Actuators 2025, 14(1), 34; https://doi.org/10.3390/act14010034 (registering DOI) - 16 Jan 2025
Abstract
Current trends in the development of technology are linked inextricably to the increasing level of automation in technological processes and production systems. In this regard, the development of systems for supplying working fluids with adjustable pumps that have high performance characteristics, an increased
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Current trends in the development of technology are linked inextricably to the increasing level of automation in technological processes and production systems. In this regard, the development of systems for supplying working fluids with adjustable pumps that have high performance characteristics, an increased service life and low operating costs is an important scientific and technical task. A primary challenge in the development of such systems lies in achieving low fluid flow rates while maintaining stable operating characteristics. This challenge stems from the fact that currently available controlled hydraulic pumps exhibit either a high cost or suboptimal life and efficiency parameters. This work focuses on the development of a plunger hydraulic pump with a small working volume. A mathematical model has been developed to investigate the characteristics, optimize the design of this pump and further expand the size range of such pumps. The solution was implemented on a computer using the dynamic modelling environment MATLAB/Simulink. In order to verify the mathematical model’s adequacy, a plunger pump prototype was built and integrated with a test bench featuring a measurement system. The test results showed higher pump efficiency and a significant reduction in hydraulic losses. An analysis of the obtained data shows that the pump is characterized by increased efficiency due to optimal flow distribution and reduced internal leakage, which makes it promising for use in hydraulic systems requiring improved operating characteristics. The developed pump has more rational characteristics compared to existing alternatives for use in water supply systems for induction superheaters. The experimental external characteristics of the developed pump are 10% higher than the external characteristics of the ULKA EX5 pump selected as an analogue, and the pressure characteristics are 65% higher. It offers production costs that are several times lower compared to existing cam-type plunger or diaphragm pumps with oil sumps and precision valve mechanisms. Additionally, it has significantly better operating characteristics and a longer service life compared to vibrating plunger pumps.
Full article
(This article belongs to the Section Control Systems)
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Figure 1
Figure 1
<p>Construction of a low-flow plunger pump: 1—asynchronous electric motor, 2—cam mechanism, 3—shaft coupling, 4—plunger, 5—fluid liner, 6—pump cylinder, 7—valve spool, 8—control valve sleeve, 9—end plates, 10—hydraulic control valve.</p> Full article ">Figure 2
<p>Pump calculation diagram.</p> Full article ">Figure 3
<p>Pump model fragment in Matlab/Simulink programme.</p> Full article ">Figure 4
<p>Time dependence of pressures in plunger chambers.</p> Full article ">Figure 5
<p>Time dependence of pressures in the discharge and suction lines.</p> Full article ">Figure 6
<p>Time dependence of plunger displacement and velocity.</p> Full article ">Figure 7
<p>Time dependence of the displacement of the first plunger and the discharge areas of the first discharge channel and the first suction channel.</p> Full article ">Figure 8
<p>Calculated momentary flow rates at different pressures.</p> Full article ">Figure 9
<p>Theoretical flow rate from pump rotation speed.</p> Full article ">Figure 10
<p>Calculated pump performance curves.</p> Full article ">Figure 11
<p>Calculated momentary leakage rates at 300 rpm and different pressures.</p> Full article ">Figure 12
<p>Hydraulic circuit diagram of the test bench.</p> Full article ">Figure 13
<p>Static and dynamic pump performance test bench: 1—tank, 2—discharge line throttle, 3—suction line throttle, 4—filter, 5—manometric pressure sensor, 6—vacuum pressure sensor, 7—manometer, 8—vacuum meter, 9—pump prototype, 10—induction motor, 11—rotation speed sensor, 12—measuring tank, 13—frequency converter, 14—tachometer, 15—base box, 16—DAC/ADC E20-10, 17—laptop.</p> Full article ">Figure 14
<p>Time dependence of pressures in suction and discharge lines at different rotational speeds.</p> Full article ">Figure 15
<p>Time dependence of measured and calculated pressures in suction and discharge lines at different rotational speeds.</p> Full article ">Figure 16
<p>Dependences of theoretical, computational and experimental pumping flows on pump rotational speed.</p> Full article ">Figure 17
<p>Pressure dependencies of pumping flow at different pump rotational speeds.</p> Full article ">Figure 18
<p>Pressure dependence of pumping flow of analogue pumps.</p> Full article ">
<p>Construction of a low-flow plunger pump: 1—asynchronous electric motor, 2—cam mechanism, 3—shaft coupling, 4—plunger, 5—fluid liner, 6—pump cylinder, 7—valve spool, 8—control valve sleeve, 9—end plates, 10—hydraulic control valve.</p> Full article ">Figure 2
<p>Pump calculation diagram.</p> Full article ">Figure 3
<p>Pump model fragment in Matlab/Simulink programme.</p> Full article ">Figure 4
<p>Time dependence of pressures in plunger chambers.</p> Full article ">Figure 5
<p>Time dependence of pressures in the discharge and suction lines.</p> Full article ">Figure 6
<p>Time dependence of plunger displacement and velocity.</p> Full article ">Figure 7
<p>Time dependence of the displacement of the first plunger and the discharge areas of the first discharge channel and the first suction channel.</p> Full article ">Figure 8
<p>Calculated momentary flow rates at different pressures.</p> Full article ">Figure 9
<p>Theoretical flow rate from pump rotation speed.</p> Full article ">Figure 10
<p>Calculated pump performance curves.</p> Full article ">Figure 11
<p>Calculated momentary leakage rates at 300 rpm and different pressures.</p> Full article ">Figure 12
<p>Hydraulic circuit diagram of the test bench.</p> Full article ">Figure 13
<p>Static and dynamic pump performance test bench: 1—tank, 2—discharge line throttle, 3—suction line throttle, 4—filter, 5—manometric pressure sensor, 6—vacuum pressure sensor, 7—manometer, 8—vacuum meter, 9—pump prototype, 10—induction motor, 11—rotation speed sensor, 12—measuring tank, 13—frequency converter, 14—tachometer, 15—base box, 16—DAC/ADC E20-10, 17—laptop.</p> Full article ">Figure 14
<p>Time dependence of pressures in suction and discharge lines at different rotational speeds.</p> Full article ">Figure 15
<p>Time dependence of measured and calculated pressures in suction and discharge lines at different rotational speeds.</p> Full article ">Figure 16
<p>Dependences of theoretical, computational and experimental pumping flows on pump rotational speed.</p> Full article ">Figure 17
<p>Pressure dependencies of pumping flow at different pump rotational speeds.</p> Full article ">Figure 18
<p>Pressure dependence of pumping flow of analogue pumps.</p> Full article ">
