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Procedia Engineering 00 (2017)000–000
Procedia Engineering 00 (2017)000–000 www.elsevier.com/locate/procedia
ScienceDirect www.elsevier.com/locate/procedia
Procedia Engineering 206 (2017) 1684–1689

International Conference on Industrial Engineering, ICIE 2017

International Conference on Industrial Engineering, ICIE 2017
Influence of Engine Load on Concrete Pump Operating Parameters
Influence of Engine Load on Concrete Pump Operating Parameters
Ye. Koshkarev*
Ye. Koshkarev*
Moscow State University of Civil Engineering (National Research University), 26, Yaroslavl highway, Moscow 129337, Russia
Moscow State University of Civil Engineering (National Research University), 26, Yaroslavl highway, Moscow 129337, Russia

Abstract
Abstract
The article deals with the energy balance of a stationary two-piston concrete pump equipped with a hydraulic actuator and S-
shaped
The bypass
article valve,
deals withanalyzes thebalance
the energy power balance and determines
of a stationary two-pistonpower consumption
concrete rates to ensure
pump equipped with a operation
hydraulic of a pump
actuator unit,
and S-
screw rotary mixer, bypass valve and water pump. As an example we consider the operation of a serial concrete
shaped bypass valve, analyzes the power balance and determines power consumption rates to ensure operation of a pump unit, pump with two
options of liquid
screw rotary feed
mixer, to thevalve
bypass hydraulic ramspump.
and water duringAsoperation:
an example in piston above the
we consider andoperation
under space,
of a with
serialdetermining difference
concrete pump with twoin
the use of
options of the machine.
liquid feed to the hydraulic rams during operation: in piston above and under space, with determining difference in
To establish
the use of the the rational parameters of the machine use we introduce the engine load factor with concrete pump output
machine.
parameters such as performance
To establish the rational and pressure
parameters of the machine use we introduce the engine load factor with concrete pump output
© 2017 Thesuch
parameters Authors.
as Published by
performance and Elsevier
pressureB.V.
© 2017 The Authors.
Peer-review Published by
under responsibility ofElsevier Ltd. committee of the International Conference on Industrial Engineering.
the scientific
© 2017 The
Peer-review Authors. Published
under responsibility by Elsevier B.V.committee of the International Conference on Industrial Engineering
Keywords:
Peer-reviewtwo-piston concrete pump;of
under responsibility
the power;
offluid
scientific
valve
the scientific (gate); loadoffactor;
committee paddle screw Conference
the International mixer; feed bin;
on hydraulic
Industrialram; concrete ram.
Engineering.
Keywords: two-piston concrete pump; fluid power; valve (gate); load factor; paddle screw mixer; feed bin; hydraulic ram; concrete ram.

The output operational parameters of the concrete pump are performance and pressure, which, in turn,
determine its power.
The output operational parameters of the concrete pump are performance and pressure, which, in turn,
The engine
determine power must satisfy all energy needs of the machine. In modern two-piston stationary concrete pump
its power.
equipped with apower
The engine hydraulic
mustactuator,
satisfy allenergy
energyisneeds
consumed
of theduring operation
machine. by: two-piston stationary concrete pump
In modern
1. hydraulic
equipped with a rams arranged
hydraulic in series
actuator, withisthose
energy of concrete
consumed duringpump, which
operation by:ensure alternate pumping of a mixture;
2. hydraulic rams of
1. valve (gate)
arranged actuator,
in series connecting
with those a corresponding
of concrete pump, which ram to thealternate
ensure concretepumping
pipe during
of a pumping
mixture;
2. cycle;
hydraulic rams of valve (gate) actuator, connecting a corresponding ram to the concrete pipe during pumping
3. hydraulic
cycle; motor actuating the screw mixer rotor housed in the receiving bin;
4. hydraulic
3. water pump hydraulic
motor motor
actuating thedesigned to flush
screw mixer rotorthe bin and
housed in concrete pipe bin;
the receiving after the work.
4. water pump hydraulic motor designed to flush the bin and concrete pipe after the work.

* Corresponding author. Tel.: +7-905-756-9225;

E-mail address:author.
* Corresponding KoshkarevEV@mgsu.ru
Tel.: +7-905-756-9225;
E-mail address: KoshkarevEV@mgsu.ru

1877-7058 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the International Conference on Industrial Engineering .
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.698
 Ye. Koshkarev / Procedia Engineering 206 (2017) 1684–1689 1685
2 Ye. Koshkarev / Procedia Engineering 00 (2017) 000–000

Only first three mechanisms are simultaneously operating while the concrete mixture is being pumped [1,2].
Let’s define the power of the said mechanisms during pumping.
Fluid power of the mixture flow at the output of the concrete ram is determined as follows [3,4]:

P
b Qb  pb , kW , (1)

where: Qb - theoretical performance (flow rate) of the concrete mixture, m3/s;

pb - pressure of the concrete mixture flow, kPa.
Theoretical performance of the two-piston concrete pump [5]:

  Dcc2
n m3
Qb  s 0, 013  Dcc2  s  n, , (2)
4 60 c

where: Dcc - diameter of the working ram, m;

S– piston stroke, m;
n– number of double strokes of the piston per minute.
Thus, the power required to pump the concrete mixture can be expressed in terms of structural and kinematic
parameters of the concrete pump when substituting the expression (2) to the equation (1):

Pb  0, 013  Dcc2  s  n  pb , кW (3)

There are two options to feed the actuating hydraulic ram with liquid during operation of the concrete pump unit
[6,7]:
1. on the piston side – high force and pressure, which is preferable for operation at high altitudes;
2. on the stem side – high velocity and, thus, performance, which is more appropriate for small altitudes.
The options are changed in the concrete pump remotely.
The power required for operation of the concrete pump unit connected to the engine flywheel is [3]:

Pb
Pbm  , kW (4)
v mech

where: ηv-volume efficiency of the hydraulic actuator;

ηmech -mechanical efficiency, taking into account losses due to friction in the hydraulic rams.
The power required to actuate the valve (gate) depends on the design of the device.
The mechanical energy required to rotate the S-valve used in the vast majority (85%) of concrete pumps is
determined by the condition that the gate rotated in the concrete mixture is affected by frontal and vortex resistance
forces as well as by friction forces [8,9]. The product of frontal pressure by the gate area determines the force of
the frontal resistance, the largest one of all those in the vortex motion of the valve in the “pseudo-fluid” – concrete
mixture.
The friction resistance is taken into account through introduction of the hydraulic resistance factor ψ.
The valve moving in the concrete mixture is affected by the force of resistance:

2
R     F  ,N (5)
2

where: F – maximum area of the valve projection perpendicular to the velocity vector, m2;
ρ – density of the “pseudo-liquid”, kg/m3;
v – linear velocity of the valve movement, m/s;
1686 Ye. Koshkarev / Procedia Engineering 206 (2017) 1684–1689
Ye. Koshkarev / Procedia Engineering 00 (2017) 000–000 3

ψ – hydraulic resistance factor determined experimentally, depending on the shape of the gate, the state of its
surface, the properties of the concrete mixture and Reynolds number.
Studies by K.M. Korolev [8] found that the factor ψ depends on water/cement ratio (W/C), type of filler, cone
slump and motion velocity.
Finally K.M. Korolev proposed and experimentally verified a simpler formula to determine the force of frontal
pressure:

R k  F , kN (6)

where: k – resistance factor, that depends on velocity, value k for the concrete mixture are in the range of (20-75)
kPa.
To determine the power consumed for valve rotation, we use the following formula [10]:

Pv  M  rot , kW (7)

where: M – the torque required to rotate the valve from the 1st concrete ram to the 2nd one and vice-versa, kNm;
ωrot - angular velocity of valve rotation relative to its axis in the bin with concrete mixture, s-1.

 rot 1
rot  , (8)
trot с

where: αrot - rotation angle of the S-valve, radian;

trot- valve rotation time [9],
Valve torque is determined using the following expression [10]:

М  R  e, kNm (9)

e is coordinate of the point of application of resistance to valve rotation, we conditionally take its greatest value
equal to the valve eccentricity, m.
The power of the actuator of the horizontal shaft-equipped screw rotary mixer installed in the concrete mixture
receiving bin is determined using the following expression [8]:

k  b    ( ro2  ri 2 )  z  
Pcm  , kW (10)
2000

where: k – resistance factor, that depends on velocity, value k for the concrete mixture are in the range of (20-
75) kPa;
b – blade width plane projection perpendicular to the direction of rotation, m;
ω – angular velocity of the blades, s-1;
‫ݎ‬௢ – radius of the blade outer edge, m;
‫ݎ‬௜ – radius of the blade inner edge, m;
z – number of blades, pcs.;
φ – factor taking into account the degree of blade immersion in the concrete mixture, in case of a two-piston
concrete pump, φ = 1.
The power consumed to actuate the water pump:

Pw  pw  Qw , kW (11)
 Ye. Koshkarev / Procedia Engineering 206 (2017) 1684–1689 1687
4 Ye. Koshkarev / Procedia Engineering 00 (2017) 000–000

where: pw – pressure developed by the water pump, kPa;

௠య
Qw – pump output flow, .
௖
Thus, the total power of the diesel engine flywheel during concrete mixture pumping and full use of the engine
power is as follows [12]:

Pdm  Pbm  Pvm  Pcm , kW (12)

The engine power used only to pump the concrete mixture:

Pbm  Pdm  Pvm  Pcm , kW (13)

Let’s consider the modes of concrete mixture pumping when the engine power is not used to the full extent, to
do this we use the engine load factor.
The concrete pump diesel engine load factor [13]:

P
kP  (14)
Pdm

where:P∑– power required based on calculation, kW;

Pdm– power of the installed engine, kW.
To study the influence of the engine load on the output parameters of the concrete pump Schwing-Strtter
SP2800D we checked the power balance under the maximum performance and pressure parameters at various
engine loads [14].
1. The power required to rotate the valve. Accepted designations and parameters: k = 75kPa;


F 0,1
  m 2 ; e 0, 2  m;  rot rad ; trot 0.5 c;rot 2.1 c 1 .
3

Pv 75
  0,1  0, 2  2,1 3,15 kW

The power supplied to the engine shaft, taking into account mechanical and hydraulic losses to rotate the valve
(gate) is:

3.15
Pvm
  3.5 kW
0.9

2. The power required to actuate the screw rotary mixer. Accepted designations and parameters: b =0.4m: k =
75kPa; b = 0.4m; ω = 40с-1; ‫ݎ‬௘ = 0.4m; ‫ݎ‬௜ = 0.3m; z = 4; φ = 1.

75  0.4  40  (0.32  0.22 )  4 1

Pcm   2, 25 kW
2000

The power supplied to the engine shaft, taking into account mechanical and hydraulic losses for the bin mixer
is:

2.25
P
cmm  2.5 kW
0.9
1688 Ye. Koshkarev / Procedia Engineering 206 (2017) 1684–1689
Ye. Koshkarev / Procedia Engineering 00 (2017) 000–000 5

3. The power required to actuate the water pump. Accepted designations and parameter

1 m3
 Qw 75  1, 25 103
pw 2000 kPa;  .
mn c

Pw  2000 1, 25 103  2, 25 kW

The power required to actuate the water pump and supplied to the engine shaft is not taken into account in
calculation, since the engine is not operated during concrete mixture pumping.
The engine stated power is 136kW. The engine power used only to pump the concrete mixture under engine full
load:

Pbm  136  3,5  2,5  130 kW

The power required to actuate the concrete pump unit is:

Pb 130  0,9  117 kW

where: 0.9 – total efficiency of the pump unit actuator.

Using power value and concrete pump manufacturer’s stated maximum pressure and performance values we
constructed the graphs of variances of these parameters [16], [17] for the two cases of use, i.e. when supplying
fluid: 1. on the piston side (Fig. 1) and 2. on the stem side (Fig 2) at the engine load factors of 1; 0.9 and 0.8.

Fig. 1. Fluid pressure from the piston;

Fig. 2. Fluid pressure from the rod;

 Ye. Koshkarev / Procedia Engineering 206 (2017) 1684–1689 1689
6 Ye. Koshkarev / Procedia Engineering 00 (2017) 000–000

Analysis of the parameters variances curves shows that the engine load significantly affects the concrete pump
parameters, limiting its application. The output parameters found through these curves allow to rationally use the
machine in the processes where maximum pressure and performance is not required [18].

References

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