Pumps My Notes and Calculations

Chapter 2

Pumps
Objective
Although various types of hydraulic pumps exist, the sole purpose of pumps is to
provide flow for the hydraulic system. In this course, you will learn more about the
three basic types of hydraulic pumps. It is important to understand the differences
and similarities between these pumps, their fluid displacement capabilities, and
their proper application in a hydraulic system.
Gear Pumps
Gear pumps are very common in the mobile hydraulic industry. The two basic
gear pump designs are external gear and internal gear. Most external and internal
pumps can be configured with multiple pumping sections using standard mounting
flanges and shaft options. Gear pumps can also be piggybacked to other pumps.
Gear pumps are fixed displacement pumps that limit the availability of different
control options.

Figure 2.1 Internal and external gear pumps

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Pumps My Notes and Calculations

External gear pumps are the most commonly used pumps in the mobile industry
for several reasons: they are very simple in design, easily manufactured, have very
few moving parts, and are available from many different manufacturers. These
pumps are lighter in weight because the outer housing of the pump is commonly
manufactured of aluminum. These characteristics make the external gear pump
inexpensive compared to other options.
These pumps are very compact for their displacement capacities and have the ability
to operate in circuits with higher contamination levels. They are self-priming and
are less susceptible to cavitation or high-suction characteristics. However, they are
noisier and less efficient when compared to their more expensive counterparts.
Applications include, but are not limited to, construction equipment, aerial work
platforms, bucket and boom trucks, forklifts, dump and refuse trucks, tailgate lifts,
portable auxiliary equipment, and DC voltage-operated equipment.
Internal gear and crescent pumps are in many cases about the same size as the
external gear pumps and have many of the same characteristics as the external
gear pumps. However, they cannot rotate as fast, and are not as readily available
because fewer manufacturers make this type of gear pump. Their unique design
does provide for higher pressure, higher efficiencies, and less noise. But, they are
not as contamination-tolerant as external gear pumps. Iron housings make these
pumps heavier and more costly than external gear pumps.
Applications would include those mentioned earlier, but serious consideration
should be given to this product when energy savings and noise are important
considerations.
Gerotor pumps are the least common pump of the gear pumps in service today.
They are generally used in applications where lower pressure and flow is required.
Flooded suction and slower rotation speed are preferred. These pumps are quite
inexpensive and are quiet during operation, but they are not highly efficient
pumps.

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Pumps My Notes and Calculations

External
Pumps are fluid power components that transform mechanical energy, transmitted
by a prime mover, into fluid power energy. Gear pumps are compact, relatively
inexpensive, and have few moving parts. External gear pumps consist of two gears,
usually equal in size, that mesh with each other inside a housing. The driving gear
is an extension of the drive shaft. As it rotates, it drives the second gear. As both
gears rotate, fluid is drawn in through the inlet. This fluid is trapped between the
housing and the rotating teeth of the gears where it travels around the housing and
is pushed through the outlet port. The pump creates flow at a given pressure, which
transfers energy from the mechanical input source to a fluid power actuator.

Figure 2.2 External gear pump schematic

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Pumps My Notes and Calculations

Crescent Pumps
A crescent pump is an internal gear design. The main components of the crescent
pump include: the housing (with a crescent seal and ports), the end cover, the
input shaft, the drive gear (which is an external gear), and the ring gear (which is an
internal gear). The drive gear, which has fewer teeth than the ring gear, sits offset
in the ring gear. This creates an open cavity between the two gears. The crescent
seal, which is machined into the housing, divides this cavity, creating a positive seal
between the inlet and the outlet sides of the pump.

Figure 2.3 Crescent pump showing the direction of flow within the pump

The input shaft turns the drive gear, which drives the ring gear. As the teeth unmesh
near the inlet, atmospheric pressure pushes the fluid into the pump inlet.
The fluid flows through a kidney-shaped opening in the housing, and into the
cavity between the gears. The two gears move the fluid across the cavity, past the
crescent seal, to the high-pressure side. As the gears mesh near the outlet, the fluid
is forced out of the other kidney-shaped opening to the outlet.

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Pumps My Notes and Calculations

Gerotor Pumps
A gerotor pump is an internal gear design. The main components of the gerotor
pump include: the outer gerotor element (an internal gear), the rotor or internal
gerotor element (an external gear), the input shaft, and the housing with the
ports.

Figure 2.4 Gerotor gear pump showing the direction of flow within the pump

The rotor, which has one less tooth than the outer gerotor element, sits offset in
the outer element. This creates an open cavity between the two gears. The two
opposing teeth divide this cavity, creating a positive seal between the inlet and the
outlet.
The input shaft turns the rotor, which drives the outer gerotor element. As the
teeth unmesh near the inlet, atmospheric pressure pushes the fluid into the pump
inlet.
The fluid flows through a kidney-shaped opening in the end cover to the cavity
between the gears. The two gears move the fluid across the cavity, past the opposing
teeth, and to the high-pressure side. As the gears mesh near the outlet, the fluid is
forced out the other kidney-shaped opening to the outlet.

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Pumps My Notes and Calculations

Vane Pumps
Vane pumps, which are very common in the mobile hydraulic industry, come in
two basic designs: balanced and unbalanced. Most pumps can be configured with
multiple pumping sections.

Figure 2.5 Balanced and unbalanced vane pumps

Balanced vane pumps are commonly used in the mobile industry. They have many
uses in medium-pressure circuits and are used as fixed displacement units, limiting
the availability of different control options. Component envelope sizes are compact
for even large displacement units.
Vane pumps are relatively inexpensive, but they are more costly than external gear
pumps. They have several moving parts and are generally available with standard
mounting flanges and shaft configurations. Multiple pumping elements are available
in the same assembly that can also have separate or combined suction inlets. These
pumps can be adapted to other pumps by means of a common drive-through
shaft. Vane pumps can handle some contamination and can become very noisy
with high system pressure and high suction characteristics.
Applications include, but are not limited to, steering applications, construction and
agricultural equipment, and mining equipment.

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Pumps My Notes and Calculations

Unbalanced vane pumps are most generally used as variable displacement

pumps in circuits requiring a variable flow to different circuits within the system.
Displacements are not as large as balanced pumps and generally operate at lower
pressures and speeds. Some through drive capabilities are available. Control
options that are also available include pressure compensation, flow, and unloading
controls.
Unbalanced
The rotating portion of the pump, or rotor, is positioned off center of the cam
ring, or housing. The rotor is connected to a prime mover by means of a shaft. As
the rotor is turned, the vanes are thrown out by centrifugal force and contact the
ring, or housing, forming a positive seal. Fluid enters the pump and fills the large
volume area formed by the offset rotor. As the vanes push the fluid around the
cam, the volume decreases, and the fluid is pushed out of the outlet port.

Figure 2.6 Unbalanced vane pump

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Pumps My Notes and Calculations

Balanced
In the unbalanced vane pump, which
has been previously illustrated, one
half of the pumping mechanism is at
less than atmospheric pressure. The
other half is subjected to full system
pressure. This results in side loading
the shaft while under high-pressure
conditions. To compensate for this,
the ring in a balanced vane pump is
changed from circular to cam-shaped.
With this arrangement, the two
pressure quadrants oppose each other.
Two ports intake fluid, and two ports
pump fluid out. The two intake ports
and the two outlet ports are connected
inside the housing. Because they are Figure 2.7 Balanced vane pump
on opposite sides of the housing,
excessive force or pressure buildup
on one side is canceled out by equal but opposite forces on the other side. With
the forces acting on the shaft balanced, the shaft side load is eliminated. Flow is
created in the same manner as was illustrated in the unbalanced vane pump. The
only difference is that there are two discharge and two suction cavities rather than
one. It is notable that constant volume, positive displacement vane pumps used in
industrial systems are generally of the balanced design.
Piston Pumps
Piston pumps are more widely used in the mobile industry than ever before.
They are classified in two groups: fixed and variable displacement. Piston pumps
are highly efficient, operate well in mid-speed ranges, and are capable of higher
pressures than the gear or vane pump products. The cost of manufacturing is
much higher because of the many moving parts and close machining tolerances
that must be maintained to achieve higher efficiencies. Many manufacturers provide
piston pumps with a variety of displacements, controls, shafts, and mounting
configurations.

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Pumps My Notes and Calculations

Figure 2.8 Fixed displacement bent axis piston pump

and a variable displacement axial piston pump

Piston pump usage is very diverse and is used in many mobile applications, including
construction, timber, agriculture, mining, offshore, marine, automotive, aerospace,
and exploration industries.
Fixed displacement piston pumps are generally highly efficient and have the
capacity for achieving higher pressures. These pumps are classified in three general
categories: axial, bent axis, and radial piston pumps.
Fixed displacement axial piston pumps are constructed with an input or drive shaft
that rotates the rotary group or pumping element. The pistons are mechanically
held to the swashplate by means of the slipper shoes and hold-down plate. The
angle of the swashplate, the number of pistons, and the piston diameter determine
the displacement of the pump. These pumps are generally medium pressure pumps
and are susceptible to failure with high suction characteristics. These pumps can be
coupled with other pumps using the same drive shaft.

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Pumps My Notes and Calculations

Figure 2.9 Internal component views of three piston pumps

Fixed displacement bent axis pumps are commonly used when high pressure is
mandatory and when there is no need for variable flow or another pump. They are
quite simple in construction, having an input or drive shaft and the rotary group
or pumping element tilted several degrees. This configuration allows the pistons to
be connected to the drive shaft at an angle, thereby allowing the pistons to move
inside the barrel and providing the displacement of the pump. These pumps are
very durable, compact, and efficient because of their close machining tolerances
and simple construction. Fixed radial piston pumps are constructed with a basic
crankshaft and pistons actuated by the lobes on the shaft. They are generally slower
rotating pumps, but they have high-pressure capacities.

Figure 2.10 Two types of variable displacement piston pumps

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Pumps My Notes and Calculations

A variable displacement piston pump provides many opportunities to engineer

circuits that optimize horsepower usage, give infinite control to the operator, and
automate systems for very smooth and easy actuation. These pumps are classified
in two categories, axial and bent axis piston pumps. The axial piston pump allows
for multiple pumps to be driven by one common drive or input shaft.
The construction of the axial pump is basically the same as its fixed displacement
counterpart, but it allows the swashplate to swivel in order to change the
displacement of the rotary group or pumping element. Many control configurations
are available, including, but not limited to, pressure compensated, load sense,
horsepower limiting, remote pressure control, and unloading type controls. Variable
displacement bent axis pumps are much like their fixed displacement counterparts.
However, the rotary group or pumping element is allowed to move from zero
degrees to full angle with many types of controls. These pumps use many of the
same controls as the variable axial piston pumps.
Axial Piston Pump
Axial piston pumps convert rotary motion of an input shaft to an axial reciprocating
motion, occurring at the pistons. This is accomplished by a swashplate that is
either fixed or variable in its degree of angle. With the swashplate vertical, no
displacement occurs because there is no reciprocating motion. As the swashplate
increases in angle, the pistons move in and out of the barrel as it follows the angle
of the swashplate surface. In actual design, the cylinder is barrel is fitted with
many pistons. During one half
of the circle of rotation,
the piston moves out of the
cylinder barrel and generates an
increasing volume. In the other
half of the rotation, the piston
moves into the cylinder barrel
and generates a decreasing
volume. This reciprocating
motion draws fluid in and
pumps it out.
Figure 2.11 Piston pump

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Pumps My Notes and Calculations

DID YOU KNOW?

Fluid is pushed or drawn into a pump.
Pumps do not pump pressure; their purpose is to create flow.
(Pressure is a result of resistance to flow.)
To determine the required pump capacity, use this equation:
speed (rpm) x disp (in 2/rev)
gpm (theoretical) =
231

Fixed vs. Variable

There are two types of positive displacement hydraulic pumps: a fixed pump that
produces a fixed flow (gpm) based on the rpm of the prime mover or electric
motor, and a variable pump that can vary its rate of flow (gpm) while the input
speed (rpm) remains constant. Although displacement is typically measured in
volume displaced per revolution, output is measured in gpm.

Figure 2.12 A hydraulic system with a gear pump and output device

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Pumps My Notes and Calculations

In Figure 2.12, a motor turning at 1200 rpm is driving a fixed displacement gear
pump producing 5 gpm flow. The flow (gpm) can be changed if the speed (rpm)
of the motor changes.
When a variable displacement pump is used in the system, the flow (gpm) can
be varied in two ways. As with fixed displacement pumps, the flow (gpm) will be
changed if the speed (rpm) of the motor is changed. The second way is to vary
the displacement of the pump. For example, the displacement of an axial piston
pump is determined by the distance the pistons are pulled in and pushed out of
the cylinder barrel.
Since the swashplate angle controls this distance in an axial piston pump, we need
only to change the angle of the swashplate to alter the piston stroke and pump
volume.
Several means of varying the swashplate angles are used. They may include hand
levers, mechanical stops, or more sophisticated, hydraulically positioned devices. If
the pump produces 5-gpm flow with 1200 rpm and maximum displacement, the
flow (gpm) can be varied by moving the swashplate in the upright position or de-
stroking the pump. This will vary the flow from 5 0 gpm.

Figure 2.13 A hydraulic system with a variable

displacement pump and output device

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Pumps My Notes and Calculations

Pump Controls
Pressure Compensated
A variable displacement, pressure compensated pump, is designed to respond to
the pressure changes that occur in a hydraulic system. There are several advantages
of a pressure compensated circuit:
Energy conservation
Better controllability
Concurrent actuation of several circuit functions
Some of these advantages may be offset as a result of higher component costs. A
variable displacement pressure compensated pump is most often used in a closed
center system.

Figure 2.14 A pressure compensated piston pump

In this example, weve used a pressure compensated pump. It is helpful to

understand the functionality of a piston pump. If you need to review this, return
to the piston pumps section.

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Pumps My Notes and Calculations

In this example, when the control valve is in the center or closed position, the
pressure forces the compensator spool to shift up against the spring setting, allowing
the pressurized fluid to shift the control piston, and moving the swashplate to a
vertical position. When the swashplate is vertical, the pump is at zero stroke, or no
flow, and the pressure at the outlet port is maintained at the set pressure.
A very slight amount of flow is produced to lubricate the pump and maintain
compensated pressure. This flow is vented through the pump case drain port.
When a circuit is actuated and the pump control senses a pressure drop, the spool
shifts away from the spring, fluid is vented from the control chamber into the case
of the pump, and the swashplate rotates on stroke to produce the pressure and
flow required by the actuator.
Of the three types of hydraulic pumps discussed (gear, vane, and axial piston) only
the vane and piston may be pressure compensated.
Load Sensing
A variable displacement, pressure compensated, load sense pump, is designed to
respond to the load changes that occur in a hydraulic system and goes to a very low,
preset standby pressure when all of the system circuits are at rest. There are several
advantages of a load sense circuit:
Energy conservation
Greater controllability
Concurrent actuation of several circuit functions with very little dynamic
effect on each other
Greater customization of individual circuit functions
Some of these advantages may be offset as a result of higher component costs. A
load sense pump is most often used in a closed center system.
In this example, weve used a pressure compensated, load sense piston pump. It
is helpful to understand the functionality of a piston pump. If you need to review
this, return to the piston pumps section. In this example, when the control valve is
in the closed position, no load sense signal is present at the pump.
The control is set at the low standby pressure. This provides a differential pressure
to control the pump.

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Pumps Pumps

At standby, internal low SUMMARY

pressure flow passes to the
end of the compensator spool A pumps purpose is to provide flow for the hydraulic system. Pumps transform
and flow spool of the pump mechanical energy, transmitted by a prime mover, into fluid power energy.
control. This signal shifts the External gear pumps are common in the mobile industry. They are simple in
flow spool against the setting design, easily manufactured, lightweight, and inexpensive.
of the spring, passes standby
pressure to the control piston, A crescent pump has an internal gear design. The main components of the
and holds the swashplate at crescent pump include the housing (with a crescent seal and ports), the end cover,
zero stroke against the stroke the input shaft, the drive gear, and the ring gear.
spring. A gerotor pump has an internal gear design. The main components of the gerotor
Only a small amount of flow pump include: the outer gerotor element, the rotor or internal gerotor element, the
is produced to control the input shaft, and the housing with the ports.
pump at standby. This is used The balanced vane pump has two pressure quadrants which cancel each other
to stabilize and lubricate the out because they are on opposing sides of a cam-shaped cylinder.
pump and is vented into the In the unbalanced vane pump, one half of the pumping mechanism is at less
case of the pump and out to than atmospheric pressure.
the reservoir.
An axial piston pump converts the rotary motion of an input shaft to an axial
When the control valve is reciprocating motion occurring at the pistons.
shifted, the pump senses the
resistance of the actuator load A fixed pump produces a fixed flow based on the rpm of the prime mover or
via the load sense line which electric motor. A variable pump can vary its rate of flow while the input speed
Figure 2.15 A load sensing circuit remains constant.
is additive to the flow spool
spring. This signal shifts the A pressure compensated piston pump de-strokes, or moves to zero output, at
flow spool away from the spring, blocking the internal pressure signal from flowing a predetermined pressure.
to the control piston. A variable displacement, pressure compensated, load sense pump, is designed to
respond to the load changes that occur in a hydraulic system and goes to a very low,
Simultaneously, the swashplate is allowed to move on-stroke as the pressure is preset standby pressure when all of the system circuits are at rest.
vented from the control piston to the case, and the outlet pressure of the pump
raises to a level higher than the resistance of the load. Centering the control
valve removes the load sense signal and the pump returns to standby pressure as
described earlier.

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Pumps
QUESTIONS
Gear Pumps
1. Which of the following gear pump
designs are not considered external?
a. gear and crescent
b. gerotor
c. Both a and b are correct.
d. Neither a or b are correct.
2. Which of the following is not a
consideration in gear pump design?
a. the mounting flange
b. shaft options
c. the number of pumping sections
d. fixed or variable displacement
Crescent Pumps
3. Which is not considered a component of
a crescent pump?
a. the housing
b. an external gear
c. a ring gear
d. an output shaft
4. The drive gear in a crescent pump
_____.
a. has more teeth than the ring gear
b. has fewer teeth than the ring
gear
c. meshes with the ring gear
d. Both b and c are correct.
e. Both a and c are correct.
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Gerotor Pumps
5. A gerotor pump input shaft ______.
a. drives the outer gerotor element
b. is part of the outer gerotor
element
c. drives the rotor
d. Both a and c are correct.
e. Both b and c are correct.
6. A gerotor pump is considered an
external gear pump by design.
a. True
b. False
Vane Pumps
7. Vane pumps can be configured with
multiple pumping sections.
a. True
b. False
8. A balanced vane pump is often
configured with pressure compensation
control.
a. True
b. False
9. On a multi-sectional vane pump ______.
a. each rotor has a separate input
shaft
b. both sections share the same
ring
c. one common inlet is typical
d. both sections must have the
same displacement
10. An unbalanced vane pump has an
elliptical ring.
a. True
b. False
Piston Pumps
11. Piston pumps may be classified as
______.
a. fixed displacement
b. variable displacement
c. axial
d. Only a and b are correct.
e. a, b and c are correct.
12. Fixed displacement radial pumps are
constructed with a crank-shaft and
pistons actuated by the lobes on the
shaft.
a. True
b. False
13. Bent axis piston pumps are most
common to ______ applications.
a. high pressure
b. very low contamination
c. variable flow
d. Only a and c are correct.
Fixed vs. Variable
14. Gear pumps _____.
a. may be variable
b. are usually not used in hydraulics
c. change displacement with
changes in rpm
d. give constant output with
constant rpm
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Pumps
15. Variable displacement piston pumps
change the output flow by _____.
a. changing either the pumps rpm
and/or swashplate angle
b. only changing the swashplate
angle
c. only changing the pumps rpm
d. None of the above are correct.
16. Variable volume pumps may also be
pressure compensated.
a. True
b. False
17. Axial piston pumps _____.
a. increase flow by increasing the
swashplate angle
b. decrease flow by increasing the
swashplate angle
c. are at full displacement when the
rotating group is turning
Pressure Compensated
18. A variable displacement, pressure
compensated pump is most often used
in a tandem center circuit.
a. True
b. False
19. During compensation, when the
swashplate is vertical, the pump is at
zero stroke and full flow.
a. True
b. False
Pumps My Notes and Calculations

20. An indication of wear, or low pump

volumetric efficiency, may be indicated
by an unusually high case flow.
a. True
b. False

Load Sense
21. A load sense pump is most often used
in a closed center circuit.
a. True
b. False

22. Standby pressure provides a low

differential pressure to control the
pump.
a. True
b. False

23. With load sense controls, a small

amount of flow is produced during
standby to ______.
a. control the pump
b. shift to DCV
c. lubricate the pump
d. Both a and c are correct.

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