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System Approach in Noise Reduction in Fluid Power Units

Conference Paper · September 2018

DOI: 10.1115/FPMC2018-8855

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 Proceedings of the 2018 Bath/ASME Symposium on Fluid Power and Motion Control
FPMC2018
October 16-19, 2018, Bath

DRAFT FPMC2018-8855

SYSTEM APPROACH IN NOISE REDUCTION OF FLUID POWER UNITS

W. Fiebig, J. Wrobel
Department of Mechanical Engineering,
Wroclaw University of Science and Technology
Wroclaw
Poland

ABSTRACT made on the loudest noise source or sources [2-6]. Reduced

The paper presents a methodology developed to reduce the noise emission of hydraulic power units could significantly
noise emission in fluid power units. Investigations confirms impact the work comfort of production workers and machine
that during the operation of fluid power units there are many operators, especially in case of 24-hour noise exposure [8].
coupled causes of noise generation. In order to propose changes
aimed at reducing noise emission the location of sound sources, CAUSES FOR NOISE DEVELOPMENT IN FLUID
testing of dynamic properties of the mechanical structure of the POWER UNITS
aggregate and identification of resonant phenomena should be
carried out. The causes of noise emission in fluid power units are shown
in Figure 1. In most cases increased noise emission in hydraulic
INTRODUCTION units, is caused by propagation of vibration from the hydraulic
pump to other elements of the hydraulic system. Additionally,
Fluid power units (FPU) determine often the noise other phenomena such as pressure ripple, flow, control valves
development of many stationary industrial machines like and mechanical impacts may contribute to the increased
hydraulic presses, machine tools, plastics molding machines, emission of noise [6]. The noise caused by flow of the fluid is
etc. Similar situation is also in the field of mobile hydraulics. strongly enhanced in sections where the diameter of flow
Noise reduction in fluid power drives is increasingly important channels is small and due to the local increase of flow velocity
in view of their increasing power and stricter requirements the cavitation occurs.
concerning noise control of machines. Noise generated by
power units cannot be sufficiently decreased only with primary
approaches towards single components. There are guidelines
for the design of power units regarding noise reduction.
However, transferring empirical results from one type of FPU
to another is rarely successful.
Several investigations [1-7] have shown that noise emitted
by pumps depends on their mounting, i.e., the application and
the layout of the piping system. Practical experiences also show
that a pump considered as silent in an anechoic room can cause
high noise emission when built into a real system. These results
show that the noise behavior of a pump is strongly system
dependent. Similar phenomena can be observed in case of
hydraulic control valves [1, 6]. The complete sound power of a
hydraulic system is defined by the sum of the single sound
powers of each component. The total sound power level is
determined by the loudest source or sources of noise.
Therefore, detection of the loudest noise sources in a FPU is
most important. Successful noise reduction of hydraulic
systems can only be achieved, when the design changes will be Figure 1.Causes of noise emission in fluid power units

1 Copyright © 2018 by ASME

 The variable forces inside the pump mainly depend on
variations of pressure within the pump. They change
periodically with the change of the load at the displacement
elements. The variable forces cause vibrations and dynamic
loads on displacement elements, which are transmitted through
the gaps filled with fluid and through the bearings. The
excitation forces from flow ripple of the pump are important
especially at lower pressures and in the lower frequency range.
Additional variable forces caused by mechanical shocks should
be taken into consideration. Both causes of noise development
in a real system for structure- and fluid borne noise, cannot be
separated in most cases [2-7]. Investigations have shown that
the noise behavior of a FPU with a horizontal mounted pump-
motor group is quite different from a vertical FPU [5]. Noise
behavior of a FPU depends on the type of the pump, too.
a)
Figure 2. Noise transmission paths in horizontal FPU [4]
Noise transmission paths in horizontal and vertical fluid
FPUs are shown in Fig. 2. Structure borne noise is transmitted
from the pump to the electric motor along path 1. Transmission
occurs through damping flange and bell housing 1a as well as
through coupling 1b. From the motor housing structure borne
noise is transmitted to the fan cover (path 2) and to the top plate
of the tank (path 3). Some structure borne noise is transmitted
from the pump directly to the valve and the tank structure
through pipes and hoses (path 4). With the pipes and hoses the
fluid borne noise from the pump is transmitted to valve and to
the tank (path 5). Due to vibrations of the pump and the
attached suction pipe, fluid-borne noise is excited into the oil
volume in the tank (path 6). Depending on the acoustic
behavior of the fluid volume in the tank some pump vibrational
energy is transmitted to the tank structure. Airborne noise of the
FPU comes from the pump to the tank structure (path 7)with its
attached components. In case of vertical FPU (Fig. 2b) the fluid
borne noise is transmitted (path 5) from the pump directly to
the tank structure.
NOISE SOURCES LOCATION IN FLUID POWER
UNITS
In [4, 5] the localization of noise sources on hydraulic units
was carried out with use of sound intensity method. The use of
acoustic cameras for localization of noise sources in hydraulic
equipment is relatively new and the results have been compared
with the results of sound intensity method. The good
coincidence of results using acoustic camera with Beamforming
and Acoustic Holography algorithms and sound intensity
method has been stated. The major advantage of the acoustic
cameras over sound intensity measurements is the reduced time
of measurements.
An acoustic camera (Fig. 3) uses an array of microphones
coupled with a video camera, digital signal processing
hardware and computing algorithms [9-11]. The microphone
array pattern, number of acoustic transducers and the size of the
array define measurement parameters such as resolution,
frequency range and dynamic of the map [12,13]. The video
camera is positioned in the center of the microphone array.
Acoustic pressure registered by each microphone with digital
signal processing is compared and computing algorithms like
Beamforming and Acoustic Holography were used. As the
result of the measurement an acoustic photo or video with color
coded acoustic pressure distribution is created.
Figure 3. Acoustic camera
In Fig 4 the frequency spectra of the sound pressure signal from
a selected microphone has been shown.
Figure 4. FFT analysis of sound pressure signal.
2 Copyright © 2018 by ASME
 It is to see, that the higher amplitudes of sound pressure
level occur at the pump basic frequency and its harmonics. The
sound distribution on the surface, which is defined by definition
of the distance between microphone array and noise source, can
be shown for the selected frequency or frequency range. In this
way, the noise from different sources can be identified. Also,
video films for define time frame can be recorded in which the
change of sound pressure of main noise sources at variable
operational conditions of the FPU can be shown. In Fig.5 and
Fig. 6 the noise sources for different frequency ranges have
been shown. The measurements with the acoustic camera have
been carried out in a semi anechoic chamber.
Figure 5. Acoustic camera results for horizontal FPU: a) Range:
630-675 Hz, max level: 62 dB(A), b) Range: 940-990 Hz, max
level: 63,8 dB(A)
In the horizontal FPU in lower frequency range 630-675 Hz
the noise radiation from the tank has been identified. In the
range 940-990 Hz the fan cover of the electric motor is
radiating the noise and in the range1575-1675 Hz bell housing
and the delivery side of the pump are responsible for the noise
emission.
Figure 6. Acoustic camera results for vertical FPU: a) Range:
620-660 Hz, max level: 62,3 dB(A), b) Range: 920-990 Hz,
max level: 61,5 dB(A)
At the vertical FPU, the noise from the tank front wall
occurs in the frequency range 620-660 Hz. In the range 920-
990 Hz the electric motor is a main noise source and in the
higher frequency range 1900-2000 Hz the fan cover is
responsible for the noise radiation.
RESULTS OF EXPERIMENTAL MODAL ANALYSIS
(EMA)
For further identification of noise sources and the dynamic
behavior of the FPU Experimental Modal Analysis (EMA) has
been carried out. The measurement setup has been shown in
Fig. 7. Vibrations have been excited with an electrodynamic
shaker connected via a stinger [13] to the gear pump housing.
Excitation signal was measured with a piezoelectric force
sensor at the excitation point. A total of 340 measurement
points have been chosen for the horizontal FPU, and 240 points
for the vertical FPU. Points located at the hydraulic tank were
the same for both units, the rest of them was evenly spaced
across other components. Acceleration signals were measured
at each point witch use of a triaxial piezoelectric accelerometer.
3 Copyright © 2018 by ASME
 in both cases of hydraulic units. Additional points were located
at the hydraulic pump, foot bracket and electric motor.

The rpm value was changed from 435 – 1450 rpm in 70

increments. Load on the pump was set to 15 MPa with use of a
pressure relief valve, throughout the rpm range. Acceleration
spectrum signals were measured for each rotational velocity
increment and plotted on a waterfall diagram.

a))

Figure 7. Measurement setup for Experimental Modal Analysis

(EMA)
In Table 1 natural frequencies horizontal and vertical fluid Z
X
power units have been shown.
Y

Natural Frequencies [Hz]

b)
Mode Horizontal Vertical
No. FPU FPU
1 6,8 14,4
2 10,5 23,27
3 18,2 39,2
4 26,3 62,4
5 42,6 97,7
6 56,1 100,0
7 69,4 120,1
8 71,2 172,1
9 90,4 186,6
10 106,3 199,9
11 162,6 211,6
12 191,3 289,4
13 195,7 303,8 Figure 8.Measurement points a) horizontal FPU b) vertical
14 205,2 402,0 FPU.
15 233,1 523,0
16 260,4 544,4 In Fig. 9 the waterfall diagram for the measurement point
17 292,8 610,9 P6 on the pump (Fig. 8a) and P7 on the electric motor (Fig. 8b)
18 395,7 626,3 have been shown. In Fig. 9a for the measurement point P6 on
19 492,2 661,8 the pump the variable excitation frequency during the
20 543,6 791,2 increasing of rpm can be noticed as well as the natural
21 746,6 835,0
frequencies at 940 Hz and 3 kHz. For the measurement point
P7 on the motor resonance frequencies around 640 Hz, 1,57
Table 1. Natural frequencies of investigated FPUs. kHz, 1,9 kHz and 3 kHz have been identified.
From Fig. 9c can be stated that the vibration amplitudes of
Additional investigations of versions were conducted during the tank wall (P1) in case of vertical FPU occur at 630 Hz, 930
normal operation of both hydraulic units. A variable frequency Hz, 1,57 kHz but also in higher frequency range 2,8 to 3,8 kHz.
drive was used to control the rotational velocity of the electric For horizontal FPU higher vibrations amplitudes occur mainly
motor and therefore the rotational velocity of the pump. Mode in lower frequency range up to 900 Hz.
shapes obtained in EMA were used to identify points at the
HPU that strongly participate in vibrations. Five points were
located at the hydraulic reservoir and one point at the fan cover,

4 Copyright © 2018 by ASME

 a) b)
a)

b)

Figure 10. FEM models a) horizontal FPU, b) vertical FPU.

Contact was defined at the interface of oil and tank surface.
Contact side was set at the oil volume and target at the tank
side. Farther contact parameters were chosen: contact
formulation – MPC, Detection method – Nodal-projected
c) Normal From Contact. Material parameters of oil such as
density speed of sound in oil were implemented with
Mechanical APDL commands. A Fluid Structure Interface (FSI)
was defined between the oil and structure of the tank. Top side
of oil volume was defined as a free surface.

The FEM models consist of 67946 elements in case of the

horizontal FPU and 69399 elements for the vertical FPU. The
average mesh quality for the first model was equal to 0,865 and
0,859 for the second one.
Figure 9. Waterfall spectrum at measurement points along X
axis: a) P6- pump- horizontal FPU b) P7- motor- vertical FPU, COMPARISON OF RESULTS
c) P1- tank wall- vertical FPU.
The comparison the results of FE- Simulation and
SIMULATION Experimental Modal Analysis has been shown in Fig. 11 - 14.
For each natural frequency two extreme deflection shapes of
The FEM modal analysis has been performed for both
fluid power units have been shown.
horizontal and vertical FPUs shown in Fig. 8. FEM models The good coincidence between the calculated and measured
(Fig. 10) were similar for both types the FPUs. The tank
natural frequencies and mode shapes has been established. The
assembly and the hydraulic pump – electric motor assembly
best way to achieve the significant reduction of vibration
were similar for both FEM models. Main differences were in amplitudes and noise is to decouple the natural frequencies of
the positioning of the hydraulic pump – electric motor structure
the mechanical structure of fluid FPU with the excitation
on tank and support elements. The geometry models of both PU
frequencies, which are equal to the basic pump frequency and
were simplified. harmonics. Based on the methodology (Fig. 15) the structure
modifications for vibration and noise reduction have been
SHELL181 elements were used to model the structure of obtained, which have been verified on many design of fluid
the tank for both types of FPUs. Other components of the FPU FPUs [4].
such as gear pump, bell housing, foot bracket, coupling electric
motor were defined with SOLID 187 and SOLID186 elements.
The top plate of the hydraulic tank was attached to the flange of
the tank with use of bolts and frictional contact at the interface
of both bodies. The side and top covers were attached to the
reservoir in the same manor.

5 Copyright © 2018 by ASME

 a) a)

b) b)

Figure 11. Mode shapes of horizontal FPU a) FEM at 486,9 Figure 12. Mode shapes of horizontal FPU a) FEM at 992,1 Hz,
Hz, b) EMA at 485,3 Hz b) EMA at 960,5 Hz

6 Copyright © 2018 by ASME

 a)
a)

b)
b)

Figure 13. Mode shapes of vertical FPU a) FEM at 16,4 Hz, b) Figure 14. Mode shapes of vertical FPU a) FEM at 419,1 Hz, b)
EMA at 14,2 Hz EMA at 423,5 Hz

7 Copyright © 2018 by ASME

METHODOLOGY FOR NOISE REDUCTION IN FLUID
POWER UNITS
Decoupling of the dominant excitation frequencies from the
resonant frequencies plays a major role when reducing noise in
the power units. Thanks to the sensitivity analysis it is possible
to determine which parameters of FPU affect the individual
natural frequencies. In this way construction changes are
determined, which lead to the reduction of vibrations and noise.
The methodology for noise reduction in fluid power units has
been shown in Fig. 15.
Figure 15. Methodology for noise reduction in FPU
CONCLUSIONS
This paper discusses noise generation mechanisms and
methodology for noise reduction of FPUs with horizontal and
vertical mounted pump motor group. Major noise sources in
fluid FPUs has been identified. The pumps are identified as a
source of structure and fluid borne noise which are transmitted
to the mechanical system of FPUs. Components of FPUs with
larger sound radiating surfaces such as the electric motor and
the oil reservoir produce often a major part of global noise
radiation.
The system approach is necessary to establish the methods
for noise reduction in FPU. Significant noise reduction in FPUs
can be achieved when the compliance of excitation frequencies
and natural frequencies of the mechanical structure will be
avoided. Avoiding of resonance phenomena for both fluid and
structure borne vibrations has a great potential for noise
reduction in fluid power units. Knowledge of dynamic
properties of fluid power units is especially important in the
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context of variable speed drives in which the frequency of
excitations is constantly changing.
The methodology described in this paper has been used in
many applications and its use lead to significant noise reduction
of fluid power units.
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