Thus, no flow limiting valve is required. Depending on the type, several pistons, driven by an eccentric shaft, perform a stroke in the radially arranged cylinder bores. Preloaded compression springs provide for the return of the pistons. In the process, the pistons are immersed in the oilfilled suction chamber and their interior can be filled with oil through transverse bores. The subsequent discharge stroke forces the oil into the pressure line. Automatic outlet valves prevent the pressure oil from flowing back into the piston chamber. Depending on type and

application, pressure relief is by a valve either in the pump or at some other suitable location of the hydraulic system.

ZF Radial piston pump RN, with 8 cylinders and suction-controlled flow rate.

ZF Radial Piston Pump RN

17

ZF Tandem Pumps

The tandem pump manufacturing range of ZF Lenksysteme GmbH is project-dependent and intended to meet a very wide range of different customer requirements. While circuit I always supplies the steering system with pressurized oil, circuit II can, due to differing pump variants, be used for the following: for cooling water of combustion engines for supplying hydraulic fan systems for supplying systems for roll steer for brake power assistance for presupply of fuel The two pump systems are driven by the same pump shaft and generate two oil flows that are independent of each other. Examples of tandem pumps on passenger cars In the field of passenger car equipment, a combination of a vane pump CP 1 with a water pump is used. In it, the vane pump supplies the hydraulic steering system with pressurized

oil and the water pump ensures the transport of cooling fluid for engine cooling. In the event of a combination of vane pumps FP 4 and CP 1, the type FP 4 pump generates the pressurized oil for the steering gear, whereas the vane pump CP 1 drives a hydraulic fan system. An electromagnetic solenoid control valve, which is influenced by the vehicle electronic system and is open in the zero-current condition, determines the flow rate of the CP 1 and thus the intensity of the hydraulic fan drive. Both pump elements are connected by an intermediate housing and a shaft coupling. Another variant is the combination of a vane pump FP 4 or FP 6 with a radial piston pump. In the same, the vane pump supplies the steering system, and the radial piston pump equipped with several pistons provides for supply to systems for roll steer and/or brake power assistance.

Examples of tandem pumps on commercial vehicles Depending on the specified requirements, these pump combinations developed for installation on commercial vehicles consist of a vane pump FN 4, FN 31 or FN 32 and a gear pump. The vane pump is used for pressure supply to the hydraulic steering system while it is the function of the gear pump to ensure presupply of the fuel. Drive can either be free from radial load via air compressor or via a pulley or gear.

Figure at top: ZF Tandem pump TN 4. Figure at bottom: ZF Tandem pump TP with hydraulic fan system.

18

ZF Tandem Pumps

Technical Summary

Passenger cars and light commercial vehicles

Model range

CP 14

CP 1

FP 2

FP 4

FP 6

VARIOSERV

Optional energy saving system ECO Design

vane cell

Theoretical displacement (cm3/rev) Max. speed (rpm) Controlled flow rate (l/min) Max. pressure (bar) Course of control characteristic Type of mounting
VDA 4 10

5.9 12

7 8.5

7 12.6

11 15

9.6 / 13 controlled 9000

8500

4 10 (12)

4 10

12 max.

15 max.

12

112

120

106

120 (130)

135 (150)

135

constant / falling / falling in steps

constant

CP 1 or transverse installation

VDA / specific, to be agreed upon 120 (135)

VDA or transverse installation

specific, to be agreed upon

Max. oil temperature (C) Belt pull (N) (depending on line of action) Weight (kg) Possible drives
2000 1500 / 2000 1500

2000

2000 / 3000

1.28

1.05

1.3

1.35

1.58

2.2

belt pull / chain pull / direct

belt pull

belt pull / chain pull / direct

Additional attachment parts

bracket / heat shield / pulley oil reservoir

bracket / pulley / pressure switch

bracket / heat shield / pulley / oil reservoir

Technical data of radial piston pumps are individual, please consult us when required. Technical data of tandem pumps: for values of circuit I see above, values of circuit II are specific.

Technical Summary

19

Technical Summary
Commercial vehicles

Model range

FN 4

FN 31

FN 32

Optional energy saving system ECO Design

(X) vane cell

Theoretical displacement (cm3/rev) Max. speed (rpm) Controlled flow rate (l/min) Max. pressure (bar) Course of control characteristic Type of mounting

14 28

14 25

28 32

4000 / 5000 depending on size

7 25

16 25

165 185 (200) 1) constant

185

2-bolt flange / SAE A

various 2-bolt flanges

Max. oil temperature (C) Belt pull (N) (depending on line of action) Weight (kg) Possible drives
2.3 max. 1200
2)

120

3.2 3.6

direct belt pull gear pulley gear oil reservoir pulley gear

direct / gear

Additional attachment parts

1) 2)

gear

Under development. Only applies to ball-bearing-mounted version.

Technical data of radial piston pumps are individual, please consult us when required. Technical data of tandem pumps: for values of circuit I see above, values of circuit II are specific.

Technical Summary

20

Steering Pumps

for Passenger Cars and Commercial Vehicles

Car r ge n se s Pa

s
CP 1

CP 14

FP 2

Ene

a vi n g rg y s

FP 4 - ECO FP 6 - ECO

FP 4

FP 6

VARIOSERV

FN 4 FN 31 FN 32 Radial Piston Pump

om

er cia

TN 4

l Ve hicle s

TN 31 TN 32

Steering Pumps

21

ZF Lenksysteme GmbH: the systems partner ZF Lenksysteme GmbH is one of the largest independent manufacturers of power steering systems for passenger cars and commercial vehicles. Renowned automotive manufacturers from all over the world value us as a creative and efficient systems partner for the development of new and innovative solutions. As a joint venture of Robert Bosch GmbH and ZF Friedrichshafen AG, ZF Lenksysteme GmbH offers its customers a unique source of expertise when it comes to integrating a wide range of top technologies in modules, system modules or entire chassis systems. ZF Lenksysteme GmbH Richard-Bullinger-Strasse 77 D-73527 Schwbisch Gmnd Germany Phone: +49 (0)71 71 / 31-0 Telefax: +49 (0)71 71 / 31-32 22 www.zf-lenksysteme.com The benefits for the manufacturer are clear to see: even shorter development times and optimized production processes with quality standards which just get better and better.

[Steering the right way]

A Joint Venture of Robert Bosch GmbH and ZF Friedrichshafen AG

Technical modifications reserved.

ZFLS 7612 P - KB 11/08 e Printed on paper bleached without use of chlorine