processes
Article
Study on the Influence of Flow Distribution Structure of Piston
Pump on the Output of Pulsation Pump
Ruichuan Li, Jilu Liu *, Xinkai Ding and Qi Liu
Citation: Li, R.; Liu, J.; Ding, X.; Liu,
Q. Study on the Influence of Flow
Distribution Structure of Piston
Pump on the Output of Pulsation
Pump. Processes 2022, 10, 1077.
https://doi.org/10.3390/pr10061077
Academic Editor: Blaž Likozar
Received: 18 May 2022
Accepted: 25 May 2022
Published: 27 May 2022
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Processes 2022, 10, 1077. https://doi.org/10.3390/pr10061077
School of Mechanical Engineering, Qilu University of Technology (Shandong Academy of Sciences),
Jinan 250000, China; liruichuan@qlu.edu.cn (R.L.); 10431200080@stu.qlu.edu.cn (X.D.);
10431200035@stu.qlu.edu.cn (Q.L.)
* Correspondence: liugiroud@163.com; Tel.: +86-186-6628-3053
Abstract: According to the working principle of the A10VNO swashplate axial piston pump, the
output flow model of an axial piston pump in an ideal state and the output flow theoretical model
of an axial piston pump considering the leakage and flow distribution process are established. The
output flow pulsations of odd and even piston pumps are simulated and analyzed by Matlab, and the
influence of a closed dead angle and a mismatch angle of the port plate on the output flow pulsation
of the pump is obtained. Based on the theoretical model, AMESim is used to establish the overall
model of the axial piston pump considering leakage, flow distribution process and oil compressibility
under constant working conditions. By setting six different flow distribution boundary conditions
corresponding to the theoretical research, the influence of flow distribution plate structure on pump
output flow pulsation is studied. A test-bed was built and verified by experiments. The results
show that when the mismatch angle of the valve plate is 3–5◦ and the dead angle is 6–10◦ , the
difference between the output flow pulsations of the odd and even piston pumps is very small, so
in the hydraulic pump hydraulic motor system, when the hydraulic pump is used as a hydraulic
motor under the condition of power recovery, the odd number or adjacent even number of hydraulic
motors are appropriate.
Keywords: axial piston pump; flow pulsation; port plate; port plate angle
1. Introduction
Due to its structural characteristics, the axial piston pump will produce flow pulsations
in the working process. The flow pulsations are bound to cause pressure pulsations. The
flow and pressure pulsations will directly affect the service life and service performance
of the pump, and produce a lot of noise, which will directly affect the performance of the
whole hydraulic system [1]. The noise generated by axial piston pump mainly comes from
the flow distribution process [2]. In practical work, when each piston cavity switches from
the valve plate in the high- and low-pressure areas, it will produce large flow backflow and
hydraulic impact, which will cause pump output pressure and flow pulsation, generate flow
distribution noise and reduce system efficiency [3]. Therefore, the influence of port plate
structure should be considered in the research of reducing pump output flow pulsation and
reducing its distribution noise. Many scholars have done a lot of research on the structure
of the port plate. The method of optimizing the size of the damping groove and damping
hole of the port plate is widely used, and some results have been obtained.
A large number of theoretical and simulation analyses have been carried out on the
flow pulsation characteristics of swashplate axial piston pumps. Zhang et al. [4,5] found
that the main influencing factor of the flow pulsation of the piston pump under ideal
working conditions is the number of plungers, and it was concluded that an odd number
of plunger pumps is obviously better than an even number of plunger pumps. Through
theoretical analysis, Wang et al. [6,7] concluded that considering the leakage and flow
distribution geometric factors, the number and parity of the plunger of the plunger pump
https://www.mdpi.com/journal/processes
Processes 2022, 10, 1077 2 of 20

are not the decisive factors of the flow pulsation. The flow pulsation rates of the pump with
an odd number of plungers and an even number of plungers are almost the same, and both
are higher than the flow pulsation rate under the ideal working conditions. Na et al. [8,9]
analyzed the influence of oil compressibility and damping groove structure on the flow
pulsation of a piston pump. Yan et al. [10], through modeling and simulation analysis of the
axial piston pump in AMESim, concluded that the structure and leakage parameters of the
piston pump have an important impact on the flow pulsation. Zhang et al. [11] modeled and
simulated the axial piston pump in AMESim, and concluded that the actual flow pulsation
of the piston pump is related to the load pressure. Harrison et al. [12,13] optimized the
structure of the valve plate. The research results show that two one-way valves are set in
the oil suction and discharge tank, which can effectively reduce the flow pulsation of the
plunger pump. Liu et al. [14] comprehensively analyzed the main influencing factors of the
structure and performance of the plunger pump and concluded that the optimal number
of plungers is nine. Bergada et al. analyzed the leakage, pressure, force and torque of key
friction pairs; established a new theoretical model of pump output flow; and focused on the
influence of fluid properties on the movement of plunger pair. In addition, the influence of
the slipper curved surface on hydrostatics and dynamics was also studied and verified by
experiments [15–17].
In this paper, the author takes the A10VNO swashplate axial piston pump developed
by a company as the research object, establishes the hydraulic model of the axial piston
pump in AMESim, simulates and analyzes its flow pulsation characteristics, analyzes the
influence of port plate structure on the flow pulsation of the axial piston pump through
continuous debugging parameters and builds an experimental platform for verification.

2. Working Principle of Valve Plate of Axial Piston Pump

The main working parts of the A10VNO swashplate axial piston pump are swashplate,
cylinder block, drive shaft, plunger, sliding shoe, return plate, port plate, variable piston
rod, etc. [18,19]. The inclination angle of the swashplate is γ. Under constant working con-
ditions, when the prime mover drives the cylinder block 3 to rotate through the drive shaft,
due to the action of the swashplate, the plunger is forced to make periodic reciprocating
motions in the cylinder block, and the volume of the sealing cavity between each plunger
and the cylinder block increases and decreases. When the oil absorption and oil drainage
are realized through the arc oil absorption window and oil drainage window of the port
plate, as shown in Figure 1, the port plate is provided with two axially symmetrical oil
suction grooves and oil discharge grooves, two centrally symmetrical vibration reduction
grooves (holes) and the upper and lower dead center axes have a certain included angle
with the symmetrical axis of the oil suction and discharge groove, that is, the mismatch
angle ϕ0 forming staggered oil distribution, and the valve plate is provided with a closed
compression area, ∆ϕ1 , while ∆ϕ2 is the dead angle of pre-lifting and pressure relief, so
that the pressure in the plunger cavity can be pre-boosted or pre-relieved, and the pressure
remains stable when switching between high- and low-pressure areas. The plunger cavity
Processes 2022, 10, x FOR PEER REVIEW 3 of 21 but connects with the
avoids oil suction and drainage at the upper and lower dead centers,
oil drainage groove at ϕ0 + ∆ϕ1 /2 and stops oil drainage at π − ∆ϕ2 /2 + ϕ0 .

Figure 1. The typical symmetric port plate structure.

Figure 1. The typical symmetric port plate structure.
3. Analysis of Output Flow Pulsation of Axial Piston Pump
3.1. Analysis of Output Flow Pulsation of Axial Piston Pump under Constant Working
Conditions
Under constant working conditions, regardless of the leakage and oil distribution
process, the instantaneous output flow of a single plunger when discharging oil [20] is
Processes 2022, 10, 1077 3 of 20

3. Analysis of Output Flow Pulsation of Axial Piston Pump

3.1. Analysis of Output Flow Pulsation of Axial Piston Pump under Constant Working Conditions
Under constant working conditions, regardless of the leakage and oil distribution
process, the instantaneous output flow of a single plunger when discharging oil [20] is

Q0i = Aυi = AωR tan γ sin ϕi (1)

where ω is the rotation angle speed of the cylinder block, R is the radius of plunger
distribution circle, ϕi is the rotation angle of the i plunger and υi is the movement speed of
the i plunger in the plunger pump relative to the cylinder block.
Without considering leakage, flow distribution and other factors, assuming that the
number of plungers connected to the oil discharge chamber at a certain time is m, the
number of plungers is z, the theoretical instantaneous output flow Q0 of the plunger
pump is
m
Q0 = Q01 + Q02 + Q03 + . . . . . . + Q0m = ∑ Q0i
i =1 (2)
m m
= AωR tan γ ∑ sinϕi = AωR tan γ ∑ sin[ ϕ1 + (i − 1)α]
i =1 i =1

According to Formula (2):

 
m −1
m sin ϕ1 + z π sin mπ
z
Q0 = AωR tan γ ∑ sin[ ϕ1 + (i − 1)α] = AωR tan γ (3)
i =1
sin πz

The flow pulsation rate of plunger pump [21] is δ1 :

Q0,max − Q0,min
δ1 = ·100% = Q0 0,max − Q0 0,min (4)
Qt

where Q0,max maximum instantaneous output flow, Q0,min is the minimum instantaneous
output flow, Q0 0,max is the maximum value of the ratio of instantaneous output flow to
average theoretical flow and Q0 0,min is the minimum value of the ratio of instantaneous
output flow to average theoretical flow.
Set up α is the angle between two adjacent plungers, α = 2π/ z. When the number
of plungers is odd, the number of plungers m connected to the oil discharge chamber at
a certain time can be divided into two cases [22–25]: 0 ≤ ϕ1 < α/2 when the number of
plungers in the oil drainage area m = (z + 1)/2 and α/2 ≤ ϕ1 ≤ α when the number of
plungers in the oil drainage area m = (z − 1)/2. For an even number of plungers m = z/2.
When the number of plungers is odd, substitute m into Equation (3) and simplify the
arrangement to obtain:

 AωR tan γ cos( 2z −πϕ1 )
π
0 ≤ ϕ1 < α/2

2 sin 2z
Q0 = 3π − ϕ (5)
 AωR tan γ ( 2z π 1 )
 cos
α/2 ≤ ϕ 1 ≤ α
2 sin 2z

The output flow pulsation of plunger pump is analyzed. According to Formulas (4) and (5):

 π cos( 2z −π ϕ1 )
π
0 ≤ ϕ1 < α/2

Q 0 2z sin 2z
Q0 0 = = 3π − ϕ (6)
Qt π cos ( 2z 1 )


2z sin π α/2 ≤ ϕ 1 < α
2z

When the number of plungers is even, substitute m into Equation (3) and simplify the
arrangement to obtain:

cos ϕ1 − πz
Q0 = AωR tan γ (7)
sin πz
Processes 2022, 10, 1077 4 of 20

The output flow pulsation of the plunger pump is analyzed according to Formulas (3) and (7):


0 Q0 π cos ϕ1 − πz
Q0= = (8)
Qt z sin πz

According to Equations (6) and (8), under ideal conditions, the output flow pulsation
of the axial piston pump is closely related to the number of plungers.
Processes 2022, 10, x FOR PEER REVIEW For the plunger pump with an odd number of plungers, when 0 ≤ ϕ1 < α/2 and
5 of 21
α/2 ≤ ϕ1 ≤ α cases and when the number of plungers is z = 5, 7, 9 or 11, the output
Processes 2022, 10, x FOR PEER REVIEW 5 flow
of 21
pulsation curve of the odd number of plunger pumps under constant working conditions
can be obtained by programming and analysis in Matlab, as shown in Figure 2.

Figure 2. Output flow pulsation curve of piston pump with odd piston (z = 5, 7, 9, 11).
Figure
Figure 2.
2. Output
Output flow pulsation curve of piston pump with odd piston (z = 5, 7, 9, 11).
11).
For the piston pump with an even number of plungers, i.e., when z = 6, 8, 10 and 12,
For the
For
the outputthe piston
pistonpulsation
flow pump with
pump with an even
an
curve even number
number
of the of
even of plungers,
plungers,
number i.e.,
of i.e., when
plunger zz == 6,
whenpumps 6, 8,
8, under
10 and
10 and the
12,
12,
the
the output flow
outputofflow
condition pulsation curve
pulsation
constant of the even
curve ofcan
displacement number
the be
even of
number
obtained plunger
by of pumps under
plunger pumps
programming the condition
under the
and analysis in
of constantofdisplacement
condition constant can be obtained
displacement can beby programming
obtained and analysis
by programming andin analysis
Matlab, as
in
Matlab, as shown in Figure 3.
shown in
Matlab, asFigure
shown3.in Figure 3.

Figure 3.
Figure 3. Output
Output flow
flow pulsation
pulsation curve
curve of
of piston
pistonpump
pumpwith
witheven
evennumber
numberofofpistons
pistons(z(z==6,6,8,8,10,
10,12).
12). 3. Output flow pulsation curve of piston pump with even number of pistons (z = 6, 8, 10,
Figure
12). Under constant working conditions, it can be seen from Figures 2 and 3:
Under constant working conditions, it can be seen from Figures 2 and 3:
Under
For theconstant working
odd number conditions,
(5, 7, it can pumps,
9, 11) of piston be seen from
whenFigures 2 and body
the cylinder 3: turns on
For the
an angle odd number
of 2π/z, (5, 7, 9, 11)output
the instantaneous of piston pumps,
flow when
has two the cylinder
pulsations, bodypulsation
the flow turns on
an angleis of
period π/z2π/z,
and the
the instantaneous
pump output output
flow is flow has two
an ideal pulsations,
cosine the flow
curve. When φ1 is pulsation
π/2z and
period is π/z
3π/2z, the flowand
hasthe
twopump
maximumoutputvalues,
flow is an ideal cosine
respectively, curve.
and the flowWhen φ1 isfrequency
pulsation π/2z and
Processes 2022, 10, 1077 5 of 20

For the odd number (5, 7, 9, 11) of piston pumps, when the cylinder body turns on
an angle of 2π/z, the instantaneous output flow has two pulsations, the flow pulsation
period is π/z and the pump output flow is an ideal cosine curve. When ϕ1 is π/2z and
3π/2z, the flow has two maximum values, respectively, and the flow pulsation frequency is
f = ω/T = ωz/2π. With the increase of the number of plungers, the output flow pulsation of
the pump decreases significantly.
For an even number (6, 8, 10, 12) of piston pumps, when the cylinder body turns to an
angle of 2π/z, the instantaneous output flow has a pulsation, the flow pulsation period is
2π/z and the pump output flow is also an ideal cosine curve. When ϕ1 is π/z, the flow has a
maximum value and the flow pulsation frequency is f = ω/T = ωz/2π. With the increase of
the number of plungers, the output flow pulsation of the pump also decreases significantly.
From Figures 2 and 3, the flow pulsation rate values corresponding to the piston
pumps with odd and even plunger numbers can be obtained respectively, as shown in
Table 1.

Table 1. Output flow pulsation rates of axial piston pumps.

Z is an odd Z is an even
5 7 9 11 6 8 10 12
number number
Pulsation rate Pulsation rate
4.97 2.52 1.53 1.02 14.03 7.66 4.97 3.45
δ1/% δ1/%

Combined with Figures 2 and 3 and Table 1, it can be concluded that under ideal
conditions, the output flow pulsation rate of odd pumps is obviously less than that of even
pumps, and with the increase of the number of plungers, the pump output flow pulsation
rate decreases. The larger the number of plungers, the slower the decreasing trend of
flow pulsation.

3.2. Analysis of Output Flow Pulsation of an Axial Piston Pump in Practical Situation
When the piston pump is actually working, when studying its output flow pulsation,
the influence of important factors such as internal oil leakage, flow distribution process, oil
compressibility and load pressure should be considered. This paper does not consider the
influence of oil compressibility and load pressure, and focuses on the influence of leakage
and port plate structure on the output flow pulsation of axial piston pump.

3.2.1. Analysis of Oil Leakage in a Plunger Pump

The main oil leakage of an axial piston pump is the oil leakage [26] between the
plunger and cylinder bore, swashplate and slipper, cylinder and port plate and other
key components.
(1) Oil leakage between plunger and cylinder bore Qzg
As shown in Figure 4, the gap between the plunger and the cylinder bore is an annular
gap, because the plunger will be affected by the vertical reaction of the swashplate during
its movement, making the plunger and the cylinder bore have different axes. Therefore,
the oil leakage between the plunger and the cylinder bore can be regarded as an eccentric
annular gap leakage. When a single plunger moves, its leakage Qzg is:

  πdh3 πdh0
Qzg = 1 + 1.5ε2 0
4 p h0 ± µ0 (9)
12µl 2

In the formula, ε—relative eccentricity, E = e/h0 , where e is the eccentricity; d—plunger

diameter; h0 —fit clearance between plunger and cylinder bore; ∆ph0 —pressure difference
at both ends of the gap; µ—dynamic viscosity of oil; l—contact length between plunger
and cylinder bore; µ0 —movement speed of plunger relative to cylinder block.
 As shown in Figure 4, the gap between the plunger and the cylinder bore is an
annular gap, because the plunger will be affected by the vertical reaction of the swashplate
during its movement, making the plunger and the cylinder bore have different axes
Therefore, the oil leakage between the plunger and the cylinder bore can be regarded as
Processes 2022, 10, 1077 6 of 20
an eccentric annular gap leakage. When a single plunger moves, its leakage Qzg is:
Processes 2022, 10, x FOR PEER REVIEW 7 of 21

In the formula, ε—relative eccentricity, ԑ = e/h0, where e is the eccentricity; d—plunger

diameter; h0—fit clearance between plunger and cylinder bore; Δph0—pressure difference
at both ends of the gap; μ—dynamic viscosity of oil; l—contact length between plunger
and cylinder bore; μ0—movement speed of plunger relative to cylinder block.
When a single plunger discharges oil, its contact length with the cylinder block hole
increases, and the oil leakage between them is:

π dh3 π dh0
Figure 4. TheQpiston
= (1and
+ 1.5ε 2 ) bore.
cylinder 0
 ph − ω R tan γ sin ϕi (10)
12 µ (bore.
l0 + R tan γ (1 − cos ϕi ) )
zgi
Figure 4. The piston and cylinder 2 0

When a single plunger discharges oil, its contact length with the cylinder block hole
where, l0—the
increases, contact
and the length
oil leakage between
between themtheis: plunger and the cylinder block hole at the
2 π dh0 π dh0
3
maximum extension.
When
Qzgi =there is the
(1 + 1.5ε
Q zg = 1 3+ 1.5
2 maximum eccentricity
)
πdh 0
ε( 12 µ
)ph
4l ph0 −
between 0
±
πdh µ0
2ωR tanand
the plunger
0 the
γ sin ϕi cylinder
(9)
(10) block
12µ(l0 + R tan γ(1 − cos ϕi )) 2
e h0
hole, thatl is ε = =
= 1 , substitute it into Formula (10):
where,
h h
0 —the contact length between the plunger and the cylinder block hole at the
maximum extension. 0 0
When there is the maximum eccentricity between the plunger and the cylinder block
5 π dh 3
π dh0
=hole, that is ε Q 0
p − ω R tan γ sin ϕ
h0
= h = h = 1, substitute it into Formula(10):
e
(11)
24 µ ( l0 + R tan γ (1 − cos ϕi ) )
zgi0 h0 i
2
0

5πdh30 πdh0
Qzgi = 4 p h0 − ωR tan γ sin ϕi (11)
Total oil leakage
24µbetween
l
(0 + R plunger
tan γ ( 1 − and
cos ϕ cylinder
i )) 2 Qzg:
bore

m  oil leakage5between
mTotal
π dh03 plunger and cylinder π dhbore Qzg: 
Qzg
= ∑
= Qzgi ∑
=i 1 =i 1  24 µ (m
  p − 0
ω R tan γ sin ϕ i 
l0 + R tanmγ (1 − cos ϕ5πdhi )) 0
h0
2 
Qzg = ∑ Qzgi = ∑ 24µ(l + R tan γ(1−cos ϕ )) 4 ph0 − 2 ωR tan γsin ϕi
 
3
πdh0

(12)
0 i
5π dh03  ph0 5πdh30 4 ph0
i =1 i =1
π dh mm
sin((ϕ α))
(12)
− 2ω R tan γ ∑ ∑sin + ((ii −
− 11))α
= − 0
πdh 0
ωR tan γ ϕ11 +
m
 
 
m24µ l + R tan γ ∑ (1−cos( ϕ +(i −1)α))
2
(
24 µ  l0 + R tan γ ∑ 1 − cos (ϕi=1 1+ ( i − 1) α )  )
i =1
0 1 i =1

 =1
(2) iOil leakage between swashplate  and slipper Q
xh
AsOil
(2) shown in Figure
leakage 5, theswashplate
between oil flows through Qxhhole of the sliding shoe from
the central
and slipper
the central hole of the plunger ball head, radiates outward from the gap between the
As shown in Figure 5, the oil flows through the central hole of the sliding shoe from
swashplate and the sliding shoe, and generates oil pressure support. The oil leakage
the central
between thehole of the and
swashplate plunger ball head,
the slipper can be radiates
calculatedoutward from of
by the formula theannular
gap between
plane the
swashplate
gap flow. and the sliding shoe, and generates oil pressure support. The oil leakage
between the swashplate and the slipper can πhbe
3 calculated by the formula of annular plane
Q= 1
∆p (13)
gap flow. 6µ ln rr2
1

Figure 5. The swash plate and slipper.

Figure 5. The swash plate and slipper.

π h13
=Q ∆p
r2 (13)
6µ ln
Processes 2022, 10, 1077 7 of 20

When the number of plungers is odd, when 0 ≤ ϕ1 < α/2, m = (z + 1)/2, Qxh can be
obtained from Equation (13):

z + 1 πh31 (z + 1)πh31
Q xh = · r2 ∆p h1 = ∆ph1 (14)
2 6µ ln r 12µ ln rr2
1 1

where h1 —fit clearance between swashplate and sliding shoe, ∆p—pressure difference at
both ends of the gap, r1 —inner radius of sliding shoe seal ring and r2 —outer radius of
sliding shoe seal ring.
When α/2 ≤ ϕ1 ≤ α, m = (z − 1)/2, Qxh can be obtained from Equation (13):

z − 1 πh31 (z − 1)πh31
Q xh = · ∆p h1 = ∆ph1 (15)
2 6µ ln rr2 12µ ln rr2
1 1

When the number of plungers is even, m = z /2, Qxh can be obtained from Equation (13):

z πh31 zπh31
Q xh = · r2 ∆p h1 = ∆ph1 (16)
2 6µ ln r 12µ ln rr2
1 1

(3) Oil leakage between port plate and cylinder block Q pg

The cylinder block rotates relative to the valve plate, each plunger sucks and discharges
oil and the oil is output through the valve plate. Ideally, the clearance between the port
plate and the cylinder block remains unchanged, and the oil leakage between them can also
be calculated by the formula of annular plane gap flow [27].
When the number of plungers is odd, when 0 ≤ ϕ1 < α/2, m = (z + 1)/2, Qpg can be
obtained from Formula (13):
3  
2 · 12µ ln r4 −ln r3 + ln r6 −ln r5 ∆p h2
z+1 αh2 1 1
Q pg =
3
(z+1)αh2
  (17)
ln r4 −ln r3 + ln r6 −ln r5 ∆p h2
1 1
= 24µ

where h2 —fit clearance between cylinder block and port plate, r3 and r4 —inner and outer
radius of sealing area in port plate, r5 and r6 —inner and outer radius of the sealing area
outside the port plate and α—wrap angle of waist groove of cylinder block.
When α/2 ≤ ϕ1 ≤ α, m = (z − 1)/2, Q pg can be obtained from Formula (13):
3 
z−1 αh2
2 · 12µ ln r4 −ln r3 + ln r6 −ln r5 ∆p h2
1 1
Q pg =
(z−1)αh32
  (18)
ln r6 −ln r5 ∆p h2
1 1
= 24µ ln r4 −ln r3 +

When the number of plungers is even, m = z/2, Qpg is:

αh3
 
Q pg = 2z · 12µ2 ln r −1 ln r + ln r −1 ln r ∆ph2
4 3 6 5
zαh32
  (19)
= 24µ ln r −ln r + ln r −ln r ∆ph2
4
1
3
1
6 5

The total oil leakage QL inside the plunger pump is:

Q L = Qzg + Q xh + Q pg (20)
Processes 2022, 10, 1077 8 of 20

3.2.2. Influence of Port Plate Structure on Output Flow Pulsation of Axial Piston Pump
From the above analysis, it can be concluded that when considering the flow distribu-
tion process, the actual output flow Qs of the even piston pump is:

πd2 cos ϕ1 ∆ϕ2


z
4 ωR tan γ tan πz − Q L 0 < ϕ1 ≤ 2 + ϕ0 , m = 2 − 1;

Qs = cos( ϕ1 − πz ) ∆ϕ1
(21)
πd2

4 ωR tan γ sin πz
− QL 2 + ϕ0 < ϕ1 ≤ 2π
z ,m = 2z ;

Actual output flow Qs of odd piston pump is:


πd2 cos( 2z
π +ϕ
1) ∆ϕ


 4 ωR tan γ 2 sin π − QL 0 < ϕ1 ≤ 2 1 + ϕ0 , m = z−2 1 ;
 2z
cos( 2z 1)

∆ϕ1 ∆ϕ2
π −ϕ
Qs = πd2 z +1
4 ωR tan γ 2 sin π − QL 2 + ϕ0 < ϕ1 ≤ z − 2 + ϕ0 , m =
π
2 ;
 2z
3π
 πd2 ωR tan γ cos( 2z −πϕ1 ) − Q L ∆ϕ2

2π z −1

z − 2 + ϕ0 < ϕ1 ≤ z , m = 2 ;
 π
4 2 sin 2z
(22)
The average theoretical flow Qm of odd and even piston pumps is:

πd2 z ∆ϕ1 ∆ϕ1

 
Qm = ωR tan γ cos( ϕ0 + ) + cos( ϕ0 − ) (23)
4 2π 2 2

It can be seen from Equations (21) and (22) that the actual output flow of the axial
piston pump has an important relationship with the structure of the port plate [28,29]. Dead
angles and mismatch angles are important parameters of the port boundary. In this section,
different port boundary conditions are obtained by setting different sizes of dead angles
and mismatch angles, and their influence on pump output flow pulsation is mainly studied.
Given that the dead angles of the pre-boost and relief of the symmetrical deflection
port plate are equal to the top, ∆ϕ is used, which is called a closed dead angle for short.
∆ϕ/2 = ϕ0 = 6◦ is often used in engineering. ∆ϕ/2=ϕ0 =1~6◦ is taken during simulation
to obtain six different flow distribution boundary conditions. Take the prime mover
speed n = 1500 r/min, plunger diameter d = 17 mm and swashplate inclination γ = 12.5◦ ,
h0 = 0.005 mm, µ = 0.04025 Pa.s, l0 = 16.5 mm, h2 = 0.01 mm, r3 = 19.9 mm, r4 = 24.8 mm,
r5 = 32.2 mm, r6 = 41.8 mm, α = 33.32◦ , h1 = 0.002 mm, r1 = 7.0 mm, r2 = 9.8 mm. When
the number of plungers is 8, 9, 10 and 11, the actual output flow curve of plunger pump
under constant working conditions is obtained by Matlab simulation, and the actual output
flow curve of plunger pump under constant working conditions is obtained by Matlab
simulation, as shown in Figures 6–11.
From Figures 6–11, it can be seen that when ∆ϕ/2 = ϕ0 decreases from 6◦ to 1◦ , the
output flow curves of odd (9,11) and even (8,10) plunger pumps become more and more
regular, the minimum value of pump output flow gradually increases, the flow pulsation
decreases significantly and the output flow pulsation of the odd pump decreases faster
than that of the even pump. Under the same port plate structure, with the decrease of the
dead angle and the mismatch angle, the output flow pulsation difference of adjacent odd
and even piston pumps increases significantly, but the difference is very small.
From Figures 6–11, the variation curves of output flow pulsation rate of 8~11-piston
pumps under six flow distribution boundary conditions can be obtained, as shown in
Figure 12.
As can be seen from Figures 6–12,
(1) ∆ϕ/2 = ϕ0 = 6◦ , δz = 11 < δz = 10 < δz = 9 < δz = 8, that is, the larger the number
of plungers, the smaller the pump output flow pulsation rate. The flow pulsation
rate values are greater than the theoretical instantaneous flow pulsation rate, but the
regularity is consistent with it. However, when ∆ϕ/2 = ϕ0 = 1~5◦ , δz = 11 < δz = 9 <
δz = 10 < δz = 8, that is, the output flow pulsation of odd pump is obviously less than
that of even pump.
 Processes 2022, 10, 1077 9 of 20

(2) When ∆ϕ/2 = ϕ0 decreases from 6◦ to 1◦ , the output flow curves of 8~11-piston
pumps become more and more regular, the flow pulsation rate decreases gradually,
the flow pulsation of odd number pump decreases faster than that of even number
pump and the gap between them becomes larger and larger.
(3) When ∆ϕ/2 = ϕ0 = 1◦ , the flow pulsation rate of 8~11-plunger pumps reaches the
minimum value, which is close to the theoretical value. When ∆ϕ/2 = ϕ0 = 3◦ , the
fluctuation of the difference of the pump flow pulsation rate of the number of adjacent
plungers is the smallest. When ∆ϕ/2 = ϕ0 = 5~6◦ , the flow pulsation rates of 9- and
Processes 2022, 10, x FOR PEER REVIEW 10-plunger pumps are very close. Under this port plate structure, the number of
10 of 21
plungers is designed as 9 or 10, which breaks the convention that odd piston pumps
Processes 2022, 10, x FOR PEER REVIEW 10 of 21
are better than even piston pumps.
37 41
36.5 40.5
37 41
36 40
36.5 40.5
35.5 39.5

Qs(L/min)
Qs(L/min)

36 40
35 39
35.5 39.5

Qs(L/min)
Qs(L/min)

34.5 38.5
35 39
34 38
34.5 38.5
33.5 37.5
34 38
33 37
33.5 0 1 2 3 4 5 37.5 0 1 2 3 4 5
φ(rad) φ(rad)
33 37
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)
(a) (b)
46
(a) 50
(b)
45.5
46 50 49.5
45
45.5 49.5 49

44.5
45 49 48.5
Qs(L/min)
Qs(L/min)

44.5
44 48.5 48
Qs(L/min)
Qs(L/min)

44
43.5 48 47.5
43.5
43 47.5 47
43
42.5 47 46.5
42.5 46.5
42 46
0 1 2 3 4 5 0 1 2 3 4 5
42 φ(rad) 3 46 φ(rad)
0 1 2 4 5 0 1 2 3 4 5
φ(rad) φ(rad)
(c) (d)
(c) (d)
Figure 6.6.Actual
Actual output
output flow
flow rate ofofpiston pumps with 8~11 pistons for
forΔφ/2
∆ϕ/2=φ =0 ϕ=(a)
6°. 6(a) output
◦ . (a)
Figure6.
Figure Actual output flow raterate piston
of piston pumps
pumps withwith
8~118~11 pistons
pistons for Δφ/2 = φ0 = 6°. 0 =output output
flow
flow of 8-plunger
flowofof 8-plunger
8-plunger pump;
pump;
pump; (b) output
(b) (b) output
output flow
flowflowof 9-plunger pump;
of 9-plunger
of 9-plunger pump;pump; (c) output
(c) output
(c) output flow of
flow offlow 10-plunger
of 10-plunger
10-plunger pump;
pump; pump;
(d) output
(d) outputflow
flowofof11-plunger
11-plungerpump.
pump.
(d) output flow of 11-plunger pump.

37
37 41
41
36.5
36.5 40.5 40.5
36
36 40 40
35.5
35.5 39.5 39.5
Qs(L/min)

Qs(L/min)
Qs(L/min)

Qs(L/min)

35
35 39 39
34.5
34.5 38.5 38.5
34
34 38 38
33.5
33.5 37.5 37.5
33
330 37 37
0 11 2 2 3 3 4 4 5 5 0 0 1 1 2 2 3 3 4 4 5 5
φ(rad)
φ(rad) φ(rad) φ(rad)
(a)
(a) (b) (b)
46 50
46 50
45.5 49.5
45.5 49.5
45 49
45 49
44.5 48.5
Qs(L/min)
Qs(L/min)

44.5 48.5
Qs(L/min)
Qs(L/min)

44 48
44 48
43.5 47.5
43.5 47.5
43 47
43 47
42.5 46.5
42.5 46.5
42 46
0 1 2 3 4 5 0 1 2 3 4 5
42 φ(rad) 46 φ(rad)
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad)
(c)φ(rad) (d)
(c) (d)
Figure
Figure7.7.
Actual output
Actual flow
output raterate
flow of piston pumps
of piston withwith
pumps 8~118~11
pistons for Δφ/2
pistons = φ0 = 5°.
for ∆ϕ/2 = ϕ(a) output
◦
0 = 5 . (a) output
Figure
flow 7. Actual output
of 8-plunger flow
pump; (b) rate of
output piston
flow pumps with
of 9-plunger 8~11
pump; (c) pistons for Δφ/2
output flow = φ0 = 5°.pump;
of 10-plunger (a) output
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger pump;
flow
(d) of 8-plunger
output pump; (b) pump.
flow of 11-plunger output flow of 9-plunger pump; (c) output flow of 10-plunger pump;
(d) outputflow
(d) output flowofof11-plunger
11-plungerpump.pump.

37 41

36.5 40.5 41
37
36 40 40.5
36.5
35.5 39.5
(L/min)
(L/min)

36 40
35 39
)
)
 42.5 46.5

42 46
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)

Processes 2022, 10, 1077
(c) (d)
Figure 7. Actual output flow rate of piston pumps with 8~11 pistons for Δφ/2 = φ0 = 5°. (a) output
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger pump;
10 of 20
(d) output flow of 11-plunger pump.

37 41

36.5 40.5

36 40

35.5 39.5

Qs(L/min)
Qs(L/min)
35 39
34.5 38.5
34 38

Processes 2022, 10, x FOR PEER REVIEW 33.5 37.5 11 of 21

Processes 2022, 10, x FOR PEER REVIEW 330 1 2 3 4 5 37 11 of 21
0 1 2 3 4 5
φ(rad) φ(rad)

(a) (b)
46 50
46 50
45.5 49.5
45.5 49.5
45 49
45 49
44.5 48.5

Qs(L/min)
Qs(L/min)

44.5 48.5

Qs(L/min)
Qs(L/min)

44 48
44 48
43.5 47.5
43.5 47.5
43 47
43 47
42.5 46.5
42.5 46.5
42 46
420 1 2 3 4 5
46 0 1 2 3 4 5
0 1 2 φ(rad) 3 4 5 0 1 2 φ(rad) 3 4 5
φ(rad) φ(rad)
(c)
(c) (d)
(d)
Figure
Figure 8.8.Actual
Figure8. Actual output
Actualoutput flow
outputflow rate
flowrate of
rateof piston
ofpiston pumpswith
pistonpumps
pumps with8~11
with 8~11pistons
8~11 pistonsfor
pistons forΔφ/2
for Δφ/2= =
∆ϕ/2 =φ0φ ==4°.
ϕ=004°. ◦ .(a)
4(a) output
output
(a) output
flow
flow of
of 8-plunger
8-plunger pump;
pump; (b)
(b) output
output flow
flow of
of 9-plunger
9-plunger pump;
pump; (c)
(c) output
output flow
flow ofof 10-plunger
10-plunger
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger pump; pump;
pump;
(d) output
(d) output flow of of 11-plungerpump.
pump.
(d) outputflowflow of11-plunger
11-plunger pump.

37 41
37 41
36.5
36.5 40.5
40.5
36
36 4040
35.5
35.5 39.5
Qs(L/min)

39.5
Qs(L/min)
Qs(L/min)

Qs(L/min)

35
35 3939
34.5
34.5 38.5
38.5
34
34 3838
33.5
33.5 37.5
37.5
33
33 37370
00 11 22 33 44 55 0 1 1 2 2 3 3 4 4 5 5
φ(rad)
φ(rad) φ(rad)
φ(rad)

(a)
(a) (b)
(b)
46
46 5050
45.5
45.5 49.5
49.5
45
45 4949
44.5
44.5 48.5
48.5
Qs(L/min)
Qs(L/min)

Qs(L/min)
Qs(L/min)

44
44 4848
43.5
43.5 47.5
47.5
43
43 4747

42.5
42.5 46.5
46.5
42
420 4646
0 11 22 33 44 55 0 0 1 1 2 2 3 3 4 4 5 5
φ(rad)
φ(rad) φ(rad)
φ(rad)

(c)
(c) (d)
(d)
Figure
Figure9.
Figure 9.9.Actual
Actualoutput
Actual outputflow
output flowrate
flow rateof
rate ofpiston
of pistonpumps
piston pumpswith
pumps with8~11
with 8~11pistons
8~11 pistonsfor
pistons for Δφ/2= =φ
forΔφ/2
∆ϕ/2 =0φϕ=00 3°.3(a)
==3°. output
(a)
◦ . (a)
output
output
flow
flowof
flow ofof8-plunger
8-plungerpump;
8-plunger pump;(b)
pump; (b)output
(b) outputflow
output flowofof
flow 9-plunger
of9-plungerpump;
9-plungerpump;
pump;(c) output
(c)
(c)output
outputflow
flowofof
flow 10-plunger
of 10-plunger
10-plunger pump;
pump;
pump;
(d)
(d) output
output flow
flow of
of 11-plunger
11-plunger
(d) output flow of 11-plunger pump.pump.
pump.

37 50
37 50
36.5 49.5
36.5 49.5
36 49
36 49
35.5 48.5
Qs(L/min)
Qs(L/min)

35.5 48.5
Qs(L/min)
Qs(L/min)

35 48
35 48
34.5 47.5
34.5 47.5
34 47
34 47
33.5 46.5
33.5 46.5
33 46
330 1 2 3 4 5 046 1 2 3 4 5
0 1 2 φ(rad) 3 4 5 0 1 2 φ(rad) 3 4 5
φ(rad) φ(rad)
(a) (b)
(a) (b)
46 50
46 50
45.5 49.5
45.5 49.5
45 49
45 49
44.5 48.5
/min)

/min)

44.5 48.5
in)

in)
 42.5 46.5

42 46
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)

(c) (d)
Figure 9. Actual output flow rate of piston pumps with 8~11 pistons for Δφ/2 = φ0 = 3°. (a) output
Processes 2022, 10, 1077 11 of 20
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger pump;
(d) output flow of 11-plunger pump.

37 50
36.5 49.5
36 49
35.5 48.5

Qs(L/min)
Qs(L/min)
35 48
34.5 47.5
34 47
33.5 46.5
33 46
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)

(a) (b)
46 50
45.5 49.5
45 49
44.5 48.5
Qs(L/min)

Qs(L/min)
44 48
43.5 47.5

43 47

42.5 46.5
Processes 2022, 10, x FOR PEER REVIEW 46
12 of 21
42 0 1 2 3 4 5
0 1 2 3 4 5
φ(rad) φ(rad)

(c) (d)
Figure
Figure10.10.Actual
Actualoutput
outputflow
flowrate
rateof
ofpiston
pistonpumps
pumps with
with 8~11
8~11 pistons
pistons for ∆ϕ/2==φϕ0 0= =2°.2◦(a)
for Δφ/2 output
. (a) output
flow
flowofof8-plunger
8-plungerpump;
pump;(b)
(b)output
outputflow
flowofof
9-plunger pump;
9-plunger pump;(c)(c)
output flow
output of of
flow 10-plunger
10-plunger pump;
pump;
(d)
(d)output
outputflow
flowofof11-plunger
11-plungerpump.
pump.

37 41
36.5 40.5
36 40
35.5 39.5
Qs(L/min)
Qs(L/min)

35 39

34.5 38.5

34 38

33.5 37.5

33 37
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)

(a) (b)
46 50
45.5 49.5
45 49
44.5 48.5
Qs(L/min)
Qs(L/min)

44 48
43.5 47.5
43 47
42.5 46.5
42 46
0 1 2 3 4 5 0 1 2 3 4 5
φ(rad) φ(rad)

(c) (d)
Figure
Figure11.
11.Actual
Actualoutput
outputflow
flowrate
rateof
ofpiston
pistonpumps
pumps with
with 8~11
8~11pistons
pistons for ∆ϕ/2==φϕ0 0= =1°.1◦(a)
for Δφ/2 output
. (a) output
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger
flow of 8-plunger pump; (b) output flow of 9-plunger pump; (c) output flow of 10-plunger pump; pump;
(d)
(d)output
outputflow
flowofof11-plunger
11-plungerpump.
pump.

From Figures 6–11, it can be seen that when Δφ/2 = φ0 decreases from 6° to 1°, the
output flow curves of odd (9,11) and even (8,10) plunger pumps become more and more
regular, the minimum value of pump output flow gradually increases, the flow pulsation
decreases significantly and the output flow pulsation of the odd pump decreases faster
than that of the even pump. Under the same port plate structure, with the decrease of the
dead angle and the mismatch angle, the output flow pulsation difference of adjacent odd
and even piston pumps increases significantly, but the difference is very small.
From Figures 6–11, the variation curves of output flow pulsation rate of 8~11-piston
pumps under six flow distribution boundary conditions can be obtained, as shown in
Figure 12.
 than that of the even pump. Under the same port plate structure, with the decrease of the
dead angle and the mismatch angle, the output flow pulsation difference of adjacent odd
Processes 2022, 10, x FOR PEER REVIEW 13 of 21
and even piston pumps increases significantly, but the difference is very small.
From Figures 6–11, the variation curves of output flow pulsation rate of 8~11-piston
Processes 2022, 10, 1077 pumps under
As cansix
be flow
seen distribution
from Figuresboundary
6–12, conditions can be obtained, as shown in20
12 of
Figure 12.
(1) Δφ/2 = φ = 6°, δz = 11 < δz = 10 < δz = 9 < δz = 8, that is, the larger the number of
0
plungers, the smaller the pump output flow pulsation rate. The flow pulsation rate values
are greater than the theoretical instantaneous flow pulsation rate, but the regularity is
consistent with it. However, when Δφ/2 = φ0 = 1~5°, δz = 11 < δz = 9 < δz = 10 < δz = 8, that
is, the output flow pulsation of odd pump is obviously less than that of even pump.
(2) When Δφ/2 = φ0 decreases from 6° to 1°, the output flow curves of 8~11-piston
pumps become more and more regular, the flow pulsation rate decreases gradually, the
flow pulsation of odd number pump decreases faster than that of even number pump and
the gap between them becomes larger and larger.
(3) When Δφ/2 = φ0 = 1°, the flow pulsation rate of 8~11-plunger pumps reaches the
minimum value, which is close to the theoretical value. When Δφ/2 = φ0 = 3°, the
fluctuation of the difference of the pump flow pulsation rate of the number of adjacent
plungers is the smallest. When Δφ/2 = φ0 = 5~6°, the flow pulsation rates of 9- and 10-
plunger pumps are very close. Under this port plate structure, the number of plungers is
designed as 9 or 10, which breaks the convention that odd piston pumps are better than
even piston pumps.
Figure 12. Output flow pulsation rate curve of piston pumps with 8~11 pistons under 6 flow
Figure 12. Output flow pulsation rate curve of piston pumps with 8~11 pistons under 6 flow
4. System
distribution
distribution Modeling
boundary
boundary and Simulation Analysis of Axial Piston Pump
conditions.
conditions.
4. 4.1. Modeling
System and Correctness
Modeling Verification
and Simulation Analysis of Axial Piston Pump
Considering factors such as oil leakage, flow distribution process and oil
4.1. Modeling and Correctness Verification
compressibility, the overall
Considering factors simulation
such as model
oil leakage, flow of a nine-plunger
distribution processpump is built,
and oil as shown
compressibil-
ity,inthe
Figure 13.simulation
overall After completing
model ofthe model building
a nine-plunger pump and sub-model
is built, matching,
as shown in Figureset13.
the
parameters
After of the
completing thewhole
modelmodel in the
building andparameter
sub-model mode. The main
matching, simulation
set the parameters
parameters of the
are shown
whole model in Table
in the 2.
parameter mode. The main simulation parameters are shown in Table 2.

Figure
Figure 13.13. Simulation
Simulation model
model of of
anan axial
axial piston
piston pump
pump with
with 9 pistons.
9 pistons.

TheThe adjacent
adjacent included
included angleangle
of eachofplunger
each plunger of a nine-plunger
of a nine-plunger pump is 40◦pump is 40°.
. According
to According
its working to its working the
characteristics, characteristics, the first
first plunger moves plunger
from moves extension
the minimum from the position
minimum
andextension
starts theposition and starts
oil absorption the oilwithin
process absorption
0~180process within
◦ . The angle 0~180°.
offset The
of the oilangle offset of
absorption
the signal
cycle oil absorption
switch is cycle
set to signal
0◦ , the switch
secondisis set
1 ×to360
0°,◦ /z,
thethe
second
third is
is 12 ××360°/z,
360◦ /z,the third
to the is 2 ×
ninth
360°/z,intoturn.
plunger the ninth plunger
The signal ofin turn.
the The signal
oil drain switchoflags
the oil180drain
◦ switch lags 180° accordingly.
accordingly.
For the A10VNO axial piston pump, its rated pressure is 30 MPa. Therefore, in
this paper, 46# anti-wear hydraulic oil, which is suitable for the working pressure and
temperature of the plunger pump studied in this paper, is selected, with hydraulic oil
density of 875 Kg/m3 , dynamic viscosity of 40.25 cP and bulk modulus of elasticity of
1700 MPa. Continuous commissioning and operation allows us to reasonably configure
parameters and set the simulation time to 0.3 s to obtain the pump output flow, as shown
in Figure 14.
 Contact length between plunger and cylinder block 34.6 mm
Viscous damping coefficient 5 Nm (rev
Coulomb friction torque loss 3 Nm
Static friction torque loss 7 Nm
Plunger pair fit clearance 0.005 mm
Processes 2022, 10, 1077 13 of 20

Shoe pair clearance 0.002 mm

Clearance
Table 2. Main simulation of port pair
parameters. 0.01 mm
Moment of inertia of cylinder block 0.0016 Kgm
Name Numerical Value Unit
Initial tank pressure 2 ba
Radius of plunger distribution circle 29.7 mm
Maximum opening diameter
Prime mover speedof oil drain throttle valve
1500 2.9r/min mm
Maximum opening diameter
Plunger diameterof oil suction throttle valve
17 4.3 mm mm
Inclined plate 12.5 degree
Contact length between plunger and cylinder block 34.6 mm
For the A10VNO
Viscous damping axialcoefficient
piston pump, its rated pressure5 is 30
NmMPa. Therefore,
(rev/min)
Coulomb friction torque loss 3 Nm
paper, 46# anti-wear hydraulic
Static friction torque loss oil, which is suitable 7 for the working
Nm pressur
temperature ofPlunger
the plunger pump studied in this paper,
pair fit clearance 0.005 is selected,
mm with hydrau
density of 875 Kg/m , dynamic viscosity of 40.25 cP and
Shoe3pair clearance 0.002
bulk modulus mm
of elasticity o
Clearance of port pair 0.01 mm
MPa. Continuous commissioning
Moment of inertia of cylinder blockand operation 0.0016
allows us toKgmm reasonably
2 con
parameters and Initial
set the simulation
tank pressure time to 0.3 s to obtain
2 the pump output
bar flow, as s
Maximum opening diameter of oil drain throttle valve 2.9 mm
in Figure
Maximum14. opening diameter of oil suction throttle valve 4.3 mm

Figure 14. Output flow rate of axial piston pump.

Figure 14. Output flow rate of axial piston pump.
It can be seen from Figure 14 that the pump output flow reaches a steady state at about
0.22It canmaximum
s, the be seen value
fromremains
Figureat 14 that
about theL/min
40.32 pump andoutput flow reaches
the minimum a steady s
value is stable
about 0.22 s, the maximum value remains at about 40.32 L/min and the minimum v
at about 38.64 L/min, which is more or less consistent with the data in Figure 9, which
verifies the accuracy of the established simulation model.
stable at about 38.64 L/min, which is more or less consistent with the data in Fig
which verifiesAnalysis
4.2. Simulation the accuracy of the
of Influence established
of Port simulation
Plate Structure model.
on Output Flow Pulsation of Axial
Piston Pump
4.2. Simulation Analysis
Using AMESim of Influence
simulation ofsimulation
platform, Port Platemodels
Structure
of theon Output
axial piston Flow
pumpPulsation
with of
Piston Pump
8–11 pistons considering the flow distribution process, friction, volume effect and other
factors in steady state are established. The closed dead angle and mismatch angle of port
plateUsing AMESim
are taken as ∆ϕ/2simulation platform,
= ϕ0 = 1~6◦ , set simulation
corresponding modelsflow
to six different of distribution
the axial piston
with 8–11 pistons considering the flow distribution process, friction, volume
and overflow area curves in the AMESim simulation platform. Take the prime mover speed effe
◦;
other factors in steady state are established. The closed dead angle and mismatch an
as n = 1500 r/min, plunger diameter d = 17 mm and swashplate inclination angle γ = 12.5
simulate and analyze the piston pumps with 8, 9, 10 and 11 plungers, respectively; and
port plate are taken as Δφ/2 = φ0 pumps
obtain the output flow curves of 8~11 piston
= 1~6°, set corresponding to six different
under six flow distribution boundary
conditions, as shown in Figures 15–18.
 distribution and
distribution and overflow
overflow area area curves
curves inin the
the AMESim
AMESim simulation
simulation platform.
platform. Take Take the
the
distribution
prime mover and overflow
speed as n area
= 1500curves
r/min,inplunger
the AMESim
diametersimulation
d = 17 platform.
mm and Take the
swashplate
prime mover speed as n = 1500 r/min, plunger diameter d = 17 mm and swashplate
prime mover
inclination speed
angle as12.5°;
n = simulate
1500 r/min,andplunger
analyze diameter
pistondpumps
= 17 mm and swashplate
inclination angle γγ == 12.5°; simulate and analyze the piston
the pumps with
with 8,8, 9,9, 10
10 and
and 11
11
inclination
plungers, angle γ = 12.5°;
respectively; and simulate
obtain and
the analyze
output flow the piston
curves of pumps
8~11 withpumps
piston 8, 9, 10under and 11six
plungers, respectively; and obtain the output flow curves of 8~11 piston pumps under six
Processes 2022, 10, 1077 plungers, respectively;
flowdistribution
distribution and obtain
boundary the output
conditions, flow in
asshown
shown curves of 8~11
Figures piston pumps under14six
15–18. of 20
flow boundary conditions, as in Figures 15–18.
flow distribution boundary conditions, as shown in Figures 15–18.

Figure 15. Actual output flow rate of piston pump with 8 pistons for Δφ/2 = φ = 1~6°. (a) Pump
Figure 15. Actual output flow rate of piston pump with 8 pistons for Δφ/2 = φ00 = 1~6°. ◦(a) Pump
Figure
output15.
Figure 15.Actual
flow; output
(b) Pump
Actual flow
output
output flowrate
rateof(enlarged
flow ofpiston
pistonpump
pumpwith
view A).8 8pistons
atwith pistonsfor ∆ϕ/2
forΔφ/2 = =
φ0ϕ0= =1~6°.
1~6 (a) Pump
. (a) Pump
output flow; (b) Pump output flow (enlarged view at A).
output flow;
output (b)(b)
flow; Pump
Pumpoutput
outputflow
flow(enlarged
(enlargedview
viewatatA).
A).

Figure 16. Actual output flow rate of piston pump with 9 pistons for Δφ/2 = φ0 ϕ=0 1~6°.
∆ϕ/2 (a) Pump
◦ (a)
Figure 16.16.
Figure Actual
Actualoutput flow
output rate
flow of of
rate piston pump
piston pumpwith 9 pistons
with forfor
9 pistons Δφ/2 = φ=0
= 1~6°.
= 1~6(a). Pump
Pump
Figure
output16. Actual
flow; (b) output
Pump flow
output rate
flowof piston pump
(enlarged viewwith
at 9
A). pistons for Δφ/2 = φ = 1~6°. (a) Pump
output flow; (b) Pump output flow (enlarged view at A).
output flow; (b) Pump output flow (enlarged view at A). 0
output flow; (b) Pump output flow (enlarged view at A).

Figure 17. Actual output flow rate of piston pump with 10 pistons for ∆ϕ/2 = ϕ0 = 1~6◦ . (a) Pump
output flow; (b) Pump output flow (enlarged view at A).
Processes 2022, 10, x FOR PEER REVIEW 16 of 21

Processes 2022, 10, x FOR PEER REVIEW 16 of 21

Figure 17. Actual output flow rate of piston pump with 10 pistons for Δφ/2 = φ0 = 1~6°. (a) Pump
Processes 2022, 10, 1077 output flow; (b) Pump output flow (enlarged view at A). 15 of 20
Figure 17. Actual output flow rate of piston pump with 10 pistons for Δφ/2 = φ0 = 1~6°. (a) Pump
output flow; (b) Pump output flow (enlarged view at A).

Figure 18. Actual output flow rate of piston pump with 11 pistons for Δφ/2 = φ0 = 1~6°. (a) Pump
output
Figure flow;
Figure18. (b) Pump
18.Actual
Actual output
output
outputflow flow
flowrate (enlarged
rateofofpiston
piston viewwith
pump
pump at A).
with1111
pistons forfor
pistons ∆ϕ/2
Δφ/2 = φ
= ϕ=0 =
1~6°.
◦ . (a) Pump
1~6(a) Pump
0
output
outputflow;
flow;(b)
(b)Pump
Pumpoutput
outputflow
flow(enlarged
(enlargedview
viewatatA).
A).
It can be seen from Figures 15–18 that as the mismatch angle increases from 1° to 6°,
the output
It can flow
be seenpeak, rising
from speed
Figures and
15–18 flow
that aspulsation ofangle
the mismatch odd (9,
angle 11) andfrom
increases even
from (8,1◦10)
to
◦ , the output flow peak, rising speed and flow pulsation of odd (9, 11) and even (8,6°,
It can be seen from Figures 15–18 that as the mismatch increases 1° to
plunger
6
the output pumps
flow increase,
peak, risingand speed
the peak
andsharp
flowangle becomes
pulsation more(9,and
of odd 11)more
and obvious.
even (8, The
10)
10)
variation
plunger pumpscurve of flow
increase, pulsation
and the rate
peakofsharp
the pump
angle under six
becomes flow
more
plunger pumps increase, and the peak sharp angle becomes more and more obvious. distribution
and boundary
more obvious. The
The
variation
conditions curve
when of flow pulsation rate of the pump under six flow distribution boundary
variation curve ofthe
flow number of plungers
pulsation is 8~11
rate of the pump is under
obtained, as shown
six flow in Figure
distribution 19.
boundary
conditions when the number of plungers is 8~11 is obtained, as shown in Figure 19.
conditions when the number of plungers is 8~11 is obtained, as shown in Figure 19.

Figure 19. The flow pulsation rate curve of piston pump with 8~11 pistons under 6 flow distribution
Figure 19. The flow pulsation rate curve of piston pump with 8~11 pistons under 6 flow distribution
boundary conditions.
boundary conditions.
Figure 19. The flow pulsation rate curve of piston pump with 8~11 pistons under 6 flow distribution
boundary conditions.
Given that factors such as oil compressibility [30], friction and volume effect are
Given that
considered in thefactors such as
simulation oil compressibility
process, the simulation[30], friction
value in Figure and19volume
is larger effect
thanare the
considered
Given that
theoretical in the
value simulation
factors such12.
in Figure process,
asItoil the simulation
cancompressibility
be seen from Figure value in
[30], frictionFigure
19 that the 19 is
andoverall larger
volume than
effecttrend
change the
are
theoretical
considered
diagram ofin value
the in
output Figure
simulation
flow 12. It canrate
process,
pulsation be
theseen from
andFigure
ofsimulation
odd value
even 19inthat
piston Figurethe 19
pumpsoverall
is change
larger
under sixthan trend
kinds theof
diagram
theoretical of output flow
value inboundary
flow distribution pulsation
Figure 12.conditions rate of
It can be seen odd and even
from Figure
is consistent piston
19the
with pumps
thattheoretical under six
the overallresearch, kinds
change trend which of
flow
diagramdistribution
verifies of
theoutput boundary
correctness conditions
flow pulsation
of analyzing ofisinfluence
ratethe consistent
odd and even with
of the theplate
piston
port theoretical
pumps under
structureresearch,
sixthe
on kindswhichof
output
verifies the correctness of analyzing the influence of the port plate
flow distribution boundary conditions is consistent with the theoretical research, which
flow pulsation of the axial piston pump in the simulation. structure on the output
flow pulsation
verifiesFigure of the axial
the correctness
20 shows the pistoncurve
of analyzing
change pump
the of inoil
the
influence simulation.
of the
suction andport plate structure
discharge flow of aon the output
single plunger
flow Figure
pulsation
under 20
six flowof shows the change
the axial piston
distribution pump
boundary curve of oil suction
It can beand
in the simulation.
conditions. seendischarge flow that
from the curve of aa certain
single
plunger
flowFigureunder
backflow six
20 shows flow
occursthe distribution
when change boundary
curve
a single conditions.
of oilissuction
plunger switched and It can be
in discharge seen
the high- and from
flowlow- the curve
of apressure
single
that
plungera certain
areas. underthe
With flow backflow
sixincrease
flow occurs
distribution
of the dead when
anglea and
boundary singletheplunger
conditions. It is
mismatch can switched
be seen
angle, in
the the the
from
degree high- and
curve
of flow
low- pressure areas. With the increase of the dead angle and
that a certain flow backflow occurs when a single plunger is switched in the high- and
backflow decreases. In the pre-boost stage, when the mismatch the mismatch
angle is greater angle,
than the
3◦ ,
low-
therepressure
is almostareas.
no flow With the increase
backflow. of the dead
In the pre-relief stage,angle
whenand thethe mismatch
mismatch angle angle, the
is greater
than 2◦ , the flow backflow is almost zero and the pressure can achieve a smooth transition,
but when the plunger just enters the oil absorption area or oil discharge area, the flow
overshoot occurs. With the increase of the dead angle and mismatch angle, the flow rises
 degree of flow backflow decreases. In the pre-boost stage, when the mismatch angle is
greater than 3°, there is almost no flow backflow. In the pre-relief stage, when the
mismatch angle is greater than 2°, the flow backflow is almost zero and the pressure can
achieve a smooth transition, but when the plunger just enters the oil absorption area or oil
Processes 2022, 10, 1077 16 of 20
discharge area, the flow overshoot occurs. With the increase of the dead angle and
mismatch angle, the flow rises faster and faster, and the degree of flow overshoot
increases, which will cause a certain pressure impact. When the mismatch angle is 6°, the
faster
flow and faster,
overshoot andmost
is the the significant.
degree of flow overshoot increases, which will cause a certain
pressure impact. When the mismatch angle is 6◦ , the flow overshoot is the most significant.

Figure20.
Figure Thecurve
20.The curveofofinlet
inletand
andoutlet
outletflow
flowrate
rateofofsingle
singlepiston
pistonfor
forΔφ/2 = 1~6◦ .
∆ϕ/2= =φ0ϕ=0 1~6°.

The theoretical and simulation analyses of the output flow pulsation of 8~11 piston
The theoretical and simulation analyses of the output flow pulsation of 8~11 piston
pump show that when the closed dead angle and mismatch angle are reduced, the output
pump show that when the closed dead angle and mismatch angle are reduced, the output
flow pulsation of 8~11 piston pump is significantly reduced. From this point of view, the
flow pulsation of 8~11 piston pump is significantly reduced. From this point of view, the
smaller the closed dead angle and mismatch angle are set, the more conducive they are to
smaller the closed dead angle and mismatch angle are set, the more conducive they are to
reducing the flow pulsation. However, if the settings of the dead angle and mismatch angle
reducing the flow pulsation. However, if the settings of the dead angle and mismatch
are too small, the process of pre-pressure rise and pre-pressure relief is reduced, and the
angle are too small, the process of pre-pressure rise and pre-pressure relief is reduced, and
time of pressure rise and fall is insufficient, which is not conducive to the stable transition
the time of pressure rise and fall is insufficient, which is not conducive to the stable
of pressure. If the dead angle and mismatch angle are too large, there is a certain flow
transition
fluctuationof pressure.
when justIfentering
the dead the
angleoiland mismatch
suction angle areareas,
and drainage too large, there is
resulting inaacertain
certain
flow fluctuation when just entering the oil suction and
◦ drainage areas, resulting
pressure impact. Therefore, it is reasonable to take 3~5 for the mismatch angle and 6~10 in a ◦
certain pressure impact. Therefore, it is reasonable to take 3~5° for the mismatch
for the dead angle. Moreover, under this port plate structure, the difference of output flow angle
and 6~10° for
pulsation the dead
between oddangle. Moreover,
and even piston under
pumpsthis portsmall,
is very plate structure, the difference
so it is appropriate of
to adopt
output
odd or adjacent even numbers for the number of pistons, breaking the convention that is
flow pulsation between odd and even piston pumps is very small, so it an
appropriate
odd pump is to better
adoptthan
odd anor even
adjacent
pump. even numbers for the number of pistons, breaking
the convention that an odd pump is better than an even pump.
5. Experimental Verification
5. Experimental Verification
Based on A10VNO axial 9-piston pump, a 10-piston pump prototype was developed
Based
to test on A10VNO
its flow pulsationaxial 9-piston pump,
characteristics. a 10-piston
The shell pump
size of the prototype
prototype is 183was
mmdeveloped
× 144 mm
to×test
156its
mm flow
andpulsation characteristics.
made of cast The shell
iron. The prototype size
has 10 of the prototype
plungers is 183 mm
with a diameter × 144
of 17 mm.
The physical structure is shown in Figure 21a, and the disassembly drawing is shown in
Figure 21b. The flow pulsation characteristics of the 9-piston pump and 10-piston pump
were tested. The test schematic diagram is shown in Figure 22 and the test bench is shown
in Figure 23. The axial piston pump is composed of pump body 3, variable cylinder 6, servo
proportional valve 7, angular displacement sensor 8 and controller 9. The motor 4 drives
 mm × 156 mm and made of cast iron. The prototype has 10 plungers with a diameter
mm.mm.
mm. TheThe
The physical
physical
physical structure
structure
structure isisis
shown
shown
shown in Figure
in
in Figure
Figure 21a,
21a,
21a, andand
and the disassembly
the
the disassembly
disassembly drawing
drawing
drawing isisis
sho
s
sh
in Figure
inFigure
in 21b.
Figure21b. The
21b.The flow
Theflow pulsation
flowpulsation characteristics
pulsationcharacteristics
characteristicsof of the
ofthe 9-piston
the9-piston pump
9-pistonpump and
pumpand 10-piston
and10-piston
10-pistonpp pu
were
were tested.
tested.The
Thetest schematic
test schematic diagram
diagram is shown
is shown in Figure
in Figure
were tested. The test schematic diagram is shown in Figure 22 and the test bench 2222andandthe
thetest bench
test bench isisis
sho
s
sh
in inFigure
in Figure23.
Figure 23.The
23. Theaxial
The axialpiston
axial pistonpump
piston pumpisisiscomposed
pump composedof
composed ofofpump
pumpbody
pump body3,3,3,variable
body variable
variable cylinde
cylind
Processes 2022, 10, 1077 17 of 20 cylind
servo proportional
servoproportional
servo valve
proportionalvalve 7, angular
valve7,7,angular displacement
angulardisplacement
displacementsensorsensor 8 and
sensor88and controller
andcontroller 9. The
Themot
controller9.9.The momo
drives
drives the pump body, the pressure at the oil discharge port is set through throttleva
drives the pump
the pump body,
body,thethepressure
pressure at the
at theoil discharge
oil discharge port
portis set
is through
set through throttle
throttle v
1the
and
1 and
1 and
pumpthrottle
throttle
throttle valve
valve
valve
body, the 11,
11,and
and
11, and
pressure overflow
at the overflow
overflow valve
valve
valve
oil discharge 2 2and
2 is
port and
and overflow
overflow
set overflow valve
valve 1212
valvevalve
through throttle are
are
12 are used
usedas
used as sa
1 and assas
valves.
valves.
valves.
throttle valve 11, and overflow valve 2 and overflow valve 12 are used as safety valves.

(a)
(a)
(a) (b)
(b)
(b)
Figure
Figure
Figure
Figure 21.
21. 10-plunger
21. 10-plunger
10-plunger
21. pump
pump
10-plunger pump prototype.
prototype.
prototype.
pump (a) Physical
(a)
(a) Physical
prototype. (a) Physicalstructure;
structure;
Physical structure;(b) Disassembly
(b)
(b) Disassembly
structure; (b) drawing. drawing.
Disassembly
Disassembly drawing.
drawing.

Figure
Figure
Figure
Figure 22.
22.
22. Axial
22. Axial
Axial
Axial piston
piston
piston pump
piston test test
pump
pump
pump testsystem.
test system.
system.
system.

Figure
Figure
Figure
Figure 23.
23.
23. The
23. The
The
The experimental
experimental
experimental
experimental station.
station.
station.
station.
Processes 2022, 10, x FOR PEER REVIEW 19 of 21
Processes 2022, 10, x FOR PEER REVIEW 19 of 21

Processes 2022, 10, 1077 The pump speed was set to 1500 r/min and the inclined angle of swashplate to 12.5°,
18 of 20
and The
the results
pump of 9-piston
speed pump
was set and r/min
to 1500 10-piston andpump experimental
the inclined angle offlow pulsation
swashplate tocurves
12.5°,
in Δφ/2 =
and the results φ = 4° were obtained, which are shown in Figures
0 of 9-piston pump and 10-piston pump experimental flow pulsation curves 24 and 25. The simulation
and
in experimental
Δφ/2 = pump
The φ0 = 4° speedvalues
were was of tothe
obtained,
set 1500flow
which
r/minpulsation
are the of
andshown the piston
in Figures
inclined angle of pump
24 and were
25. The
swashplate calculated,
to simulation
12.5 ◦, as
shown in Table 3. The pump outlet flow pulsation obtained
and experimental values of the flow pulsation of the piston pump were calculated, as
and the results of 9-piston pump and 10-piston pump experimental flowfrom the
pulsation test was
curves more
in ∆ϕ/2
intense,
shown inand
=Tablethe
ϕ0 = 4◦3.difference
Theobtained,
were pump between
outlet the shown
which flow
are maximum
pulsation flow 24and
obtained
in Figures the
andfrom minimum
25. Thethesimulation
test was flowmorewas
and experimental
relatively large, values
because of
in the
the flow
actualpulsation
operation of the
of piston
the pump
plunger were
pump, calculated,
the flow as
pulsation
intense, and the difference between the maximum flow and the minimum flow was
shown in Table 3. The pump outlet flow pulsation obtained from the test was more intense,
will be affected
relatively large, by other factors,
because in the actualsuch as leakage of
operation pulsation, geometric
the plunger pump,pulsation
the flow and elastic
pulsation
and the difference between the maximum flow and the minimum flow was relatively large,
pulsation,
will be affected
because which will
by other
in the actual make the
factors,
operation flow
of such pulsation
as leakage
the plunger pump,of the plunger
pulsation, pump
geometric
the flow pulsation willlarger than
pulsation
be affected that
and in the
by elastic
simulation.
pulsation,
other factors, The
which
such simulation
will make the
as leakage dataflowarepulsation
pulsation, ingeometric
good agreement
ofpulsation
the plungerwithpump
and the experimental
elastic larger than
pulsation, data.
that
which in It
theis
verified
simulation. that
will make the when
The the
simulation
flow mismatch
pulsation data
of theare angle is
in good
plunger 3~5°
pump and
agreement the
larger thandead
with angle
thatthe
in the is 6~10°,
experimental the
simulation. The difference
data. It is
ofsimulation
output
verified thatflow
when
data pulsation
are the
in good between
mismatch
agreement odd
angle
withand
is the even
3~5° and piston pumps
the dead
experimental Itisis very
angle
data. small.
is 6~10°,
verified thewhen
that difference
◦ and the dead angle is 6~10◦ , the difference of output flow
ofthe
output flow angle
mismatch pulsation between
is 3~5 odd and even piston pumps is very small.
pulsation between odd and even piston pumps is very small.

Figure 24. Experimental diagram of a 9-piston plunger pump.

Figure 24. Experimental diagram of a 9-piston plunger pump.
Figure 24. Experimental diagram of a 9-piston plunger pump.

Figure 25. Experimental diagram of a 10-piston plunger pump.

Figure 25. Experimental diagram of a 10-piston plunger pump.
Figure
Table 25. Experimental
3. Flow pulsation. diagram of a 10-piston plunger pump.
Table 3. Flow pulsation.
Table 3. Flow Name
pulsation. Simulation Value Experimental Value
Name
9 plunger pump
Simulation
6.56
Value Experimental
7.45
Value
Name
910plunger pump
plunger pump Simulation
7.916.56 Value Experimental
8.65 7.45 Value
910plunger
plungerpump
pump 7.91
6.56 8.65
7.45
10 plunger pump 7.91 8.65
6. Conclusions
6. Conclusions
(1) Without considering leakage and flow distribution, the output flow pulsation rate
of an(1)odd pumpconsidering
Without is obviouslyleakage
lower and
thanflow
that distribution,
of an even pump. Withflow
the output the increase
pulsationofrate
the
of an odd pump is obviously lower than that of an even pump. With the increase of the
Processes 2022, 10, 1077 19 of 20

6. Conclusions
(1) Without considering leakage and flow distribution, the output flow pulsation rate of
an odd pump is obviously lower than that of an even pump. With the increase of the
number of plungers, the pump output flow pulsation rate decreases. The larger the
number of plungers, the slower the decreasing trend of flow pulsation.
(2) The influence of the port plate structure on pump output flow pulsation under dif-
ferent flow distribution conditions was studied. It is more reasonable when the
mismatching angle of the valve plate is 3~5◦ and the dead angle is 6~10◦ . At this
time, the difference between the output flow pulsation of odd and even piston pumps
is very small, and the odd or adjacent even number of pistons is appropriate. In
the hydraulic pump hydraulic motor system, when the hydraulic pump is used as a
hydraulic motor under the condition of power recovery, the odd number or adjacent
even number of hydraulic motors are appropriate.
(3) Through the comparison of the prototype pump bench test and simulation data, the
correctness of the simulation conclusion was verified, which provides a reference for
the design and improvement of the piston pump.

Author Contributions: Methodology, R.L.; writing—review and editing, J.L.; investigation, J.L.;
resources, X.D.; data curation, J.L.; writing—original draft preparation, J.L.; supervision, Q.L. All
authors have read and agreed to the published version of the manuscript.
Funding: Funding was obtained from Key R&D plan of Shandong Province, China, grant number
2020CXGC010806; Key R&D plan of Shandong Province, China, grant number 2021CXGC010813; Key
R&D plan of Shandong Province, China, grant number 2020CXGC011005; Innovation team project of
colleges and universities of Jinan science and Technology Bureau, Shandong Province, China, grant
number 2020GXRC042.
Acknowledgments: I would like to thank my tutor, Ruichuan Li, for all his support and guidance. I
would like to thank my colleagues for their care and help in my daily work.
Conflicts of Interest: The authors declare no conflict of interest.

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