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Pressure Transients in an Axial Piston Hydraulic Pump


B. O. Helgestad, K. Foster and F. K. Bannister
Proceedings of the Institution of Mechanical Engineers 1974 188: 189
DOI: 10.1243/PIME_PROC_1974_188_021_02

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189

FLUID POWER TRANSMlSSlON GROUP

PRESSURE TRANSIENTS IN AN AXIAL PISTON


HYDRAULIC PUMP
B. 0. Helgestad, PhD* K. Foster, PhD, CEng, FIMechEj-
F. K. Bannister, CBE, PhD, CEng, FIMechES

A method is given for calculating pressure transients in an axial piston hydraulic pump. Some theoretical
predictions are given of the effect of port timing and the effect of introducing restricting grooves at the ends
of the kidney ports in the valve plate and suggestions are made of the effects of these parameters on noise
emission; comparative measurements of noise are then quoted that support the general arguments. A parallel
shot is recommended as the best compromise for the restrictor groove geometry to give good results over the
widest range of operating conditions, including reverse rotation. Finally, mention is made of the use of a relief
valve in the port plate for noise reduction.

1 INTRODUCTION shape and timing of intake and delivery ports for minimum
BECAUSEof an inherent flexibility and high power-to- pressure pulses.
weight ratio, hydraulic units have found an increasing Experimental measurements of the pressure variations
industrial use over the past few years for sequence con- are then presented for comparison with those predicted
trols, feedback servomechanisms and for variable speed theoretically. Experimental measurements of noise have
power transmissions. During this time, working pressures already been published in (I)$.
and speeds have risen, whilst the mass of individual units
has tended to fall, so that radiated noise has become rela- 1.1 Notation
tively greater. At the same time, more concern has been
shown over environmental conditions inside factories, so A , Effective area of valve F.
that the noise problem created by the increasing number A , Normal port area of cylinder number n at crank angle
of hydraulic units in use must be solved. 8,.
b Constant (= I +(clearance volume)/J VJ.
The present investigation comprises a theoretical and
experimental examination of the cyclic variations in oil C, Discharge coefficient of port at 8,.
pressure in the cylinder and inlet and delivery chamber of D, Diameter of piston restrictor hole.
F , Axial spring load/cylinder.
a Lucas ID 500 pump (Fig. 1). Since such fluctuations
produce in the pump members large cyclic forces with a s The reference i s given in Appendix 2.
strong vibration-exciting potential, an understanding of
them is a prerequisite to any rational study of pump noise
Kistler pre;sure transducer
generation. It is thus a first step towards identifying the
sources of noise and their eradication by design modi-
fication.
Neglecting progressive waves in the pipework, differen-
tial equations are established for the transient pressures
in the cylinders and inlet and delivery chambers, the
motion of the piston/slipper assembly also being covered.
This step-by-step computer solution gives theoretical
results for various geometric arrangements and running
conditions and hence leads to conclusions concerning the

This paper is published for written discussion. The MS. was received
on 8th September 1972 and accepted for publication on 26th
October 1973. 13
* T.O.S., 3601 Kongsberg, Norway. Formerly Mechanical Engin-
eering Department, University of Birmingham.
t. Reader in Fluid Power and Control, Mechanical Engineering Variable stroke control
Department, University of Birmingham.
$ Professor of Thermodynamics, Mechanical Engineering Depart-
ment, University of Birmingham. Fig. 1. Section through axial-piston slipper-pad pump

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B. 0.HELGESTAD, I<. FOSTER A N D F. K. BANNISTER

Slipper bearing load at 8,. pump (J), relief valve (N), filter (K) and cooler (L) supply
Gap between slipper and swashplate at en. cooled and filtered oil at 100 lb/in2 pressure to the low-
Constant used in inferring A,. pressure side of the drive pump-motor. The high-
Length of piston in cylinder at t.d.c. pressure side of the drive unit is connected to the low-
Length of piston restrictor hole. pressure side of the test pump, whereby valves (E) and (G)
Mass of oil in cylinder at On or equivalent mass of enable the base (i.e, test pump suction) pressure to be
piston-slipper assembly. varied in the range 0-1000 lb/in2. The valve (F) and the
Total number of pump cylinders. relief valve (H) control the delivery pressure from the test
Pump speed (revjmin). pump. The pump is separated from its driving motor,
Suffix giving identifying number of individual transmission and auxiliaries by a main laboratory wall,
cylinders. thereby substantially excluding noise from these sources
Pressure in pump casing. in preparation for the acoustic tests to be carried out on the
Pressure in cylinder at 0. pump later.
Pressure in delivery chamber a t 8. Using a Kistler 601G miniature piezoelectric transducer
Pressure in inlet chamber at 8. and slip rings (S), the pressure variations in one of the
Pressure in slipper cavity at 8. cylinders were recorded; those in the inlet and delivery
Time average of Pd over a cycle (= nominal delivery pipes were measured using similar transducers. In the
pressure). present investigation all pipes were short enough to
Time average of P, over a cycle (= nominal suction eliminate the effects of progressive waves within them.
pressure). An anechoic chamber was not available and, therefore,
Volume rate of flow through port at 8. only comparative noise measurements were possible. In
Leakage past piston at 19. order that these should be significant, the noise measure-
Leakage past slipper at 8. ments were made at specific points around, and close to,
Sum of flows from inlet or delivery chambers to the pump and all the tests were carried out at night when
cylinders at 8. no other machinery was working.
Radius to centre line of kidney port.
Outer radius of slipper annulus. 3 THEORY
Inner radius of slipper annulus.
Radius of piston. 3.1 General
Radius of an annular element on slipper. Fig. 3 shows a developed view of the pump, indicating
Time or radial clearance of piston in cylinder. how several cylinders communicate simultaneously with
Volume of cylinder at 8. the inlet chamber, of volume V , including associated pipe-
Volume of delivery chamber and pipework. work, during their outward, i.e. suction, strokes and with
Volume of inlet chamber and pipework. the delivery chamber, of volume V , including pipework,
Swept volume/cylinder. during their inward, i.e. delivery strokes. Fig. 4 shows a
Speed of separation of slipper and swashplate at OR. simple arrangement that ensures this. The broken line
Swashplate angle. represents the outlet from a cylinder, whilst the full lines
Bulk of oil. represent the two kidney-shaped apertures that collect the
Crank angle at commencement of port opening. flow during the inward motion of the pistons and supply
Crank angle past t.d.c. (suffix n denotes an individual the oil to the pistons during the suction stroke.
cylinder). During one revolution, each cylinder experiences a
Oil viscosity. square wave application of pressure. This is reacted back
Restrictor groove angles (Fig. 5). on to the structure of the pump in various ways. For
Oil density. example, in a seven-piston pump, sometimes four pistons
Pump speed (radis). will be pressurized at one time and at other times only
three; the resulting force on the casing of the pump is a
2 INSTRUMENTATION train of square pulses at a frequency seven times the
In Fig. 2, which shows the layout of the apparatus, the rotational speed of the pump. The resulting strain in
pump under test (A) is driven by a constant speed electric the case is radiated as noise. Finally, the flow from the
motor (M) through a variable-ratio hydrostatic transmis-
sion comprising a pump (C) and motor (B). The boost

L I
Fig. 2. Arrangement of test rig Fig. 3. Developed view of the pump

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PRESSURE TRANSIEXTS IN AN AXIAL PISTON HYDRAULIC PUMP 191

En I

Fig. 4. A cylinder opening into a kidney port w i t h no


silencing grooves. The port area is given by
.
-?

Fig. 5. A cylinder opening into a kidney port w i t h a tri-


angular groove, as shown in the projected views. The
port area is given by
output port is not uniform, but will contain a ‘ripple’ at a
frequency equal to the rotational speed times the number (7
A, = R i - Hsin2 q)
tan (~,/2),(e,-sy
of pistons, thus contributing to the noise in the pipework.
With the simple arrangement of Fig. 4 and depending
on the port timing chosen, further undesirable events may control of the four opening/closingpoints is a disadvantage,
as is the mechanical complexity.
occur when successive cylinders are near the top and
bottom dead centres (t.d.c. and b.d.c.), the flow and An alternative method of noise reduction over a wide
pressure waveforms thereby being adversely modified. operating range is to minimize the reverse flow, cavitation
and pressure overshoots by the port modification of Fig. 5.
For example, as the cylinder approaches b.d.c. (corre-
sponding to position 4 of Fig. 3) the piston is moving With the leading edge of each kidney port displaced
outwards and if the kidney port (S of Fig. 4) closes off backwards, a sloping V-groove is milled in the land with
too soon a low pressure will be created in the cylinder, its apex at the point of nominal port opening. This results
whereas, if it is open until after b.d.c., fluid will be forced in a progressive increase in effective area during the earlier
back into the suction port as the piston moves inwards. stages of port opening that allows an early opening, but
restricts the reverse flow. The V-groove is long enough to
As the cylinder passes b.d.c., corresponding to position 5
of Fig, 3, and moves into the delivery stroke, the fluid in cater for the different timing conditions required over a
range of pressure-swashplate angle combinations. This,
the cylinder will begin to be compressed. If the delivery
kidney slot opens too soon, the cylinder, initially contain- however, introduces the further difficulty that the volume
ing low-pressure oil, is suddenly exposed to the high- of flow through the groove depends on time and therefore
pressure delivery chamber; a transient reverse flow thus the pressure changes in the cylinder are now a function of
occurs inwards through the port until the cylinder con- rotational speed as well as rotational angle. Thus although
tents are thereby rapidly compressed to the appropriate the groove geometry may be suitable for one speed-
high pressure and the normal piston-produced outflow pressure combination, it may give too little restriction at
begins. If, on the other hand, the delivery kidney slot lower speeds, but too much and hence a large pressure
opens too late, the oil in the cylinder is compressed to too overshoot at higher speeds. On the suction stroke, cavita-
high a level and a large pressure peak occurs. Similar tion may occur at higher speeds. The present section
examines the theoretical flows and pressures in the pump
transient effects may occur at the beginning of each suction
stroke (movement 1 to 2) where either the initially high- with two important assumptions :
pressure oil left in the cylinder suddenly expands into the (1) The varying flow through the V-grooves is treated
inlet chamber if the port opens too soon or the cylinder as quasi-steady, the instantaneous coefficients of dis-
oil is expanded to too low a level, causing cavitation, if the charge at successive points during opening being as
port opens too late. The port timing that gives equality of determined from steady flow tests on large-scale models
cylinder and port pressures at the point of opening (or at appropriate Reynolds numbers or on actual port
closing) is referred to as ‘ideal timing’; its dependence on plate assemblies for confirmation.
swashplate angle and delivery pressure-both of which (2) The drop in pressure of the delivered oil is con-
may vary-limits its practical significance, but the concept sidered to occur, not in a motor as would be the case in
is useful. a hydrostatic transmission, but in an adjustable restrictor
Variable timing, where the port plate is rotated by a valve, corresponding to (F) in the test arrangement of
cylinder sensitive to delivery pressure, has been used and Fig. 2, before the oil is returned to the suction side of
gives some noise reduction, but the lack of independent the pump.
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192 B. 0. HELGESTAD, K. FOSTER AND F. K. BANNISTER

The reason for this second assumption is that a pump iteration later in the calculation and corrected by adjust-
produces a flow pulsation that is only converted into a ment of K, which in practice lies between 0.98 and 1-01.
pressure pulsation by the resistance or impedance of the The inlet chamber outflow at time t is the sum 24, of
circuit. T o be able to compare experiment with theory, the instantaneous flows q, into the various cylinders then
this relatively simple output circuit has been chosen. communicating with that chamber. For any cylinder, n,
For a full hydrostatic transmission, the analysis would in the process of opening into, or closing from, the suction
require some extension, but no new principles would arise. stroke,
The analysis is based on simultaneous consideration of
the instantaneous rates of volume inflow to (qinflow)and/or
outflow from (qoutrlow)the respective cylinders and the
inlet and delivery chambers, including pipes. Hence, ex- where, for that cylinder, P,,, C, and A, are the instantan-
pressions are obtained for the net instantaneous rate of eous values of cylinder pressure, discharge coefficient and
gain of mass in each cylinder and, in the respective port area, C , and A, depending on the angular position
chambers, from the known rates of cylinder volume On (= O1 -(a- 1)2n-/m) reached by the cylinder, 8, being
changes and a knowledge of the isentropic oil bulk the angle rotated by cylinder 1 past t.d.c. and wz the num-
modulus, the rates of pressure change follow. The result- ber of pistons. The area of the grooves may be calculated
ing simultaneous differential equations are solved step-by- according to the geometry and the algebraic expressions
step using a computer. An approximate allowance is made for the two port configurations initially considered are
in the analysis for both the leakage past the pistons and indicated in Figs 4 and 5. C, depends on the port, the port
the controlled oil flow through the piston body to the opening and, in a manner determined from steady flow
cam plate slippers. tests on the port plate assembly or a large-scale model, on
The fundamental equation that, for any cylinder or the instantaneous Reynolds number.
chamber, relates changes in the volume, V, oil density, p, When A , has become so large that (Pi-P,,) is negli-
and oil mass, M (= pV), with time is gible-a situation occurring over most of the kidney port--
dM dV d the flow depends on the geometry and rotor speed, and
-dt
=p-&+V$. . . . (1) equation (5a) is replaced by
which, with the bulk modulus P = p(dP/dp), i.e. dpldt = q, = $V,W sin On 0 < 0, < T . (5b)
(pIP)(dPidt) and, with dMldt = P(qintlow-qoutrlow), be- In a seven-piston pump (Fig. 3), there are at any instant
comes
either two or three fully open cylinders obeying equation
(5b) and zero, one or two partly open ones obeying equa-
tion (5a), depending on the rotor position.
This basic expression is applied to the various chambers Writing w = doidt and putting dVi/dt = 0, equation
as follows. ( 2 ) is now applied to the inlet chamber and, with equations
(4) and (5) substituted, gives
3.2 Inlet chamber
For simplicity, the flow into the inlet chamber is regarded
as coming from a source of constant high pressure, p,,
in which the various qn values are based on equations (5a)
through a restrictor of effective area A i (including dis-
or (5b).
charge coefficient).The value of p, is the time average of
If, in applying equation (5a) to determine a q, value for
the slightly-fluctuating delivery pressure P,, i.e. the steady
equation (6), the term (Pi- Pen) becomes negative, this
value as recorded by the delivery pressure gauge. The
indicates a reversal in port flow and z/(Pi-Pcn) must be
pressure Piin the inlet chamber fluctuates cyclically since
replaced by - 2/(Pcn- Pi). A similar procedure is neces-
the finite number of pistons creates a cyclic variation in
sary anywhere else in the theory when the variable under
outflow; the instantaneous flow into a constant inlet
a root becomes negative; the discharge coefficient must
volume V, also must vary cyclically, and is given by
also be changed to that for the reverse flow.

3.3 Delivery chamber


The value of A, depends on the setting of valve F in the
Outflow from the delivery chamber is regarded as occur-
apparatus and is unknown. In the computation, p d and the
ring through a restrictor to a region of constant low pres-
average value of Pi (i.e. Pi)are those used in the experi-
sure (pi), this being the time average of the slightly-
ments. A , is then estimated assuming that equation ( 3 )
fluctuating suction pressure Pi,i.e. the reading of the
holds good for average values of the parameters and where
suction pressure gauge. By arguments similar to those for
qinflowis given in terms of the pump volumetric displace-
the inlet chamber the equation for the variations in delivery
ment setting and the speed of rotation. Thus,
chamber pressure P, become

where V , is the swept volume/cylinder, m is the number


of pistons and AT is the pump speed in revlmin. K is a In reality Pd will always be larger than Fi, but the sign-
constant arising from the non-linearity of equation (3). changing convention adopted a t the end of Section 3.2
The error in the initial estimate of A, is arrived at by will automatically take care of this point.

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PRESSURE TRANSIENTS I N AN AXIAL PISTON HYDRAULIC PUMP 193

The outflow (-4,) from cylinder n to the chamber is


given by either

or
qn = +V,w sin 0% 7r < 8, < 2n . (8b)
Planes o f constant
delivery pressure, Ibflin'
the choice depending on whether or not the port is fully
open.

3.4 Typical piston/cylinder


Equation (2) is now applied to a cylinder space, n, of
which the instantaneous volume, V , is V,, = +Vs(b- cos
0,) and hence dV/dt = +wV, sin On. Thus, replacing the
net inflowterm (qinflow-qoubflow) by (qn--m--sn), in which
qpn and qsn are the leakage flows past the piston and into
the slipper bearing respectively, gives equation (9) for
the variations in the cylinder pressure P,, :

For a cylinder communicating with the inlet chamber, qn


follows from either equation (5a) or (5b) depending on
whether the port is partly or fully open; for one com-
municating with the delivery chamber the equation is
either (8a) or (8b).
The leakage from the cylinder should also include that Jbd c Angle of part opening from t d c , 6
part of the leakage between the port plate and the cylinder rad
block that is appropriate to the particular cylinder. Both
the leakage past the piston and the leakage past the port Fig. 6. Calculated angle of port opening t o give perfect
plate is difficult to estimate. Therefore, to compare experi- precompression of oil in cylinder, shown as a function
of both piston swept volume and delivery pressure.
ment with theory, the total average leakage was measured Effect of leakage is included a t rotational speed of
for each chosen operating condition and divided by 39 to 3000 rev/min
find the average leakage from each piston (since on
average 34 pistons are in the high-pressure region at any
one time) and assuming negligible leakage from the pis- means of the above equations, the angle of port opening S
tons connecting with the low pressure port. Then the necessary to provide 'ideal' precompression of the oil in a
leakage past the slipper was calculated as in Appendix 1 cylinder on the delivery stroke is shown in Fig. 6, plotted
and subtracted from the experimental figure. The term qDn against the piston swept volume (directly related to swash-
was then adjusted to give this resulting average figure, plate angle) and the delivery pressure for a speed of
whilst still retaining the characteristic that it was propor- 3000 rev/min. This shows the very wide range of port
tional to the instantaneous pressure between the cylinder timing required if the pump is to operate under the full
and the case. range of delivery pressures and swashplate angles; rota-
The reason for separating the slipper flow from the tional speed is only important if leakage is important and
cylinder leakage is that the slipper clearance varies this will be the case only at very small swashplate angles.
throughout the cycle. Appendix 1 includes the equations For a given swashplate angle, the variation of S with
for the dynamic motion of the piston and slipper assembly, delivery pressure could be approximated to by a straight
which have a further importance in that they make possible line, at least for a limited pressure range. This fact has
a better understanding of the way in which the motion of led to the use of variable port plate timing where the port
the piston assembly increases the possibility of cavitation plate is rotated by a spring-loaded cylinder connected to
under the slipper. the delivery line. By inclining the axis of rotation of the
swashplate it would also be possible to compensate par-
3.5 Solution of equations tially for the effect of swashplate angle.
Equations (5a) or (5b), (6) and (9) or alternatively equa-
tions (8a) or (8b), (7) and (9) are combined with equations 4.2 Effect of port plate configuration on pressure
(13) and (15) from Appendix 1 for solving. These are transients
non-linear simultaneous differential equations and were Theoretical solutions of the above equations are presented
solved by a variable step-length Runge-Kutta standard
in the main diagram of Fig. 7 for various port plate con-
programme on the University KDF 9 computer. figurations when N is 3000 rev/min, Pd is 2000 lbf/in2,
4 THEORETICAL RESULTS
Pi is 100 lbf/in2 and the swashplate angle CI is 20". The
separate graphs at the top of Fig. 7 show the non-
4.1 Timing for 'ideal' precompression dimensional effective port area C,A,/A,, i s . the coeffi-
Before presenting the pressure transients calculated by cient of discharge times the actual area of port opening,
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194 B. 0. HELGESTAD, K. FOSTER AND F. K. BANNISTER

3000

2000

1000

g
,
- , I 225 270 315 360 ! ! 45

a Round kidney port with 'ideal' compression and expansion. d Suction stroke transients with narrow V (6 = 26', r) = lo",
b Round kidney port with early opening (6 = 0.5'). ( = 60").
c V-groove at port opening ( 6 = 2 4 " , TJ = 14.5",f = 60"). e V-groove at each end of kidney ( 6 = 26", = 1 4 . 9 , 5 = 60").
Fig. 7. Theoretical cylinder pressure versus rotational angle for various valve plate geometries (N = 3000 rev/min.
pd = 2000 Ibf/in2, pi = 100 Ibf/in2, a = 20")

divided by the maximum effective port area, plotted 7 = 14.5" and angle f = 60" (see Fig. 5). The area before
against angle of rotation. pressure equalization is much smaller than in the previous
Fig. 7a shows the results for ideal precompression where case and the reverse flow is thus reduced. A penalty for
the angle of port opening measured from b.d.c. is 23". In this gain is, however, apparent in the undesirable over-
this case, the curve of port area shows that the port shoot in cylinder pressure, P,, early in the delivery period.
suddenly opens very close to the point where the pressure This is caused by throttling of the piston-excited outflow,
in the cylinder equals the required delivery pressure. As the groove restriction continuing well beyond the point of
would be expected, the rate of cylinder pressure rise (Pc) pressure equalization.
is lower than for other configurations. The pressure ripple A further penalty of introducing restrictions is shown
in the delivery line (Pd)is also smaller, but this would not in Fig. 7 4 where the predicted transients for the suction
necessarily follow since the effect of port timing on the flow stroke are plotted; the running conditions are as before,
fluctuations is quite separate from the effect on pressure except that a narrow angle groove (7 = 10') has been
rise. chosen to accentuate the effects of the restriction and S is
Fig. 7 b illustrates the penalty of a very early port open- now 26". The potential pressure 'undershoot' (shown
ing (6 = 0.5"). The pressure Pc rises very quickly because dotted) corresponding to the previous overshoot of pres-
of the backflow of oil into the cylinder, which occurs from sure in Fig. 7c is prevented from materializing by cavi-
the point at which the port opens up to the point at which tation. The formation of a cavity allows the flow into the
the pressures in cylinder and delivery line are equal. The cylinder to be significantly smaller than the rate of volu-
sudden backflow also modifies the flow ripple unfavour- metric displacement of the piston and during this phase
ably and thus in turn causes sharper changes in the pres- the pressure in the cylinder remains constant at the vapour
sure ripple in the delivery line, Pd. pressure. The duration of cavitation, indicated in Fig. 7d
Fig. 7c shows the result for a V-groove at the beginning by the flat base to the graph of cylinder pressure, is con-
of the kidney port. The groove begins to open at 6 = 2-8" siderable and is due to the continued restriction of the
and the shape of the groove is characterized by angle port area beyond the point where the cylinder and delivery
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PRESSURE TRANSIENTS I N AN AXIAL PISTON HYDRAULIC PUMP 195

port pressures equalize. A further effect of cavitation is oscillation as the cylinder pressure equalizes with the
that there is no pressure force available to hold the piston delivery pressure. Case ( b ) is that of a large swashplate
and slipper pad in close contact with the cam plate. If it angle and a small difference between suction and delivery
were not for the auxiliary cam plate, the predicted rise pressures, resulting in too much precompression and a
of the slipper would be 0.158 in. Also, cavitation will be consequent large pressure overshoot. In both cases, the
experienced both below the slipper pad and in the ball slope of the pressure rise depends upon the speed of pump
joint holding the slipper on to the piston. rotation and the restriction afforded by the entry groove
It is clear that the ‘overshoot’ and ‘undershoot’ of the and the correlation is seen to be good over the whole of
cylinder pressure P, shown by curves c and d of Fig. 7 the trace, both when the groove is dominant and when it
are the result of grooves that are too long. It might be is not.
thought that it would be better to limit the length so that I n case (b), in addition, using a high suction pressure
the pressure swings are acceptable. The problem is that means the cavitation is inhibited and it is possible to see
the length required varies with pressure and swashplate the effect of a groove in causing a very severe undershoot
setting in a manner similar to the variation of the ideal in cylinder pressure when passing from delivery to suction.
timing and also depends upon the speed of rotation, be-
cause time is now required for any equalizing flow. Some
compromise is possible where the reversed flow and over- 5.2 Noise
shoot are minimized for some optimum running conditions Noise is regarded as the result of rate of change of strain
and the variation of both of these quantities is kept within in the casing of the pump or in the connecting pipes that
reasonable bounds over the rest of the operating range. is transmitted to the surroundings as pressure waves in the
I n all the cases presented so far, the pressure in the air. The results of an investigation into the vibrations in
cylinder at b.d.c. has been assumed to be suction pressure the pump are given in (I), but very briefly the procedure
and at t.d.c. has been assumed to be delivery pressure; was as follows. The basic shape of the variation of strain
this would be the case if the kidney ports closed exactly at with time in various parts of the pump body, which was
b.d.c. and t.d.c. respectively without any prior restrictions. periodic, with a sharp rise and fall at a frequency of seven
In Fig. 7e, however, the case is presented for a port plate times the speed of the pump, was predicted theoretically.
with a V-groove cut at each end of the kidney ports to Experimentally, strain gauge measurements on the pump
allow reversed rotation. The problem here is that at the end body showed a good agreement with the basic shape, but
of the suction stroke, the groove that is not required for also showed that ripples of various higher frequencies
the particular direction of rotation chosen restricts the were superimposed on the basic shape. These super-
flow into the cylinder more severely than the same size of imposed frequencies corresponded with the natural fre-
groove at the beginning of the stroke. I n the latter case, quencies in the pump casing and assembly which were
there is already high-pressure oil in the cylinder as it later identified by electrically exciting the pump whilst
enters the groove in the port and suction into the cylinder stationary and empty.
will only occur towards the end of the groove, where it is The strain records were analysed to find the frequency
widest. At the end of the kidney port, however, suction spectra of the noise. These results were cross-checked
occurs over the whole of the travel of the cylinder along with accelerometer measurements at the same points and
the groove right to the narrowest part and, in consequence, also with acoustic signals picked up close to the mounting
cavitation may be severe. A fuaher effect is that cavitation points for the strain gauges and accelerometers. The
does not end till the pump has rotated 12” past b.d.c., i.e. majority of these tests were carried out with a standard
almost at the end of the V-groove, so that the pressure port plate that gave the highest noise when the port timing
rises late and quickly. To be effective on the delivery was not ‘ideal’.
stroke, the restriction provided by the groove should begin The analysis of the accelerometer and noise measure-
later, but if this were done, it would make the cavitation ments showed that the natural frequencies of the pump
worse. Thus it is clear that using triangular grooves in a casing were excited enough to make a significant contri-
bi-directional pump does not necessarily give the same bution to the noise. The total noise measured in each case
benefit as a uni-directional one. showed that a standard pump with no delay in timing was
One further point about Fig. 7e is that the grooves are the most noisy, the pump with ideal timing was least
shorter than in Figs 7c and d. This results in less overshoot noisy, whilst a pump with V-grooves in the port plate gave
for the running conditions chosen. For smaller swashplate a noise level slightly higher than that for ideal timing. For
angles, the groove would not be long enough and there operating at a speed of 1000 revlmin, delivery pressure of
would be much more reverse flow. 2000 Ibf/in2, boost pressure of 100 lbf/in2 and maximum
swashplate angle, the measured values close to the centre
of the middle of the rear cover plate of the unit were
5 EXPERIMENTAL R E S U L T S
97.2 dB, 87 dB and 90 dB respectively for each of the
5.1 Pressure fluctuations three port plate configurations.
The good agreement between theory and experiment is Although these results are for a specific condition of
shown in Fig. 8. This comprises two specimen diagrams, measurement and operation, the trend of difference shown
chosen to represent the extreme ends of the working range between the port plates was similar for all the measure-
of a pump with triangular entry grooves in the kidney ments. Thus the evidence is that ‘ideal’ timing gives the
ports. Case (a) is that of a low swashplate angle with a lowest noise levels, but that V-restrictors are a good second
high delivery pressure where there is insufficient pre- best. A difference of 7-2 dB between the ‘standard’ and
compression so that there is no overshoot, but an initial V-grooves port plate was noted, a very significant reduction
reverse flow into the cylinder resulting in a slight pressure from a noise and discomfort viewpoint.

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196 B. 0. HELGESTAD, K. FOSTER AND F. K. BANNISTER

Angle o f rotatlon, 0
rad

Fig. 8a. Comparison of theory (full line) and experiment (broken line) for port plate
with triangular entry groove. In both cases, N is 1000 rev/min, S is 24",q i s 10" and
5 is 60". p d is 3000 Ibf/in2, p , is 100 Ibf/in2 and a is 2"

0 d 2d
tdc bdc t d.c.
Angle o f r o t a t i o n , 0
rad

Fig. 8b. Comparison of theory (full line) and experiment (broken line) for port plate
w i t h triangular entry groove. In both cases, N is 1000 rev/min, S is 2.8". q is 10"
and is 60". pd is 1500 Ibf/inz, Pi is 100 Ibf/in2 and a is 20"

6 T H E U S E OF PARALLEL S L O T S parallel slot varies linearly with angle of rotation of the


A S RESTRICTORS cylinder block and therefore is roughly proportional to the
It has been pointed out that, theoretically, using V-grooves piston-produced flow passing through the slot early in the
in a bi-directional pump has the disadvantage that greater delivery stroke. By calculating the width of the slot to give
cavitation may occur at the end of the suction stroke than a pressure difference at maximum pump speed and swash-
at the beginning. Similarly a greater pressure peak could plate angle that is just equal to the boost pressure, cavitation
be predicted at the end of the delivery stroke than at the is avoided at any point in the cycle. The length of the slot
beginning. A better compromise may be to use parallel is fixed for operation at a minimum swashplate angle,
slots rather than V-grooves so that the restriction is less where a larger rotation of the pump is required for pre-
severe at the end of a kidney port. It is easier to design compression of the fluid in the cylinder. The disadvantage
parallel slots for use as restrictors because the area of a of this design is that, on the delivery stroke, the backflow

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PRESSURE TRANSIENTS I N AN AXIAL PISTON HYDRAULIC PUMP 197

Fig. 9. Comparison of theory (full line) and experiment (broken line) for port plate
w i t h parallel entry slot 0.04 in wide. N is 1000 rev/min, Fd is 2000 Ibf/in*, is
100 Ibf/inz, a is 1.58" and S is 0.5'

is not reduced as much as in the case for a narrow groove


so that the rate of pressure change in a cylinder at the
beginning of the stroke is somethat greater (similarly for
the beginning of the suction stroke). A comparison be-
tween theory and experiment for the delivery stroke is
given in Fig. 9 for the case of a parallel slot restrictor.
Comparison with Fig. 8a illustrates the rather faster
pressure change, but also the absence of both overshoot
and cavitation.
Finally, further noise and vibrator tests were carried
out to assess the effect of this design of port plate, and the
noise level under the same conditions quoted in the pre-
vious section was 92 dB. Thus the noise is higher than for
the cases with 'ideal' precompression and with V-
restrictors. It is, however, significantly lower than for the
pump with the standard port plate-5 dB is a considerable
improvement.

7 SUMMARY OF EFFECTS OF GROOVES


The more rapid the rise in cylinder pressure during change-
over from suction to delivery, the closer the loading of the
mechanical parts approaches sudden loading with its well-
laown attendant noise problems. The gradient dPJdt
would therefore appear to he of some interest in the pump
noise context and Fig. 10 shows it plotted against angle of
rotation for various configurations. The standard port
plate clearly gives the highest value for dPJdt, whilst the
ordinary shape of kidney port with delayed opening to
give precompression and expansion provides the lowest
value. Neither the groove nor the parallel slots give such a
low value of dPJdt as the 'ideal' precompression arrange-
Radians rotated from b d c
ment, but nevertheless are significantly better than the
A Standard port plate. standard port plate. The negative values of dPJdt for the
B Port plate with parallel entry slots.
C Port plate with triangular entry grooves. slot and groove indicate a pressure overshoot in each case,
D Port plate set to give 'ideal' timing. hut in the case of the parallel slot this has a lower value
Fig. 10. Rate of rise of cylinder pressure against rotation and, as explained earlier, the pressure overshoot in this
from b.d.c. for various port configurations latter case is more controllable. Fig. 11 indicates the
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198 B. 0. HELGESTAD, K. FOSTER AND F. K, BANNISTER

about the generation of pressure transients and that, with


careful design of the port plate. the rate of pressure rise and
fall in the cylinders may be controlled in such a way that
the noise level of a given pump may be reduced. The main
recommendations are as follows :
(1) For a pump rotating in one direction and oper-

Y I
ating at a substantially constant pressure and flow, it is
better to use a port plate without silencing grooves. The
port timing should be such that full precompression and
pre-expansion is achieved on delivery and suction strokes
respectively. The cut-off at the end of each of the
kidneys should be exactly at b.d.c. or t.d.c. as appro-
priate.
(2) For a pump operating in one direction, but under
varying output conditions, triangular silencing grooves
should be used to optimize the pressure transients at
some chosen operating conditions. A final design can
only be achieved by trial and error, but use of the com-
puter can reduce the problem to manageable propor-
tions.
(3) For a bi-directional pump, parallel slot restrictors
I at each end of each kidney slot are desirable. The design
of these is relatively simple; by choosing the width so
that the pressure drop is equal to the boost pressure at
i the maximum flow conditions, cavitation is avoided, but
at the same time, some degree of control of the pressure
I
transient is maintained.
1000 21 0 3000 When this has been done, the noise can only be reduced
Pump rotational s p e e d further by increasing the stiffness of the pump casing.
revirnin
Some of the theoretical results show that modifications
Fig. 11. Effect of rotational speed on the maximum pre- to the port timing change the shape of the pressure ripple
dictedvaluesof dPJdtforvarious port plate configura- in the output and suction lines. There does not appear to
tions. The key is as in Fig. 10 except that for case
C, two triangular grooves are considered, i.e. for (i)
be a simple correlation between the cylinder pressure
q = 23.5' and for (ii) q = 19.9"; 5. = 60" transients and this ripple, so that an improvement in the
one does not necessarily mean an improvement in the
other. Our work has concentrated on the effects in the
variation of the maximum value of dPJdt with speed and, pump proper, but in a system with a considerable pipe
taking into consideration the reduction of cavitation for run, the input and output ripple could be an important
reversed rotation, the parallel slot is seen as a reasonable source of noise. In such a situation the effect of progres-
compromise. sive waves could provide an additional complication by
The previous arguments suggest that if the port can be further modifying the shape of the ripple and thus the
arranged to suddenly open fully when the cylinder pres- frequency spectrum of the noise.
sure is equal to the delivery pressure (or to the suction Finally, it would be desirable to assess the effects of
pressure on the suction stroke), then the timing is as good alternative output loadings on the pressure transients in
as one can achieve. This ideal may be realized on the the pump and pressure ripple in the connecting pipes. An
delivery stroke by connecting a non-return valve from a important case in mobile equipment is the complete
hole in the land of the port plate at b.d.c., midway between hydraulic transmission where the output is a motor with
the ends of the two kidney ports, to the delivery chamber. inertia and friction loading. The effect of interaction
This allows oil to pass only when the pressure in the cylin- between pump and motor on the pressure ripple could be
der is greater than that of the delivery chamber. The a particularly challenging problem.
delivery kidney port is arranged to open rather later than
normal to prevent any reverse flow. Such a design was
9 ACKNOWLEDGEMENT§
tested and gave a considerable reduction in noise. Further
work will be carried out on this particular feature. We would like to thank Lucas Industrial Hydraulics
Limited for sponsoring this project and for permission
8 CONCLUSIONS
to publish the results.
It is possible to connect the pressure variations in the
APPENDIX 1
cylinders of an axial piston pump with the strain wave-
forms in the casing. It may also be shown that the pressure LEAKAGE FROM S L I P P E R B E A R I N G
transients excite the natural frequencies of various parts Oil from a drilling in each piston (Fig. 12) enters the
of the pump and it is thought that the rate of pressure rise slipper cavity through a restrictor hole of length Lr and
in a cylinder is a significantparameter in this respect. The diameter D, before leaking radially to the pump casing
paper shows that there is nothing fundamentally obscure through the complete slipper gap (annular radii R, and
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PRESSURE TRANSIENTS IN AN AXIAL PISTON HYDRAULIC PUMP 199

or

the choice depending on the Reynolds number.


With R, the piston radius and Rb the outer slipper
radius, the leftward axial forces on the piston-slipper
assembly of Fig. 12 at position 8, are (1) the net force
~(Pc,R,'-PbR,2+PbR,,2 cos a ) due to the oil in the cylin-
der and pump casing, (2) the bearing thrust component
(-Fs cos a), (3) a small viscous drag ( - C dsldt =
(-wCVJ2rrRP2) sin 8,) on the piston, with the constant C
calculated for Couette flow in the clearance, and (4)the
axial spring force Fa per cylinder due to the central spring,
Fig. 12. Section through slipper and ball-joint assumed constant. Thus, considering the acceleration
assembly W2(d2s/dP) of the piston-slipper assembly (of total
equivalent mass M ) :
Rb).The leakage thus depends on the resistances, in series,
of the restrictor and gap; the latter depends on the gap ~(l',,R~~-l'bR,~+PbRb~ cos a)-Fs cos c(.
height h, which varies cyclically, as determined by the MVsw2
balance between the external and inertia forces on the - (wCYs/27rRp2)sin 0, Fa = +
27rRp2
cos 8,~

piston-slipper assembly.
mu2 d2h
The present analysis gives approximate relationships cos olden2 (15)
between the cylinder, slipper cavity and pump casing
pressure (Po, P,,, P h ) y the leakage rate qsn, slipper bearing Of these forces, the axial spring force is the most difficult
load F,, and gap height h,. The slipper separation velo- to assess because this may or may not be shared between
city v, (=dh,/dt = w dh,/d0) relates to the squeezing out or all the slippers, depending on the amount they are lifted
sucking in of oil, within the varying gap. Sliding between off the cam plate, dependent in turn on the solution of
slipper and cam plate is neglected. seven simultaneous equations of motion such as equation
For radial laminar flow through the gap h, the total flow (15). Since this analysis was concerned with the worst
(qsn-rr2vn) and pressure P, both at radius r and time t , problem of piston motion, that is when a particular piston
are related by makes a very large movement away from the cam plate on
first entering the suction port, the assumption was made
that this one piston carries the auxiliary cam plate away
from the main cam plate, causing it to pivot about the two
Integration with appropriate boundary conditions gives slippers directly opposite to it. The effect of the spring
force is thus simply calculated. If during the time of this
large excursion, any other piston had a large movement off
the cam plate, then this assumption would be suspect.
Reference the cavitation portion of curve e of Fig. 7 shows
that the slipper would have left and returned to the cam
plate in 1 rad, i.e. about one sixth of a revolution. With
seven pistons, this means that there would be some inter-
ference with the motion from another piston, but the effect
will only occur at the end of this particular phase of
motion which is of least interest.
and hence, by integration of 2 ~ r dr
P over the annulus and
In calculating the effective mass of the piston-slipper
adding rRS2Psnfor the cavity, the instantaneous slipper
assembly for equation (15), the effective inertia due to the
bearing load is
rocking of the auxiliary cam plate is also included,
referred to the centre line of the piston.

APPENDIX 2
For flow, qsn, through the restrictor hole, the standard REFERENCE
equations for laminar or turbulent pipe flow give (I) HELGESTAD, B. O., FOSTER, K. and BANNISTER, F. K. 'Noise
in an axial piston p u m p ' , Noise emitted by fluid power equip-
ment-its cause3 and control 1973, 51-62 (Institution of
Mechanical Engineers, London).

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Discussion on B. 0. Helgestad, K. Foster and F. K. Bannister: PRESSURE TRANSIENTS IN AN AXIAL PISTON HYDRAULIC PUMP

Discussion

D. E. Bowns Member and D. McCandlish The paper contains a useful comparison of the pressure
Member transients for various valve plate configurations, but the
emphasis is on asymmetrical configurations. In this
The authors have tackled a difficult but important aspect the authors proceed in the same way as Zaichenko and
of fluid power equipment design. They have given Boltyanskii (3) who also showed theoretically and
interesting comparisons between theory and experi- practically that positive asymmetrical overlap gave lower
mental results. pressure-peaks than did positive symmetrical overlap.
We are, however, having difficulty in relating equa- They also showed that, with ideal precompression, a
tions (3) and (4) to the rig drawing of Fig. 2. If valves E reduction in noise level of up to 4 dB could be obtained
and G are open so that the base pressure can be varied, on the Russian pump tested, compared with the sym-
then it should be possible to control the inlet pressure Pi metrical case.
within narrow limits and, because of the opening, the Neither the present paper nor that quoted above
inlet capacitance would be large. This would correspond mentions the possibility of the symmetrical case with a
with the normal arrangement in hydrostatic systems. small underlap so that distance 6 becomes negative. Such
The base pressure in these systems is usually controlled arrangements allow reversed rotation. The pressure
by a relief valve, and the pressure fluctuations in the transient is then displaced towards the t.d.c. and b.d.c.
base line (due to pump and motor flow fluctuations) positions, the rate of pressure rise may be controlled to
will depend very much on the relief valve dynamic any given value, and there is no tendency to cavitation.
characteristics. The design calculations are simplified if the grooves are
The authors state that the paper provides a method for wedge-shaped rather than triangular, giving a linear
calculating pressure transients in an axial piston pump. change of cross-sectional area with rotation.
This is an important design parameter and such a Finally, we would point out that discussion of pressure
method would be valuable. It appears, however, that the transients caused by the degree of precompression can be
differential equations may only be solved if empirical extended to the whole field of hydrostatic pump design.
pump-performance data available, enabling various Similar factors occur in the porting of vane pumps and
constants to be evaluated. We suggest the paper con- in the detail design of gear pumps. Improved designs
tributes more to an understanding of the behaviour of with careful control of pressure variation can possibly
an existing pump, rather than predicting that of a reduce noise of these units in the same manner as in axial
proposed pump. piston units.
The pressure transients occur in each cylinder close to
top- and bottom-dead-centre when the piston is barely REFERENCES
moving. The instantaneous cylinder volume is changing (2) ROYLE,J. K. and RAIZADA, R. S. ‘Numerical analysis of effects of
slowly and leakage effects are important. The authors tilt, sliding and squeeze action on externally pressurized oil-film
bearings’, I. Mech.E. Lubrication and Wear, 4th Convention.
admit the difficulty of estimating leakages past the piston May 1966.
and past the port plate and suggest that experimental (3) ZAICHENKO, I. Z. and BOLTYANSKII, A. D. ‘Reducing noise levels of
values are used. Leakage past the slippers is even harder axial-piston pumps’, Russian Engnng J. 1969.
to estimate, despite the analysis given in Appendix 1.
Royle and Raizada (2) have shown the important
effects of slipper tilt. The authors have ignored this C. M. Edghill Liverpool
parameter, assuming a parallel oil film, though it is well Designers should find the paper valuable in that it clearly
known that the pads run in a tilted attitude. Typically, indicates the effect of so-called silencing grooves altering
the leakage from a stationary pad is increased by some the rate of change of pressure as the rotor kidney-ports
27 per cent if the angle of slipper tilt is 25 per cent of pass from delivery to inlet and vice versa. It should also
maximum for a pad with radius ratio Rb/Rs= 1.5. This be clear that placing a restriction in the port creates a
effect is increased if the pad moves axially or transversely. cylinder pressure (equation (9)) well above the system
An even more fundamental problem is the instanta- pressure and designers must, of course, take this into
neous value of the oil film thickness h. An assumption account.
that the piston pad makes a large excursion from the In similar work we found it necessary to express the
cam plate, moving the auxiliary cam plate, at the start of final equation of peak cyclinder pressure in a simple
the suction stroke requires confirmation. The time form :
available for this excursion is extremely short (a few
milliseconds) which suggests variations in oil film thick-
+
P , = A4p Y x rev/min
ness of a few micrometres. where P, = peak cylinder pressure; A4 = a constant;

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D34 DISCUSSION ON B. 0. HELGESTAD, K. FOSTER A N D F. K. BANNISTER

p = system pressure and Y = a constant. This empirical have not yet been able to make use of it. The problem
equation is easily handled by the designer. lies in determining the actual tilt of the slipper under
I realize such an equation would not adequately running conditions. Friction at the ball-joints is likely to
describe all types of groove considered in the paper, but create a dominant moment whence, under real condi-
wonder if the authors would comment on this simpler tions, slipper and piston will rotate. The resulting
approach for a particular design of insert. motion appears difficult to predict. Some attempt is
There are a few minor points which perhaps they could being made at present to instrument a pump in order
clarify. In Fig. 8b the graph shows pressure rising from to obtain practical data on this point, but we would,
1000 to just over 2000 lbf/in2 but the text suggests that certainly welcome any other information.
the inlet pressure is 100 lbf/in2. We have assumed this This proposed instrumentation will also shed some
should read 1000 lbf/in2 (6.9 MPa). Also, Fig. 10 does light on the possible instantaneous excursion of the
not show a speed but I assume this is 3000 rev/min. slipper from the cam plate at the start of the suction
stroke, which we agree requires confirmation. We point
B. 0. Helgestad Kongsberg, Norway, K. Foster out in the paper that, if rather narrow silencing grooves
Fellow and F. K. Bannister Fellow (Authors) are employed, there is always the possibility of cavitation
in the slipper recess at this point in the rotation, and that
Replying to D. E. Bowns and D. McCandish, we agree if it were not for the auxiliary cam plate, piston and
first of all that conditions on the suction side of the slipper could be predicted to move a good distance off
pump are less controlled than on the pressure side, so the swashplate-in other words, the inertia effects are
agreement between theory and experiment for the considerable. Nevertheless, this was an extreme case
pressure pulsation in the input line is less good. Never- unlikely to be met in practice.
theless, prediction of pressure transients in a cylinder The contributors quote from Zaichenko and Bolty-
coming on to suction is still good and, in particular, anskii (3) and go on to say that a small underlap allows
prediction of possible cavitation is valuable. the rate of pressure rise to be controlled to any given
Whether one considers the paper to present a method values and there is no tendency to cavitate. This simply is
of calculation or merely an understanding of the be- not true. The purpose of the groove is to restrict the flow
haviour of an existing pump, it is still true that solution of into the cylinder due to compression or decompression
the equations listed can give a good first-assessment of of the oil at the beginning of the pressure stroke or suc-
pressure transients in an axial piston unit. At the time tion stroke respectively. Under these conditions, the full
of writing the paper, the only unit for which sufficient system pressure is available to drive oil through the
experimental information was available was that for groove, whereas at the end of the suction or pressure
which the results were presented. One has to start some- ports, the pressure in the kidney port is substantially the
where! More recently, the method has been applied to a same as in the cylinder. Thus the pressure differences
totally different unit, and the results have proved useful are not symmetrical and no arrangement of symmetrical
design-aids even without accurate leakage data. The ports can, whether with underlap or overlap, satisfy all
reason is that, whilst leakage is important, it is not totally conditions. To be specific, if a groove is used with an
dominant: for example, if the port opens suddenly to area so small that the rate of pressure rise during a
high pressure at b.d.c., the rate at which flow rushes into transient is limited almost to the ideal value, the restric-
the piston is much greater than flow due to leakage. At tion will be too great at the end of the suction port, and
the other extreme, one might consider port timing to give cavitation will occur. If a groove is used that gives a linear
full precompression. In this case a simple way of viewing change of area with rotation, the size can be easily
the effect of leakage is to say that the compressibility loss calculated to avoid cavitation. We chose a parallel slot
in a pump is typically some 2 per cent with leakage some- (rather than a wedge) to give this characteristic and the
what higher. But whereas the compression loss for one results in Fig. 10 illustrate the point. The parallel slot is
piston occurs within perhaps half a piston pitch of rota- designed to just avoid cavitation if direction of rotation
tion, the leakage is spread over half a revolution and is is reserved, and curve B shows that the maximum rate
therefore bound to be a somewaht lower effect. of pressure rise is somewhat higher than for the tri-
Nevertheless, we agree that design information should angular slot which was not designed to avoid cavitation,
be less empirical. In a separate project at Birmingham and higher than the ideal precompression which is only
we have, for the last five years, been developing a better to be used for undirection pumps. In addition, the use
prediction of the conditions at the port-plate/cylinder- of underlap worsens the output flow ripple and also the
block interface. The distortions of casing and of shaft efficiency of the pump unit, so we cannot recommend it.
with cylinder block are calculated in order to derive the We thank D. E. Browns and D. McCandish for raising
tilt of the block against the port plate. This allows the a number of useful points and agree that similar argu-
hydrodynamic forces on the block to be calculated, ments apply to the porting of other types of positive
which in turn modifies the conditions of equilibrium. An displacement pump.
iterative procedure gives a reasonable prediction of tilt C . M. Edghill’s easily handled empirical equation is
and film thickness and this, in turn, allows a better interesting. We had not discounted such an idea, but so
estimate of local leakage around the port plate. The far had not found a simple analytical expression that
results are now being fed back into the calculation of would deal with a wide range of cases. However, one can
pressure transients. appreciate the value of producing an expression in which
The problem of slipper behaviour is much more the constants can be determined experimentally for a
complex and, though we appreciate the value of the given pump geometry and a certain range of operating
information in the paper by Royle and Raizada (2) we conditions.

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PRESSURE TRANSIENTS IN A N AXIAL PISTON HYDRAULIC PUMP D35

To comment specifically on the form of expression be a function of swashplate angle, rotational speed and
used, one could observe that the peak pressure in the system pressure. Therefore, if a linearized equation of
cylinder is a function of the compression of oil in the the type suggested were generally possible, we would
cylinder and pressure drop across the silencing groove. expect it to include an additional team consisting of a
Thus, for a given geometry, peak pressure would primarily coefficient x swashplate angle.

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