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FundamentalsofHydraulicPumps
(Unpublished)Hydraulics&Pneumatics

BytheEditorsofHydraulics&Pneumatics
Sun,20120101(Allday)

Ahydraulicpumpisamechanicaldevicethatconvertsmechanicalpowerintohydraulicenergy.Itgenerates
flowwithenoughpowertoovercomepressureinducedbytheload.
Whenahydraulicpumpoperates,itperformstwofunctions.First,itsmechanicalactioncreatesavacuumatthe
pumpinletwhichallowsatmosphericpressuretoforceliquidfromthereservoirintotheinletlinetothepump.
Second,itsmechanicalactiondeliversthisliquidtothepumpoutletandforcesitintothehydraulicsystem.

Apumpproducesliquidmovementorflow:itdoesnotgeneratepressure.Itproducestheflow
necessaryforthedevelopmentofpressurewhichisafunctionofresistancetofluidflowinthesystem.For
example,thepressureofthefluidatthepumpoutletiszeroforapumpnotconnectedtoasystem(load).
Further,forapumpdeliveringintoasystem,thepressurewillriseonlytothelevelnecessarytoovercome
theresistanceoftheload.
Related
Hydraulicpowerunits
Hydraulicmotors
Lowspeed/hightorquemotors

Classificationofpumps
Allpumpsmaybeclassifiedaseitherpositivedisplacementornonpositivedisplacement.Mostpumpsused
inhydraulicsystemsarepositivedisplacement.
Anonpositivedisplacementpumpproducesacontinuousflow.However,becauseitdoesnotprovide
apositiveinternalsealagainstslippage,itsoutputvariesconsiderablyaspressurevaries.Centrifugaland
propellerpumpsareexamplesofnonpositivedisplacementpumps.
Iftheoutputportofanonpositivedisplacementpumpwereblockedoff,thepressurewouldrise,and
outputwoulddecreasetozero.Althoughthepumpingelementwouldcontinuemoving,flowwouldstop
becauseofslippageinsidethepump.
Inapositivedisplacementpump,slippageisnegligiblecomparedtothepump'svolumetricoutputflow.
Iftheoutputportwereplugged,pressurewouldincreaseinstantaneouslytothepointthatthepump's
pumpingelementoritscasewouldfail(probablyexplode,ifthedriveshaftdidnotbreakfirst),orthe
pump'sprimemoverwouldstall.

Positivedisplacementprinciple
Apositivedisplacementpumpisonethatdisplaces(delivers)thesameamountofliquidforeachrotating

cycleofthepumpingelement.Constantdeliveryduringeachcycleispossiblebecauseoftheclosetolerance
fitbetweenthepumpingelementandthepumpcase.Thatis,theamountofliquidthatslipspastthe
pumpingelementinapositivedisplacementpumpisminimalandnegligiblecomparedtothetheoretical
maximumpossibledelivery.Thedeliverypercycleremainsalmostconstant,regardlessofchangesin
pressureagainstwhichthepumpisworking.Notethatiffluidslippageissubstantial,thepumpisnot
operatingproperlyandshouldberepairedorreplaced.
Positivedisplacementpumpscanbeofeitherfixedorvariabledisplacement.Theoutputofafixed
displacementpumpremainsconstantduringeachpumpingcycleandatagivenpumpspeed.Theoutputofa
variabledisplacementpumpcanbechangedbyalteringthegeometryofthedisplacementchamber.
Othernamestodescribethesepumpsarehydrostaticforpositivedisplacementandhydrodynamicpumps
fornonpositivedisplacement.Hydrostaticmeansthatthepumpconvertsmechanicalenergytohydraulic
energywithcomparativelysmallquantityandvelocityofliquid.Inahydrodynamicpump,liquidvelocity
andmovementarelargeoutputpressureactuallydependsonthevelocityatwhichtheliquidismadeto
flow.

Reciprocatingpumps
Thepositivedisplacementprincipleiswellillustratedinthereciprocatingtype
pump,themostelementarypositivedisplacementpump,Figure1.Asthepiston
extends,thepartialvacuumcreatedinthepumpchamberdrawsliquidfromthe
reservoirthroughtheinletcheckvalveintothechamber.Thepartialvacuum
helpsseatfirmlytheoutletcheckvalve.Thevolumeofliquiddrawnintothe
chamberisknownbecauseofthegeometryofthepumpcase,inthisexample,a
cylinder.
Asthepistonretracts,theinletcheckvalvereseats,closingthevalve,andtheforce
ofthepistonunseatstheoutletcheckvalve,forcingliquidoutofthepumpand
intothesystem.Thesameamountofliquidisforcedoutofthepumpduringeach
reciprocatingcycle.
Allpositivedisplacementpumpsdeliverthesamevolumeofliquideachcycle(regardlessofwhetherthey
arereciprocatingorrotating).Itisaphysicalcharacteristicofthepumpanddoesnotdependondriving
speed.However,thefasterapumpisdriven,themoretotalvolumeofliquiditwilldeliver.

Rotarypumps
Inarotarytypepump,rotarymotioncarriestheliquidfromthepumpinlettothepumpoutlet.Rotary
pumpsareusuallyclassifiedaccordingtothetypeofelementthattransmitstheliquid,sothatwespeakofa
gear,lobe,vane,orpistontyperotarypump.
Externalgearpumpscanbedividedintoexternalandinternalgeartypes.Atypicalexternalgearpump
isshowninFigure2.Thesepumpscomewithastraightspur,helical,orherringbonegears.Straightspur
gearsareeasiesttocutandarethemostwidelyused.Helicalandherringbonegearsrunmorequietly,but
costmore.
Agearpumpproducesflowbycarryingfluidinbetweentheteethoftwomeshinggears.Onegearisdriven
bythedriveshaftandturnstheidlergear.Thechambersformedbetweenadjacentgearteethareenclosed
bythepumphousingandsideplates(alsocalledwearorpressureplates).
Apartialvacuumiscreatedatthepumpinletasthegearteethunmesh.Fluidflowsintofillthespaceandis
carriedaroundtheoutsideofthegears.Astheteethmeshagainattheoutletend,thefluidisforcedout.
Volumetricefficienciesofgearpumpsrunashighas93%underoptimumconditions.Runningclearances
betweengearfaces,geartoothcrestsandthehousingcreateanalmostconstantlossinanypumpedvolume

atafixedpressure.Thismeansthatvolumetricefficiencyatlow
speedsandflowsispoor,sothatgearpumpsshouldberun
closetotheirmaximumratedspeeds.
Althoughthelossthroughtherunningclearances,or"slip,"
increaseswithpressure,thislossisnearlyconstantasspeed
andoutputchange.Foronepumpthelossincreasesbyabout
1.5gpmfromzeroto2,000psiregardlessofspeed.Changein
slipwithpressurechangehaslittleeffectonperformancewhen
operatedathigherspeedsandoutputs.Externalgearpumps
arecomparativelyimmunetocontaminantsintheoil,which
willincreasewearratesandlowerefficiency,butsudden
seizureandfailurearenotlikelytooccur.
Thelobepumpisarotary,externalgearpump,Figure3.Itdiffersfromtheconventionalexternalgear
pumpinthewaythe"gears"aredriven.Inagearpump,onegeardrivetheotherinalobepump,bothlobes
aredriventhroughsuitabledrivesgearsoutsideofthepumpcasingchamber.
Ascrewpumpisanaxialflowgearpump,similarinoperationto
arotaryscrewcompressor.Threetypesofscrewpumpsarethe
singlescrew,twoscrew,andthreescrew.Inthesinglescrew
pump,aspiraledrotorrotateseccentricallyinaninternalstator.
Thetwoscrewpumpconsistsoftwoparallelintermeshingrotors
rotatinginahousingmachinedtoclosetolerances.Thethree
screwpumpconsistsofacentraldriverotorwithtwomeshing
idlerrotorstherotorsturninsideofahousingmachinedtoclose
tolerances.
Flowthroughascrewpumpisaxialandinthedirectionofthe
powerrotor.Theinlethydraulicfluidthatsurroundstherotorsis
trappedastherotorsrotate.Thisfluidispusheduniformlywith
therotationoftherotorsalongtheaxisandisforcedouttheotherend.
Thefluiddeliveredbyascrewpumpdoesnotrotate,butmoveslinearly.Therotorsworklikeendless
pistons,whichcontinuouslymoveforward.Therearenopulsationsevenathigherspeed.Theabsenceof
pulsationsandthefactthatthereisnometaltometalcontactresultsinveryquietoperation.
Largerpumpsareusedaslowpressure,largevolumeprefillpumpsonlargepresses.Otherapplications
includehydraulicsystemsonsubmarinesandotheruseswherenoisemustbecontrolled.
Internalgearpumps,Figure4,haveaninternalgearandanexternalgear.Becausethesepumpshave
oneortwolessteethintheinnergearthantheouter,relativespeedsoftheinnerandoutergearsinthese
designsarelow.Forexample,ifthenumberofteethintheinnerandoutergearswere10and11
respectively,theinnergearwouldturn11revolutions,whiletheouterwouldturn10.Thislowrelativespeed
meansalowwearrate.Thesepumpsaresmall,compactunits.
Thecrescentsealinternalgearpumpconsistsofaninnerandoutergearseparatedbyacrescentshaped
seal.Thetwogearsrotateinthesamedirection,withtheinnergearrotatingfasterthantheouter.The
hydraulicoilisdrawnintothepumpatthepointwherethegearteethbegintoseparateandiscarriedtothe
outletinthespacebetweenthecrescentandtheteethofbothtears.Thecontactpointofthegearteeth
formsaseal,asdoesthesmalltipclearanceatthecrescent.Althoughinthepastthispumpwasgenerally
usedforlowoutputs,withpressuresbelow1,000psi,a2stage,4,000psimodelhasrecentlybecome
available.

Thegerotorinternalgear
pumpconsistsofapairofgears
whicharealwaysinsliding
contact.Theinternalgearhas
onemoretooththanthegerotor
gear.Bothgearsrotateinthe
samedirection.Oilisdrawninto
thechamberwheretheteethare
separating,andisejectedwhen
theteethstarttomeshagain.
Thesealisprovidedbythe
slidingcontact.
Generally,theinternalgearpumpwithtoothcrestpressuresealinghashighervolumetricefficiencyatlow
speedsthanthecrescenttype.Volumetricandoverallefficienciesofthesepumpsareinthesamegeneral
rangeasthoseofexternalgearpumps.However,theirsensitivitytodirtissomewhathigher.
Invanepumps,anumberofvanesslideinslotsinarotor
whichrotatesinahousingorring.Thehousingmaybe
eccentricwiththecenteroftherotor,oritsshapemaybeoval,
Figure5.Insomedesigns,centrifugalforceholdsthevanesin
contactwiththehousing,whilethevanesareforcedinandout
oftheslotsbytheeccentricityofthehousing.Inonevane
pump,lightspringsholdthevanesagainstthehousingin
anotherpumpdesign,pressurizedpinsurgethevanes
outward.
Duringrotation,asthespaceorchamberenclosedbyvanes,
rotor,andhousingincreases,avacuumiscreated,and
atmosphericpressureforcesoilintothisspace,whichisthe
inletsideofthepump.Asthespaceorvolumeenclosed
reduces,theliquidisforcedoutthroughthedischargeports.
BalancedandunbalancedvanepumpsThepumpillustratedinFigure5isunbalanced,becauseall
ofthepumpingactionoccursinthechambersononesideoftherotorandshaft.Thisdesignimposesaside
loadontherotoranddriveshaft.Thistypevanepumphasacircularinnercasing.Unbalancedvanepumps
canhavefixedorvariabledisplacements.Somevanepumpsprovideabalancedconstructioninwhichan
ellipticalcasingformstwoseparatepumpingareasonoppositesidesoftherotor,sothatthesideloads
cancelout,Figure6.Balancedvanepumpscomeonlyinfixeddisplacementdesigns.
Inavariablevolumeunbalanceddesign,Figure7,thedisplacementcanbechangedthroughanexternal
controlsuchasahandwheelorapressurecompensator.Thecontrolmovesthecamringtochangethe
eccentricitybetweentheringandrotor,therebychangingthesizeofthepumpingchamberandthusvarying
thedisplacementperrevolution.
Whenpressureishighenoughtoovercomethecompensatorspringforce,thecamringshiftstodecrease
theeccentricity.Adjustmentofthecompensatorspringdeterminesthepressureatwhichtheringshifts.
Becausecentrifugalforceisrequiredtoholdthevanesagainstthehousingandmaintainatightsealatthose
points,thesepumpsarenotsuitedforlowspeedservice.Operationatspeedsbelow600rpmisnot
recommended.Ifspringsorothermeansareusedtoholdvanesoutagainstthering,efficientoperationat
speedsof100to200rpmispossible.
Vanepumpsmaintaintheirhighefficiencyforalongtime,becausecompensationforwearofthevaneends

andthehousingisautomatic.Asthesesurfaceswear,thevanes
movefurtheroutintheirslotstomaintaincontactwiththe
housing.
Vanepumps,likeothertypes,comeindoubleunits.Adouble
pumpconsistsoftwopumpingunitsinthesamehousing.They
maybeofthesameordifferentsizes.Althoughtheyare
mountedanddrivenlikesinglepumps,hydraulically,theyare
independent.Anothervariationistheseriesunit:twopumpsof
equalcapacityareconnectedinseries,sothattheoutputofone
feedstheother.Thisarrangementgivestwicethepressure
normallyavailablefromthispump.Vanepumpshaverelatively
highefficiencies.Theirsizeissmallrelativetooutput.Dirt
toleranceisrelativelygood.

Pistonpumps
Thepistonpumpisarotaryunitwhich
usestheprincipleofthereciprocating
pumptoproducefluidflow.Insteadof
usingasinglepiston,thesepumpshave
manypistoncylindercombinations.Part
ofthepumpmechanismrotatesabouta
driveshafttogeneratethereciprocating
motions,whichdrawfluidintoeach
cylinderandthenexpelsit,producing
flow.Therearetwobasictypes,axialand
radialpistonbothareaavailableasfixed
andvariabledisplacementpumps.The
secondvarietyofteniscapableofvariablereversible(overcenter)displacement.
Mostaxialandradialpistonpumpslend
themselvestovariableaswellasfixed
displacementdesigns.Variable
displacementpumpstendtobe
somewhatlargerandheavier,because
theyhaveaddedinternalcontrols,such
ashandwheel,electricmotor,hydraulic
cylinder,servo,andmechanicalstem.
AxialpistonpumpsThepistonsin
anaxialpistonpumpreciprocateparallel
tothecenterlineofthedriveshaftofthe
pistonblock.Thatis,rotaryshaftmotion
isconvertedintoaxialreciprocatingmotion.Mostaxialpistonpumpsaremultipistonandusecheckvalves
orportplatestodirectliquidflowfrominlettodischarge.
InlinepistonpumpsThesimplesttypeofaxialpistonpumpistheswashplatedesigninwhicha
cylinderblockisturnedbythedriveshaft.Pistonsfittedtoboresinthecylinderblockareconnected
throughpistonshoesandaretractingring,sothattheshoesbearagainstanangledswashplate.Astheblock
turns,Figure8,thepistonshoesfollowtheswashplate,causingthepistonstoreciprocate.Theportsare

arrangedinthevalveplatesothatthepistonspasstheinletasthey
arepulledoutandtheoutletastheyareforcedbackin.Inthese
pumps,displacementisdeterminedbythesizeandnumberofpistons
aswellastheirstrokelength,whichvarieswiththeswashplateangle.
Invariabledisplacementmodelsoftheinlinepump,theswashplate
swingsinamovableyoke.Pivotingtheyokeonapintlechangesthe
swashplateangletoincreaseordecreasethepistonstroke.Theyoke
canbepositionedwithavarietyofcontrols,i.e.,manual,servo,
compensator,handwheel,etc.
BentaxispumpsThispumpconsistsofadriveshaftwhich
rotatesthepistons,acylinderblock,andastationaryvalvingsurface
facingthecylinderblockboreswhichportstheinletandoutletflow.
Thedriveshaftaxisisangularinrelationtothecylinderblockaxis.
Rotationofthedriveshaftcausesrotationofthepistonsandthe
cylinderblock.
Becausetheplaneofrotationofthepistonsisatanangletothevalvingsurfaceplane,thedistancebetween
anyoneofthepistonsandthevalvingsurfacecontinuallychangesduringrotation.Eachindividualpiston
movesawayfromthevalvingsurfaceduringonehalfoftheshaftrevolutionandtowardthevalvingsurface
duringtheotherhalf.
Thevalvingsurfaceissoportedthatitsinletpassage
isopentothecylinderboresinthatpartofthe
revolutionwherethepistonsmoveaway.Itsoutlet
passageisopentothecylinderboresinthepartofthe
revolutionwherethepistonsmovetowardthevalving
surface.Therefore,duringpumprotationthepistons
drawliquidintotheirrespectivecylinderbores
throughtheinletchamberandforceitoutthroughthe
outletchamber.Bentaxispumpscomeinfixedand
variabledisplacementconfigurations,butcannotbe
reversed.
Inradialpistonpumps,thepistonsarearranged
radiallyinacylinderblocktheymoveperpendicularly
totheshaftcenterline.Twobasictypesareavailable:
oneusescylindricallyshapedpistons,theotherball
pistons.Theymayalsobeclassifiedaccordingtotheportingarrangement:checkvalveorpintlevalve.They
areavailableinfixedandvariabledisplacement,andvariablereversible(overcenter)displacement.
Inpintleportedradialpistonpump,Figure9,thecylinderblockrotatesonastationarypintleandinsidea
circularreactingringorrotor.Astheblockrotates,centrifugalforce,chargingpressure,orsomeformof
mechanicalactioncausesthepistonstofollowtheinnersurfaceofthering,whichisoffsetfromthe
centerlineofthecylinderblock.Asthepistonsreciprocateintheirbores,portinginthepintlepermitsthem
totakeinfluidastheymoveoutwardanddischargeitastheymovein.
Thesizeandnumberofpistonsandthelengthoftheirstrokedeterminepumpdisplacement.Displacement
canbevariedbymovingthereactionringtoincreaseordecreasepistontravel,varyingeccentricity.Several
controlsareavailableforthispurpose.
Plungerpumpsaresomewhatsimilartorotarypistontypes,inthatpumpingistheresultofpistons
reciprocatingincylinderbores.However,thecylindersarefixedinthesepumpstheydonotrotatearound

thedriveshaft.Pistonsmaybereciprocatedbya
crankshaft,byeccentricsonashaft,orbyawobble
plate.Wheneccentricsareused,returnstrokeisby
springs.Becausevalvingcannotbesuppliedby
coveringanduncoveringportsasrotationoccurs,
inletandoutletcheckvalvesmaybeusedinthese
pumps.
Becauseoftheirconstruction,thesepumpsoffertwo
featuresotherpumpsdonothave:onehasamore
positivesealingbetweeninletandoutlet,permitting
higherpressureswithoutexcessiveleakageofslip.
Theotheristhatinmanypumps,lubricationof
movingpartsotherthanthepistonandcylindrical
boremaybeindependentoftheliquidbeingpumped.
Therefore,liquidswithpoorlubricating
propertiescanbepumped.Volumetricand
overallefficienciesareclosetothoseofaxialand
radialpistonpumps.

Measuringpump
performance
Volumeoffluidpumpedperrevolutionis
calculatedfromthegeometryoftheoilcarrying
chambers.Apumpneverquitedeliversthe
calculated,ortheoretical,amountoffluid.How
closeitcomesiscalledvolumetricefficiency.
Volumetricefficiencyisfoundbycomparingthecalculateddeliverywithactualdelivery.Volumetric
efficiencyvarieswithspeed,pressure,andtheconstructionofthepump.
Apump'smechanicalefficiencyisalsolessthanperfect,becausesomeoftheinputenergyiswastedin
friction.Overallefficiencyofahydraulicpumpistheproductofitsvolumetricandmechanicalefficiencies.
Pumpsaregenerallyratedbytheirmaximumoperatingpressurecapabilityandtheiroutput,ingpmorlpm,
atagivendrivespeed,inrpm.

Matchingpumppowerwiththeload
Pressurecompensationandloadsensingaretermsoftenusedtodescribepumpfeaturesthatimprovethe
efficiencyofpumpoperation.Sometimesthesetermsareusedinterchangeably,amisconceptionthatis
cleareduponceyouunderstandthedifferencesinhowthetwoenhancementsoperate.
Toinvestigatethesedifferences,considerasimplecircuitusingafixeddisplacementpumprunningat
constantspeed.Thiscircuitisefficientonlywhentheloaddemandsmaximumpowerbecausethepumpputs
outfullpressureandflowregardlessofloaddemand.Areliefvalvepreventsexcessivepressurebuildupby
routinghighpressurefluidtotankwhenthesystemreachesthereliefsetting.AsFigure10shows,poweris
wastedwhenevertheloadrequireslessthanfullfloworfullpressure.Theunusedfluidenergyproducedby
thepumpbecomesheatthatmustbedissipated.Overallsystemefficiencymaybe25%orlower.
Variabledisplacementpumps,equippedwithdisplacementcontrols,Figure11,cansavemostofthiswasted
hydraulichorsepowerwhenmovingasingleload.Controlvariationsincludehandwheel,lever,cylinder,
stemservo,andelectrohydraulicservocontrols.Examplesofdisplacementcontrolapplicationsarethe

levercontrolledhydrostatictransmissionsusedtopropelwindrowers,skidsteerloaders,androadrollers.
Whilematchingtheexactflowandpressureneedsofa
singleload,thesecontrolshavenoinherentpressureor
powerlimitingcapabilities.Andso,otherprovisions
mustbemadetolimitmaximumsystempressure,and
theprimemoverstillmusthavecornerhorsepower
capability.Moreover,whenapumpsuppliesacircuit
withmultipleloads,theflowandpressurematching
characteristicsarecompromised.
Adesignapproachtothesysteminwhichonepump
powersmultipleloadsistouseapumpequippedwitha
proportionalpressurecompensator,Figure12.Ayoke
springbiasesthepumpswashplatetowardfull
displacement.Whenloadpressureexceedsthe
compensatorsetting,pressureforceactsonthe
compensatorspooltoovercometheforceexertedby
thespring.
Thespoolthenshiftstowardthecompensatorspringchamber,portspumpoutputfluidtothestroking
piston,anddecreasespumpdisplacement.Thecompensatorspoolreturnstoneutralwhenpumppressure
matchesthecompensatorspringsetting.Ifaloadblockstheactuators,pumpflowdropstozero.
Usingavariabledisplacement,pressurecompensatedpumpratherthanafixeddisplacementpump
reducescircuithorsepowerrequirementsdramatically,Figure13.Outputflowofthistypeofpumpvaries
accordingtoapredetermineddischargepressureassensedbyanorificeinthepump'scompensator.
Becausethecompensatoritselfoperatesfrompressurizedfluid,thedischargepressuremustbesethigher
say,200psihigherthanthemaximumloadpressuresetting.Soiftheloadpressuresettingofapressure
compensatedpumpis1,100psi,thepumpwillincreaseordecreaseitsdisplacement(andoutputflow)based
ona1,300psidischargepressure.
Atwostagepressurecompensator
control,Figure14,usespilotflowatload
pressureacrossanorificeinthemainstage
compensatorspooltocreateapressuredropof
300psi.Thispressuredropgeneratesaforceon
thespoolwhichisopposedbythemainspool
spring.Pilotfluidflowstotankthroughasmall
reliefvalve.Aspringchamberpressureof4,700
psiprovidesacompensatorcontrolsettingof
5,000psi.Anincreaseinpressureoverthe
compensatorsettingshiftsthemainstagespool
totheright,portingpumpoutputfluidtothe
strokingpiston,whichovercomesbiaspiston
forceandreducespumpdisplacementtomatch
loadrequirements.
Theearlierstatedmisconceptionstemsfromanobservationthatoutputpressurefromapressure
compensatedpumpcanfallbelowthecompensatorsettingwhileanactuatorismoving.Thisdoesnot
happenbecausethepumpissensingtheload,ithappensbecausethepumpisundersizedfortheapplication.
Pressuredropsbecausethepumpcannotgenerateenoughflowtokeepupwiththeload.Whenproperly
sized,apressurecompensatedpumpshouldalwaysforceenoughfluidthroughthecompensatororificeto
operatethecompensator.

Superiordynamically
Withrespecttoitsmatchingfunction,atwostage
compensatorisidenticaltotheproportional
compensatorcontrolshowninFigure12.The
dynamicperformanceofthetwostagecontrolis
superior,however.Thisbecomesobviouswhen
oneanalyzesatransientwhichinvolvesasudden
decreaseinloadflowdemand,startingfromfull
strokeatlowpressure.
Thesinglestagecontrolspoolportspressure
fluidtothestrokepistononlywhenpump
dischargepressurereachthecompensator
setting.Themainstagespoolofthetwostagecontrolstartsmovingassoonaspumpdischargepressure
minusspringchamberpressureexceedsthe300psispringsetting.Becausepilotfluidflowsthroughthe
orificeandbecauseoftheflowneededtocompressthefluidinthespringchamber,thespringchamber
pressurelagspumpdischargepressure.Thiscausesthespooltobecomeunbalancedandshifttotheright.
Pumpdestrokingstartsbeforepumpdischarge
pressurereachesthecompensatorsetting,Figure15.
Notethatinsystemequippedwithanaccumulator,a
twostagecompensatorcontrolprovideslittle
advantage.Inexcavatorhydraulicsystems,however,
superiorityofthetwostagecompensatorisevident:it
providessystemcomponentsmuchgreaterprotection
againstpressuretransients.
Loadsensing:thenextstep
Asimilarcontrol,whichhasrecentlybecomepopular,
istheloadsensingcontrol,sometimescalledapower
matchingcontrol,Figure16.Thesinglestagevalveis
almostidenticaltothesinglestagecompensator
control,Figure12,exceptthatthespringchamberis
connecteddownstreamofavariableorificerather
thandirectlytotank.Theloadsensingcompensator
spoolachievesequilibriumwhenthepressuredrop
acrossthevariableorificematchesthe300psispring
setting.
Anyofthreebasicloadsensingsignalscontrolaload
sensingpump:unloaded,working,andrelieving.In
theunloadedmode,thelackofloadpressurecauses
thepumptoproducezerodischargeflowatbiasorunloadpressure.Whenworking,loadpressurecauses
thepumptogeneratedischargeflowinrelationtoasetpressuredrop,orbiaspressure.Whenthesystem
reachesmaximumpressure,thepumpmaintainsthispressurebyadjustingitsdischargeflow.
Likethepressurecompensatedpump,aloadsensingpumphasapressurecompensationcontrol,butthe
controlismodifiedtoreceivetwopressuresignals,notjustone.Aswithpressurecompensation,theload
sensingcontrolreceivesasignalrepresentingdischargepressure,butitalsoreceivesasecondsignal
representingloadpressure.Thissignaloriginatesfromasecondorificedownstreamfromthefirst.This
secondorificemaybeaflowcontrolvalveimmediatelybeyondthepumpoutlet,thespoolopeningofa

directionalcontrolvalve,oritmaybearestrictionina
fluidconductor.
Comparisonofthesetwopressuresignalsinthe
modifiedcompensatorsectionallowsthepumpto
sensebothloadandflow.Thisreducespowerlosses
evenfurther,Figure17.Outputflowofthepump
variesinrelationtothedifferentialpressureofthe
twoorifices.Justasthepressurecompensatedpump
increaseditsdischargepressurebytheamount
requiredtorunthepressurecompensator,theload
andflowsensingpump'sdischargepressuretypically
isbetween200and250psihigherthanactualload
pressure.
Furthermore,aloadsensingpumpcanfollowtheload
andflowrequirementsofasinglecircuitfunction
ormultiplesimultaneousfunctions,relating
horsepowertomaximumloadpressure.This
consumesthelowestpossiblehorsepowerand
generatestheleastheat.

Operatorcontrol
Ifthevariableorificeisamanuallyoperatedflow
controlvalve,thesystemcanoperateinaload
matchedmodeatthedirectionofanoperator.As
heopenstheflowcontrolvalve,flowincreases
proportionally(constantpressuredropacrossanincreasingdiameterorifice),atapressureslightlyabove
loadpressure.
AssuggestedinFigure17,wastedpowerisverylowwithaloadsensingvariablevolumepumpcompensator.
Sincethecontrolsensespressuredropandnotabsolutepressure,areliefvalveorothermeansoflimiting
pressuremustbeprovided.
Thisproblemissolvedbyaloadsensing/pressurelimitingcontrol,Figure18.Thiscontrolfunctionsasthe
loadsensingcontrolpreviouslydescribed,untilloadpressurereachesthepressurelimitersetting.Atthat
point,thelimiterportionofthecompensatoroverridestheloadsensingcontroltodestrokethepump.
Again,theprimemovermusthavecornerhorsepowercapability.

Loadsensinggearpumps
Pistonandvanepumpsrelyontheirvariabledisplacementcapabilitytoaccomplishloadsensing.How,
then,canagearpumpaccomplishloadsensingifitsdisplacementisfixed?Likestandardgearpumps,load
sensinggearpumpshavelowinitialcostwhencomparedtootherdesignswithequivalentflowandpressure
capabilities.However,loadsensinggearpumpsoffertheversatilityofvariabledisplacementaxialpiston
andvanepumpsbutwithoutthehighcomplexityandhighcostofvariabledisplacementmechanisms.
Aloadsensinggearpumpcan:
providethehighefficiencyofloadsensingwithoutthehighcostassociatedwithpistonorvane
pumps,
producezerotofulloutputflowinlessthan40millisecondswithlittleornopressurespikingand

withoutpumpinletsupercharging,
drivecircuitswithlow(approaching
atmospheric)unloadreliefpressures,
providepriorityflowandsecondaryflowwitha
lowunloadpressuretoreducestandbyand
secondaryloadedpowerdraw,and
interchangewithloadsensingvaneorpiston
pumpswithouthavingtochangelineor
componentsizes.
Loadsensingpistonpumpsuseapressure
compensatorandahydrostattovaryvolumetric
outputtoasysteminreferencetoloadpressureand
flowrequirements.Ahydrostatisaspringloaded
devicethatmetersflowaccordingtothespringforce
acrossitsequalbutopposingeffectiveareas.Itmaybe
restrictive,asinaseriescircuit,oritmaybypass
primaryloadpressuretoasecondaryortankpressure.
Insimpleterms,ahydrostatseparatesthetotalflow
intotwoflows:onerepresentstherequiredflowand
theotherrepresentstherequiredpressureofthe
primarycircuit.Aloadsensingpistonpumpusesits
hydrostattoregulateoutputflowrelativetoload
pressureandbypassestheexcesspumpflowtoa
secondaryroute,whichmaybeportedtotankortoa
secondarycircuit.
Aloadsensinggearpump,ontheotherhand,usesa
hydrostatincombinationwithanunloadertovaryits
volumetricoutputinresponsetoloadandflowrequirements.Becauseloadsensingpistonandgearpumps
bothuseasingleloadsensingsignaltocontrolpumpdischargepressureandflow,theyareinterchangeable
inloadsensingcircuits.Bothtypeshavemuchincommonandoffersubstantialpowersavingsoversystems
usingfixeddisplacementpumps.Bothofferreducedpowerconsumptionintherunningmodewhenflow
andpressurearerequiredtooperateafunction.Theyalsoconservepowerinthestandbymodewhenthe
systemisidlingorinanonoperationalmode.Furthermore,theycanreducetherequiredsizeand,
therefore,costofvalves,conductors,andfiltersneededforthecircuit.
TheloadsensinggearpumpillustratedinFigure19minimizespowerconsumptionintherunningmodeby
separatingtotaldischargeflowaccordingtoaremoteprimaryfunctionpressureandaprimaryflow.Thisis
accomplishedthroughasingleloadsensingsignaloriginatingfromtheprioritycircuitandroutedascloseas
possibletothedischargesideofthepump'sgears.
Addinganunloadercontroltothepumpcircuit,Figure20,allowsthesystemtoconservepowerinthe
standbymodeofoperationaswellasintherunningmode.Thiscontrolmustbeinstalledinparallelwiththe
inletportofthehydrostatandascloseaspossibletothedischargesideofthegears.Itmustbepilotedby
thesameloadsensingsignalasinFigure19.Thissignalcausesthepumptodumpallflowfromtheoutletto
thesecondarycircuitandatapressurewellbelowthehydrostat'spressuredropsettinginthestandby
mode.
Theunloadercontrolmustoperateoffthesameremoteloadsensingsignalthatcontrolsthehydrostat.
Unlikethehydrostat,theunloaderpoppetoftheunloadercontrolisdesignedwithopposingareashavinga
ratioofatleast2:1.Anylinepressuresensedthatexceeds50%ofpumpdischargepressurewillclosethe

unloadercontrol.Theabilityoftheunloadercontrol
tounloadthepumptonearatmosphericdischarge
pressureiscontrolledbythepoppetorplungerspring
force.Theunloadercontrolissettothelowestvalue
tomaintaintheinternalpressureloadingofthegear
pump.Whencomparedtoastandardfixed
displacementgearpumpcircuit,thiscontrolcan
reducestandbypowerconsumptionby90%.

Dualandcombinedcontrols
Theloadsensingsignalcanbeconditionedby
limitingpressureintheremotesensinglineor
takingitto0psig.Doingsocausesthehydrostat
andtheunloadercontroloftheloadsensinggear
pumptorespondtotheconditionedsignal
accordingtothedischargepressure.Thisis
accomplishedbyprovidingapilotrelief,Figure
21,whichcausesthehydrostattoactasthemain
stageofapilotoperatedreliefvalve.Theability
toconditiontheloadsensinglineispatentedand
makestheloadsensinggearpumpusefulfor
functionsotherthanjustloadsensing.
Thecombinedcontrolloadsensinggearpump,Figure22,isintendedforlargedisplacementpumpsand
bypassessecondaryflowtotank.Italsoispatented,andcanbeusedinthesameapplicationsasthedual
controlpump.However,becausesecondaryflowmustberoutedtotank,itcannotbeusedwhenthe
secondarycircuitdrivesaload.
SourceURL:
http://hydraulicspneumatics.com/200/TechZone/HydraulicPumpsM/Article/False/6401/TechZone
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