Hydraulic Pumps

The heart of the fluid power system is the pump. A

hydraulic pump converts mechanical power from the
prime mover to hydraulic power (the flow of
pressurized fluid). Hydraulics requires the use of
positive displacement pumps. A positive
displacement pump uses a series of moveable cavities
which expand to receive liquid and contract to expel
it. This requires clearances inside the pumping
chambers to be very small so that the pump has
minimal internal leakage.

1
Oshkosh Corp. Pump Symbols

2
 Spur Fixed

Geroter Fixed
Pump Types Gear
Crescent Fixed

Screw Fixed

Fixed

Vane
Positive
Displacement Variable

Pumps Non-Positive Fixed

Displacement
Axial
Variable

Fixed

Piston Bent Axis

Variable

Fixed
Radial
Variable 3
 Centrifugal Pump (pg278)
(Non Positive
Displacement) Outlet

Inlet

4
Talk about fluid transfer.
Positive Displacement Pump (pg280)
to circuit to circuit

Outlet

Atmospheric Inlet
Atmospheric
Pressure
Pressure

Inlet Phase Output Phase

5
Displacement
All high pressure pumps are positive displacement. In the previous
example, suppose that the piston had a diameter of 1" and a stroke length of
1.5". The displacement is defined as the fluid expelled for one complete
stroke or revolution. Therefore the displacement of this hydraulic pump
would be:

D pump = A piston x X strokedistance

1.18in3/rev = π 12/4 in2 * 1.5in

Notice that theoretically the intake and discharge volumes are the same.
Actually the expelled volume is less than the intake due to leakage and
hydraulic capacitance.

Also notice that mechanical stops could be provided to limit the stroke of
the pump. This introduces the idea of a variable displacement pump.
6
Hand Pump Examples

7
Flow versus Pressure
It must be emphasized that pumps pump flow not pressure. The pressure the
system is running at is a function of the downstream circuit. (The system’s
relief valve or the pump’s pressure compensator circuit is only capable of
limiting the maximum pressure the system will see.)

8
 Fixed vs. Variable Displacement
Fixed displacement means that the pump’s chamber size cannot change without
modifying the internals of the pump. Variable displacement refers to several
schemes of varying the chamber size while the pump is operating.

Rotor Cam
Rotation

Timing adjustment for

noise reduction
Inlet Outlet
Outlet Port

Rotor Vane Maximum

Volume Pressure
Adjustment Compensator

Figure 15-14 Rotating group with inlet and outlet ports

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Inlet Port

Figure 15-35 Variable Displacement Vane Pump 9

 Gear Pump, External (spur) (pg 286)
“External gear pump is the most simple and popular pump in fluid power”

Volume on this side decreases

as gear teeth mesh.

Volume on this side increases

as gear teeth un-mesh.

10
 Gear Pump, Advantages
Pros Cons
• Low Weight • Maximum Pressure 2000-4000psi
• Very Compact • Noise
• Good Suction • Overall Efficiency
• Many Displacements • Fixed Displacement
• Low Cost •Not Balanced
• Great Reliability •Sheds
•No Case Drain Port
 13
Gear Pump, Parts 3
12

11
5

12

3
11 9
10 3
6
7
8
7
6
5
4
3
2
1

13
ηvol is a Function of Internal Clearances.

➢ Need to minimize oil leakages between the gear wheel shoulder and the thrust plate
➢ Need to minimize oil leakages between the head of the tooth and the body (break-in path)

➢ Need to minimize oil leakages in the meshing area (grooves on thrust plate)

14
 Volumetric efficiency vs. speed
The volumetric efficiency increases if the speed increases
100.0

95.0
Rendimento Volumetrico %

90.0

85.0
500 rpm
80.0 1000 rpm
1500 rpm
75.0
2000 rpm
2500 rpm
70.0

65.0

60.0
0 50 100 150 200
bar

If:
Dp = cost.
S = cost.
Qleak = cost. Dp

Q Qth  Qleak Q Act

v 
nD

Qth

Qth
Qth ↑ v ↑

15
 Volumetric efficiency vs. pressure
The volumetric efficiency change with the pressure and speed
100.0 When the pump is new, the
center of the gears are inline
95.0
with the center of the housing.
Rendimento Volumetrico %

90.0

85.0
500 rpm
80.0 1000 rpm
1500 rpm
75.0
2000 rpm
2500 rpm
70.0 During the run in process, pressure
pushes the gears into the low pressure
65.0
1 2 3 side of the housing. The gears “wear”
60.0
0 50 100 150 200
into the body removing material.
bar

Focus: Clearance and elastic deformations of

the components
Low pressure High pressure

Pressure Gap Dp Leakage

1 ↑ ↓ ↓
2 ↑ ↑ ↑
3 ↓ ↑ ↓

16
Thrust plate
Seal side

IN OUT

- The bearing area is communicating with the inlet port, internally draining the pump
(no case drain required)
- The seals separate the high pressure and low pressure areas to obtain a correct axial
balance

17
Thrust plate
Gear side Leakage Grooves

- In the meshing zone, leakage is controlled by groove profiles, allowing the

trapped volume to release. This minimizes peak pressure and noise.
Thrust plate
High Speed Grooves Low speed High speed

Low speed High speed High speed (AV)

-The pressure is carried

around the gear by the
high speed groove on the
plate; the purpose is to
balance radially the gear
and maintain a constant
pressure distribution at
various speeds
Classification
1) By size  Dimensional group

10 20 25 30 35 40

Shaft diameter
Port position

Rear Side
Front Flange Options
SAE European

German Special solutions

Shaft Options

Spline Straight

Tapered Tang
Integrated Valves

- Relief valve
- Anti-cavitation valve (motor)
- Priority valve
- Priority Load Sensing valve
- Electric valve
Gear Pump
Examples
Gear Pump
Examples
Gear Pump, Internal (Crescent) (pg287)
(Used in High Viscosity Applications)
Gear Pump, Internal (Geroter) pg 288)
A gerotor is a positive displacement pumping element. The name gerotor is
derived from "Generated Rotor". A gerotor unit consists of an inner and outer
rotor. The inner rotor has N teeth, and the outer rotor has N+1 teeth. The inner
rotor is located off-center and both rotors rotate. During part of the assembly's
rotation cycle, the area between the inner and outer rotor increases, creating a
vacuum. This vacuum creates suction, and hence, this part of the cycle is
where the intake is located. Then, the area between the rotors decreases,
causing compression. During this compression period, fluids can be pumped,
or compressed (if they are gaseous fluids).
Screw Pump
 Rotor Cam
Rotation

Vane Pump
(pg282)
Inlet Outlet

Rotor Vane

Increasing Decreasing
Volume Volume
Inlet side Outlet side

Figure 15-14 Rotating group with inlet and outlet ports

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Vane Pump, Balanced (pg 284)
Outlet

Inlet

Rotation

Figure 15-15 Balanced vane pump design

Vane Pump, Balanced (pg 286)
Various Displacements

Cam Ring Ring thickness

throw

Figure 15-16 Interchangeable cam rings provide a selection of flows

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Vane Pump, Cut Away (pg 283)
Outlet

Inlet

Vane

Pressure
Plate Shaft
Seal

Rotor
Cam
Ring

Note: Ring/Rotor/Vane
assembly shown in red

Figure 15-18 Fixed displacement “square pump”

Vane Pump Example
 Variable, Vane Pump (pg304)
Timing adjustment for
noise reduction
Outlet Port
Maximum
Volume Pressure
Adjustment Compensator

Inlet Port

Figure 15-35 Variable Displacement Vane Pump

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Piston Pump Concept
flywheel

RPM A pump's displacement is the amount

of fluid discharged per revolution of
the input shaft.

stroke
2.32 in. Displacement is3 usually
measured in in /rev (sometimes
abreviated CIR or CID)

piston
area
2
1 in

from to
reservoir circuit

Figure 15-28 The piston pump concept

Radial Piston Pump (pg289)

Figure 15-29 A radial piston pump

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 Bent Axis Piston Pump (pg 291)
Case Drain

Outlet

Rotation

Inlet
Bent Axis, Variable Displacement
Piston Pump(pg306)
Case Drive Shaft Flange
Piston
Drain

Outlet
Port Rotation
Inlet
Port Drive Shaft
Displacement
Control Piston Rod
Cylinder Block
Valve Plate

Figure 15-37 Variable displacement bent axis piston pump

Bent Axis, Variable Piston Pump

Maximum Displacement

Reduced Displacement

Zero Displacement
Bent Axis, Over Center Piston Pump
(pg306)
Axial Piston Pump (pg 290)
Axial Piston Pump Parts (pg308)
Valve
Shoe
Plate
Retractor
Cylinder Block Plate
Pre-Load Spherical
Spring Washer
Swash
Plate

Load
Pins
Pistons
Case

Bearing
Shaft

Shaft
Seal

Figure 15-33 Components of an in-line piston pump

VARIABLE DISPLACEMENT PISTON PUMP

STROKE

Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)

VARIABLE DISPLACEMENT PISTON PUMP

STROKE

Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)

VARIABLE DISPLACEMENT PISTON PUMP

STROKE

Q = (No. of Pistons) x (Piston Size) x (Piston Stroke) x (Drive Speed)

VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP
VARIABLE DISPLACEMENT PISTON PUMP

QMAX
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
Q

P
PRESSURE COMPENSATOR CONTROL
Q

P
 Pressure Compensator
Pressure Compensator
Schematic
Q

Q0

PRESSURE
Pressure Compensator
QMAX

LIMIT
Q

PMAX

Q0

QMAX
PMAX
LOAD SENSE COMPENSATOR
LOAD PRESSURE
LOAD SENSE COMPENSATOR
LOAD PRESSURE
Approx 200 PSI

fL PL LSSpool DP DYNAMIC
LOAD SENSE COMPENSATOR
LOAD PRESSURE
LOAD SENSING + PRESSURE LIMITING

LOAD
SENSING

PRESSURE
LIMITING
LOAD SENSING + PRESSURE LIMITING

LOAD
SENSING

PRESSURE
LIMITING
LOAD SENSING + PRESSURE LIMITING

LOAD
SENSING

PRESSURE
LIMITING
LOAD SENSING + PRESSURE LIMITING

LOAD
SENSING

PRESSURE
LIMITING
 Variable Displacement Piston Pump
With Electronic Pressure Control

The motor speed is regulated by the piston pump

displacement, without any waste of power: only the
flowrate really needed is generated
Max flow: approx 210 l/min
Max pressure: 280 bar

❖ The same piston pump can be used as main pump in a LS system

❖ The same software is used to control both fixed and variable displacement pump fan drive systems
❖ The reverse function can be introduced through a reverse block on the gear motor.
 PEC: control type

Inverse
Pump pressure is proportional to current signal

Inverse type is almost mandatory for fan drive

applications: flow is guaranteed even in case
of electrical failure
 PEC: different options

Rotated
configuration
Standard
configuration
Piston Pump Examples
Pump Cost Con- Pres- Speed Suc- Robus Dirty Nois Eff. Comments
Type trols sure tion tness Oil e
Spur Low Integral Med.- Med. Very Very Very Poor Med. Most Common
Gear Valves High Good Tough Good
Geroter Very None Low Low High Very Very Poor Low Great for Lube
Low Tough Good

Cres- Med- None Low Low Best Very Low High Viscosity
cent High Good Fluids

Screw Very None Low Very Very Med. High Flowrates

High Low Good No Ripple

Vane Low V_Disp Med Med. Med. Weak Poor Very Good Very Versatile
P_Comp Good
Axial Med. V_Disp High High Very Okay Good Good Very Most Popular
Piston P_Comp High Good Many Options
LS, HP Lots of Competition
& Torq
Limiting
Bent High V_Disp High Very Very Okay Good Okay Very High End
Axis P_Comp High High High
Piston
Radial Very V_Disp Very Low Very Very Very ?? High Multiple Outlets
Piston High P_Comp High High Tough Good
Causes of Pump Failures (pg 294)
Contamination

11-22
Contamination
On thrust plates
Contaminated oil
On gears
Aeration (pg296)

Copyright  Eaton Corporation 2006

Cavitation (pg297)
Cavitation
Cavitation
to circuit

Outlet

Inlet
Atmospheric
Pressure

Inlet Phase

Figure 15-7 Cavitation bubbles formed by a restricted inlet

Effects of Cavitation & Aeration
High velocity microjet formation

Outlet

Inlet
Atmospheric
Pressure

Output Phase

Figure 15-5 Pressurizing the fluid collapses the bubbles

Effects of Cavitation & Aeration
Effects of Cavitation & Aeration
Effects of Cavitation
 Causes of Cavitation and Aeration
Causes of Cavitation
1. Clogged or restricted strainer
2. High fluid viscosity
3. Low fluid temperature
4. Clogged reservoir breather
5. Pump inlet line too small
6. Pump too far above reservoir
7. Pump too far from reservoir
8. Excessive pump RPM
9. Too many bends in pump inlet line
10. Collapsed hose on pump inlet line
11. Restriction on pump inlet line
12. Failure of supercharge pump
Causes of Aeration
1. Low reservoir fluid level
2. Defective pump shaft seal
3. Return line above fluid level
4. Improper baffling in the reservoir
5. Loose fitting on pump inlet line
6. Defective seal on pump inlet line
7. Incorrect reservoir design
8. Porous hose on pump inlet line

Figure 15-8 Causes of aeration and cavitation

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Pressure peaks
Crack on gear housings

Cast iron
Pressure peaks
Crack on gear housings

Fitting too tight

Aluminum
Pressure peaks
Material removal
Typical

Peak of pressure
Description:
Excessive wear on the gear housing suction side due to
excessive pressure peaks.
Consequences:
High internal leakage, poor volumetric efficiency, overheat
of the system.
The relationship between the material removal deepness and the pressure Actions:
depends on the clearence of the pump: the only way to estimate the Check the relief valve setting value.
pressure peaks is to measure every component and the material removal
deepness.
Pressure peaks
Rear Cover Blow-Out
Pressure peaks
Shaft end of the drive gear

Static failure Fatigue failure

Static failure is due to extremely
high pressure peaks.

Description:
Drive shaft breakage due to pressure peaks or to fatigue
stress.
Consequences:
No flow.
Actions:
Check the relief valve setting value.
Pressure peaks
Damaged bushings

The misalignments of the gears

due to bushings failure can
generate the collapse of the
gears teeth.
Pressure peaks
Driven gear failure
Overheating
 Hydraulic Pump Performance
Consider the following circuit:

Output Characteristics of Ideal Pump

If we were to plot
flow as a function of 35

pressure at a constant 30
25
speed we would have: 20
N=1000
Flow

N=2000
15
N=3000
10
5
0
1 2 3 4 5 6 7 8 9 10
Pressure
But, as we know the Ideal Pump does not exist. Each pump has internal
leakage. Therefore:

QActual = QIdeal - Qleakage

The ideal flowrate of the pump is dependent upon the displacement of the
pump and the speed of the pump:

Q I = f (D & N)
If the flowrate of the pump is in gallons per minute, the speed is in RPM,
and the Displacement in cubic inches per revolution, then:

Dp N p
QI =
231
Substituting into the actual pump flow equation yields:
DP N P
Q Actual = - Qleakage
231

The pumps leakage flow is dependent upon the differential pressure or the
load across the pump.

Ql f ( DP) Output Characteristics of Actual Pump

35
30 N=1000
Looking at a graph 25 N=2000
and comparing the 20 N=3000
Flow

ideal flow to the 15 N=1000

10 N=2000
actual flow produces:
5 N=3000
0
1 2 3 4 5 6 7 8 9 10
Pressure
We call this a graph of the output characteristics of the pump. The slope of
this line is called the leakage coefficient (Cl)

If we multiply the slope of the line times the pressure differential, we

have determined the leakage flow rate. Therefore the leakage coefficient
must have units of gpm/psid. Finally the output characteristic equation of
the pump is:
D N
Q act = P P - C l DP
231
This equation is only an approximation of the output characteristics
of the pump. It is a first order mathematical representation of the
pumps flow characteristics. Actual pumps may best be described
by higher order math models, but experience has shown this to be a
good approximation.

We can also calculate the volumetric QI - Ql Q

N v (%) = x 100 = act x 100
efficiency of the pump from this plot: QI QI
The input
characteristics of a Input Characteristics of Ideal Pump
pump can be developed
35
in the same manner. 30
The two input 25
P=1000

Torque
parameters for a pump 20
P=2000
15
are Torque and Speed. 10
P=3000

If we look at a graph of 5
Torque versus Speed we 0
1 2 3 4 5 6 7 8 9 10
have.
Speed

T act = T I +T Loss
Notice once again that the input torque stays constant over the entire speed range of the
pump. This is only true for an ideal pump. In reality the amount of torque required by
the pump to maintain a constant differential pressure increases as the input speed of the
pump increases. This is due to mechanical friction and windage losses. The
characteristic equation is:
The ideal torque is equal to: D P DP
TI=
2
The torque loss is once again the slope of the line. We will call the
coefficient Cf. Therefore:
T Loss = C f N
Therefore we can expand the input characteristic equation to read:

D P DP
T act = +C f N
2
The mechanical efficiency of the pump can be determined by:
TI = TI
 mech =
T I + T Loss T act
And finally the overall efficiency equals:
overall =  vol  mech
JLTV PS Pump
JLTV PS Pump Cat. Data
Actual
Pump
Data
 Summary
• Pump is the Heart of the Hydraulic System
• Hyd Pumps are Positive Displacement
• Hyd. Pumps are Fixed and Variable Displ.
• Variable Displacement Pump Control:
– Can Save Energy
– Provide Means for Safety
• Understanding Pump Construction can Help
One Pick the Best Pump for an Application
• Provide the Pump with Ample, Clean, Cool,
and it will last a long, long time.
Homework Problem
1. A trucks lift gate has two cylinders in parallel that are 2” bore, ?” rod
and 36” stroke(sketch the circuit). The gate is rated at 5 tons. Size the
pump for this application to lift the gate in 30 seconds while the engine
is running at 2700rpm. Assume pump’s ηvol at 90%.

2. What will the lift time be at engine idle (700rpm)?

3. What must the pump’s minimum rated pressure be to lift the load?
Homework Problem
A vehicle requires a winch with a rated capacity of 25tons and a pay in speed
of 10 in/sec. The ACME winch company manufacturers a winch with a 30:1
planetary drive with an 8” drum and a 9cir LSHT motor.
1. Assuming no losses what flow is required by the motor?

2. If the motor is 90% Ƞvol, what flow is required from the pump?
3. Size the pump at 2000rpm. Assume it to be 90% Ƞvol.

4. What nominal relief valve setting is required?

5. Assuming no mechanical losses, what engine power is to handle the

hydraulic load?