Hydrostatic drives

- dimensioning

Huhtala 2010

Pump controlled hydrostatic system; efficiency of the

components
Q

Tp

Tm

Cm

Cp
p p

Qlp

pm

pC p

Q p C p Qlp

vp
hmp
tp

Huhtala 2010

Q
pC p

m Cm

m
Qlm

Q mCm Qlm

vm

m Cm
Q

p C p p p C p p p

pT p
Tp

hmp

Qp p

tp

pT p

TL

mTm

mCm pm
mTm

Qpm

Tm
Cm pm

Volumetric and hydromechanical losses at pumps

and motors
Flow losses is compounded of
Slip or leakages in narrow clearances
Dependent on pressure
Leakage normally laminar flow Q K p
Oil compressibility losses
V d p
Dependent on oil bulk modulus (oil B1500 MPa)
V 0
B dt
Effective volumetric displacement smaller than geometric
Torque losses
Based on friction in narrow lubrication films between moving parts
Different friction types
Viscous friction
Direct proportional to speed
Coulombin friction (dry friction)
Direct proportional to pressure
At the biggest on startingConstant friction
Constant friction
e.g. sealing friction

Huhtala 2006

Flow types
Laminar:
Flow rate is linearly dependent on pressure. Flow rate
is dependent on oil viscosity, which is changing as a
function of temperature. Q K p , K is dependent on
flow area shape and lenght.
Turbulent:
Flow rate is nonlinearly dependent on pressure. Oil
viscosity is not effecting to flow rate. Q K p
or
2p
Q Cq A

Huhtala 2006

Pump controlled hydrostatic system

Q

Tp

Tm
Cm

Cp
p

Qlp k p p

TL
Qlm k m p

pC p

m Cm

V0 d p
mCm k m p
B dt
C
p
k pkm V0 d p
m p p
Cm Cm
Cm B dt
Q p C p k p p

Huhtala 2006

Displacement control of pump and motor

Cm max

C m min
Cp

C p max

m kCp

m pC p

p const

p const

Cm const
Huhtala 2006

Cm

C p max

Cm max

1
Cm

Displacement
control of pump
and motor

Cm
1

Cm max 3

Cm
1

Cm max 2

m
p

Cm
1
Cm max

Cp
C p max

1/3

Huhtala 2006

1/2

Cp
C p max

Cm
C m max

1
2

Load types
Constant torque or force

Constant power

Inertia force

Inertia force and viscous friction

Tm T
Fm F
Pm Tm m P
Pm Fm vm F
d m
dt
dv
Fm m m
dt

Tm J

d m
f m
dt
dv
Fm m m fvm
dt

Tm J

Huhtala 2006

The angular speed of hydrostatic motor when

Constant torque or force

m p

m p

Constant power

Cp
Cm

Cp
Cm

T
C hmm
2
m

k m

P
k pkm V0 d P
QC m tm
Cm B dt Qtm

V0
d 2 m
d m
k p k m 2
m p

J
C m C m2 hmm
dt
dt
C
B

m
hmm
Cp

Inertia force

Inertia force and viscous

friction

V0
d 2 m f k p k m
V f d m
d m
k p k m 2
m p
2
J
2
m 2 0

C m C m hmm
dt
dt
dt
C
B

C
B

m
hmm
m hmm
m
hmm
Cp

Huhtala 2006

Example 1
Hydrostatic drive consists of variable displacement pump and constant
displacement motor
Qmax = 500 ml/s
Volumetric displacement of the motor Vm = 2Cm = 25 ml/r
System maximum pressure pmax = 70 bar
Efficiecies are 100%
Define
Maximum power
Maximum rotational speed
Maximum torque at motor axle
If constant output power is 2 kW, so define
Minimum rotational speed
Torque, when motor is running at full speed
If the torque is constant at lower rotational speeds than minimum speed, so
define the rotational speed when 20% of the system maximum power is reached

Huhtala 2006

Example 1
Max Power
Pm ax pm axQ m ax 70 105 500 106 W
3500W
Max rotational speed
Q
500
nm m ax m ax
r/s 20 r/s
Vm
25
Max torque
25 106
Tm C m pm ax
70 105 Nm
2
27.87 Nm

Huhtala 2006

When const output Power (2kW)

Tm m ax 2nm m in 2000W
Rotational speed
2000
nm m in
r/s 11.43 r/s
27.87 2
Torque
Tm 2nm m ax 2000W
2000
Nm 15.93Nm
2 20
Rotational speed in which the 20% of max power is reached
20% 3500W 700 W
Tm m ax 27.87 Nm

Tm

700W 2n 27.87 Nm
n 4 r/s ( 11.43 r/s)

Hydrostatic drive

V gp

V gm

n p , vp
T p , mhp

nm , vm
Q

Tm , mhm
i

Dieselmoottori

Fa ma g

P, n

Tr ,n r

f ,

Huhtala 2006

v
F

Traction force diagram

F [N]
F (max)

F (min)

Piste 1

Corner power
F(max), v(max)

Piste 2

v (max)

Huhtala 2006

v [km/h]

Example for calculating corner power and

conversion ratio
Starting values
Diesel engine power is 19.7 kW and torque is 67 Nm
Maximum needed speed is 35 km/h and maximum traction force is
10000 N

Huhtala 2006

Example continues

Corner power
PCP

F [kN]
1

Corner power
(Nurkka teho)

PCP Fvaad vvaad 10000

Moottorin
teho

Conversion ratio
3
4
V [km/h]

Huhtala 2006

35000
W 97.2 KW
3600

PCP

PDhst gear

97.2
7.3
19.7 0.8 0.85

Example continues; evaluation of conversion

ratio
General guideline is
When conversion ratio is R<3 in hydrostatic drives, that leads
to variable displacementpump and constant motor
When conversion ratio is R>3 both units need to be variable.

If both units are variable the total conversion range is divided to

both units in identical ratio. Rp is hydraulic pump and Rm is
hydraulic motor conversion ratio.
So

R p Rm R 7.3 2.7

Huhtala 2006

Example continues
In our case it should be used variable displacement units,
because the conversion ratio is 7.3.
If we are using variable displacement pump and constant motor,
the pump size will be increasing. That is because the whole
conversion range will be executed by means of the pump

The new conversion ranges are now

Rp 7.3 ja Rm 1

Huhtala 2006

Defining the size of hydraulic components

The pump volumetric displacement can be calculated as

Vp

Fvaad vvaad
pmaxn phst gear Rm

It can be seen from the equation that the demands (spped

and traction force) is effecting together with pressure to the
size of the pump. When pressure level is increasing the size of
the pump and motor is decreasing.

Huhtala 2006

Example continues
The size of the hydraulic motor is defined as

Vm

Fvaad vvaad
pm axnm m ax mhm gear

where
nm m ax

Huhtala 2006

vvaad igear
r

Example continues
According to the equations the size
of the components will be as
defined in the table. The gear ratio
between hydraulic motor and
wheel is igear = 18.

Kardaani

Diesel

Variable pump/
Constant motor

Variable pump/
variable motor

pmax (bar)

350

400

350

400

Vp (cm3/r)/ (nearest standard

size)

66/71

57/56

26/25

23/25

Vm (cm3/r )/ (nearest standard

size)

48/46

42/42

48/46

42/44

Huhtala 2006

Kardaani

Jakovaihde

Tasauspyrst

Tasauspyrst

Traction force curves

[daN ]

Drive Diagram

1.0

1000

0.9

900

0.8
0.7

700

0.6

600
0.5
500
0.4

400

0.3

300

0.2

200

Max.drive resistance (m ass m ax.), gradient = 10.0%

100
0
0

Hydraulic efficiency

2
5

10

15

20

25

30

35

40

45

0.1
0
[km /h]

Velocity v
Proj. resp.
Date 07.12.2004

No.
File VPVM.FA4

FADI 4.1
IHA/Huhtala

[daN ]

Drive Diagram

1.0

1200

0.9

1100

Both variable

0.8

1000
900

0.7

800

0.6

700
0.5
600
0.4

500
400

0.3

300

0.2

200

Max.driv e resistance (m ass m ax.), gradient = 10.0%

100
0
0

10

15

20

25

30

Velocity v
Proj. resp.
Date 07.12.2004

Huhtala 2006

No.
File VPFM.FA4

FADI 4.1
IHA/Huhtala

35

0.1
0
[km /h]

Hydraulic efficiency

Tractive effort FGes

Tractive effort FGes

800

Variable pump /
constant motor

Example continues
When using low speed motors the size of the motors are Vm =
160 cm3/r (4 motors). The pump size is almost the same as
previous case.

Diesel

Huhtala 2006

Traction force when using variable pump

and radial pistons motors (low speed
motors )

900
850
800
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
0
0

Drive Diagram

0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2

Max.drive resistance (mass max.), gradient = 10.0%

0.1

10

20

30

Velocity v
Proj. resp.
Date 07.12.2004

Huhtala 2006

1.0

No.
File VPFM.FA4

FADI 4.1
IHA/Huhtala

40

20

[km/h]

Hydraulic efficiency

Tractive effort FGes

[daN]