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Design and Modeling of Fluid Power Systems

ME 597/ABE 591 Lecture 4

Dr. Monika Ivantysynova MAHA Professor Fluid Power Systems MAHA Fluid Power Research Center Purdue University

SICFP05, June 1-3, 2005, Linkping

Content

Displacement machines design principles & scaling laws Power density comparison between hydrostatic and electric machines

Volumetric losses, effective flow, flow ripple, flow pulsation


Steady state characteristics of an ideal and real displacement machine Torque losses, torque efficiency

Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Historical Background SICFP05, June 1-3, 2005, Linkping


Hydrostatic transmissiom

Williams und Janney


Archimedes
230 0 1500

Pascal
1651 1600 1700

Bramah
1795 1800 1905 1900 2000

Kepler

Vane pump
Ramelli

Gear pump

Axial Piston Pump


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3

Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping Displacement machine

due to compressibility of a real fluid

p 2 , Qe

Pumping
Adiabatic expansion

VB

Te , n p1

Adiabatic compression

Suction

Vmin=VT

with VT .. dead volume

KA.. adiabatic bulk modulus

Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Displacement machine SICFP05, June 1-3, 2005, Linkping due to viscosity & compressibility of a real fluid
Pressure drop between displacement chamber and port Port pressure Port pressure

Pressure in displacement chamber

Pressure in displacement chamber

Pump
Dr. Monika Ivantysynova

Motor
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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Power Density SICFP05, June 1 -3, 2005, Linkping

Electric Motor

Hydraulic Motor

F e
r r

F h

b b

I
Fe I B L sin

J b h
with I current [A]

J current density [A/m2]

Fh
T

p L h
p L h r

B magnetic flux density [ T ] or [Vs/m2] Torque:

I B L sin

r
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Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Example SICFP05, June 1-3, 2005, Linkping Power:


For electric motor follows: For hydraulic motor follows:

P
P

T 2
I B L r 2

n
n
assuming =90

p L h r 2

n
Hydraulic Motor

Force density:

Electric Motor

Fe L h
6 -2

J b h B L L h
-2 3

J b B

Fh L h
4

7.6 10 A m 1.8Vs m
Dr. Monika Ivantysynova

3 10 m 4.1 10 Pa

up to 5 107 Pa
Design and Modeling of Fluid Power Systems, ME 597/ABE 591

with a cross section area of conductor: 9

10 6 m2

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Mass /June Power Ratio SICFP05, 1-3, 2005, Linkping Electric Machine
mass = power Positive displacement machines (pumps & motors) are: 10 times lighter min. 10 times smaller much smaller mass moment of inertia (approx. 70 times) much better dynamic behavior of displacement machines
Dr. Monika Ivantysynova

Positive displacement machine


0.1 1 kg/kW

1 . 15 kg/kW

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Axial Piston Pumps SICFP05, June 1-3, 2005, Linkping


Cylinder block Pitch radius R Outlet

Inlet p 2 , Qe

Swash plate Piston

Valve plate (distributor)

Cylinder block

Te , n Piston stroke = f (,R) Variable displacement pump Requires continous change of


Dr. Monika Ivantysynova 10

p1

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Bent Axis & Swash Plate Machines SICFP05, June 1-3, 2005, Linkping

Torque generation on cylinder block

Torque generation on swash plate

Swash plate design FR

FR

Fp
FR FN

Fp

FN

Driving flange must cover radial force

FR
Fp

FN

Fp

FN

FR
FR Fp FN

Radial force FR exerted on piston!

Fp
11

FN

Bent axis machines


Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Dr. Monika Ivantysynova

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Axial Piston Pumps SICFP05, June 1-3, 2005, Linkping


Openings in cylinder bottom In case of plane valve plate

In case of spherical valve plate

Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Axial Piston Pumps SICFP05, June 1-3, 2005, Linkping


Plane valve plate Inlet opening Outlet opening

Plane valve plate Inlet Outlet

Connection of displacement chambers with suction and pressure port


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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Axial Piston Pumps SICFP05, June 1-3, 2005, Linkping


Kinematic reversal: pump with rotating swash plate Check valves fulfill distributor function Suction valve

Pressure valve for each cylinder

Outlet
Dr. Monika Ivantysynova

Inlet
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can only work as pump


Design and Modeling of Fluid Power Systems, ME 597/ABE 591

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Steady state characteristics SICFP05, June 1-3, 2005, Linkping


ideal displacement machine

Displacement volume of a variable displacement machine:


const p const
n const const

Vmax

const p const

n
const n const

p
p const const

n
const n const

p
Dr. Monika Ivantysynova

n
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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping Example

The maximal shaft speed of a given pump is 5000 rpm. The displacement volume of this pump is V= 40cm3/rev. The maximal working pressure is given with 40 MPa. Using first order scaling laws, determine: - the maximal shaft speed of a pump with 90 cm3/rev - the torque of this larger pump - the maximal volume flow rate of this larger pump - the power of this larger pump For the linear scaling factor follows:
3

V V0
1

90 40

1.31

Maximal shaft speed of the larger pump: n

n0

1.31 1 5000 rpm 3816 .8 rpm

Torque of the larger pump: T

p V 2

40 10 6 Pa 90 10 -6 m 3 2

573.25 Nm

Maximal volume flow rate: Qmax V nmax 90 10 6 m 3 /rev 3816.8 rpm 0.3435 m 3 /min 343.5 l/min 1 -1 6 3 p Q 40 10 Pa 0.3435 m s 229 kW Power of the larger pump: P 60
Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping Real Displacement Machine

Cylinder Distributor Inlet Piston Outlet p 2 , Qe

p2

p1

Te , n
QSe

QSi

p1

QSe external volumetric losses QSi internal volumetric losses Effective Flow rate: Effective torque:
Dr. Monika Ivantysynova

Qe

Vmax n QS

QS volumetric losses TS torque losses


Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Te

p 2

Vmax
10
19

TS

Volumetric Losses SICFP05, June 1-3, 2005, Linkping


n m

QS
i 1

QSei
j 1

QSij

QSK

QSf

losses due to Incomplete p2, Qe filling Te , n QSe p1 QSi

external

internal volumetric losses

losses due to compressibility

QSL external and internal volumetric losses = flow through laminar resistances: b h3 p Q p 12

QSL

Assuming const. gap height Dynamic viscosity


Dr. Monika Ivantysynova

f ( , p)
11
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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3,Losses 2005, Linkping Volumetric

Effective volume flow rate is reduced due to compressibility of the fluid


C

dV V B
VB

1 dp KA
1 pC p B KA

ln VC

ln VB

1 pC KA
VB

pB

Pumping

VB 1 e

simplified

VB

p VB KA

Suction

QSK

VB

with n pump speed


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Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping Steady state characteristics

of a real displacement machine

Qi

V n

Vmax n

Effective volumetric flow rate

Qe

Qi QS

nmin

QS
Dr. Monika Ivantysynova

p, n,V ,
13
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...temperature
Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Steady state characteristics SICFP05, June 1-3, 2005, Linkping


Effective mass flow at pump outlet Qme Loss component due to compressibility does not occur!

Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Instantaneous Pump Flow SICFP05, June 1-3, 2005, Linkping


Instantaneous volumetric flow Qa

Qa

dV dt

Volumetric flow displaced by a displacement chamber

Qai

The instantaneous volumetric flow is given by the sum of instantaneous flows Qai of each displacement element:
k

Qa
i 1

Qai

k number of displacement chambers, decreasing their volume, i.e. being in the delivery stroke

z is an even number z is an odd number

k
k

z 2
z 0 .5 2

z number of displacement elements

or

z 0 .5 2
Pressure pulsation
Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Flow pulsation of pumps


Dr. Monika Ivantysynova

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Flow pulsation SICFP05, June 1-3, 2005, Linkping


Non-uniformity grade of volumetric flow is defined:

Qmax Qmin Qmi


Qmax Qmin 2

Qmi

Qmax Qmin 2 Qmax Qmin


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Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Torque Losses SICFP05, June 1-3, 2005, Linkping

TS
TS

TS
kT

TS
n

TSp TSc
CT n

constant value

Torque loss due to viscous friction in gaps (laminar flow) hgap height

Torque loss to overcome pressure drop caused in turbulent resistances

TS

CT

ps

l d
d

v2 2
v l

v2 2

Torque loss linear dependent on pressure

TSp
Te

CTp
p 2

p
Vmax TS

drag coefficient
flow resistance coefficient

0.3164
turbulent 4

Re

effective torque required at pump shaft

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Steady state characteristics SICFP05, June 1-3, 2005, Linkping


Torque losses of a real displacement machine
p const

TS

f (n, p,V , )
p const

TS

TS

TS

n const

p
n const

TS

TSp

TSp

n const

p const

p
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Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Steady state characteristics SICFP05, June 1-3, 2005, Linkping


Effective Torque

Te

Ti TS

p 2

Vmax

TS
Effective torque Te
n const

Effective torque Te TS
TS

TS T S TS

TS
p

TSc T

TSc

T
p const

Ti

Ti

p
Design and Modeling of Fluid Power Systems, ME 597/ABE 591

TS
Dr. Monika Ivantysynova

p, n,V ,
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Axial Machine SICFP05,Piston June 1-3, 2005, Linkping


Kinematics Piston displacement: sP

HP

sP

R tan

1 cos

sP

Outer dead point AT =0

Piston stroke:

HP

2 R tan
z
R pitch radius

b tan R y R cos

Inner dead point IT

b y
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Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Kinematic Parameters SICFP05, June 1-3, 2005, Linkping


Piston velocity in z-direction:
vP ds P dt ds P d d dt R tan sin

Piston acceleration in z-direction:


aP dv P dt dv P d d dt
2

R tan

cos

vP

aP

au

Circumferential speed

vu

vu

Centrifugal acceleration:

au

Coriolis acceleration ac is just zero, as the vector of angular velocity and the piston velocity vP run parallel

Dr. Monika Ivantysynova

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Instantaneous Flow SICFP05, June 1-3, 2005, Volumetric Linkping


Geometric displacement volume:

Vg
Vg

z AP H P
z
2 dP R tan 2

z number of pistons

In case of pistons arranged parallel to shaft axis:


2 dP R tan 2
k

For an ideal pump without losses

Geometric flow rate: Qg

n z

Mean value over time k number of pistons, which


are in the delivery stroke

Instantaneous volumetric flow:

Qa
i 1

Qai

with Qai instantaneous volumetric flow of individual piston

Qai

vP

R tan

sin

Qai

v p AP

AP R tan
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sin

i
Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Dr. Monika Ivantysynova

SICFP05, June 1-3, 2005, Volumetric Linkping Instantaneous Flow

In case of even number of pistons: k


In case of odd number of pistons:

0.5 z

Qa
i 1

Qai

z k1 0.5 for 0 2 z z and k 2 0.5 for 2 z

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping

Flow & Torque Pulsation

kinematic flow and torque pulsation due to a finite number of piston


Flow Pulsation:
Non-uniformity grade:
Q

Qmax Qmin Qmi

with Qmi

Qmax Qmin 2

Even number of pistons:

Odd number of pistons:


Q

tan

2 z
T

2 z

tan

4 z

Torque Pulsation

Tmax Tmin Tmi


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with Tmi

Tmax Tmin 2

Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping

Flow &Pumps Torque Pulsation Piston

kinematic flow and torque pulsation due to a finite number of piston z number of pistons
Non-uniformity
mean mean

Even number of pistons:

Odd number of pistons:

NON-UNIFORMITY of FLOW / TORQUE

NON-UNIFORMITY of FLOW / TORQUE

Flow and torque pulsation frequency f: Even number of pistons:

f=zn f=2zn
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Odd number of pistons:


Dr. Monika Ivantysynova

Design and Modeling of Fluid Power Systems, ME 597/ABE 591

SICFP05, June 1-3, 2005, Linkping

Flow Pulsation

Non-uniformity grade:
Q

Qmax Qmin Qmi


3 0.140

with Qmi

Qmax Qmin 2

Kinematic non-uniformity grade for piston machines:


Number of pistons z Non-uniformity grade 4 0.325 5 0.049 6 0.140 7 0.025 8 0.078 9 0.015 10 0.049 11 0.010

Volumetric losses Qs=f() and

QS

p, n,Vi ,

Flow pulsation of a real displacement machine is much larger than the flow pulsation given by the kinematics
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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

Flow Pulsation SICFP05, June 1-3, 2005, Linkping

180 160

Q th e o K in e m a t ic N o n - u n if o r m it y o f F lo w R a te z = 9

Q [l/m in ]

140 120 100 80 60 40 20 0 0 60 120 180 240 300 360

E f f e c t iv e F lo w R a t e Q

P u m p O u tle t

r o ta tin g a n g le [d e g ]

Flow pulsation leads to pressure pulsation at pump outlet

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Design and Modeling of Fluid Power Systems, ME 597/ABE 591

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