)

HYDRAULIC MOTORS

Introduction

Hydraulic motors are used for converting hydraulic energy into mechanical energy. There are
a variety of different types and designs of hydraulic motors. A few motors may be used at
both very low speeds and some are at high speeds of over 1000 rpm. Hence hydraulic motors
may be categorised into
high speed motors (n = 500 to 10,000 rpm) and
slow speed motors (n = 0.5 to 1,000 rpm),
The torque produced by the motor is dependent on its displacement and the pressure drop
across the motor. Slow speed hydraulic motors are designed in such a way that large torque
produced at small speed. These LSHT (low speed - high torque) motors will be described in a
separate section.
The power produced by a hydraulic motor is dependent on the flow and pressure drop at the
motor. As the power is directly proportional to the speed, high speed motors are suitable for
applications where a high power output is required.

Basic principles of design

Fig. 1 Gear Motor

Fig. 2 Gear ring or

epicyclic gear motor

Fig. 3 Vane motor

 )

Fig. 5 Axial piston motor in swash

Fig. 4 Radial piston motor with plate design
internal eccenter

Fig. 6 Multi-stroke radial piston motor

with external cam Fig. 7 Multi-stroke axial piston
motor with rotating case

Fig. 9 Multi-stroke piston motor with

rotating shaft
Fig. 8 Axial piston motor in bent axis
design

Gear motors
Gear motors are very similar in design to gear pumps They are different in that the axial
pressure field is different and gear motors have a case drain port, as they are designed for
changing directions of rotation. The fluid flowing to the hydraulic motor acts on the gear
wheels that produces the output torque on the motor shaft. Gear motors are often used in
mobile hydraulics and in agricultural machinery to drive conveyor belts, dispersion plates,
ventilators, screw conveyors or fans.
 )

Important parameters

Displacement: approx. 1 to 200 cm3/rev

Max. operating pressure: up to 300 bar
Range of speeds: 500 to 10,000 rpm

Fig. 10 Gear

Gear motors and axial piston motors are high speed motors. High speed motors are used for
speeds of over 500 rpm. For applications requiring low speeds, either high speed motors are
used with gears or slow speed hydraulic motors are used. Slow speed motors or LSHT (low
speed - high torque) motors exhibit their best characteristics and efficiencies for speeds of
less than 500 rpm.

Epicyclic gear motors with cardan shafts (Fig. 11)

In this type of motor, the torque is transferred from the rotating rotor (2) to the output shaft
(3) via an internal cardan shaft (1) instead of an internal gear. The operating fluid flowing to
the hydraulic motor is distributed in the output shaft via bores (4) and fed to the displacement
chambers in the housing via bores. The fluid is returned by the same method.

Fig. 11
 )

Important parameters

Displacement: approx. 10 to 1,000 cm3/rev

Max. operating pressure: up to 250 bar
Range of Speeds: approx. 5 to 1,000 rpm

Basic principle of multi-stroke piston motors (Fig. 12)

In this type of motor, each piston carries out

several operating strokes per revolution of the
shaft. Hence high displacements and thus high
operating torques are produced in this motor.
Control windows (3) are connected to the feed
and return sides of the motor via pipe
connections (1) and control (2). Depending on
the current position, cylinder chambers are
either emptied or filled. The piston is supported
by the stroke cam (8) via a ball or roller (7). The
force FT which is converted into torque is
dependent on the force FA (area of the piston x
operating pressure) and on the angle of the Fig. 12 Multi-stroke hydraulic motors
stroke cam α. have very good slow speed
characteristics and are used in many
applications.
Multi-stroke piston motors are basically built according to two types:

 The shaft is stationary with integrated control and pipe connections. The housing
rotates.
 The housing is fixed, and inside it the control and pipe connections are integrated. The
shaft rotates.

Fig. 13
 )

Multi-stroke radial piston motor (Fig. 14)

In this type of motor the pistons are (3) arranged radially and supported via the rollers (8) on
the cam (4). The cylinder chamber is supplied with fluid via the axial bores in the control (5).
Each piston is charged and discharged with fluid as many times per revolution of the shaft as
there are number of cams on the stroke cam. The torque resulting from the curve of the cam
ring is transferred from the rotor/ piston group (3) to the output shaft (7) via a spline (6). A
tapered roller bearing is integrated into the housing (1), which is capable of receiving high
axial and radial forces. A multiple-disc brake (9) may be mounted onto the control housing
(2) via a through drive. If the release pressure decreases below a certain value in the ring
chamber (10) of this brake, the plate spring (11) presses the multiple discs (12) together.

Fig. 14

Fig. 15 Left not switched: 100% speed, 100% torque; right switched: 200% speed,

Thus the brake is actuated. If the release pressure exceeds the required value, the brake piston
(13) is pushed against the plate spring. The multiple discs are separated and the brake is
released.

Important parameters
Displacement: approx. 200 to 8,000 cm3/rev
Max. operating pressure: up to 450 bar
Range of Speeds: 1 to 300 rpm
 )

Max. Torque: up to 45,000 Nm

HYDRAULIC ACCUMULATORS

General

One of the main tasks of an accumulator is to take a specific amount of fluid under pressure
from the hydraulic system and store it until it is required within the system. The weight load
or spring force or the force of the compressed gas determines the size of the hydraulic
pressure in accumulators, as the forces always remain in balance. In most hydraulic systems,
hydro-pneumatic (gas pressurised) accumulators with a separating element are used.

Function

Hydro-pneumatic accumulators have to carry out various functions in a hydraulic system, e.g.

- Energy storage
- Emergency operation
- Cushioning of pressure shocks
- Compensation of leakage oil
- Cushioning of shocks and vibrations
- Cushioning of pulsations
- Vehicle suspension
- Generation of braking energy
- Maintaining constant pressure
- Compensation of flow (expansion tank)

Energy storage

The power required in the steering and braking systems of mobile machines clearly illustrates
that maximum power is only required for a short period when it is operating at a high speed.
However, the pump must be designed with sufficient pump power even for this short period
of maximum power.
By using hydro-pneumatic accumulators, the pump power may be decreased. The smaller
flow of the pump fills the accumulator during an operation cycle if the required flow for the
system is smaller than the flow from the pump. If the maximum flow is then required, the
difference to the flow from the pump is taken from the accumulator.

Emergency operation

In emergencies, e.g. in case of a power failure, a working or closing stroke is carried out with
the help of the energy present in the accumulator. In Fig. 1 a circuit diagram for emergency
operation is shown. If power fails, the spring causes valve (1) to close and return to its initial
position and switches valve (2) into its mid-position. Hence the accumulator and the piston
rod side of the cylinder are connected. This causes pressurised oil volume in the accumulator
to enable the piston to retract.
 )

Another application of emergency operation using accumulators is when an operating cycle

that has started needs to be completed when a pump or valve malfunctions (see Fig. 2).

Fig. 1 Energy storage decrease stroke time Fig. 2 Extension of hydraulic cylinder
During system failure

Emergency braking

Accumulators may be used for the emergency operation of brakes and steering systems of an
automobile, cable cars, motor cars, etc. The accumulators are charged either by motor pumps
or hand pumps within the station. Hence accumulators always have sufficient energy
available to execute emergency braking. Often the operating principle is reversed, i.e. a
spring force operates the brakes and the brake cylinders are kept "open" by the accumulator
against the spring force. This is shown in Fig. 3.
 )

Fig. 3 Emergency braking system in a car

Types of hydraulic accumulators with separating element

Accumulators basically comprise a fluid compartment and a gas compartment with a gastight
separating element. The fluid compartment is connected to the hydraulic circuit. When
pressure increases, the gas becomes compressed and fluid is fed into the accumulator.

The following types of accumulators with separating elements are used in hydraulic systems:
- Bladder accumulators
- Diaphragm-type accumulators
- Piston accumulators
Bladder accumulators (Fig. 4)
Bladder accumulators comprise a fluid compartment and a gas compartment with a bladder
being used as the gastight separating element. The fluid compartment surrounding the bladder
is connected to the hydraulic circuit. Hence when pressure increases, the bladder accumulator
is filled and the gas is compressed. When pressure decreases, the compressed gas expands
and pushes the stored fluid into the circuit. Bladder accumulators comprise a welded or
forged pressure vessel (1), an accumulator bladder (2), valves for gas inlet (3) and oil inlet
(4). Gas and hydraulic fluid are separated by the bladder (2).

Diaphragm accumulators (Fig. 5)

Diaphragm accumulators comprise a pressure-resistant steel vessel that is usually either

spherical or cylindrical. Inside the accumulator is a diaphragm made of an elastic material
(elastomer) that is used as the separating element.
There are two types of diaphragm accumulator available:
– welded construction
– screwed construction.
In the welded model, the diaphragm is pressed into the lower part before the circular seam
welding is carried out. The elastomer material is not damaged when the welding is carried out
by using a suitable welding process. In the screwed model, the diaphragm is held in position
by screwing the top and bottom part together and fastening them with a coupling nut.
 Fig 23 Bladder accumulator

Fig 24 Diaphragm accumulator; top: welded

Fig. 4 Bladder Accumulator Fig. 5 Diaphragm Accumulator

Piston accumulators

Piston accumulators comprise fluid and gas compartments with a piston being used as the
gastight separating element. The gas side is pre-filled with nitrogen. The fluid part is
connected to the hydraulic circuit. Hence when pressure increases, the piston accumulator is
filled and the gas is compressed. When pressure decreases, the compressed gas expands and
pushes the stored fluid into the circuit. Piston accumulators may be installed in any position.
However the preferred position is the vertical one with the gas side at the top, so that deposits
of dirt particles from the fluid on the piston seals are avoided.
Normally nitrogen losses are very low in hydro-pneumatic accumulators. To prevent a
change in the machining cycle parameter caused by a possible decrease in pre-charge
pressure p0, the pre-charge pressure must be checked at regular intervals. By using the filling
and testing device, accumulators are filled with nitrogen or the nitrogen pre-charge pressure
available is altered. For this purpose, the filling and testing devices are screwed onto the gas
valve of the accumulator and connected to a standard nitrogen bottle via a flexible filling
hose. If the nitrogen pre-charge pressure is to be checked or only reduced, the filling hose
need not be connected. The pre-charge pressure p0 cited on the accumulator must be set
before each new installation and after any repair and then be checked at least once a week
following this initial setting. If no nitrogen losses are detected, then a further examination
should take place after approx. four months. If a change in pressure has not occurred during
this time, then further examinations once a year are sufficient. Nitrogen charging devices
allow quick and economical filling or adding of nitrogen into accumulators. They guarantee
optimum use of standard nitrogen bottles up to a residual pressure of 20 bar and a max.
accumulator charging pressure of 350 bar.