Design and Modeling of Fluid Power Systems: ME 597/ABE 591 - Lecture 6

Design and Modeling of Fluid Power Systems
ME 597/ABE 591 - Lecture 6
Dr. Monika Ivantysynova

MAHA Professor Fluid Power Systems
MAHA Fluid Power Research Center

Purdue University
Content
Steady state characteristics, measurement and modeling
Volumetric and torque efficiency
Measurement of steady state characteristics
Determination of derived displacement volume
Measurement based steady state models
Aim: Application of basic equations for calculation of performance

data of pumps
Performance test circuit design
Basic knowledge about the generation of steady state models
Design and Modeling of Fluid Power

© Dr. Monika Ivantysynova 2
Systems, ME 597/ABE 591
Losses - displacement machines
Axial piston machine – swash plate design
A B
Volumetric Losses
C
D
B C F G I
Torque Losses
A B C D E
G H J
E F G H I J

Pump Efficiency
Volumetric efficiency: p2, Qe
where Vi …. represents the derived displacement volume

Te , n
p1
Torque efficiency
(hydraulic-mechanical efficiency):
Total efficiency:
The derived displacement volume can only be

determined by measurement
Volumetric Efficiency of a Pump
Volumetric efficiency
Qe = α ⋅ Vmax ⋅ n - Qs
v
Vi ⋅ nmin = Qs
Dynamic viscosity of fluid: [Pa·s]

7 Systems, ME 597/ABE 591
Volumetric Efficiency of a Pump
Volumetric efficiency
Qe = α ⋅ Vmax ⋅ n - Qs Variable displacement pump
Typical values of dynamic viscosity

used in displacement machines: 0.0435 Pa ⋅ s ÷ 0.0087 Pa ⋅ s
with: Kinematic viscosity [cSt, mm2/s] and μ=ν⋅ρ

ν = 10mm2 ⋅s-1 ÷ 50 mm2 ⋅s-1 with ρ = 870kg ⋅ m-3
Torque Efficiency of a Pump
Ts = TSμ + TSρ + TSp + TSc = Cμ ⋅ μ ⋅ n + Cρ ⋅ ρ ⋅ n2 + Cp ⋅ Δp +TSc

Total Efficiency of a Pump

Steady State Characteristics
v = 20cSt

Example Lecture 2
The displacement pump with a displacement volume of V=100 cm3/rev is

driven by an electric motor at 1800 rpm. At steady state conditions the
pressure difference across the pump is Δp= 380 bar. Determine the
effective flow rate at the pump outlet Qe and the power required to drive
this pump. Assume the following values for efficiency: p2 Qe
- volumetric efficiency ηv=0.87
n
- torque efficiency ηhm=0.95
The effective volume flow rate:
p1
The effective torque yields:
The power required to drive the pump:

Steady State Measurement
The aim of steady state measurements is
determination of steady state characteristics p2, Qe
of pumps.
Losses and their dependency on operating QSi

Te , n
parameters
QSe
Efficiency and its dependency on operating p1
parameters
Effective torque Te and effective volumetric Under stable conditions, all

Flow rate Qe in the whole parameter range parameters remain constant,
including temperatures !
Parameters to be measured: Inlet pressure p1 Outlet pressure p2
Torque Te Shaft speed n

Temperatures θ1, θ2 θSe
, Volume flow rate at pump outlet Qe=Q2
Vi derived displacement volume to be determined during measurements

QS must be calculated using
Qe = α ⋅ Vmax ⋅ n - Qs
measurement results
Measured value
TS must be calculated using

measurement results
Pin = Pout + PS = Δp ⋅ Qe + Ps = Te ⋅ 2 ⋅ π ⋅ n
PS must be calculated using
measurement results
Derived displacement volume
Vi Measurement of effective volume flow rate at pump outlet
under defined conditions
Δ
Δ
Qe
Qe
Δ
Vi=Qe/n
measured values
0 Δ 0
Vi required for determination of losses and volumetric and torque efficiency

Test Circuit
Measured Values: Inlet pressure p1 Torque T Shaft speed n
Outlet pressure p2 Temperature θ1, θ2 θSe
ISO 4409 Volume flow rate at pump outlet Q2
Temperature θ1 must remain constant during measurements
Pressure relief valve

θ1 θ2
θSe
T, n
Additional measured
values: EM
Flow meter
Case flow rate QSe
Pressure case line pSe
In case that Q2 is measured in low pressure line, the measured θ3
Q3 3
value must be corrected with respect to p2 and θ2
θ1 θ2
with
K … bulk modulus
ßθ …thermal volumetric
expansion coefficient
θSe
T
K=2·109 Pa
ßθ=0.65·10-3 K-1

Measurement in pumping and motoring mode
QA
θA
θL
θB
QA θA pA θB pB QB θL pL QL T n
Less temperature problems, because only a small amount

of volume flow is throttled in pressure relief valve
ISO measurement accuracy classes

Table 1: Permissible systematic errors of measuring instruments as determined during calibration
Permissible systematic
errors for classes of
Parameter of measuring instrument measurement accuracy
A B C
Rotational frequency [%] ± 0.5 ± 1.0 ± 2.0

Torque [%] ± 0.5 ± 1.0 ± 2.0
Volume flow rate [%] ± 0.5 ± 1.5 ± 2.5
Pressure below 2 bar gauge [bar] ± 0.01 ± 0.03 ± 0.05
Pressure greater than or equal to 2 bar gauge
± 0.5 ± 1.5 ± 2.5
[%]
Temperature [°C] ± 0.5 ± 1.0 ± 2.0
Permissible temperature variation

Accuracy class A B C
Temperature variation [K] ±1.0 ±2.0 ±4.0
Pressure Measurement
The different types of pressure differ only
Types of pressure
with respect to their reference point.
Absolute pressure pabs

pamb=p0
Fluctuation of pamb ~ ±5%
Atmospheric pressure pamb p2
p1
Δp
p [Pa]
Differential pressure Δp
pabs 1
pg
pamb
Gauge pressure pg
0
pg=pmeasured-pamb
t [s]
Direct measuring pressure instruments Using a liquid column
Indirect measuring pressure instruments Using the effect of a pressure

acting on a material or on bodies
Electrical pressure sensors of a certain shape
Electrical Pressure Sensors

Flow Measurement
Flow measuring instrument is defined as device which measures

the flow rate of a fluid. Displacement of a spring loaded
Pressure difference across an orifice floated element
D<<d0
p1 p2
αD…flow discharge coefficient

Should not be used for determination of steady state characteristics!
Flow Measurement
Flow meter – device which directly indicates the rate of flow of a fluid
Displacement principle Hydrodynamic principle
Using kinetic energy of a fluid to drive
Gear flow meter a rotating system of blades (an impeller),
whereas the rotational speed of the rotor
is measured with an electric speed sensor
(frequency measurement device)
Turbine
Screw flow meter

Test Procedure
1. Keep p1 and θ1 constant
p2, Qe θ2
2. Adjust different pressure levels at constant shaft speed
3. Record all measured values under steady state conditions Te , n
Repeat measurements for different speed settings p1 θ1
In case of variable displacement pump repeat measurements for

75%, 50% and 25% of Vmax
Repeat measurements for different temperatures θ1
Provide table with measurement results
No. n T p1 θ1 p2 Q2 θ2 pSe QSe θSe
[l/ [bar [l/
[RPM] [Nm] [bar] [°C] [bar] min] [°C] ] min] [°C]
1 2001.46 15.03 19.77 50.50 25.11 145.13 61.20 1.20 0.21 65.30
2 2001.63 68.78 19.79 50.30 69.65 144.02 60.30 1.25 0.43 66.00
3 2001.79 130.59 19.86 50.30 120.82 142.92 60.40 1.28 0.56 65.20
© Dr. Monika Ivantysynova
Measurement Results
Determination of derived displacement volume
k k k k
p2, Qe
∑ Q ⋅ ∑ Δp −∑ Δp ⋅∑ Δp
ej
2
j j j ⋅ Qej
1
Vi = ⋅ j=1 j=1 j=1 j=1
Te , n
n k ⎛ k ⎞2
k ⋅ ∑ Δp 2j − ⎜⎜ ∑ Δp j ⎟⎟ p1
j=1 ⎝ j=1 ⎠
k …number of measurements and
In case of variable displacement pumps,
Determination of Losses the derived displacement volume must
be determined for each adjusted value!
Qs = Vi ⋅ n − Qe ηt = ηv ⋅ ηhm
Vi ⋅ Δp Qe Δp ⋅ Vi
Ts = Te − ηv = ηhm =
2⋅ π n ⋅ Vi 2 ⋅ π ⋅ Te

Measurement Based Steady
State Model
Precise Model of the Machine

Steady State Models
What are the approaches?
Models are based on use of data found by steady state measurements.

The main difference of existing models is given by the type of mathematical
description.
Use of physical laws of known Pure mathematical approach for

physical processes to find a approximation of measured curves
basic mathematical expression
Who were the authors in the past?
QS = Cµ ⋅ Δp ⋅ QSc
Wilson, 1948 - introduction of TS and QS
TS = C f ⋅ Δp ⋅ Cµ ⋅ n ⋅ TSc
Schlösser, 1961 – extension of Wilson model
QSρ = CQρ ⋅ Δp
turbulent flow
Thoma, 1969 TSρ = CTρ ⋅ n 2
Steady State Models
Zarotti and Nervegna, 1981 Non-linear terms for both QS and TS

Increase of the number of terms
Rydberg, 1983 Introduction of new terms without

physical background
Dorey, 1988 Non-linear terms for both QS and TS,

using also variable coefficients
Bavendiek, 1987 Totally 22 loss terms for Qs and TS
Ivantysyn and Ivantysynova, 1993 First pure mathematical approach
Huhtala, 1997 – two line model
Ivantysynova, 1999 - Polymod

Steady State Model

Vi=100% Vi=100%
TS
Measured points

Scaling of steady state maps
ηt = ηv ⋅ ηhm Vi
Assume the same efficiency λ=3
Vi0
Consider change of maximum operating speed !!
−1
n = λ ⋅ n0
Qe = n ⋅ Vi ⋅ ηv Qs = Vi ⋅ n − Qe
Δp ⋅ Vi Vi ⋅ Δp
Te = TS = Te −
2 ⋅ π ⋅ ηhm 2⋅ π


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Design and Modeling of Fluid Power Systems

ME 597/ABE 591 - Lecture 6

Dr. Monika Ivantysynova

MAHA Fluid Power Research Center

Steady state characteristics, measurement and modeling

Volumetric and torque efficiency

Measurement of steady state characteristics

Determination of derived displacement volume

Measurement based steady state models

Aim: Application of basic equations for calculation of performance

Design and Modeling of Fluid Power

Axial piston machine – swash plate design

Design and Modeling of Fluid Power

Volumetric efficiency: p2, Qe

where Vi …. represents the derived displacement volume

The derived displacement volume can only be

Dynamic viscosity of fluid: [Pa·s]

Design and Modeling of Fluid Power

Qe = α ⋅ Vmax ⋅ n - Qs Variable displacement pump

Typical values of dynamic viscosity

with: Kinematic viscosity [cSt, mm2/s] and μ=ν⋅ρ

Ts = TSμ + TSρ + TSp + TSc = Cμ ⋅ μ ⋅ n + Cρ ⋅ ρ ⋅ n2 + Cp ⋅ Δp +TSc

Design and Modeling of Fluid Power

Design and Modeling of Fluid Power

Design and Modeling of Fluid Power

The displacement pump with a displacement volume of V=100 cm3/rev is

The effective torque yields:

The power required to drive the pump:

Design and Modeling of Fluid Power

Losses and their dependency on operating QSi

Effective torque Te and effective volumetric Under stable conditions, all

Parameters to be measured: Inlet pressure p1 Outlet pressure p2

Torque Te Shaft speed n

Vi derived displacement volume to be determined during measurements

TS must be calculated using

Vi required for determination of losses and volumetric and torque efficiency

Design and Modeling of Fluid Power

Pressure relief valve

Design and Modeling of Fluid Power

Less temperature problems, because only a small amount

ISO measurement accuracy classes

Rotational frequency [%] ± 0.5 ± 1.0 ± 2.0

Permissible temperature variation

Absolute pressure pabs

Direct measuring pressure instruments Using a liquid column

Indirect measuring pressure instruments Using the effect of a pressure

Design and Modeling of Fluid Power

Flow measuring instrument is defined as device which measures

αD…flow discharge coefficient

Design and Modeling of Fluid Power

Repeat measurements for different speed settings p1 θ1

In case of variable displacement pump repeat measurements for

Design and Modeling of Fluid Power

Precise Model of the Machine

Design and Modeling of Fluid Power

Models are based on use of data found by steady state measurements.

Use of physical laws of known Pure mathematical approach for

Zarotti and Nervegna, 1981 Non-linear terms for both QS and TS

Rydberg, 1983 Introduction of new terms without

Dorey, 1988 Non-linear terms for both QS and TS,

Bavendiek, 1987 Totally 22 loss terms for Qs and TS

Ivantysyn and Ivantysynova, 1993 First pure mathematical approach

Huhtala, 1997 – two line model