ME 4232:

FLUID POWER CONTROLS LAB

Class #6
Hydraulic Pumps

Notes
Next Friday:
Van de Ven Traveling
Servo Hydraulic Overview & System Dynamics Review

Upcoming Labs:
Lab 11/12: Synchronous / Asynchronous &
Tandem / Parallel Connections
Lab 13: Power Steering
Lab 14: Integrated Lab (Part I)
2

Agenda
Feedback: Lab Sections
Power Steering Valve
Pump Classification
Positive Displacement Types

Pump Theory
Flow Ripple
Inefficiencies
Aeration/Cavitation

Hydrostatic Transmissions
Types / Characteristics
Hybrid Vehicle Architectures
3

Feedback: Lab Sections

Overall Going Well
Helpful / Knowledgeable TAs (right amount of guidance)

Issues:
Some labs tight on time
Sometimes confusion
Lab assignments vague

Power Steering Valve (Lab 13)

Open center steering

Power beyond steering

Pumps - Introduction

Non-Positive Displacement Pump

Types of Positive Displacement Pumps

Gear pump (fixed displacement)
internal gear (gerotor)
external gear

Vane pump
fixed or variable displacement
pressure compensated

Piston pump
axial design
radial design
bent-axis design

External Gear Pump

Driving gear and driven gear
Fluid trapped between gear
teeth and housing

Gerotor pump
Inlet port

Outlet port

Internal/External Gear Pair

Inexpensive
Low-Pressure Applications
Low Flow (0.1 11.5 in3)
10

Vane Pump
Vanes in slots in rotor
Vanes loaded against
cam ring
Eccentricity determines
displacement
Quiet
Limited Pressure

11

Pressure Compensated Vane Pump

12 curve
Spring determines P-Q

Axial Piston Pump

Pistons rotate with cylinder
block
Pistons translate against swash
plate
Displacement determined by
swash plate angle
Fluid enters/exits through valve
plate

13

Radial Piston Pump

Cam moves pistons radially
Displacement determined by
cam profile
Displacement variation can be
achieved by moving the cam
(not common)
High pressure capable, and
efficient
Pancake profile
14

Bent Axis Pump

Drive shaft coupled to cylinder block

Stationary valve plate
Low piston side load
High efficiency

15

Pumping Theory - Flow Ripple

16

Pumping Theory Power Variable Calculations

17

Pumping Theory Efficiency

18

19

Aeration and Cavitation

Disastrous Events
Aeration
air bubbles enter pump at low
pressure side

Cavitation
Dissolved air cavitation
Vapor cavitation

Bubbles expand in low pressure

Bubbles collapse in high
pressure
Micro-jets formed Rapid
Erosion

20

Cavitation Video

21

http://www.youtube.com/watch?v=eMDAw0TXvUo

Hydraulic Motor / Actuator

Hydraulic motors / actuators are basically
pumps run in reverse
Input = hydraulic power
Output = mechanical power

22

Hydrostatic Transmission

23

Closed Circuit Hydrostatic Trans

24

General Consideration - Hydrostats

Advantages:

Wide range of operating speeds/torque

Infinite gear ratios - continuous variable transmission (CVT)
High power, low inertia (relative to mechanical transmission)
Dynamic braking via relief valve
Engine does not stall
No interruption to power when shifting gear

Disadvantage:
Lower energy efficiency (80% versus 92%+ for mechanical
transmission)
Leaks !
25

Hydraulic Hybrid Vehicle Circuits

Series

Parallel

Pros:
Retains existing mechanical drive train
Cons:
Does not allow optimal engine
management

Pros:
Allows optimal engine management
Four-Wheel Drive Capable
Independent Wheel Torque Control
Cons:
Hydraulic Efficiency Losses
Pump/Motor Operation

26

Hydraulic Accumulators
Energy Storage Device
Oil Compresses a Pre-Charged Gas (Nitrogen)

27

Hydro-Mech w/ Wheel Torque Control

Accumulator

Planetary
Differential
Axle
Gearbox

Engine
Clutch

Mechanical
Transmission

High Efficiency & Decoupling

2 Power Paths: Mechanical & Hydraulic
Leverage Highly Efficient Mechanical Branch
Infinite Speed Variability with Hydraulic Branch

Independent Wheel Torque Control

28

Hydraulic Transformer
Q1

Q2

Used to change pressure in a power

conservative way
Pressure boost or buck is accompanied by
proportionate flow decrease and increase
Note: Hydrostatic transmission can be thought
of as a mechanical transformer
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Why Are Pumps Inefficient at Low X?

Cs
Volumetric: Q xD 1
x

Mechanical: T xpD1 Cv
x

p p
1 x

Vr

xB
2

C f

p
x

Source:
30http://www.emeraldinsight.com/content_images/fig/0180560404021.png

Improving Pump Efficiency

Mechanical:
Variable Displacement Linkage
Low Friction Pin Joints

Volumetric:
Rolling Diaphragm Seal
No Leakage
Minimal Friction

31
Source: www.diacom.com

Source: Sandor, G.N. and Erdman, A.G.,

Advanced Mechanism Design: Analysis and
Synthesis, Volume 2, Prentice-Hall, 1984.

Linkage Synthesis

Video

Video:
http://www.youtube.com/watch?v=ovVGkjuXdvE
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Configuration Analysis

Stroke/Footprint

Overlapped Case at R1,max

2
1.5
1
0.5

0.24

0.22

-0.5
-1
-1.5
-1

-0.5

0.5

1.5

2.5

3.5

0.2

Optimized Solution:

R3 = 1.8, R4 = 1.8

Max Displacement = 2.11

Footprint = 8.38

0.18
0.16

2.5
0.14

Minimum Transmission Angle of Slider = 56

Minimum Timing Ratio = .72

33

2.5
|R3| Unitless

1.5 1.5

|R4| Unitless

First Generation Prototype

Variable Pump/Motor
Design Speed: 1750 RPM
Design Flow Rate 2.6e-4
Design Max Pressure: 6.9 MPa (1000 psi)

34

First Generation Prototype

35

First Generation Prototype

36

Quantifying Energy Loss

Leakage:

Viscous Friction:

Compressibility:
Vdead
dP
( P)
PV
dP
PdV
( P)

dV

Pin Friction:

12

Ecomp

37

Energy Loss Model

Bronze Bushings

Rolling Element Bearings

System Energy Loss 1800 RPM 6.9 MPa

k = 0.173

System Energy Loss 1800 RPM 6.9MPa

18
16

Leakage
Viscous Friction
Coulomb Friction
Compressibility Losses
Total Losses

14
Energy Loss (J/rev)

Energy Loss (J/rev)

2.5

12
10
Leakage
Viscous Friction
Coulomb Friction
Compressibility Losses
Total Losses

8
6
4

1.5

0.5

2
0

k = .0015

3.5

0.1

0.2

0.3

0.4
0.5
0.6
Displacement d/dmax

0.7

0.8

0.9

0
0

38

0.1

0.2

0.3

0.4
0.5
0.6
Displacement d/dmax

0.7

0.8

0.9

Energy Loss Model

Efficiency Models at 1800 RPM and 6.9MPa
1

.0015

0.9
0.8

.173

0.7

Efficiency

0.6
0.5
0.4
0.3
0.2
Bronze Bushings
Rollerbearings
McCandlish Model

0.1
0
0.1

39

0.2

0.3

0.4
0.5
0.6
0.7
Displacement (D/Dmax )

0.8

0.9

Pumping Head Design

Outlet -8

Check Valve
Fittings

Inlet -12 (3/4 ID)

Leakage Port -6

40

Experimental Efficiency Testing

Optical encoder (not shown)

Torque Transducer

Accumulator to smooth
pulsating flow

Pressure Transducer

41

Flow Meter

Experimental Efficiency Testing

Results Validate the Model

42

2nd Generation Prototype

10kW power output

Three cylinder design
Linkage Balancing
Incorporate roller bearings into design
Multi-parameter re-optimization
Include both mechanical and fluid dynamics
simultaneously

43

Linkage Preliminary Design

Links in single shear
Rolling element bearings
used
Rotary input possibly
gear driven or drive shaft
can be used

Video

44

2 Minute Writing
Sheet of Paper
No Names
1. What do you like most about the way the
course is going?
2. What do you like least about the way the
course is going?
3. Suggestions for improvement?
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