Week 14

Topic: Hydraulic Pumps

Prepared by:
Engr. Emiliano P,. Heraña Jr.
Faculty CME, ME, MAED
A hydraulic pump is a mechanical source of
power that converts mechanical power into
hydraulic energy (hydrostatic energy i.e. flow,
pressure). Hydraulic pumps are used in
hydraulic drive systems and can be hydrostatic or
hydrodynamic. They generate flow with enough
power to overcome pressure induced by a load at
the pump outlet. When a hydraulic pump operates,
it creates a vacuum at the pump inlet, which forces
liquid from the reservoir into the inlet line to the
pump and by mechanical action delivers this liquid
to the pump outlet and forces it into the hydraulic
system. pumps of various types all work on the
principle of Pascal's law.
Hydrostatic pumps are
positive displacement pumps while
hydrodynamic pumps can be fixed
displacement pumps, in which the
displacement (flow through the pump per
rotation of the pump) cannot be adjusted, or
variable displacement pumps, which have a
more complicated construction that allows
the displacement to be adjusted.
Hydrodynamic pumps are more frequent in
day-to-day life. Hydrostatic pumps of various
types all work on the principle of Pascal's law
.
Types of hydraulic pump
1.Gear Pumps: These pumps consist of two intermeshing
gears that rotate in opposite directions within a housing.
Fluid is trapped between the gear teeth and is carried from
the inlet to the outlet. Gear pumps are known for their
simplicity, reliability, and relatively low cost.
Gear pumps (with external teeth) (fixed
displacement) are simple and economical
pumps. The swept volume or displacement of
gear pumps for hydraulics will be between

lowest volumetric efficiency (𝜂𝑣 ≈ 90 %) of all

about 1 to 200 milliliters. They have the

three basic pump types (gear, vane and piston

pumps). These pumps create pressure
through the meshing of the gear teeth, which
forces fluid around the gears to pressurize the
outlet side. Some gear pumps can be quite
noisy, compared to other types, but modern
gear pumps are highly reliable and much
quieter than older models.
2. Vane Pumps: Vane
pumps utilize slotted
rotor with vanes that
slide in and out to
maintain contact with
the housing. As the
rotor rotates, the vanes
trap and pressurize the
fluid, delivering it to the
outlet. Vane pumps
offer smooth operation
and are suitable for
medium-pressure
applications.
A rotary vane pump is a positive-displacement pump that consists of
vanes mounted to a rotor that rotates inside a cavity. In some cases
these vanes can have variable length and/or be tensioned to maintain
contact with the walls as the pump rotates. A critical element in vane
pump design is how the vanes are pushed into contact with the pump
housing, and how the vane tips are machined at this very point. Several
type of "lip" designs are used, and the main objective is to provide a tight
seal between the inside of the housing and the vane, and at the same
time to minimize wear and metal-to-metal contact. Forcing the vane out
of the rotating centre and towards the pump housing is accomplished
using spring-loaded vanes, or more traditionally, vanes loaded
hydrodynamically (via the pressurized system fluid)..
3. Screw pumps
Screw pumps (fixed displacement) consist of two Archimedes' screws that
intermesh and are enclosed within the same chamber. These pumps are used
for high flows at relatively low pressure (max 100 bars (10,000 kPa)).
[clarification needed] They were used on board ships where a constant
pressure hydraulic system extended through the whole ship, especially to
control ball valves[clarification needed] but also to help drive the steering
gear and other systems. The advantage of the screw pumps is the low sound
level of these pumps; however, the efficiency is not high.
The major problem of screw pumps is that the hydraulic reaction force is
transmitted in a direction that's axially opposed to the direction of the flow.
There are two ways to overcome this problem:
put a thrust bearing beneath each rotor; create a hydraulic balance by
directing a hydraulic force to a piston under the rotor.
Types of screw pumps:
1.single end
2.double end
3.single rotor
4.multi rotor timed
5.multi rotor untimed.
4. Bent axis pumps
Bent axis pumps, axial piston pumps and motors using the bent axis
principle, fixed or adjustable displacement, exists in two different
basic designs. The Thoma-principle (engineer Hans Thoma,
Germany, patent 1935) with max 25 degrees angle and the
Wahlmark-principle (Gunnar Axel Wahlmark, patent 1960) with
spherical-shaped pistons in one piece with the piston rod, piston
rings, and maximum 40 degrees between the driveshaft centerline
and pistons (Volvo Hydraulics Co.). These have the best efficiency of
all pumps. Although in general, the largest displacements are
approximately one litre per revolution, if necessary a two-liter swept
volume pump can be built. Often variable-displacement pumps are
used so that the oil flow can be adjusted carefully. These pumps can
in general work with a working pressure of up to 350–420 bars in
continuous work.
5. Inline axial piston pumps

Axial piston pump, swashplate principle

By using different compensation techniques, the variable displacement type of
these pumps can continuously alter fluid discharge per revolution and system
pressure based on load requirements, maximum pressure cut-off settings,
horsepower/ratio control, and even fully electro proportional systems,
requiring no other input than electrical signals. This makes them potentially
hugely power saving compared to other constant flow pumps in systems where
prime mover/diesel/electric motor rotational speed is constant and required
fluid flow is non-constant.
6. Radial piston pumps

Radial piston pump

A radial piston pump is a form of
hydraulic pump. The working
pistons extend in a radial direction
symmetrically around the drive
shaft, in contrast to the axial piston
pump.
Example 1: Problem Solving/ Pump's Calculations
A pump has a displacement of 3.4 cu.in./rev. The pump is
driven at 1860 rpm and delivers 25 GPM at 1600 psi. If the
mechanical efficiency of the pump is 92%, Calculate:
a)Theoretical Output Flow of the pump
b)Volumetric Efficiency of the pump
c) Hydraulic Horsepower produced by the pump
d)Theoretical Torque to drive the pump
e)Actual Torque to drive the pump
f)Overall efficiency of the pump g)Input Horsepower to drive
the pump
Solution: Given:
Displacement, Vd = 3.4 cu.in./rev
Number of revolutions, N = 1860 rpm
Actual flow rate, Qact. = 25 gpm
Pressure, P = 1600 psi
Mechanical efficiency, Eff mech. = 92% = 0.92
Problem 2: Solved example on pump performance
Problem:
A hydraulic pump delivers 12 L/min at a pressure of 200 bar.
1) Calculate the hydraulic power in kW and HP.
(Note: 1 kW =1.341 HP)
2) If the overall pump efficiency is 60%, what is the input
power to the pump
3) Select one of the following two motors as the realistic size
of an electric motor to drive the pump and justify your
selection
( I ) 8 HP (II) 10 HP
Problem 3: Solved example on Motor Performance
A hydraulic motor has a displacement of 14 cu.cm./rev at 1440
rpm. It operates at a pressure of 150 bar. The volumetric
efficiency is 0.90 and the overall efficiency is 0.80.
Calculate:
1) The motor input flow rate (L/min)
2) The output power at the motor shaft (kW)
PRESSURE CONTROL VALVE ON
HYDRAULIC SYSTEM
Pressure-control valves are found in virtually every
hydraulic system, and they assist in a variety of functions,
from keeping system pressures safely below a desired upper
limit to maintaining a set pressure in part of a circuit
Understanding Pressure-Control Valves
The most common valves for controlling pressure include relief,
reducing, sequence, counterbalance, and unloading valves.

Relief Valves
Most fluid power systems are designed to operate within a
preset pressure range. This range is a function of the forces the
actuators in the system must generate to do the required work.
Without controlling or limiting these forces, the fluid power
components (and expensive equipment) could be damaged.
Relief valves avoid this hazard. They are the safeguards which
limit maximum pressure in a system by diverting excess oil
when pressures get too high.
Cracking pressure and pressure override.
The pressure at which a relief valve first opens to allow fluid to
flow through is known as cracking pressure. When the valve is
bypassing its full rated flow, it is in a state of full-flow
pressure. The difference between full-flow and cracking
pressure is sometimes known as pressure differential, also
known as pressure override.
Direct-acting relief valves. A direct-acting valve may
consist of a poppet or ball, held exposed to system pressure
on one side and opposed by a spring of preset force on the
other. In an adjustable, normally closed relief valve (Fig. 1),
the force exerted by the compression spring exceeds the force
exerted by system pressure acting on the ball or poppet. The
spring holds the ball or poppet tightly seated. A reservoir port
on the spring side of the valve returns leakage fluid to tank.
1. Adjustable, direct-acting relief valve blocks flow through
the valve until force of system pressure on the poppet
overcomes the adjustable spring force and downstream
pressure.
1. Adjustable, direct-acting relief valve blocks flow through the valve until
force of system pressure on the poppet overcomes the adjustable spring
force and downstream pressure.
Most relief valves are adjustable,
which is usually accomplished with
an adjusting screw acting on the
spring. By turning the screw in or
out, the operator compresses or
decompresses the spring
respectively. The valve can be set
to open at any pressure within a
desired range.
Pilot-operated relief valves. For applications requiring
valves that must relieve large flows with small pressure
differential, pilot-operated relief valves are often used (Fig. 2).
The pilot-operated relief valve operates in two stages. A pilot
stage, which consists of a small, spring-biased relief valve
(generally built into the main relief valve), acts as a trigger to
control the main relief valve. However, the pilot may also be
located remotely and connected to the main valve with pipe or
2. Pilot-operated relief valve has
tubing.
orifice through piston, which is
held closed by force of light
spring and system pressure
acting on larger piston area at
spring end.
As system pressure rises, the pressure in
passage B rises as well, and, when it
reaches the setting of the pilot valve, the
pilot valve opens. Oil is released behind
the main valve through passage B
through the drain port. The resulting
pressure drop across orifice A in the
main relief valve opens it and excess oil
flows to tank, preventing any further rise
in inlet pressure. The valves close again
when inlet oil pressure drops below the
valve setting.
Pressure-Reducing Valves
The most practical components for maintaining secondary,
lower pressure in a hydraulic system are pressure-reducing
valves. Pressure-reducing valves are normally open, 2-way
valves that close when subjected to sufficient downstream
pressure. There are two types: direct acting and pilot
operated.
Direct acting. A pressure-reducing valve limits the maximum
pressure available in the secondary circuit regardless of
pressure changes in the main circuit. This assumes the work
load generates no back flow into the reducing valve port in
which case the valve will close (Fig. 3). The pressure-sensing
signal comes from the downstream side (secondary circuit).
This valve, in effect, operates in reverse fashion from a relief
valve (which senses pressure from the inlet and is normally
3. Direct-acting, pressure
reducing valve is held open
by spring force. Increasing
pressure at outlet port moves
the spool to the right, closing
the valve.
As pressure rises in the
secondary circuit (Fig. 3),
hydraulic force acts on
area A of the valve, closing it
partly. Spring force opposes
the hydraulic force, so that
only enough oil flows past
the valve to supply the
secondary circuit at the
desired pressure. The spring
When outlet pressure reaches that of the valve setting, the
valve closes except for a small quantity of oil that bleeds from
the low-pressure side of the valve, usually through an orifice in
the spool, through the spring chamber, to reservoir.
If the valve closes fully, leakage past the spool could cause
pressure buildup in the secondary circuit. To avoid this, a
bleed passage to reservoir keeps it slightly open, preventing
a rise in downstream pressure above the valve setting. The
drain passage returns leakage flow to tank. (Valves with
built-in relieving capability also are available to eliminate the
need for this orifice.)
Constant and fixed pressure reduction. Constant-
pressure-reducing valves supply a preset pressure, regardless
of main circuit pressure, as long as pressure in the main
circuit is higher than that in the secondary. These valves
balance secondary-circuit pressure against the force exerted
by an adjustable spring which tries to open the valve. When
pressure in the secondary circuit drops, spring force opens
the valve enough to increase pressure and keep a constant
reduced pressure in the secondary circuit.
Fixed pressure reducing valves supply a fixed amount of
pressure reduction regardless of the pressure in the main
circuit. For instance, assume a valve is set to provide
reduction of 250 psi. If main system pressure is 2,750 psi,
reduced pressure will be 2,500 psi; if main pressure is 2,000
psi, reduced pressure will be 1,750 psi.
Pilot-operated pressure reducing valves. The spool in a
pilot-operated, pressure-reducing valve is balanced
hydraulically by downstream pressure at both ends (Fig. 4). A
light spring holds the valve open. A small pilot relief valve,
usually built into the main valve body, relieves fluid to tank
when reduced pressure reaches the pilot valve’s spring setting.
This fluid flow causes a pressure drop across the spool.
Pressure differential then shifts the spool toward its closed
position against the light spring force.
4. Pilot-operated, pressure reducing
valve has reduced pressure on both
ends of the spool. A light spring
holds the spool open.
The pilot valve relieves only enough
fluid to position the main valve
spool or poppet so that flow through
the main valve equals the flow
requirements of the reduced
pressure circuit. If no flow is
required in the low-pressure circuit
during a portion of the cycle, the
main valve closes. Leakage of high-
pressure fluid into the reduced-
pressure section of the valve then
returns to the reservoir through the
pilot operated relief valve.
Sequence Valves
In circuits with more than one actuator, it is often necessary to
drive the actuators, such as cylinders, in a definite order or
sequence. This result can sometimes be achieved by sizing
cylinders according to the load they must displace. In many
installations, though, space limitations and force requirements
determine the cylinder size needed to do the job. In this case,
sequence valves can be used to actuate the cylinders in the
required order.
Sequence valves are normally closed, 2-way valves. They
regulate the sequence in which various functions in a circuit
occur (Fig. 5). They resemble direct-acting relief valves except
that their spring chambers are generally drained externally to
reservoir, instead of internally to the outlet port, as in a relief
valve.
A sequence valve usually permits
pressurized fluid to flow to a second
function only after an earlier, priority
function has been completed and
satisfied. When normally closed, a
sequence valve allows fluid to flow
freely to the primary circuit, to perform
its first function until the pressure
setting of the valve is reached.
When the primary function is satisfied,
pressure in the primary circuit rises
and is sensed in pressure-sensing
passage A. This pressurizes the spool
and overcomes the force exerted by the
spring. The spring is compressed, the
valve spool shifts, and oil flows to the
secondary circuit.
Counterbalance Valves
These normally closed valves
are primarily used to maintain a
set pressure in part of a circuit,
usually to counterbalance a
weight or external force or
counteract a weight such as a
platen or a press and keep it
from free-falling. The valve’s
primary port is connected to the
cylinder’s rod end, and the
secondary port to the
directional control valve (Fig.
6). The pressure setting is
slightly higher than that
6. Counterbalance valve stops
flow from its inlet port to its
outlet port until pressure at the
inlet port overcomes adjusting
spring force.
When pressurized fluid flows to
the cylinder’s cap end, the
cylinder extends, increasing
pressure in the rod end, and
shifting the main spool in the
counterbalance valve. This
creates a path which permits
fluid to flow through the
secondary port to the
directional control valve and to
If backpressure must be relieved at
the cylinder force increased at the
bottom of the stroke, the
counterbalance valve can be operated
remotely. Counterbalance valves are
usually drained internally. When the
cylinder extends, the valve must open
and its secondary port is connected to
reservoir. When the cylinder retracts,
it matters little that load pressure is
felt in the drain passage because the
check valve bypasses the valve’s
spool.
Unloading Valves
These valves are normally used to
unload pumps. They direct pump
output flow (often the output of one
of the pumps in a multi-pump
system) directly to reservoir
at low pressure, after system
pressure has been reached.
The force exerted by the spring
keeps the valve closed (Fig. 7).
When an external pilot signal
acting on the opposite end of the
valve spool exerts a force large
enough to exceed that exerted by
the spring, the valve spool shifts,
diverting pump output to reservoir
at low pressure.
Piloted unloading
valves. Unloading valves are
also made with a pilot to control
the main valve (Fig. 8). A port
through the main valve plunger
allows system pressure to act on
both ends of the plunger. A light
spring plus system pressure
acting on the larger area at the
spring end of the plunger holds
the valve closed. A built-in
check valve maintains system
pressure. When system pressure
drops to a preset value, the pilot
valve closes. Pump flow through
8. Piloted unloading
valve has piston with
pump pressure at
both ends.
End of Slides

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