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Student Name: Mr. Mohamed Mahmoud Semeda
First Degree: Bachelor of Engineering's power
Mechanical
University: University of Helwan - mattaria
Year of Obtaining Degree: 2004
Current Position: Technical Office MANAGER
Place of Work: Bosh Rexroth Group Egypt
Yasser Fahmy Hydraulic Engineering
 Prof.Mahmoud G. Rabie Prof . Ashraf S. Sabry

Manufacturing Engineering Mechanical Power Engineering

&Production department Modern Department
Academy for Engineering and Faculty of Engineering - Cairo
Technology, Cairo University
 Performance Investigation of The Swash Plate
Axial Piston Pumps having Conical Cylinder Block
With Constant Power Regulation with a rocker arm
Controller Incorporating a Pivoted Lever
By
Eng. Mohamed Mahmoud Elsayed Semeda

Under supervision of

Prof.Mahmoud G. Rabie Prof . Ashraf sabry

Manufacturing Engineering Mechanical Power Engineering
&Production department Department
Modern Academy for Faculty of Engineering - Cairo
Engineering and Technology, University
Cairo
 INTRODUCTION AND LITERATURE REVIEW
Swash plate axial piston pump Mathematical
Model
Constant Power Controller Mathematical
Model
Experimental work
Validation
Parametric study
There are large variety of industries and applications
that involves hydraulic parts, such as; loaders, trucks,
vehicles, robotics, etc

8
 piston stroke is larger
 decrease the pitch radius at the valve plate.
This improves the fluid fill characteristics
within the piston bores since the fluid fill
velocity is reduced. This helps to keep the
inlet pressure as high as possible to avoid
cavitations, especially at higher rotational
speeds.
 component of the piston centrifugal force
acting axially on the piston and always
pushing the piston towards the swash plate.
This component reduces the detaching effect
of the piston inertia.
(figure for Line of action of a piston during suction stroke)
 Kim S. D., model of a variable displacement axial piston
1987 pump
Kaliafetis P. They proposed a mathematical model and
and checked its validity. They showed that the
Costopoulos, operating conditions are very crucial for the
1994 pump dynamic behavior and that the dynamic
performance improves when the setting pressure
is decreased.
Manring N.D. Modeling and design of a variable geometric
and Johnson, volume axial piston pump
1996
Hugelman, designed a new adjustable stroke control module
1996 for axial hydraulic pumps
M. Wieczorek A computer aided design tool for axial piston
Ivantysynova , machines
2000
X. Zhang, 2001 introduced a reduced model of a damping swash
plate pumping mechanism
Kassem and investigated the dynamics of the swash plate axial
Bahr, 2000 piston pumps with conical cylinder blocks for first
time. They showed theoretically that the lateral
moment that acts on the swash plate increases
nearly linearly with the increase in the load
pressure and/or the decrease in the swash plate
inclination angle
Kruse,2001 Nonlinear modeling and simulation of a hydrostatic
drive
Ivantysyn, j. Hydraulic pumps and motor (book)
and Developed an approximate equation calculation for
Ivantysynova piston displacement
, M. 2001
Zhiru Dynamic modeling of a hydrstatic transmission with
Shi,2006 application to crane system characterization(thesis)
Baz A.,1980 optimization study of the dynamics of pressure-
compensated axial piston pumps
You, Z.,1987 developed a lumped-parameter model for pressure
regulated axial piston pumps using the bond graph
technique
W. Backe and investigated the design of a hydraulic-mechanical
H. Ulrich, 1988 pressure control of variable displacement pump
Akers and Lin the optimal control theory to determine the design
,1994 parameters of the pressure regulator of an axial
piston pump, which incorporates a single-stage
electro-hydraulic servovalve
Osama, The static and dynamic characteristics of a bent
G1998 axis piston pump, with constant power controller
Kassem and Comparative study on pump dynamic performance
Bahr, 2000 for conventional PD and fuzzy logic control

Anis , yasser Performance of Control Systems for Constant

2003 Power Operation of Axial Piston Swash Plate
 formulate a mathematical model and
investigate the pump dynamic characteristics
including the pump control unit.
Measurement of the transient and steady state
characteristics
Comparison and Analysis of results and model
validation
Study of the Pump Performance with power
Control through a parametric study
Piston displacement

sk L 3 L 1 / cos

L 3k =distance between cylinder tip and max piston hub

L 1k = distance between cylinder tip and min piston hub
=cone angle of cylinder
Cartesian coordinates for a piston in x direction
x K R 2 cos L3 sin cos
Cartesian coordinates for a piston in y direction
y K R 2 sin L3 sin sin
Cartesian coordinates for a piston in Z direction
z K L3 cos-L1
The variation of each piston chamber pressure
during one complete revolution of the pump is
derived with the following assumptions:
The pump rotational speed is constant
The pump suction and delivery pressures are
constants
The inertia effect of the oil column inside the
piston chamber is negligible
The total instantaneous leakage flow rate out
of the piston chamber QLk is proportional to
the piston chamber instantaneous pressure pk.
The coefficient of discharge is constant.
The oil density and bulk modulus are constants
 PS PCk
QS Cdi AS sgn PS PCk

Q S suction flowrate (m 3 / (s ))
AS suction area (m 2 )
PS suction pressure ( pa )
PCk piston chamber pressure
C d suction flow discharge coefficeint
 Pd PCk
Qd Cdd A d sgn (Pd PCk )

W here : Q d Deliveryflowrate (m 3 / s )
Ad delivery area (m 2 )
Pd delivery pressure ( pa )
PCk piston chamber pressure ( pa )
C (dd ) discharge flow discharge coefficient
flow drawn by hamonic motion of piston(m3 / s)
QK A P *v P
v P piston velocity (m / s )
A p piston area(m 2 )

Internal leakage flow (m3 / s)

P
QLEAK Ck
RL
R L leakage resistance
PCk piston chamber pressure(pa)
Piston chamber pressure pa
B
PCk QP QLEAK Qd QS dt
VC
W here B bulk modulus of elasticity
V C chamber volume (m 3 )
V P V 0
whereV 0 clearance volume
The following assumptions are considered :
- The viscous force effect is neglected.
- The friction force inside the chamber is
neglected.
Centrifugal force Newton
CF m p 2 (R1 (0.5Lc S K )sin )
Lc cylinder length, m
rotational speed,rad/s
R1 radius of the cylinder
arrangement at the base
of the cylinder block, m
Inertia force Newton
IF m p a P

Normal force on piston Newton

PCk A p mp a P m p 2 (R1 (0.5L P SK ) sin )sin FS
FN
cos K sin sin cos cos
M Y FN ZK sin X K cos
ZK cartesian coordenate in z direction (m )
X K cartesian coordenate in x direction (m )
inclination angle(rad )
 1. Housing, 2. Swash plate, 3.Slipper
pad, 4. Pump pistons, 5. Servo-piston,
6.Left servo-piston seat (maximum
displacement limiter), 7. Servo-piston
chamber, 8. Plunger chamber, 9.
Rocker arm, 10. Cut-off valve
chamber, 11. Left seat of the cut-off
valve spool, 12. Cut-off valve spool,
13. Cut-off valve damping orifice. 14.
Cut-off valves springs, 15. Cut-off
valve springs pre-compression
adjusting screw (Setting of the cut-off
pressure). 16. Damping orifice, 17.
Pressure reducing valve spool, 18.
Pressure reducing valve spring pre-
compression setting screw (Setting of
the control commencement pressure),
19. Pressure reducing valve springs,
20. Plunger, 21. Right servo-piston seat
(Minimum displacement limiter, 22.
Plunger chamber damping orifice, 23.
Servo-piston spring.
 Operation at low pressure level
 Operation at high pressure level
Motion of the servo-piston 2
dy dy
Psp Asp -Pp A p FslR FslL Fsw msp 2 f sp k sp ( y y o )
dt dt
The swash plate force is:
Fsw T sw / rs
Where
Pp=pump delivery pressue (Pa)
Psp=sevo piston pressure (Pa)
AsR=servo piston right area ( m2)
AsL=servo piston left area ( m2 )
Tsp=swash plate moment (Nm)
rsw=swash plate arm radius (m)
msp=servo piston mass (kg)
fsp=servo piston friction
ksp=servo piston spring stiffness N/m
y=servo piston displacement (m)
yo=servo piston spring precompression (m)
FslL=Stroke limiter reaction force left (N)
FslR=Stroke limiter reaction force right (N)
Rocker arm dynamics

d 2 d
Ppl A pl ( y m y ) FrL FrR l rs J 2 f ra k pr (x pro x pr ) lv
Where
dt dt
FrL=Rocker arm left-seat reaction force, N
FrR=Rocker arm Right-seat reaction force, N
lv= Lrs=Vertical distance of pressure reducer spool axis from the Rocker arm axis of rotation, m
J=Reduced moment of inertia of the rocker arm and attached moving parts, N
fra=Rocker arm viscous friction coefficient, Nm/s
Ppl=Pressure in the plunger chamber, Pa
Apl=Plunger area, m2
=Rocker arm rotational angle, rad
Xpr=Pressure reducer spool diaplacement, m
xpro =Initial compression of the pressure reducer spring, m
ym =Maximum servo-piston stroke, m
kpr =Pressure reducer spring stiffness, N/m
The spool of the plunger is directly attached to
the rocker arm and its displacement is:
x pL ( y m y ) tan( )
Also The spool of the pressure reducer is
directly attached to the rocker arm and its
displacement is:
x pr l rs tan( )
Transient response of rocker arm to step increase in
plunger chamber pressure, Ppl of different
magnitudes, at zero servo-piston displacement
Continuity equation in the plunger chamber
dx pl V plo A pl x pl dPpl
Q pl A pl
dt B dt
The flow rate through this orifice is:

Q pl C D Aopl 2(Pp Ppl ) /

Where
CD=Discharge Coefficient
Aopl=Area of the servo-piston damping orifice, m2
Fco=Pressure reducer spool viscous friction coefficient, Ns/m
=Oil density, kg/m2
Qpl=Flow rate through the servopiston damping orifice, m3/s
B=Bulk modulus of oil, N/m2
Vplo=Initial volume of oil in the inner plunger chamber, m3
Pressure reducing valve(power valve)

Fluid flow
through the
pressure
reducer

Valve spool and Xpr<0, Xpr=0, Xpr>0,

sleeve ART Zero APR
Opened lapping Opened

Pressure reducer flow rates, pressures and areas

Flow rate from the high pressure port to the reduced pressure
port

Q PR C D A PR 2(Pp Ppr ) /

Flow rate from the reduced pressure port to the return line

Q RT C D A RT 2(Ppr Pt ) /
 The pressure in the exit line is calculated by applying the
continuity equation to this line
V pr dPpr
Q PR Q RT Q R
B dt

Where
Vpr=Volume of reduced pressure chamber, m3
B =Bulk modulus of oil, N/m2
QR =Flow rate delivered to the cut-off valve, m3/s
Pressure reducing valve(power valve)

Fluid flow
through the
pressure
reducer

Valve spool and Xpr<0, Xpr=0, Xpr>0,

sleeve ART Zero APR
Opened lapping Opened

Pressure reducer flow rates, pressures and areas

Pressure reducing valve(power valve)

Fluid flow
through the
pressure
reducer

Valve spool and Xpr<0, Xpr=0, Xpr>0,

sleeve ART Zero APR
Opened lapping Opened

Pressure reducer flow rates, pressures and areas

Pump cut off valve
Equation of motion

d 2 x co dx co
Pco Aco FcoL mco 2
f co k co (x co x coo )
dt dt
Where
mco=Cut-off valve spool mass, kg
FcoL=Pressure Cut-off spool Seat reaction forces, N
fco =Pressure Cut-off spool viscous friction coefficient, Ns/m
kco=Cut-off valve spring stiffness, N/m
xcoo=Initial compression of pressure reducer spring, m
Flow rates through the cut-off valve
Flow rate outlet from Cut-off valve to servo-piston chamber

Qcoo C D Acoo 2(Pp Psp ) /

Flow rate inlet from the reduced pressure chamber to the

servo-piston chamber

Qcoi C D Acoi 2(Ppr Psp ) /

Hydraulic test bed
Description of the Hydraulic Test Bench
1. Hydraulic Pump Unit

2. Load Disturbance Unit

3. Oil Conditioning Unit
 HDA 3700

HMG2020

Evs 3100-1
the power controller of the pump
has three setting parameters:
1. maximum displacement
controller
2. Pump controller
commencement pressure
3. The maximum operating
pressure