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Lecture 6
Systems review exercise
• To be posted this weekend
• Due next Friday (3/6)

Coming week:
• Lab 13: Hydraulic Power Steering
• Lab 14: Integrated Lab (Hydraulic test bench)

Topics today:
• Pumps and motors
• (Hydraulic Hybrids)

M..E., University of Minnesota (updated 12.2013)

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Pumps
• Source of hydraulic power

• Converts mechanical energy to hydraulic energy

• prime movers - engines, electrical motors, manual power

• Two main types:

• positive displacement pumps

• non-positive displacement pumps

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Pump - Introduction

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Positive displacement pumps

• Displacement is the volume of fluid displaced cycle of pump motion
• unit = cc or in3

• Positive displacement pumps displace (nearly) a fixed amount of fluid

per cycle of pump motion, (more of less) independent of pressure
• leak can decrease the actual volume displaced as pressure increases

• Therefore, flow rate Q gpm = D (gallons) * frequency (rpm)

• E.g. pump displacement = 0.1 litre

• Q = 10 lpm if pump speed is 100 rpm
• Q = 20 lpm if pump speed is 200 rpm

M..E., University of Minnesota (updated 12.2013)

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Non positive displacement pumps

Centrifugal Pump
Impeller Pump

M..E., University of Minnesota (updated 12.2013)

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Non-positive displacement pump

• Flow does not depend on kinematics only - pressure important
• Also called hydro-dynamic pump (pressure dependent)

• Smooth flow

• Examples: centrifugal (impeller) pump, axial (propeller) pump

• Does not have positive internal seal against leakage

• If outlet blocks, Q = 0 while shaft can still turn

• Volumetric efficiency = actual flow / flow estimated from shaft speed

= 0%

M..E., University of Minnesota (updated 12.2013)

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Positive vs. non-positive displacement pumps

• Positive displacement pumps
• most hydraulic pumps are positive displacement
• high pressure (10,000psi+)
• high volumetric efficiency (leakage is small)
• large ranges of pressure and speed available
• can be stalled !

• Non-positive displacement pumps

• many pneumatic pumps are non-positive displacement
• used for transporting fluid rather than transmitting power
• low pressure (<300psi), high volume flow
• blood pump (less mechanical damage to cells)

M..E., University of Minnesota (updated 12.2013)

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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

M..E., University of Minnesota (updated 12.2013)

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External gear pump

• Driving gear and driven gear
• Inlet fluid flow is trapped
between the rotating gear teeth
and the housing
• The fluid is carried around the
outside of the gears to the outlet
side of the pump
• As the fluid can not seep back
along the path it came nor
between the engaged gear teeth
(they create a seal,) it must exit
the outlet port.

M..E., University of Minnesota (updated 12.2013)

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Gerotor pump
Inlet port
Outlet port

• Inner gerotor is slightly offset from external gear

• Gerotor has 1 fewer teeth than outer gear
• Gerotor rotates slightly faster than outer gear
• Displacement = (roughly) volume of missing tooth
• Pockets increase and decrease in volume corresponding
to filling and pumping
• Lower pressure application: < 2000psi
• Displacements (determined by length): 0.1 in3 to 11.5 in3
M..E., University of Minnesota (updated 12.2013)

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Vane Pump

• Vanes are in slots

• As rotor rotates, vanes are pushed
out, touching cam ring
• Vane pushes fluid from one end to
another
• Eccentricity of rotor from center of
cam ring determines displacement
• Quiet
• Less than 4000psi

M..E., University of Minnesota (updated 12.2013)

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Pressure Compensated Vane Pump

M..E., University of Minnesota (updated 12.2013)

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PC Vane Pump (Cont’d)

• Eccentricity (hence displacement) is varied by shifting the cam ring

• Cam ring is spring loaded against pump outlet pressure

• As pressure increases, eccentricity decreases, reducing flow rate

• Spring constants determines how the P-Q curve drops:

• small stiffness (sharp decrease in Q as P increases)

• large stiffness (gentle decreases in Q as P increases)

• Preload on spring determines

• pressure at which flow starts cutting off

M..E., University of Minnesota (updated 12.2013)

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Axial Piston Pump

• Each piston has a pumping cycle
• Interlacing pumping cycles produce nearly uniform
flow (with some ripples)
• Displacement is determined by the swash plate angle
• Generally can be altered manually or via (electro-)
hydraulic actuator.

Displacement can be varied by varying swashplate angle

M..E., University of Minnesota (updated 12.2013)

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Bent-Axis Piston Pump

• Thrust-plate rotates with shaft
• Piston-rods connected to swash plate
• Piston barrel rotates and is connected
to thrust plate via a U-joint
• More efficient than axial piston pump
(less friction)

M..E., University of Minnesota (updated 12.2013)

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Radial Piston Pump

• Similar to axial piston pump, pistons

move in and out as pump rotates.
• Displacement is determined by cam
profile (i.e. eccentricity)
• Displacement variation can be achieved
by moving the cam (possible, but not
common though)

• High pressure capable, and efficient

• Pancake profile

M..E., University of Minnesota (updated 12.2013)

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Piston Pump - flow ripples

1 piston
• Each cylinder has a
Pumping pumping cycle
• Total flow = flow of each
Filling cylinder
• More cylinders, less ripple
• Frequency:
Even # cylinders n*rpm
2 piston Odd # cylinders (2n)*rpm
Total flow
• Can be problematic for
manual operator
(ergonomic issue)
• Noise

• Displacement = # Cylinders x Stroke x Bore Area

M..E., University of Minnesota (updated 12.2013)

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# of Pistons Effect on Flow Ripples

1
n=2
0.9 n=3
n=4
0.8
n=5
0.7

0.6
Flow -

0.5

0.4

0.3

0.2

0.1

0
0 1 2 3 4 5 6
Angle - rad

M..E., University of Minnesota (updated 12.2013)

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Pumping theory
• Create a partial vacuum (i.e. reduced pressure)
• Atmospheric / tank pressure forces fluid into pump
• usually tank check valve opens
• outlet check valve closes

• Power stroke expels fluid to outlet

• outlet check valve opens
• tank check valve closes

• Power demand for prime mover (ideal calculation)

• (piston pump) Power = Force*velocity = Pressure*area*piston speed
= Pressure * Flow rate
• If power required > power available => Pumps stall or decrease speed

M..E., University of Minnesota (updated 12.2013)

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Aeration and Cavitation

• Disastrous events - cause rapid erosion

• Aeration
• air bubbles enter pump at low pressure side
• bubbles expand in partial vacuum
• when fluid+air travel to high pressure side, bubbles collapse
• micro-jets are formed which cause rapid erosion

• Cavitation
• fluid evaporates (boils) in partial vacuum to form bubbles
• bubbles expands then collapse
• as bubbles collapse, micro-jets formed, causing rapid erosion

M..E., University of Minnesota (updated 12.2013)

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Causes of cavitation and aeration

• For positive displacement pumps, the filling rate is determined by
pump speed; (Q-demand) = D * freq)

• Filling pressure = tank pressure - inlet pressure

• Q-actual = f(filling pressure, viscosity, orifice size, dirt)

• If Q-actual < Q-demand, inlet pressure decreases significantly

• This causes air to enter (via leakage) or to evaporation (cavitates)

• To prevent cavitation/aeration
• increase tank pressure
• low viscosity, large orifice
• lower speed (hence lower Q-demand)

M..E., University of Minnesota (updated 12.2013)

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Aeration and Cavitation

M..E., University of Minnesota (updated 12.2013)

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Hydraulic Motor / Actuator

• Hydraulic motors / actuators are basically pumps run in reverse

• Input = hydraulic power

• Output = mechanical power

• For motor:
• Frequency (rpm) = Q (gallons per min) / D (gallons) * efficiency
• Torque (lb-in) = Pressure (psi) * D (inch^3) * efficiency

• efficiency about 90%

• Note: units

M..E., University of Minnesota (updated 12.2013)

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Models for Pumps and Motors

•

M..E., University of Minnesota (updated 12.2013)

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Non-ideal Pump/Motor Efficiencies

• Ideal torque = torque required/generated for the ideal pump/motor
• Ideal flow = flow generated/required for the ideal pump/motor
• Torque loss (friction)
• Flow loss (leakage)
• Signs different for pumping and motoring mode
Qact u al
Pump volumetric eff:

Friction Qi deal Pump mechanical eff:

Ql oss
Tin/out (Reverse if motor case !! )
leakage
Tideal Total efficiency: vol
Ideal pump
Functions of speed, pressure
and displacements

M..E., University of Minnesota (updated 12.2013)

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Hydro-static Transmission
• A combination of a pump and a motor
• Either pump or motor can have variable displacement

• Replaces mechanical transmission

• By varying displacements of pump/motor, transmission ratio is changed

• Various topologies:
• single pump / multi-motors
• multi (pump-motor)
• Open / closed circuit
• Open / closed loop control

• Integrated package / split implementation

M..E., University of Minnesota (updated 12.2013)

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Hydrostatic Transmission

M..E., University of Minnesota (updated 12.2013)

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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 (85% versus 92%+ for mechanical transmission)
• Leaks !

M..E., University of Minnesota (updated 12.2013)

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Closed Circuit Hydrostat Circuit

Notes:
• Charge pump circuit (pump + shuttle valve)
• Bi-directional relief
• Circuit above closed circuit because fluid re-circulates.
• Open circuit systems draw and return flow to a reservoir

M..E., University of Minnesota (updated 12.2013)

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Hydrostatic Transmission
• Let pump and motor displacements be D1 and D2, with one or both
being variable.
• Let the torque (Nm) and speeds (rad/s) of the pump and motor be (T1,
S1) and (T2,S2)
• Assuming ideal pumps and motors:

Transmission ratio Infinite and negative

Variable by varying ratios possible
D1 or D2 if pump can
go over-center

M..E., University of Minnesota (updated 12.2013)

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Hydraulic Transformer
• 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 (torque boost/buck)

Q1 Q2

D1 D2 Research opportunity!

M..E., University of Minnesota (updated 12.2013)

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Hydraulic Hybrid Vehicles

M..E., University of Minnesota (updated 12.2013)

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