Hydraulic Pumps

Positive-Displacement Pumps
• By definition, PD pumps displace a
known quantity of liquid with each
revolution of the pumping elements
(i.e., gears, rotors, screws, vanes). 
• PD pumps displace liquid by creating a
space between the pumping elements
and trapping liquid in the space.  The
rotation of the pumping elements
then reduces the size of the space and
moves the liquid out of the pump. 
• PD pumps can handle fluids of all
viscosities up to 1,320,000 cSt SSU,
capacities up to 1,150 M3/Hr and
pressures up to 700 BAR / 10,000 PSI. 
• Rotary pumps are self-priming and
deliver a constant, smooth flow,
regardless of pressure variations. 
 Gear Pump
• For simple systems with a relatively low level of pressure (about 140 to
180 bar) the gear pump is the most used type of pump.
• The gear pump is a very simple, reliable, relatively cheap and less dirt
sensitive hydraulic pump.
• As the gears rotate and the teeth at the suction side come clear of
the meshing point, a vacuum is created and oil flows into the spaces
between the teeth.
• The oil in the chambers is transported to the pressure side of the
pump. There the teeth mesh and the oil is forced out the spaces
between the teeth into the output port of the pump. The meshing
of the teeth prevents the oil flowing back from the pressure to the
suction side of the pump. So the oil is transported from the suction
side to the pressure side along the housing side of the gear wheels!
• The pressure at the pressure side is determined by the resistance in
the system. The most important resistance is the load on the
hydraulic cylinder or hydraulic motor.
• In order to prevent cavitation, the pressure at the suction side of
the pump should not exceed 0.1 to 0.2 bar below atmospheric
pressure (minimum absolute pressure: 0.8 bar or 80 kPa).
External-Gear Pump
•The gear pump that has
been described above is an
external gear pump; that is,
both meshing gears have
teeth on their outer
circumferences. These
pumps are sometimes
referred to as gear-on-gear
pumps.
•There are basically three
types of gears used in
external gear pumps - spur,
helical, and herringbone.
Since the spur gear is the
easiest to manufacture, this
type pump is the most
common and the least
expensive of the three.
•Gear pumps are generally
an unbalanced design.
 The gear pump with three wheels
• The drawing shows a gear pump with three wheels. The wheel in the center is
driven by the pump shaft. Comparing this pump with a two wheel pump, the
delivery of this pump is twice as high.
• The two suction and pressure ports are internally connected. The functioning
of this pump is just the same as the functioning of the 'gear pump'
 Reversing Gear Pump
• This type of rotary gear pump moves
liquid in the same direction regardless of
the direction the gears turn.
• The valves (yellow) are forced open and
closed by the difference in pressure on the
input and output sides.
• Fluid in the higher-pressure output side is
shown in light blue while fluid in the
lower-pressure input side is dark blue.
• Notice that when the green gear starts
moving clockwise, the fluid in the outer
circular tubes changes pressure but stops
flowing, and fluid flows more or less
straight up.
• When the red gear is moving clockwise,
fluid travels in a sideways 'S' shape
through the outer circular tubes.
Gear Pump, 3-Lobe
• This is a basically a type of
Gear Pump but with lobes
instead of gears.
• The three-lobe gear pump is
commonly used to force
high-pressure air into
combustion compartments
of a diesel engine.
• The output of these pumps is
more pulsed than the output
of a gear pump because
there are fewer teeth. The
fluid is delivered in
comparatively larger packets.
Gear Pump, 2-Lobe
• This type of gear pump has two
lobes on each shaft. The lobes
nearly touch each other in the
center forming a fairly tight seal.
• They also nearly touch the
casing and when they revolve
they carry fluid around the outer
edge to the outlet, at the top in
this drawing.
• This type of gear pump is often
used as a supercharger for diesel
engines, forcing air (not liquid)
into the power cylinder.
Crescent Pump (Internal Gear)
• The pump consists of two rotating
gears; an Internal Gear with the teeth
on the outside, and an External gear
with the teeth on the inside. The
External Gear is larger and has more
teeth, but the teeth are the same
size.
• As the teeth separate (lower left side
in this drawing) they pass over the
intake hole they "suck" in fluid, then
the gears are separated by a Crescent
Seal (shown in brown.)
• When the teeth start to come
together again (upper right here)
they squeeze the fluid through the
outlet hole
• Advantages of the crescent pump
include its simple design, low noise
and low maintenance requirements.
Internal-Gear Pump
Gerotor Pump
Ge-Rotor Pump
 Gerotor pump
• Since the outer element has one more tooth than the
inner element, one tooth volume is swept each rotation.
As the elements rotate, spaces between the teeth on the
suction side increase, drawing fluid into the pump.
Simultaneously, on the other half of the pump, the spaces
between the teeth decrease, forcing fluid out the
discharge port.
• Gerotor pumps have no inlet or outlet valves, and have
low wear as the inter-element speed is reduced by the
gear ratio of the two elements. The relative speed
between the elements is less than 15% of the motor rpm.
Pressure pulsation at the pump outlet is minimized both
by the high tooth count and the fact that compression and
discharge each take place over nearly 180° of rotation.
 Gerotor Pump
•As the inner gear is turned by a prime mover, it rotates the larger outer
gear. On one side of the pumping mechanism, an increasing volume is
formed as gear teeth unmesh. On the other half of the pump, a decreasing
volume is formed.
Vane Pump • On many industrial
installations with a maximum
pressure of about 200 bar,
vane pumps are applied.
• The advantage of vane pumps
is the pulse free delivery and
low level of noise.
• The shaft of the rotor with
the radial mounted vanes is
driven by an engine or motor.
Vane Pump
 • The vanes are in slots in the rotor.
Vane Pump When the rotor spins, centrifugal
force pushes the vanes out to
touch the casing, where they trap
and propel fluid. Sometimes springs
also push the vanes outward.
• When the vanes reach the return
side they are pushed back into the
rotor by the casing. Fluid escapes
through a channel or groove cut
into the casing, shown here on the
lower right side in black.
• On this vane pump there is
considerable unbalanced force on
the drive shaft, since the high-
pressure, outlet area is all on one
side. Vane pumps can be designed
•A very common type of pump, in balanced configurations where
there are two inlet and two outlet
this is one of many variations. ports.
•Power steering units often rely on
a vane pump to obtain the
pressure needed for the Power
Cylinder. Automatic transmissions
often use them too.
Vane Pumps
Vane pumps generate a
                       pumping action by causing
vanes to track along a ring.
A pumping mechanism of a
vane pump basically
consists of rotor, vanes, ring,
and a port plate with kidney-
shaped inlet and outlet ports.
Variable Volume Vane Pumps

 
 
A positive displacement vane pump delivers the
same volume of fluid for each revolution.
          
Industrial pumps are generally operated at 1200
or 1800  RPM. This indicates that the pump flow
rate                                 
remains constant.
In some cases, it is desirable that a pump's flow
    One way of accomplishing this
rate be variable.
is by varying the speed of the prime mover. This
is usually economically impractical. The only
other way, then, to vary the output of a pump is to
change its displacement.
The amount of fluid which a vane pump displaces
is determined by the difference between the
maximum and minimum distance the vanes are
extended and the width of the vanes. While the
pump is operating, nothing can be done to
change the width of a vane. But, a vane pump
can be designed so that the distance the vanes
are extended can be changed. This is known as
a variable volume vane pump.
 
The pumping mechanism of a
variable volume vane pump
basically consists of a rotor, vanes,
                               
a cam ring which is free to move, a
port plate, a thrust bearing to guide
   cam ring, and something to vary
the
the position of the cam ring. In our
illustration, a screw adjustment is
used.
Variable volume vane pumps are
unbalanced pumps. Their rings are
circular and not cam-shaped.
However, they are still referred to
as cam rings.
Since the cam ring in this type
pump must be free to move, the
pumping mechanism does not
come as a cartridge assembly.
 
Variable volume vane pump
With the screw adjusted in the rotor is held
off center with regard to the cam ring.
                       
                         
When the rotor is turned, an increasing and
decreasing
   volume is generated. Pumping
occurs.
With the screw adjustment turned out
slightly, the cam ring is not as off center to
the rotor as before. An increasing and
decreasing volume is still being generated,
but not as much flow is being delivered by
the pump. The exposed length of the vanes
at full extension has decreased.
With the screw adjustment backed
completely out, the cam ring naturally
centers with the rotor. No increasing and
decreasing volume is generated. No
pumping occurs. With this arrangement a
vane pump can change its output flow
anywhere from full flow to zero flow by
means of the screw adjustment.
Variable-displacement vane
pump
• The stator ring is circular
and is held in an eccentric
position. The amount of
eccentricity determines the
displacement of the pump.
By steering the stator ring
towards the rotor (by
hydraulic pressure, working
on a piston) the amount of
eccentricity and thus the
displacement of the pump is
decreased. At an eccentricity
of zero, the displacement of
the pump becomes 0 cm3:
from that moment on the
pump doesn't deliver any
oil.
Piston Pump
• The basic Piston Pump is very
simple having just two valves
and one stuffing box.
• In this example the
reciprocating piston is driven
back and forth by a rotating
mechanism.
• This piston pump uses suction
to raise water into the
chamber. The lower valve can
be placed below water level.
• The piston must be within
about 25 feet of the water
level, but the water can then
be raised quite high.
Swash Plate Pump• On edge on the far right is a
dark stationary disk. It contains
two semi-circular ports. It is
shown again in a head-on view
below, right.
• These ports allow the pistons
to draw in fluid as they move
toward the swash plate (on the
backside) and discharge it as
they move away.
• For a given speed swash plate
•Swash plate pumps have a pumps can be of fixed
displacement like this one, or
rotating cylinder containing
variable by having a variable
pistons. A spring pushes the
swash plate angle. The greater
pistons against a stationary swash
the slant the further the
plate, which sits at an angle to the
pistons move and the more
cylinder.
fluid they transfer.
•The pistons suck in fluid during
half a revolution and push fluid out
during the other half.
 Axial piston pump with rotating
barrel (Swash-plate pump)

• This axial piston pump consists of a non rotating swash plate (green)
and a rotating barrel (light blue). The advantage of this construction is
that the pump can operate without valves because the rotating barrel
has a determined suck and pressure zone. The animation shows the
behavior of only one piston; normally this pump has 5, 7, 9 or 11
pistons.
Swash-Plate Pump
Swash-Plate Pump
How a piston pump works

 
• This pump generates an increasing and
decreasing volume by means of a plunger
being pulled and pushed, in and out of a
cylinder body. It was pointed out that the
disadvantages of this type of pump were
that the pump developed a pulsating flow
and that it could not be easily operated by
an electric motor or internal combustion
engine.
• However, a piston can be made to
reciprocate easily by the turning motion of
a prime mover as well as develop a smooth
flow.
• In the example illustrated, a cylinder barrel
with one                 
piston bore is fitted with one
piston. A swashplate is positioned at an
angle. The shoe of the piston rides on the
surface of the swashplate.
             
As the cylinder barrel is rotated, the piston shoe follows the surface
of the swashplate. (The swashplate does not rotate.) Since the
swashplate is at an angle, this results in the piston reciprocating
within the bore. In 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 circle of rotation, this piston moves into the cylinder
barrel and generates a decreasing volume.
In actual practice, the cylinder barrel is fitted with many pistons. The
shoes of the pistons are forced against the swashplate surface by a
shoeplate and bias spring. To separate the incoming fluid from the
discharge fluid, a port plate is positioned at the end of the cylinder
barrel opposite the swashplate.
A shaft is attached to the cylinder barrel which connects it with the
prime mover. This shaft can be located at the end of the barrel
where the porting is taking place. Or, more commonly, it can be
positioned at the swashplate end. In this case, the swashplate and
shoeplate have a hole in their centers to accept the shaft. If the shaft
is positioned at the other end, the port plate has a shaft hole.
The piston pump which has been described above is known as an
axial or in-line piston pump; that is, the pistons are rotated about the
same axis as the pump shaft.
 • In this pump, the pistons are at an
Bent Axis Pump angle to the drive shaft and Thrust
Plate. The piston block shaft is
connected to the drive shaft by a
universal joint.
• The drive shaft, thrust plate,
piston block shaft, and piston
block all revolve.
• The connecting rods are attached
to the thrust plate and revolve
with it, unlike the swash plate
pump where the piston rods slide
past a stationary swash plate.
• The outlet ports are semi-circular
holes in the Valve Plate.
• As the pump revolves, half the
pistons suck in fluid as they pass
over the intake port. The other
pistons discharge their fluid
through the outlet port.
Bent-Axis Pump
 Axial piston pump with rotating swash
plate

• In hydraulic systems with a working pressure above aprox. 250 bar

the most used pump type is the piston pump.
• The pistons move parallel to the axis of the drive shaft. The swash
plate is driven by the shaft and the angle of the swash plate
determines the stroke of the piston.
• The valves are necessary to direct the flow in the right direction. This
type of pump can be driven in both directions but cannot be used as a
hydraulic motor.
Variable displacement axial
piston pump
• An axial piston pump with a
rotating cylinder barrel and
a static' swash plate.
• The cylinder barrel is driven
by the drive shaft which is
guided through a hole in
the swash plate.
• The position (angle) of the
swash plate determines the
stroke of the pistons and
therefore the amount of
displacement of the pump.
 Radial Piston Pumps
Radial piston pumps get their name from the fact that their pistons
reciprocate radially rather than along the axis of the drive shaft. There are
two different basic design concepts used for these pumps-a rotating cam and
rotating pistons.
A rotating-cam pump is shown in Figure 10. In this design the pistons
reciprocate in precision bores machined into the stationary cylinder block.
Their reciprocating action is caused by the rotating eccentric cam that is part
of the drive shaft. The fluid enters the pump through the inlet port and is
distributed through an annular passage (or gallery) that connects to the inlet
valves of each piston. As the cam rotates, the motion of the pistons causes
them to alternately fill with fluid through the inlet valve, then discharge it
through the discharge valve. The discharged fluid flows through the
discharge gallery to the outlet port.
Rotating-cam type of radial piston pump.
 Radial Piston Pump
• In variable models, flow rate changes when
the shaft holding the rotating pistons is
moved with relation to the casing (in
different models either the shaft or the
casing moves.).
• If the casing (red) is moved to the left, the
flow rate would decrease to zero. If it is
moved even further to the left the flow
would reverse.
• Input is through the two black holes near
the centre below the "Pintle" (yellow).
Output is through the top two black holes,
above the pintle.
• Higher pressure areas are indicated with a
lighter blue fluid color.
• The pistons are usually forced out by
•Radial Piston Pumps can springs. They are forced back in, expelling
produce a very smooth flow liquid, by the casing.
under extreme pressure. • An odd number of pistons is always used to
Generally they are variable- smooth the hydraulic balance.
displacement pumps. • These pumps revolve at speeds up to about
1200 RPM.
Radial-Piston Pump
 The pumping mechanism of a radial
Radial Piston piston pump basically consists of a
cylinder barrel, pistons with shoes, a
Pump ring, and a valve block.
The action of a radial piston pump is
quite similar to a vane pump. But,
instead of using vanes to track along a
ring, the pump uses pistons.
The cylinder barrel, which houses the
pistons, is positioned off-center to the
ring. As the cylinder barrel is rotated,
an increasing volume is formed within
the cylinder barrel during one half of
the barrel rotation. During the other
half, a decreasing volume is formed.
Fluid enters and is discharged from
the pump through the valve block in
the center of the pump.
 Screw Pumps

Screw pumps may have one, two or three screws.

Screw Pump
• The screw pump is a positive
displacement pump which
comes with two or three
screws.
• The pump forms hollow cavities
which contain the fluid and
move it along the screws. One
screw is the drive screw and
the other screw or screws
is/are driven by the drive
screw.
• The two-bladed pump shown
here has a plexiglass casing so
that the internal gearing can be
seen.
Pump Efficiencies
Volumetric efficiency
•While turning at a constant RPM, we
generally think of a positive
displacement pump as delivering a
constant rate of flow regardless of
system pressure. This is not entirely
true. As system pressure increases,
the internal leakage of various
pumping mechanisms increase.
This results in a decreased output
flow. The degree to which this
happens is known as volumetric
efficiency.
The expression which describes
volumetric efficiency is:
Volumetric Efficiency (%)
= (Actual Output x 100 / Theoretical
Output)
For example, if a particular pump had a theoretical output at 1200
RPM of 10 GPM, but the actual delivery at 1000 PSI were 9 GPM,
the volumetric efficiency would be 90%
Typically, piston pumps have an initial volumetric efficiency in the
high 90's. Gear and vane equipment range from the high 80's to
the mid 90's in volumetric efficiency.

Mechanical Efficiency
Mechanical losses due to mechanical and fluid fictions in the bearing and
pumping mechanisms, losses m the drive gears or coupling mechanisms,
and other losses associated with simply turning the pump all diminish the
mechanical efficiency of a pump. Such mechanical losses are difficult to
measure, so mechanical efficiency is usually calculated from the other
two efficiencies- volumetric and overall- both of which can be readily
measured. Thus, we use the equation: or overall eff.= mech. eff. * vol.
eff.
Overall Efficiency
The overall efficiency of a hydraulic pump takes into account a
pump's mechanical efficiency as well as its volumetric efficiency.
This can be determined by dividing the hydraulic horsepower
delivered to the system by the pump, by the input horsepower of
its prime mover. An expression which describes overall efficiency
is:
Overall Efficiency (%)
= (Hydraulic HP Output x 100/Input HP of Prime Mover)
•For instance, if a particular pump delivered 10 GPM to a
system at 1000 PSI, this would equal 5.8 HP (HP = GPM x PSI
x .000583).
•If an electric motor driving the pump had to develop 7 HP, then
the overall efficiency would be 83%.
•The overall efficiencies of industrial hydraulic gear, vane, and
piston pumps operating at a 1000 PSI is approximately 85%.
Conversely, the overall efficiencies of these same pumps at
200 PSI is about 60% - 70%.
•Industrial hydraulic pumps are generally designed to operate
at pressures above 200 PSI. For this reason, the overall
efficiency of a pump is diminished at this low pressure.
Graphic symbols representing fluid power
pumps.
Hydraulic pumps in a circuit
The systems which have been
described to this point were primarily
constant volume systems. In these
systems, the pump would apply
whatever pressure was required to get
its full flow out into the system.
In the shown circuit, the 50 GPM pump
delivers its flow to the work cylinder to
achieve a rapid advance. When the
cylinder rod reaches the limit switch,
the solenoid of the two-way valve is
energized and the cylinder rod goes
into a feed rate. At this point, the pump
is delivering to the system 43.7HP (50
GPM x 1500 PSI x .000583). If a hi-to
system were used in the same system,
less horsepower would be used.
Let us assume that the feed rate required
is 3.7 GPM. With a hi-to system, we could
use a 45 GPM pump and a 5 GPM pump
to achieve the rapid advance. During the
feed rate, the 45 GPM is dumped to tank
through the unloading valve. The 5 GPM
pump develops the required flow for the
feed rate. At this point, 4.4 HP is delivered
to the system. (5 GPM x 1500 PSI
x .000583).
A pressure compensated, variable volume
pump can make the system even more
efficient. With this type pump, the relief
valve is eliminated. When the cylinder
goes into its feed rate, the compensator
only allows the pump to deliver 3.7 GPM at
1500 PSI. This is equal to 3.2 HP.
Systems which use pressure
compensated, variable volume pumps are
quite efficient.
   terms and idioms associated with
hydraulic pumps
COMBINATION PUMP - a double
pump which is equipped with
accessory valuing to perform relief
and unloading functions.
SLIPPAGE - internal leakage of a
pumping mechanism.
TWO-STAGE PUMP - a pump with
two pumping mechanisms. The units
are connected in series; that is, one
feeds the other. With this
arrangement, two pumping
mechanisms rated at 1000 PSI
individually, could be used to a
maximum pressure of 2000 PSI.
Two-stage pumps were popular in
the days of hydraulics when high
pressure pumps were not available.
                             
 Effects of Air and Other Gases on
Pump Life and Performance

High Vacuum
The problems generated by a high vacuum have to do with the volatility of
the liquid and the dissolved air in the liquid. The volatility of a liquid is the
degree to which it will vaporize under given conditions of pressure and
temperature. The volatility of any liquid increases with either an increase in
temperature or a decrease in pressure. Since we have a low pressure in the
suction line, there is a chance that vaporization can occur. The higher the
vacuum is, the greater the degree of vaporization. The result is that instead
of having a continuous phase of liquid, we have a liquid filled with tiny
vapor bubbles. This phenomenon is termed cavitation. The term
“cavitation" is often used incorrectly to describe any and all of the air/gas
problems in the pump inlet line; however, it correctly defines the
evaporation process described here
 Cavitation
• An undesired phenomena in
hydraulic system is cavitation. Most
of the time cavitation occurs in the
suction part of the system. When
cavitation takes place the pressure in
the fluid decreases to a level below
the ambient pressure thus forming
'vacuum holes' in the fluid. When the
pressure increases, for example in the
pump, these 'vacuum holes' implode.