Hydraulic Pumps

A pump, which is the heart of a hydraulic system, converts mechanical energy

into hydraulic energy. The mechanical energy is delivered to the pump via a
prime mover such as an electric motor. Due to mechanical action, the pump
creates a partial vacuum at its inlet. This permits atmospheric pressure to force
the fluid through the inlet line and into the pump. The pump then pushes the
fluid into the hydraulic system.
There are two broad classifications of pumps:

1. Dynamic (non-positive displacement) pumps

This type is generally used for low-pressure, high-volume flow applications.

Because they are not capable of withstanding high pressures, they are of
little use in the hydraulics field. Normally their maximum pressure capacity
is limited to 17-20 bar. This type of pump is primarily used for transporting
fluids from one location to another. The two most common types of dynamic
pumps are the centrifugal and the axial flow propeller pumps.

The figures show the construction features of a centrifugal pump. Although

dynamic pumps provide smooth continuous flow, their output flow rate is
reduced as external resistance of the system connected to the pump is
increased. When the resistance of the external system becomes infinitely large
(for example, a valve is closed
in the outlet line), the pump will
produce no flow. This is called
the shutoff head. As the
external resistance decreases
due to the valve being opened,
the flow increases at the
expense of reduced pressure.
2. Positive displacement pumps
This type is universally used for hydraulic systems. As the name implies, a
positive displacement pump ejects a fixed amount of fluid into the hydraulic
system per revolution of pump shaft rotation. As a result, pump output flow,
neglecting changes in the small internal leakage, is constant and not dependent
on system pressure. This makes them particularly well suited for hydraulic
systems.

Gear pump as an example of Pressure relief valve must be attached

positive displacement pump to positive displacement pump

It should be understood that pumps do not pump pressure. Instead they produce
fluid flow. The resistance to this flow, produced by the hydraulic system, is what
determines the pressure. Thus, the fluid pressure in a hydraulic system is not
predetermined by the pump. It builds up in accordance with the resistances.
These resistance results from the internal and external resistances:
External resistances:
come as a result of external loads and mechanical friction and
acceleration forces.
Internal resistances:
come as a result of the total friction in the lines and components

For example, if a positive displacement pump has its discharge line open to the
atmosphere, there will be flow, but there will be no discharge pressure above
atmospheric because there is essentially no resistance to flow. However, if the
discharge line is blocked, then we have theoretically infinite resistance to flow.
Hence, there is no place for the fluid to go. The pressure will therefore rise until
some component breaks unless pressure relief is provided. This is the reason a
pressure relief valve is needed when a positive displacement pump is used. When
the pressure reaches a set value, the relief valve will open to allow flow back to the
oil tank. Thus, a pressure relief valve determines the maximum pressure level that
the system will experience regardless of the magnitude of the load resistance.

The positive displacement pumps have the following advantages over non-
positive displacement pumps:
1.High-pressure capability (up to 800 bar).
2.Small, compact size.
3. Nearly constant flow rate over the variation of the system pressure
(neglecting leakage).
4. High volumetric efficiency.
5. Small changes in efficiency throughout the design pressure range.
6. Great flexibility of performance (can operate over a wide range of pressure
requirements and speed ranges).

Positive displacement pumps can be classified by the type of motion of internal

elements. The motion may be either rotary or reciprocating. Although these
pumps come in a wide variety of different designs, there are essentially three
basic types:

1. Gear pumps (fixed displacement only)

a. External gear pumps
b. Internal gear pumps
c. Lobe pumps
d. Screw pumps
2. Vane pumps
a. Unbalanced vane pumps (fixed or variable displacement)
b. Balanced vane pumps (fixed displacement only)
3. Piston pumps (fixed or variable displacement)
a. Axial design
b. Radial design
2.1 Gear Pumps: a. External gear pump
The figure illustrates the operation of an external gear pump, which develops
flow by carrying fluid between the teeth of two meshing gears. One of the gears
is connected to a drive shaft connected to the prime mover. The second gear is
driven as it meshes with the driver gear. Oil chambers are formed between the
gear teeth, the pump housing, and the side wear plates. The suction side is
where teeth come out of mesh, bringing about a reduction in pressure to below
atmospheric pressure. Fluid is pushed into this void by atmospheric pressure
because the oil supply tank is vented to the atmosphere. The discharge side is
where teeth go into mesh and the oil is positively ejected into the outlet port.
External gear pump with spur gears (teeth are
parallel to the axis of the gear) are noisy at
relatively high speeds. To reduce noise and
provide smoother operation, helical gears (teeth
inclined at a small angle to the axis of the gear)
are sometimes used. However, these helical gear
pumps are limited to low-pressure applications
(below 20 bar) because they develop excessive
end thrust due to the action of the helical gears.
Herringbone gear pumps eliminate this thrust
action and thus can be used to develop much
higher pressures (up to 200 bar). Herringbone
gears consist basically of two rows of helical teeth
cut into one gear. One of the row of each gear is
right-handed and the other is left-handed to cancel
out the axial thrust force. Herringbone gear pumps
operate as smoothly as helical gear pumps and
provide greater flow rates with much less
pulsating action.
There must be a small clearance (about 0.03
mm) between the teeth tip and pump housing.
As a result, some of the oil at the discharge port
can leak directly back toward the suction port.
This means that the actual flow rate QA is less
than the theoretical flow rate QT, which is based
on volumetric displacement and pump
speed. This internal leakage, called pump
slippage, is identified by the term volumetric
efficiency, ηv, which equals about 90% for
positive displacement pump operating at design
pressure:
ηv = QA / QT
The higher the discharge pressure, the lower the volumetric efficiency because
internal leakage increases with pressure. This is shown by the dashed line in
figure. Pump manufacturers usually specify volumetric efficiency at the pump
rated pressure. The rated pressure of a positive displacement pump is that
pressure below which no mechanical damage due to overpressure will occur to
the pump and the result will be a long, reliable service life. Too high a pressure
not only produces excessive leakage but also can damage a pump by distorting
the casing and overloading the shaft bearings.
b. Internal gear pump
The figure illustrates the configuration and operation of the internal gear pump.
This design consists of an internal gear, a regular spur gear, a crescent-shaped
seal and an external housing. As power is applied to either gear, the motion of
the gears draws fluid from the reservoir and forces it around both sides of the
crescent seal which acts as a seal between the suction and discharge ports. As
the teeth come out of mesh, a suction zone is formed. Because this is spread
over several teeth the flow velocities and consequential noise is considerably
lower than with the conventional external gear pump. The discharge from the
pump occurring as the teeth go into mesh is also spread over several teeth.

c. Lobe pump
Also in the general family of gear pumps is the lobe
pump, which is illustrated in figure. This pump
operates in a fashion similar to the external gear
pump. But unlike the external gear pump, both lobes
are driven externally so that they do not actually
contact each other. Thus, they are quieter than other
types of gear pumps. Due to the smaller number of
mating elements, the lobe pump output will have a
somewhat greater amount of pulsation, although its
volumetric displacement is generally greater than that
for other types of gear pumps.
Pulses in the flow rate due to
The volumetric displacement is the non-continuous entering
a measure of the size of the of the pumping chambers to
pump. It indicates the volume the outlet.
of liquid supplied by the pump
per rotation (or per stroke).
d. Gerotor pump

The Gerotor pump, shown in figure, operates very much like the internal gear
pump. The inner gear rotor (Gerotor element) is power-driven and draws the
gear rotor around as they mesh together. This forms inlet and discharge
pumping chambers between the rotor lobes. The tips of the inner and outer
rotors make contact to seal the pumping chambers from each other. The inner
gear has one tooth less than the outer gear. As with the crescent-type internal
gear pump, suction and delivery takes place over several teeth giving lower
noise operation than the external gear pump. Gerotor pumps also tend to be
extremely dirt-tolerant.
e. Screw pump
The screw pump is an axial flow positive displacement unit. Three precision
ground screws, meshing within a close-fitting housing, deliver non-pulsating
flow quietly and efficiently. The two symmetrically opposed idler rotors act as
rotating seals, confining the fluid in a succession of closures or stages. The
idler rotors are in rolling contact with the central power rotor and are free to float
in their respective housing bores on a hydrodynamic oil film. There are no radial
bending loads. Axial hydraulic forces on the rotor set are balanced, eliminating
any need for thrust bearings.
2.2 Vane Pumps
a. Simple Vane Pump
The figure illustrates the
operation of a vane pump. The
rotor, which contains radial
slots, rotates inside a cam ring.
Each slot contains a vane
designed to mate with the
surface of the cam ring as the
rotor turns. The vanes are
thrown out by centrifugal force
onto the ring (therefore there is a minimum rotational speed for this kind of pump)
and this force is increased by pressure oil applied to the underside of the vanes
improving the sealing characteristics. During one-half revolution of rotor rotation,
the volume increases between the rotor and cam ring. The resulting volume
expansion causes a reduction of pressure. This is the suction process, which
causes fluid to flow through the inlet port and fill the void. As the rotor rotates
through the second half revolution, the surface of the cam ring pushes the vanes
back into their slots, and the trapped volume is reduced. This positively ejects the
.trapped fluid through the discharge port
Pressure oil is fed to the underside of the vane (intra-vane principle). This allows
high force to be applied on the vane when it is having to seal high pressure; at
other times a lower force is applied. This reduces wear and extends pump life.

b. Pressure-Compensated Vane Pump

Some vane pumps have provisions for mechanically varying the eccentricity.
Such a design is called a variable displacement pump and is illustrated in figure.
A handwheel or a pressure compensator can be used to move the cam ring to
change the eccentricity.
The pressure-compensated vane pump is one
in which system pressure acts directly on the
cam ring via a hydraulic piston on the right
side (not shown). This forces the cam ring
against the compensator spring-loaded piston
on the left side of the cam ring. If the dischar-
ge pressure is large enough, it overcomes the
compensator spring force and shifts the cam
ring to the left reducing the eccentricity.
As the discharge pressure continues to
increase, zero eccentricity is finally
achieved, and the pump flow becomes zero.
Such a pump basically has its own
protection against excessive pressure
buildup, as shown in P-Q curve shown in the
figure. When the pressure reaches a value
called Pcutoff , the compensator spring force
equals the hydraulic piston force. As the
pressure continues to increase, the
compensator spring is compressed until zero
eccentricity is achieved. The maximum
pressure achieved is called Pdeadhead, at which point the pump is protected
because it produces no more flow. As a result, there is no power wasted
.through the pressure relief valve and hence fluid heating is reduced

c. Balanced Vane Pump

Note that in simple and pressure compensated vane pumps a side load is exerted
on the bearings of the vane pump because of pressure unbalance. This same
undesirable side load exists for the gear pump. Such pumps are hydraulically
unbalanced.
A balanced vane pump is one that has two
intake and two outlet ports diametrically
opposite each other. Thus, pressure ports are
opposite each other, and a complete hydraulic
balance is achieved. Instead of having a
circular cam ring, a balanced design vane
pump has an elliptical housing, which form two
separate pumping chambers on opposite sides
of the rotor. This eliminates the bearing side
loads and thus permits higher operating
pressures. The figure shows the balanced
vane pump principle of operation.
2.3 Piston Pumps
Piston pumps are mainly used in systems where the operating pressure is 140 bar
and above. The prime characteristic of piston pumps is their high efficiency at high
pressures.
A piston pump works on the principle that a reciprocating piston can draw in fluid
when it retracts in a cylinder bore and discharge it when it extends. The basic
question is how to mechanize a series of reciprocating pistons. There are two
basic types of piston pumps. One is the axial design, having pistons that are
parallel to the axis of the cylinder block. Axial piston pumps can be either of the
bent axis configuration or of the swash plate design. The second type of piston
pump is the radial design, which has pistons arranged radially in a cylinder block.

a. Axial Piston-Pump (Bent-Axis Design)

The figure shows an axial piston pump (bent-axis type) that contains a cylinder
block rotating with the drive shaft. However, the centerline of the cylinder block is
set at an offset angle relative to the centerline of the drive shaft. The cylinder
block contains a number of pistons arranged along a circle. The piston rods are
connected to the drive shaft flange by ball-and-socket joints. The pistons are
forced in and out of their bores as the distance between the drive shaft flange and
cylinder block changes. A universal link connects the block to the drive shaft to
provide alignment and positive drive.
The volumetric displacement of the pump
varies with the offset angle θ, as shown in
right figure. No flow is produced when the
cylinder block centerline is parallel to the
drive shaft centerline. θ can vary from 0°
to a maximum of about 30°. Fixed
displacement units are usually provided
with 23° or 30° offset angles.
b. In-Line Piston Pump (Swash Plate Design)

In this type, the cylinder block and drive

shaft are located on the same centerline.
The pistons are connected to a shoe
plate, which bears against an angled
swash plate. As the cylinder rotates (see
the figure), the pistons reciprocate beca-
use the piston shoes follow the angled
surface of the swash plate. The outlet and
inlet ports are located in the valve plate so
that the pistons pass the inlet as they are
being pulled out and pass the outlet as
they are being forced back in.
This type of pump can also be designed
to have variable displacement capability.
In such a design, the swash plate is
mounted in a movable yoke, as depicted
in the figures. The swash plate angle can
be changed by pivoting the yoke on
pintles. By changing the swash plate
angle the distance moved by the pistons
change and so does the quantity of fluid
pumped. Positioning of the yoke can be
accomplished by manual operation,
servo control, or a compensator control.
c. Radial piston pump
This design consists of a pintle to
direct fluid in and out of the cylinders,
a cylinder barrel with pistons, and a
rotor containing a reaction ring. The
pistons remain in constant contact
with the reaction ring due to
centrifugal force on the pistons. For
pumping action, the reaction ring is
moved eccentrically with respect to
the pintle or shaft axis. As the
cylinder barrel rotates, the pistons on
one side travel outward. This draws
in fluid as each cylinder passes the
suction ports of the pintle. When a piston passes the point of maximum
eccentricity, it is forced inward by the reaction ring. This forces the fluid to enter
the discharge port of the pintle. In some models, the displacement can be
.varied by moving the reaction ring to change the piston stroke
3. Pump Performance
Pump manufacturers run tests to determine performance data for their various
types of pumps. The overall efficiency of a pump can be computed by comparing
the hydraulic power output of the pump to the mechanical input power supplied by
the prime mover. Overall efficiency can be broken into two distinct components
called volumetric efficiency and mechanical efficiency. These three efficiencies
are discussed on the following pages.

3.1 Volumetric efficiency (ηv)

Theoretically the ideal pump would be
one having zero clearance between all
mating parts. Although this is not
feasible, working clearances should be
as small as possible while maintaining
proper oil films for lubrication between
rubbing parts.
Volumetric efficiency indicates the
amount of leakage that takes place within
the pump. This involves considerations
such as manufacturing tolerances and
flexing of the pump casing under design pressure operating conditions:

Theoretical flow rate depends on the design of a certain pump. It could be

determined according to,

where, VD = displacement volume of pump (m3/rev)

N = rpm of pump
Volumetric efficiencies typically run from 80% to 90% for gear pumps, 82% to 92%
for vane pumps, and 90% to 98% for piston pumps.

3.2 Mechanical efficiency (ηm)

Mechanical efficiency indicates the amount of energy losses that occur for reasons
other than leakage. This includes friction in bearings and between other mating
parts. Mechanical efficiencies typically run from 90% to 95%.
 where, p = pump discharge pressure (Pa)
QT = pump theoretical flow rate (m3/s)
TA = actual torque delivered to pump (N . m)
N = pump speed (rad/s)
3.3 Overall efficiency (ηo)
The overall efficiency considers all energy losses and hence is defined as follows:

The overall efficiency can also be represented mathematically as follows:

Note that the actual power delivered to a pump from a prime mover via a rotating
shaft is called brake power and the actual power delivered by a pump to the fluid
is called hydraulic power.

Pump manufacturers specify pump performance characteristics in the form of

graphs. In order to be able to use pumps correctly, the characteristic values and
curves must be known. Using this information, it is easier to compare devices and
select the most suitable pump.
The next figures represent typical performance curves obtained for a 6-in3
(displacement volume) variable displacement piston pump operating at full
displacement. The right graph gives curves of overall and volumetric efficiencies as
a function of pump speed (rpm) for pressure levels of 3000 and 5000 psi. The left
graph gives curves of pump input horsepower (hp) and pump output flow (gpm) as
a function of pump speed for the same two pressure levels
Another example is the performance curves for the radial piston pump for three
different sizes:
PR24: 2.40-in3 displacement
PR30: 3.00-in3 displacement
PR40: 4.00-in3 displacement
Observe the linear relationship between
discharge flow (gpm) and pump speed
(rpm). Also note that the discharge flow of
these pumps is nearly constant over a
broad pressure range. The volumetric and
overall efficiency curves are based on a
2000-psi pump pressure.
Example
A pump has a displacement volume of 100 cm3. It delivers 0.0015 m3/s at 1000
rpm and 70 bars. The electric motor input torque is 120 N.m and has an overall
efficiency of 85%. The hydraulic system operates 12 hours per day for 250 days
per year. The cost of the electricity is $0.11 per kilowatt hour.
1.What is the volumetric, mechanical, and the overall efficiencies?
2.Determine the yearly cost of electricity to operate the hydraulic system.
3.Determine the amount of the yearly cost of electricity that is due to the
inefficiency of the electric motor and pump.
Solution
1.
2.
3.
Pump Performance Comparison Factors
The table compares various performance factors for hydraulic pumps. In general,
gear pumps are the least expensive but also provide the lowest level of
performance. In addition, gear pump efficiency is rapidly reduced by wear, which
contributes to high maintenance costs. Gear pumps are simple in design and
compact in size. Therefore, they are the most common type of pump used in fluid
power systems. The greatest number of applications of gear pumps are in the
mobile equipment and machine tool fields.
Vane pump costs fall between those of gear and piston pump. Vane pumps have
good efficiencies and last for a reasonably long time. However. continued satisfac-
tory performance necessitates clean oil with good lubricity. Excessive shaft speeds
can cause operating problems.

Piston pumps are the most expensive and provide the highest level of overall
performance. They can be driven at high speeds (up to 5000 rpm) to provide a
high horsepower-to-weight ratio. They produce essentially a non-pulsating flow
and can operate at the highest pressure levels. Due to very close-fitting pistons,
they have the highest efficiencies. Since no side loads occur to the pistons, the
pump life expectancy is at least several years. However, because of their complex
design, piston pumps cannot normally be repaired in the field.
Pump Noise
Noise is a significant parameter used to determine the performance of a pump. Any
increase in the noise level normally indicates increased wear and imminent pump
failure. Pumps are good generators but poor radiators of noise. As such, pumps
are one of the main contributors to noise in a hydraulic systems. Pumps are
compact, and because of their relatively small size, they are poor radiators of
noise, especially at lower frequencies.
Reservoirs, electric motors, and piping,
being large, are better radiators. Therefore,
pump-induced vibrations or pulsations can
cause them to radiate audible noise
greater than that coming from the pump.

As illustrated in the figure, pump speed

has a strong effect on noise, whereas
pressure and pump size have about
equal but smaller effects. To achieve
the lowest noise levels, use the lowest
practical speed and select the most
advantageous combination of size and
pressure to provide the needed
horsepower.
Pump noise is created as the internal rotating
components abruptly increase the fluid press-
ure from inlet to outlet. The abruptness of the
pressure increases plays a big role in the
intensity of the pump noise. Thus, the noise
level at which a pump operates depends greatly
on the design of the pump. Gear and vane
pumps generate a much higher noise level than do screw pumps. The table
.provides the approximate noise levels associated with various pump designs

Pump Cavitation
Still another noise problem,
called pump cavitation, can
occur due to entrained air
bubbles in the hydraulic fluid
or vaporization of the hydra-
ulic fluid. This occurs when
pump suction lift is excessive
and the pump inlet pressure
falls below the vapor pressure
of the fluid (usually about 0.3-
bar suction). As a result, air or
or vapor bubbles, which form in the low-pressure inlet region of the pump, are
collapsed when they reach the high-pressure discharge region. This produces high
fluid velocity and impact forces, which can erode the metallic components and
shorten pump life. The following rules will control or eliminate cavitation of a pump
by keeping the suction pressure above the saturation pressure of the fluid:

1. Keep suction line velocities below 1.2 m/s.

2. Keep pump inlet lines as short as possible.
3. Minimize the number of fittings in the inlet line.
4. Mount the pump as close as possible to the reservoir.
5. Use low-pressure drop inlet filters or strainers. Use indicating-type filters and
strainers so that they can be replaced at proper intervals as they become dirty.
6. Use the proper oil as recommended by the pump manufacturer. The importa-
nce of temperature control lies in the fact that increased temperatures tend to
accelerate the liberation of air or vapor bubbles. Therefore, operating oil
temperatures should be kept in the range of 50°C to 65°C to provide an
optimum viscosity range and maximum resistance to liberation of air or vapor
bubbles to reduce the possibility of cavitation.
Pump Selection
Pumps are selected by taking into account a number of considerations for a
complete hydraulic system involving a particular application. Among these consid-
erations are flow-rate requirements, operating speed, pressure rating, performance,
reliability, maintenance, cost, and noise. The selection of a pump typically entails
the following sequence of operations:
1. Select the actuator (hydraulic cylinder or motor) that is appropriate based on
the loads encountered.
2. Select the system pressure. This ties in with the actuator size and the
magnitude of the resistive force produced by the external load on the system.
 The general tendency is towards increased operating pressures The main
advantage of higher working pressures is the reduction in fluid flow rates for
a given system power, resulting in smaller pumps, smaller bore pipes and
smaller components. The disadvantages are that at higher working
pressures, the compressibility of the fluid used can have considerable
adverse effects where precision control is required over a wide range of
loads.
3. Determine the flow-rate requirements. This involves the calculation of the flow
rate necessary to drive the actuator to move the load through a specified
distance within a given time limit.
 The pump system selected must be capable of delivering the maximum flow
rate demanded by the circuit. Pump capacities are stated by manufacturers
for a particular viscosity fluid at given operating temperatures and pressures.
 If the circuit demand is reasonably constant, choose a fixed displacement
pump. When the demand is at a series of fixed levels, a multi-pump system
can be used. For demands which vary within a relatively narrow band, use a
variable displacement pump. If there is a wide variance in system demand,
an accumulator circuit may best satisfy the requirements. The different types
of pumping circuits are described in detail later.
4.Determine the pump speed and select the prime mover. This, together with
the flow-rate calculation, determines the pump size (volumetric
displacement).
 The faster the pump is run, the shorter will be its life and the higher noise
level it emits. The most usual number of rotations for a pump is n = 1500
r.p.m.
5.Select the pump type based on the application (gear, vane, or piston pump
and fixed or variable displacement).
 Fluid contamination: Any fluid contamination will cause pump
damage. Precision pumps with very fine clearances are more
susceptible to damage. If contaminated fluid has to be pumped, such
as in a clean-up loop, particular attention must be paid to pump
selection. Lobe pumps and gerotor pumps are the most dirt-tolerant.
 Pump noise: Noise is becoming increasingly important environm-
entally. Certain kinds do, however, propagate lower noise levels, in
particular those with internal gears.
 Size and weight of pump: Generally, the overall size and weight of
the hydraulic system is only important in mobile installations. The size
and weight of the pump is only part of the whole system and it is the
whole system that is important. In the mobile hydraulic field the trend is
to reduce the weight of the hydraulic system by:
(a) Increasing the operating pressure.
(b) Reducing the size of the reservoir and using efficient oil coolers.
Cost: The lower cost units are gear and vane pumps, the piston
types being much expensive.
6. Select the reservoir and associated plumbing, including piping,
valving, filters and strainers, and other components such as
accumulators.
7. Consider factors such as power loss, need for a heat exchanger due to
generated heat.
8. Calculate the overall cost of the system.

Normally the sequence of operation is repeated several times with different sizes
and types of components and the best overall system is selected for the given
application. This process is called optimization. It means determining the
ultimate selection of a combination of system components to produce the
most efficient overall system at minimum cost.