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Swash plate design for pressure ripple

reduction – A theoretical analysis


Cite as: AIP Conference Proceedings 2191, 020038 (2019); https://doi.org/10.1063/1.5138771
Published Online: 17 December 2019

Paolo Casoli, Mirko Pastori, and Fabio Scolari

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AIP Conference Proceedings 2191, 020038 (2019); https://doi.org/10.1063/1.5138771 2191, 020038

© 2019 Author(s).
Swash plate design for pressure ripple reduction –
A theoretical analysis

Paolo Casoli 1, a), Mirko Pastori 1, b), Fabio Scolari 1, c)


1
Department of Engineering and Architecture, University of Parma, 43124 Parma, Italy.
a)
Corresponding author: paolo.casoli@unipr.it
b) mirko.pastori@studenti.unipr.it
c) fabio.scolari@unipr.it

Abstract. The delivery pressure ripple has always been a critical aspect in fluid power applications, since it generates
noise and stresses the hydraulic circuit components at the delivery side of the pump. In this paper a possible strategy for
the reduction of the delivery pressure ripple is proposed regarding a variable displacement axial piston pump through
suitable modification of the swash plate surface. For this purpose a mathematical model of the pump has been developed,
focused on the fluid-dynamic aspect with particular attention on the piston kinematics. The model has been used to
introduce a passive control solution in order to modify the instantaneously delivered flow rate and consequently the
pressure ripple. In detail, it has been hypothesized to modify the swash plate realizing on its surface a profile with the
purpose of modifying the motion law of the pistons. The simulations results have demonstrated the effectiveness of the
proposed solution in reducing the amplitude of the pressure ripple.

INTRODUCTION

Piston pumps are used in hydraulic circuits because they are robust machines able to transmit high power density
[1] for this reason they can be found in many industrial applications and in mobile machinery applications where
this kind of variable displacement pump can be widely used for moving both the equipment and the hydrostatic
transmission [2].
A positive displacement machine delivers an oscillating flow rate generating a pressure ripple in downstream
hydraulic circuit; delivery pressure ripple produces vibrations that are transmitted to the pipe and components
connected, which generate fluid borne noise, compromising their functionality and durability.
Studies on how to solve this problem have been mainly focused on passive techniques in order to reduce the
amplitude of the flow ripple. These methodologies consist in an effective optimization of some internal components
of the pump from a geometrical point of view: a typical example is the design optimization of the port plate inlet and
outlet relief grooves to allow a progressive transition between the suction and delivery phases [3]. A new approach
is based on an active control, that is a technique for attenuating an undesirable signal by superimposing it with a
second signal properly set in terms of both amplitude and phase. A significative advantage of an active control is the
capability to adapt itself to different operating and fluid conditions.
Some researchers face the problem of active pressure ripple reduction in a hydraulic circuit by placing an
actuator with a variable chamber volume, installed along the delivery pipe, driven by a signal coming from an
adaptive filter integrated with a feedforward algorithm [4]. Focusing on the swash plate vibrations in [5]
Ivantysynova et al. present the possibility to reduce the amount of the structure borne noise generated by the swash
plate vibrations that interacts with the whole body of the pump: the control of the swash plate through a servo valve
is able to mitigate the swash plate vibrations with a reduction of the overall noise emitted by the pump.

74th ATI National Congress


AIP Conf. Proc. 2191, 020038-1–020038-10; https://doi.org/10.1063/1.5138771
Published by AIP Publishing. 978-0-7354-1938-4/$30.00

020038-1
An active control solution integrated into the pump is reported in [6], where the reduction of the pressure ripple
is achieved by properly change the swash plate tilt angle in order to vary the flow ripple and consequently the
pressure ripple could be reduced by setting a suitable control of the swash plate actuator.
In this paper the authors present the outcomes of a research where the reduction of the pressure ripple is achieved
by varying the motion law of the pistons in order to consequently change the flow rate profile, without modifying
the swash plate tilt angle. The solution proposed is based on an appropriate modification of the swash plate surface
with the introduction of a profile on it. This solution starts from the results found in [6], where the active control
applied to the swash plate have demonstrated the potential of that method; in this proposed activity the motion law
of the pistons is changed in a passive manner, simplifying the overall pump design since no displacement control
systems are required.
In this work in order to analyze the potential of the proposed solution a fluid dynamic mathematical model of the
pump has been developed. The kinematic aspect of the pump has been carefully studied and modelled, allowing the
simulation of the piston displacement at any angular position of the swash plate with the possibility of changing the
swash plate surface geometry in order to vary the law of pistons motion.
About the fluid dynamic models applied to positive displacement machines many research activities have been
carried out and many papers are available in literature.
In [7-15] the research is focused on mechanical and volumetric losses, in particular the friction between
components in relative motion, such as pistons and cylinder block, slippers and port plate or in the axial gap of gear
pumps, are evaluated. Other researchers have been focused on fluid borne noise through three-dimensional
modelling approach with particular attention to the fluid dynamic aspect [16-20]. The analyze of the forces acting on
the internal pump components and the modelling of the displacement control systems is reported in [21-25], while
the effects of the swash plate design on flow pulsations can be found in [22, 26]. The effects of fluid inertia on the
delivery pressure ripple are exhaustively modelled in [27-29] where a fluid model able to take into account the
effects of cavitation is implemented.
The fluid dynamic modelling approach followed in this paper is based on a lumped parameter, the filling and
emptying method has been implemented in order to estimate the pressures in the different volumes inside the
machine and the mass flow rates through them.
The model developed has also been validated by experimental measurements performed on the test bench
present in the department laboratory, which have demonstrated the good agreement between experimental data and
simulation results.
The model developed and used in this work is part of a more complex model that also implements a dynamic
pump model capable of determining the equilibrium position of the swash plate depending on the different forces
applied. Also with regard to this topic, several articles have been drawn up in the last years which have been useful
for the development of the model used in this work. Zeiger et al. and Lin [30, 31] presented a model for the
calculation of the torque acting on the swash plate; Schoenau et al. [32] carried out a dynamic model to achieve a
correlation between experimental and simulated results; while in [33-38] a model for the analysis of the pump
including its flow regulators has been presented and adopted for simulating mobile applications. Focusing on the
solution proposed in this paper the entire model has permitted to drive the research [6] toward a cheaper solutions
here presented able to change the law of pistons motion.
The swash plate profile design has been investigated in order to prove that a significant reduction of the
amplitude of the delivery pressure oscillations could be obtained with this approach.

FLUID DYNAMIC MODEL

The fluid dynamic model has been developed by means of the filling and emptying method (F&E) and a fluid
model has been introduced first. The phenomenon of gaseous cavitation has been implemented in the fluid model,
while the vapour cavitation has not been included due to the low value of the vapour pressure at typical working
conditions (about 50 °C) [6, 27].
Times necessary to air release and re-dissolution [29, 39] are not considered because for the target of this
research is not necessary a more detailed fluid model. The fluid has been modeled as a homogeneous fluid whose
density is a function of pressure and temperature.
In order to apply a lumped parameters model, such as the F&E, the pump has been divided in several volumes,
fixed and variable, connected through orifices as shown in Fig. 1.

020038-2
FIGURE 1. Volumes considered.

In Fig. 1 V1A and V1M are constant volumes representing the suction and the delivery volumes of the pump, the
cylinders are variable volumes (VCi) whose connections to both the delivery and the suction side have been modelled
by means of variable orifices.
A further volume V2M has been added to the delivery pipe and its outlet orifice Ω2M is variable and could be set
in order to define the delivery pressure.
The generalized Bernoulli’s equation yields to the fluid velocity in a throat:

𝐵0
𝐵0 ∙ 𝜌 + 𝑝𝑡 𝑝𝑡
𝜌𝐿0 𝐿0
𝑐 = √2 ∙ [ ∙ (1 − 𝑦) ∙ 𝑙𝑛 ( ) + 𝑅𝐺 ∙ 𝑇𝐺 ∙ 𝑦 ∙ 𝑙𝑛 ] (1)
𝜌𝐿0 𝐵0 𝑝𝑠
∙ 𝜌 + 𝑝𝑠
𝜌𝐿0 𝐿0
Where pt is the upstream total pressure and ps is the static downstream pressure.
The continuity equation permits to define the pressure inside each fluid volume, eq. (2) is referred to a variable
cylinder volume:

𝑉𝑐𝑖 (𝑧) 𝑑𝑝𝑐𝑖 𝑑𝑧𝑖


∑ 𝑚̇𝑐𝑖 + ∙ − 𝜌𝑐 ∙ Ω𝑐𝑖 ∙ =0
𝑖 𝜕𝑝 𝑑𝑡 𝑑𝑡 (2)
( ⁄𝜕𝜌)
𝑇 ,𝑐
0
where the first term considers the mass exchange, the second term includes the effects of compressibility and the
third term takes into account the volume variation due to the movement of the piston (z represents the instantaneous
translational position of the piston).
The effects of fluid inertia are considered in the delivery volume, V1M, applying the momentum equation to the
control volume delimited by the port plate and the pump delivery port [28].
Applying the above equations to each considered volume the following system of differential equations has been
obtained:

𝑑𝑝1𝐴 1 𝑑𝑝
= ∙ ( ) ∙ (𝑚̇1𝐴 − 𝑚̇𝐶𝐴 )
𝑑𝑡 𝑉1𝐴 𝑑𝜌
𝑑𝑝1𝑀 1 𝑑𝑝
= ∙ ( ) ∙ (𝑚̇𝐶𝑀 − 𝑚̇1𝑀 )
𝑑𝑡 𝑉1𝑀 𝑑𝜌
𝑑𝑝2𝑀 1 𝑑𝑝
= ∙ ( ) ∙ (𝑚̇1𝑀 − 𝑚̇2M )
𝑑𝑡 𝑉2𝑀 𝑑𝜌
𝑑𝑝𝐶,𝑖 1 𝑑𝑝 (3)
= ∙ ( ) ∙ (𝑚̇𝐶𝐴,𝑖 − 𝑚̇𝐶𝑀,𝑖 + 𝜌𝐶,𝑖 ∙ 𝐴𝑐𝑖𝑙 ∙ 𝑧̇𝑖 (𝑡)) 𝑖 = 1,2, … , 𝑁
𝑑𝑡 𝑉𝐶𝑖 𝑑𝜌
𝑁

∑ 𝜌𝑐𝑖 𝛺𝑐𝑖 𝑐𝑐𝑖 |𝑐𝑐𝑖 | − 𝜌1𝑀 𝛺1𝑀 𝑐1𝑀 |𝑐1𝑀 | + 𝑑𝑝1𝑀


𝑑𝑐1𝑀 1 1
= ∙ 𝑁
𝑖=1
− ∙ 𝑑𝑡 ∙ 𝑐1𝑀
𝑑𝑡 𝑉1𝑀 ∙ 𝜌1𝑀 𝜌1𝑀 𝑑𝑝
∑ 𝑝𝑐𝑖 𝛺𝑐𝑖 − 𝑝2𝑀 𝛺1𝑀 + (∆Ω ∙ 𝑝1𝑀 + ∆Ω′ ∙ 𝑝′ ) 𝑑𝜌
{ [ 𝑖=1 ]

020038-3
Where in the last equation ∆Ω and ∆Ω′ represent portions of impermeable surfaces at the inlet and outlet of the
considered volume V1M.
The fluid dynamic model has been developed in Simulink® environment. The solver adopted is a variable-step
solver ode23tb, which have been set with a maximum step size of 1.0 ∙ 10−4 and relative and absolute tolerances of
1.0 ∙ 10−4 .

PUMP KINEMATIC MODEL

The kinematic model of the pump has been realized in order to evaluate the instantaneous piston displacement.
The piston position depends on both the rotation angle of the cylinder block (θ) and the swash plate angular position
(α) [1]. In Fig. 2, the geometrical parameters of a single piston are represented.

FIGURE 2. Geometrical scheme for the kinematic model.

The translational i-th piston position zi has been expressed by eq. 4:


𝑎
𝑧𝑖 = + 𝑅 ∙ 𝑠𝑖𝑛𝜗 ∙ 𝑡𝑎𝑛𝛼 − 𝑒 ∙ 𝑡𝑎𝑛𝛼 + 𝜏(𝜗) (4)
𝑐𝑜𝑠𝛼
where 𝜏(𝜗) represents the swash plate profile modifications.
The speed and the acceleration of the piston, eq. 5 and eq. 6, has been calculated deriving the position:
𝑅 ∙ 𝑠𝑖𝑛𝜗 + 𝑎 ∙ 𝑠𝑖𝑛𝛼 − 𝑒
𝑧̇𝑖 = ( ) ∙ 𝛼̇ + 𝑅 ∙ 𝑁 ∙ 𝑐𝑜𝑠𝜗 ∙ 𝑡𝑎𝑛𝛼 + 𝜏̇ (𝜗) (5)
𝑐𝑜𝑠 2 𝛼
2∙𝑁∙𝑅∙𝑐𝑜𝑠𝛼 𝛼(𝑐𝑜𝑠 2 𝛼+2∙𝑠𝑖𝑛2 𝛼)+2∙𝑅∙𝑠𝑖𝑛𝛼∙𝑠𝑖𝑛𝜗−2∙𝑒∙𝑠𝑖𝑛𝛼
𝑧̈𝑖 = −𝑁 2 ∙ 𝑅 ∙ 𝑠𝑖𝑛𝜗 ∙ 𝑡𝑎𝑛𝛼 + ( ) ∙ 𝛼̇ + [ ] ∙ 𝛼̇ 2 +
𝑐𝑜𝑠 2 𝛼 𝑐𝑜𝑠 2 𝛼
𝑅∙𝑠𝑖𝑛𝜗+𝑎∙𝑠𝑖𝑛𝛼−𝑒
(6)
( ) ∙ 𝛼̈ + 𝜏̈ (𝜗)
𝑐𝑜𝑠 2 𝛼

In order to change the law of motion of the pistons the surface of the swash plate has been modified only in the
whole span of delivery. A periodic sinusoidal profile, 𝜏(𝜗), has been modelled in the high-pressure zone of the
swash plate with the aim of locally changing the instantaneous position of the pistons to reduce the peaks of the
delivery flow and consequently attenuate the pressure ripple. In detail, the number of period introduced on the swash
plate surface are equal to the number of pistons connected to the delivery at the same time.
The geometrical design of the profile is the result of a compromise that can guarantee good performance in many
working conditions, since this is a passive technique of pressure ripple reduction. The depth of the profile and its
angular position respect a piston internal dead point, on the plate surface are the parameters that have been set.
In order to permit a possible future realization of the solution proposed in this paper, appreciable results have
been sought by adopting the smallest possible depth of the profile; from the simulations performed emerge the
feasibility of achieving satisfactory results even with depth of about 0.1 mm.
About the angular position of the profile respect a piston internal dead point on the plate surface, the best
configuration has been obtained by means of several simulations.

020038-4
The frequency at which this solution intervenes in the reduction of the pressure ripple is automatically given by
the rotational speed of the shaft and does not represent a limit in applying this solution.
The hydrodynamic coupling between the slippery and the swash plate have not been investigated in this work,
this aspect should be analyzed in a future work.

EXPERIMENTAL ACTIVITY

Experimental tests on a standard variable displacement axial piston pump (Casappa® MVP60-84 with maximum
displacement equal to 84.7 cm3/rev) have been carried out to validate the fluid dynamic mathematical model, at this
stage of the research without the introduction of any profile on the swash plate surface. The pump has been installed
in a load sensing circuit on the test bench present in the Laboratory of the Engineering and Architectural Department
at the University of Parma, the following data have been acquired thanks to the mounted sensors: delivery pressure;
suction fluid temperature; torque absorbed by the shaft; swash plate angular position; delivery flow rate; drain flow
rate and shaft speed. The experimental layout is shown in Fig. 3 and the transducers features are reported in Table 1.

TABLE 1. Transducers features.


Variable Sensor Main Features
Ts Thermistor Pt100 0 – 100 °C ±0.2 °C
ps Pressure Transducer 0 – 10 bar ±0.3%FS
pd, pLS Pressure Transducer 0 – 400 bar ±0.5%FS
̇ 0.1-150 l/min ± 0.3%
𝑉𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑦 Flow Meter
measured value
0.01-80 l/min ± 0.3%
̇
𝑉𝑑𝑟𝑎𝑖𝑛 Flow Meter
measured value
α Angular sensor 0° – 360° ± 0.02°
n Speed sensor accuracy class 0.05
FIGURE 3. Scheme of the experimental layout.

FLUID DYNAMIC MODEL VALIDATION

The fluid dynamic model has been validated by comparison with experimental data. Results concerning a single
shaft revolution are presented dimensionless for confidential reasons in Fig. 4.a and in Fig. 4.b. The model presents
a satisfactory agreement between predicted results and experiments data, also considering the target of the model
that will not be used for a detailed design/optimization of the internal ports of the pump.

(a) (b)
FIGURE 4. (a) Delivery pressure at 1500 r/min, swash plate position 12.7°; (b) Delivery pressure at 2000 r/min, swash plate
position 12.8°. The mean pressure of case (b) is higher than the one of case (a).

020038-5
RESULTS

Several simulations have been performed with the variation of the main operating parameters on the fluid
dynamic model previously described which presents on the swash plate surface a sinusoidal profile.
The simulation results are presented in the following figures where the pressure and the amplitude of the Fast
Fourier Transform (FFT) have been divided by a reference value for confidential reasons.
In Fig. 5 the results relating to the pressure ripple are shown for two different values of rotation speed of the
shaft, while the delivery average pressure is the same. It is possible to notice how the introduction of the described
pressure ripple control solution allows to obtain marked improvement, permitting to significantly reduce the
amplitude of the oscillations.
The Fig. 5 confirms the advantage in this solution of not depending on the rotation speed since the frequency of
intervention is regulated automatically by the rotational speed. From the examination of the signal in the frequency
domain, Fig. 6, it is evident that only the first harmonic is affected by this control, it represents the first component
given by the equation:
𝑁∙9
𝑓= (7)
60
Where N is the rotational speed of the shaft and the number of pistons is 9.

(a) (b)
FIGURE 5. (a) Delivery pressure at 1000 r/min; (b) Delivery pressure at 2000 r/min. Mean pressure value is the same in both
case.

(a) (b)
FIGURE 6. (a) Delivery pressure FFT at 1000 r/min; (b) Delivery pressure FFT at 2000 r/min. Mean pressure value is the same
in both case.

020038-6
As the average pressure increases, the construction parameters of the swash plate surface do not guarantee such
good performance as reported in the previous cases. Figure 7.a shows the pressure ripple in the case in which the
delivery mean pressure is higher than in the cases of Fig. 5 and Fig. 6. There is still a positive effect, so the pressure
ripple has been reduced, but the effectiveness decreases, as confirmed also by the analysis of the FFT, Fig. 7.b.

(a) (b)
FIGURE 7. (a) Delivery pressure at 1000 r/min; (b) Delivery pressure FFT at 1000 r/min. The mean pressure of this case is
higher than the case of Fig.5.

In order to improve the performance also when the delivery pressure increases suitable adjustments to the profile
on the swash plate surface have been realized. The change made to the plate surface has exclusively referred to the
depth of the profile leaving its angular position unchanged. In Fig. 8 is shown the delivery pressure FFT at two
different rotational speeds, where the delivery mean pressure is equal to the case presented in Fig. 7. By means of
this change, the depth of the profile has been slightly increased, the results obtained are comparable with the one
presented in Fig. 5.

(a) (b)
FIGURE 8. (a) Delivery pressure FFT at 1000 r/min; (b) Delivery pressure FFT at 2000 r/min. Mean pressure value is the same
in both case and higher than the average pressure in Fig. 5

020038-7
CONCLUSIONS

In this paper the potential of a passive control of the pressure ripple in axial piston pumps through the
introduction of a sinusoidal profile on the swash plate surface has been studied theoretically. The mathematical
model concerning the fluid dynamic aspect of a piston pump has been developed, describing accurately the piston
kinematics. The model of a standard pump has been validated, in terms of delivery pressure ripple with experimental
data provided by experimental activity performed on a test bench.
The model permits to modify the law of piston motion due to the introduction of a profile on the swash plate
with properly amplitude and phase. Several simulations have been performed to verify the effectiveness of the
solution proposed and the results analysis have shown a significant reduction of the pressure ripple. If the working
conditions changes it is still possible to identify a profile configuration able to achieve good performance.
The solution proposed has the considerable advantage of suiting itself on the rotational speed of the pump,
conversely, this solution should be designed considering the average operating delivery pressure in order to achieve
the best effects in terms of pressure ripple reduction.

ACKNOWLEDGMENTS

The authors would like to acknowledge Casappa S.p.A. (Parma, Italy) for the active support to this research.

NOMENCLATURE

a Piston offset [m] TG Temperature [K]

α Swash plate angle [rad] θ Block cylinders angular position [rad]

B Bulk modulus [Pa] v Volume for the unit of mass [m3/kg]

c Velocity [m/s] V Volume [m3]

e Eccentricity [m] Vc Cylinder volume [m3]

𝑚̇ Mass flow rate [kg/s] 𝑉̇ Volume flow rate [m3/s]

N Shaft speed [r/min] y Gas to liquid mass fraction

Ω Cross sectional area [m2] 𝑧̇𝑖 Piston velocity [m/s]

p Pressure [Pa] Abbreviation


ρ Density [kg/m3] F&E Filling and emptying

R Piston-pitch radius [m] Subscript

RG Specific gas constant [J/(kg·K)] 0 Reference value

t Time [s]

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