Hydraulic Pump Description and Operation

All hydraulic systems require a source of hydraulic power. In most applications, the source of hydraulic
power is a variable delivery axial piston pump. Variable displacement means that pump outlet flow varies
according to system flow demands (as more sources actuator, motors, etc. are operating, the pump
will increase output to maintain maximum pump outlet pressure). Other sources of hydraulic power are
vane or gear pumps (see Motors, Hydraulic Description for description of vane or gear rotating
pumps/motors), or an accumulator (see Accumulators, Hydraulic - Description). An aerospace vehicles
main hydraulic pumps are usually mounted on the engine and connected to the engine rotating shaft
through a gearbox. Pumps may also be driven by an electric motor, APU, ram air turbine, or second
hydraulic system (using a hydraulic motor and pump combination).
To understand how a variable delivery axial piston pump operates refer to the pump cross sectional view
shown in Figure 1. The figure shows pump components and also how pump outlet pressure is controlled
through a compensator valve and control piston arrangement. The key element in control of pump outlet
flow is control of the swashplate angle, , which in turn controls piston relative displacement and hence
pump flow. Ideally, the pump delivers zero flow when there are no flow demands and the required flow
when required while maintaining system design pressure at all times. Variable displacement pumps dont
obtain this ideal goal, but they do come close when flow demands are within their design flow range.
Prior to the introduction of variable delivery pumps 50-60 years ago, pumps were fixed delivery which
means they always delivered the same amount of fluid irregardless of system flow needs. Unused fluid
was then ported back to the reservoir though a pressure relief valve. Fixed delivery pumps wasted a lot
of energy through heat. A fixed delivery pump has a fixed swashplate angle and therefore no
compensator valve or control piston (refer to Figure 1). Fixed delivery pumps may be found today in very
specialized applications where the fixed delivery (or flow) is tailored to the application to minimize wasted
energy. The benefit in this case is a lighter, less expensive pump. An example might be a standalone
hydraulic system to power a large cargo door where flow demands are constant while the door is moving
and the pump would only be on during door movement. A pressure relief valve should also be installed in
this application.

Figure 1

Simplified Pump Schematic

Referring again to Figure 1, pump flow rate is determined by the swashplate angle, , which in turn
controls pump piston displacement. Swashplate angle is controlled by the compensator valve and control
piston. The compensator valve sets the no flow outlet pressure of the pump (e.g., 3000 50 psi) and
meters flow to the compensator piston. The compensator is fed hydraulic pressure from the pump outlet
and is positioned based on a force balance between compensator chamber pressure acting on the piston
and spring force (plus, to a lesser extent, friction and flow forces). The housing is fixed and does not
rotate. The housing must remain fixed so that inlet/outlet ports, compensator valve, solenoids, and other
equipment can be mounted to the pump. All other parts rotate at the pump speed.
At the compensator pressure setting (e.g., 3000 50 psi for a 3000 psi system), the swashplate angle, ,
is zero. As the pump flow increases, the pump outlet pressure decreases. As the outlet pressure
decreases, the compensator moves towards the closed position and the pressure on the control piston is
reduced. As the control piston pressure is reduced, the control piston spring pushes the control piston so
that the swashplate angle, , increases, resulting in greater piston stoke and increased flow rate.
Figure 2 shows 3-dimensional view of a piston hydraulic pump. This figure provides a better view of how
a pump is built and how the pistons and swashplate operate. Not shown in the figure is a compensator
valve and control piston, so this is more representative of a fixed delivery pump. The pistons are
attached to the swashplate via a spherical bearing arrangement. The swashplate does not rotate. As the
cylinder rotates the piston is at the lower end of the cylinder during one part of a revolution (intake) and at
the top end of the cylinder during the other of the rotation (high pressure outlet side of the pump).
During 1 revolution of the swashplate, each piston will pull in fluid and push out high pressure fluid once.
For a nine piston pump, this will lead to 9 pressure pulsations per 1 revolution of the swashplate.

Figure 2 Pump Cross Section

The relationship of outlet flow to outlet pressure for a variable delivery pump is shown in Figure 3. This
plot can be used to estimate pump flow for a given outlet pressure. The plot also shows the flow rate
where pump outlet pressure starts to drop off dramatically. It is important to note that Figure 3 represents
pump characteristics for a fixed pump rotational speed (RPM) or displacement (in3/rev). Normally these
curves are provided for the rated pump speed, but in aircraft engine speeds vary - hence pump speed
varies and maximum flow varies also. Therefore, the curve shown in Figure 3 will shift down for lower
pump speeds and shift up for higher pump speeds up to the maximum flow of the pump.

Qmax
.95Qmax
Flow
Rate
Q

.95Pmax

Pmax

Figure 3

Typical Flow vs Outlet Pressure Plot (for a given pump rotational speed)

The response of the pump to a change in outlet flow is on the order of 50 milliseconds.
Figure 4 shows the relationship between pump flow, efficiency and outlet pressure. The drop off in flow
occurs due to hydraulic fluid leakage at higher pump outlet pressures (higher delta pressure across the
piston seals), which is equivalent to volumetric efficiency. As volumetric efficiency drops off, pump outlet
flow drops by the same amount. The other curve in Figure 4 is the overall efficiency curve (overall
efficiency = volumetric efficiency x mechanical efficiency). Pump horsepower increases linearly with
pump speed.
100

Volumetric Efficiency

90

Overall Efficiency

80
70

Efficiency,
(%)

60

100
90

Flow

80
70

50
40

60
50

30
20
10
0

10

20

30

40

50

60

70

80

90

100

110

% of
Rated
Flow

40
30
20
10
0

% of Rated Pressure

Figure 4

Typical Performance Curves for a Variable Delivery Piston Pump

Pump Design Considerations

The most important characteristics for a hydraulic pump are listed below. These parameters assume a
variable delivery constant pressure pump.
Rated Pressure this is the nominal pressure setting of the pump and must be compatible with the
design operating pressure for the system (e.g., 300050 psi for 3000 psi system or 500050 psi for a
5000 nominal psi system).
Rated Speed this is the nominal speed rating of the pump. The gearbox connecting the pump to the
driver (engine, APU, etc) will need to be compatible with the drive unit speed and the rated pump speed.
The minimum RPM of the pump may also need to be considered
Design Displacement this is the flow per revolution of the pump (in3/rev) that the pump is capable of
achieving without a significant reduction in outlet pressure.

Flow vs Pressure Curve this is a plot that has flow rate on the y-axis and pump outlet pressure on the xaxis. This plot shows the drop off in pressure at a given flow conditions and shows where the knee in the
flow curve lies (see Figure 4). This graph is required for a simulation model. Nominally, this graph is
provided at the rated speed of the pump. If available, this graph for various pump speeds would be
helpful - otherwise the flow can be ratioed using the design displacement for different pump speeds.
Temperature Rating the pump must be rated for the temperature extremes that it will see in operation,
such as engine nacelles. Pump seals are the most critical component when considering temperature.
Case Drain Pressure this is the nominal pressure that would be in the pump case. All pumps have a
case drain line to provide a flow path to the reservoir for hydraulic fluid that flows by the piston seals and
fluid that flows through the compensator. Without a case drain the pressure would blow out a case or
shaft seal. The case drain pressure needs to be greater than the reservoir pressure (and line resistance)
to assure drainage from the case to the reservoir.
Inlet Line Size Standard pumps will have an inlet port sized by the manufacturer. The connecting inlet
line/hose will need to be compatible with the port size and type.
Outlet Line Size - Standard pumps will have an outlet port sized by the manufacturer. The connecting
outlet line/hose will need to be compatible with the port size and type.
Case Drain Line Size - Standard pumps will have a case drain port sized by the manufacturer. The
connecting line/hose will need to be compatible with the port size and type.
Recommended Inlet Pressure to operate properly a pump must be supplied sufficient hydraulic fluid at a
pressure level sufficient to fill the piston cylinders as the pump rotates. A pump manufacturer will provide
recommended inlet pressures and the reservoir and reservoir to pump hydraulic lines need to
designed/sized to meet this requirement. In some instances, a boost pump may be required to achieve
desired inlet pressures and flows.
Number of Pump Pistons most aircraft piston pumps have 9 pistons. An odd number of pistons have
been shown to have smaller output pressure fluctuations than an even number of pistons and experience
has shown 9 pistons to be an optimum number for performance.
Power Requirements what horsepower is required to drive the pump at its maximum operating
condition. Horsepower is the product of flow and delta pressure across the pump, divided by the overall
efficiency of the pump.
Maximum Fluid Viscosity Pump manufacturers will provide a recommendation for the maximum
recommended fluid viscosity. If fluid viscosity is greater than the recommended value, then the pump
may start to cavitate with the pump inlet at the recommended inlet pressure. Maintaining the fluid within
the necessary viscosity range will affect the pump inlet system design.
Seals Seals must be compatible with the specific type of hydraulic fluid used in the pump. Specifically,
seal material for carbon based fluids and synthetic fluids are different.
Filtration Requirements A pump manufacturer will provide recommended fluid cleanliness requirements
to help ensure reliable pump operation. This filtration requirement needs to be taken into consideration
when designing/sizing the return filters in the hydraulic system.
Weight Is always a concern on aircraft. A oversized pump is not desirable from both a weight and cost
standpoint.
Envelope engine nacelles and APU installations usually have limited space available and the pump
installation must be compatible with available volumes
Shaft Type Shafts are usually splined and the spline characteristics must be defined to ensure a proper
interface to the
Direction of Rotation Pumps can rotate either clockwise or counterclockwise and may be of a concern in
certain installations.
Mounting The bolt flange mounting of the pump must be compatible with the attachment on the gearbox
or other attaching plate.

Relief Valve A relief valve should be installed in the outlet (high pressure) line downstream of the pump.
This relief valve will provide protection against hydraulic shock loads, thermal expansion and any possible
overpressure condition. The relief valve setting should be 5-10% greater than maximum pump pressure.
Pump Installation Considerations
Considerations for the mounting/installation of pumps include vibration, temperature, alignment of drive
motor to pump, spline matching and torque requirements. In some applications, a means of quick
installation and removal is required. Quick installation devices must uphold rigidity of the pump
installation and maintain alignment of rotating shaft.
Vibration Need to consider vibration from power source such as the engine or APU, vibration
characteristics from the pump, g-loading and possibly flutter. Mounting should be sufficient to withstand
these loads from both a stress and fatigue standpoint. Testing to appropriate levels from RTCA-DO160
or MIL-STD-810, Method 510 should be conducted.
Temperature Due to the high speed and compression of fluid, pumps operate at high temperatures.
Additionally, the power source for the pump, such as the engine, is at high temperature. Temperature
considerations should include pump seals, fluid temperature, mounting pads, connecting hoses or tubes,
etc.
Pump/Motor Alignment Alignment of pump to drive motor splines needs to held to tight tolerances.
Considerations are tolerance stickups, relative motion between drive motor and pump, possible angular
displacements on installations, spline teeth dimensions, etc. Improper alignment can cause excessive
vibration (leading to premature failure), or failure of the pump shaft seal.
Splines Beyond alignment, spline wear is an important consideration. Usually some lubrication (grease)
is applied to the splines to minimize wear. Selection of lubrication should include temperature, corrosion
inhibiting and reasonable life of the grease before breakdown occurs.
Torque Requirements Both start-up torque and running torque should be considered. Start-up torque is
higher than running torque. Start-up torque accelerates the mass/inertia of the pump and fluid, leading to
temporary high stresses within the mounting hardware and pump. This is more of a concern on APU and
RAT installations. Obviously, the speed of the drive motor must match the manufacturers recommended
speed for the pump (usually accomplished through a gear box).
Axial and Radial Shaft Load Capability Ensures pump shaft and splines are adequately sized for static
and fatigue loads that the pump will see over its operating life.
Case Drain Line A case drain line is installed to drain pump leakage flow back to the reservoir. Case
drain back pressures affect seals and bearings (via load balance across them), balance and loading of
the pump rotating hardware, and piston leakage characteristics. In most aircraft installations, the case
drain line back pressure is equal to the reservoir pressure (which is approximately the pump inlet
pressure). This minimizes leakage on the intake side of the pump. Normally, back pressure from the
case drain line is not an issue, but if back pressures are abnormally high (such as clogged filter), the
effects on the pump should be looked at more closely. Case drain pressure < 150 psi is a rule of thumb
for good pump life. The case drain line must be large enough to cover the maximum case drain flow at
the nominal case drain pressure or even a slightly lower pressure. The case drain line will normally flow
back to return through the return line filters. In some applications, a separate filter is used on the case
drain line.
Inlet Line The inlet line to the pump is designed as part of the pump inlet system. The pump inlet
system consist of reservoir and reservoir pressurization and tubes/hoses from the pressure to the pump.
This system should be designed to ensure fluid is provided to the pump inlet within the inlet pressure
range and viscosity recommended by the manufacturer. In sizing the inlet line, the length of the tubing,
bends, height fluid is pumped, reservoir pressurization, additional components (such as a heat
exchanger) in the line and other factors should be taken into account. Sizing of a pump inlet line uses
basic pipe flow equations and reservoir (or supply) pressurization (see Reservoir, Hydraulic
Description).

Outlet Line The pump outlet line should be sized to system pressure drop requirements and to minimize
affects of pump pressure pulsations. Primary considerations in design of the outlet line are pump
pressure pulsations, accumulators (see Accumulator, Hydraulic - Description), pump system response
and parallel pump installation.
Regarding pressure fluctuations, hydraulic fluid has mass and is compressible. Hence the oil in the pump
downstream tubing behaves like a very stiff spring, with variable stiffness as the downstream
configuration changes. Pulsations are a result of each piston within the pump transferring a discrete
amount of fluid to the system, leading to a pulsed input in the hydraulic system. The flow pulses decay
over time from the damping provided by internal flow friction in the downstream tubing and components.
The pulsation frequencies for a odd numbered piston pump are

Pulsation Frequency 1 = (number of pistons )(rate of pump rotation )

Pulsation Frequency 2 = 2 (number of pistons )(rate of pump rotation )
Example: For a pump running at 2700 rpm with 9 pistons
2700rev min 2 rad
Frequency1 = (9 pistons )
= 2545rad / sec = 405Hz
min 60 sec rev
2700rev min 2 rad
= 5090rad / sec = 810Hz
Frequency2 = 2 (9 pistons )
min 60 sec rev

For aircraft systems, both pulsation frequencies are usually above the response frequency of the
downstream components, however, in some cases the effects may need to be analyzed. The lower
frequency is usually more dominant with pump noise, but both should be analyzed.
System Interaction
System interaction occurs when the natural frequency of the pump compensator is at or near the natural
frequency of a downstream component (such as a servo valve or actuator). Generally there is sufficient
difference between the natural frequencies so that system interactions do not occur.
Another source of interaction occurs when pumps are connected in a parallel arrangement. This
interaction can be stopped by installation of check valves in the outlet lines of each pump.
Pump Pulsation Damping
Several methods exist to dampen the effect of pressure pulsations from a pump:
1. Change configuration (geometry, parts, characteristics, etc.)
2. Increase volumes in pump outlet line
3. Install accumulator close to the pump. Some research shows that for the accumulator to be effective,
it should be installed with 0.3 meters of the pump, and the supply line between the main line and
accumulator should be between 5 and 10 centimeters in length. Also, the volume of the gas
accumulator should be sufficient so that its resonance (response) frequency is less than the pump
pulsation frequency.
4. Install a hose at the pump outlet, or downstream plumbing.
5. Install a Helmholtz resonator (H-filter) in the pump outlet line. A H-filter consists of two lines in
series, of different volumes, that branch away from the main line. By properly selecting the
lengths and cross-sectioal area of both lines, the H-filter can be tuned to a specific frequency.

6. Install a Quincke tube in the main line. The Quincke tube is a side line with areas based on main
line area and lengths sized for a specific frequency.

2nd Tube

1st Tube

Main Line
Helmholtz Resonator

4
3

A1=A4=A2+A3
L3 is based on L2
and target wavelength

Quincke Tube

Pump Qualification
See Qualification - Hydraulic Components for discussion on hydraulic pump qualification and required
certification testing.