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Designing Quieter Hydraulic Systems
Designing Quieter Hydraulic Systems
DESIGNING
QUIETER HYDRAULIC
SYSTEMSSOME RECENT DEVELOPMENTS
AND CONTRIBUTIONS
Kevin
Centre
for Power
Department
EDGE
Transmission
of Mechanical
University
Bath,
BA2
and Motion
Engineering
Control
of Bath
7AY,
UK
(e-mail:K.A.Edge@bath.ac.uk)
ABSTRACT
KEYWORDS
Airborne
noise, Fluid
borne noise,
Structure
NOMENCLATURE
B:
F:
bulk modulus
frequency-dependent
Fe:
coefficient
V:
volume
of fluid
x:
distance
along
Zo:
characteristic
Zs:
source
in passageway
pipe
from
source
impedance
of
the
pipe
impedance
swashplate
angle
propagation
coefficient
: frequency
1.
INTRODUCTION
problem
systems
for
long
heating
high
well
loss,
lead
The
health
to
impaired
safety
levels
generated
Exposure
can
worker
and
noise
known.
periods
also
Symposium (c)
of
is
result
to
in
performance
fatigue
issues
and
hydraulic
noise
levels
clinically-significant
of
workers
associated
relating
by
high
to
and
may
carelessness.
noise
have
been
Figure
1 Noise transmission
paths from the pump
and prime mover
(but
can
also
be
a motor
or
some
other
of FBN
content fluids.
With the recent re-emergence of water
hydraulics, this is an important conclusion.
Most of the modelling and simulation developments
relating to swashplate type pumps should be applicable
to bent axis pumps and be readily extended to the design
and prediction of performance of motors (although it is
notable that much less work on motors is reported in the
literature).
Various novel methods of modifying piston pumps to
reduce FBN have been reported. A good summary of
these techniques and their limitations is provided by
Harrison. [11]. Most of the proposals are unlikely to be
employed in practice because of the high cost or the
impact on efficiency or life. The pre-compression filter
volume described by Pettersson et al [12] from
Linkoping University, Sweden is an elegantly simple
solution to the problem of FBN reduction.
In the
authors' design, a small chamber (the "filter volume") is
located such that each cylinder communicates with the
chamber before it opens to the delivery port. The fluid
in the chamber is at a higher pressure than that in the
cylinder.
Hence the flow compressing the cylinder
contents is provided by the chamber rather than the
delivery line. As a consequence when the cylinder
opens to the delivery port the difference between
cylinder and delivery pressures is much smaller than
would otherwise be the case and the consequent
"reverse flow"
is significantly
diminished
.
The
chamber has to be "recharged" from the delivery line
before the arrival of the next cylinder. However, this
can be done in a controlled manner over a sufficiently
long period to provide a smoother flow
ripple. The
authors report a valuable reduction in flow ripple over a
range of pressures and speeds.
However,
their
investigations were confined to a fixed displacement
Figure
2 An example
ripple
Another
equally-simple
delayed
delivery
valve,
Fig.
port
concept
in combination
involves
with
the
use
of
groove".
Harrison
range of operating
a non-return
3.
opening
of
normal.
the delivery
With
this
damped
valves
design
is given
FBN
and
Figure
and Edge
conditions
ABN
found
that to cover a wide
it is beneficial
to delay the
port
to a point
arrangement,
are required.
in Fig.
4.
two
much
or
An example
three
later
than
heavily-
of a two-valve
Valuable
reductions
non-return
valves
in both
are reported.
4 Heavily
in axial
damped
piston
pump
mounted
portplate
(silencers).
Such pumps are not widely used in fluid
power applications although they are adopted for use
with water and high-water-content fluids
(for example
in the steel industry and in mining) and in some
automotive systems [18, for example].
Wobble plate pumps also use self-acting valves and
hence should have the same desirable characteristics of
near perfect timing as plunger pumps. The author is
not aware of any detailed FBN investigations on such
designs of pump.
However, experimental studies
conducted at Bath in 1984 [19] established that a
specific design of machine generated substantial levels
of FBN. This was considered to be a consequence of
highly oscillatory motion of the self-acting valves.
Recent studies on a single-piston plunger pump [18]
using computational fluid dynamics have demonstrated
that delivery valve instabilities can, indeed, occur and
that these are a significant source of noise.
path,
must have reduced the volumetric efficiency
appreciably.
More recently, Ishibashi et al [25]
presented a theoretical basis for groove design focussed
on helical gear pumps (although it is stated that the
technique is suitable for other gear forms). The method
proposed is shown to improve volumetric efficiency but
also appears to have the merit of reducing flow ripple
(curiously, the authors make no claims about the
improved FBN characteristics of their design).
Another approach to the design of low FBN external
gear pumps is described by Edge & Lipscombe [31].
The authors propose the introduction of small radial
piston assembly into the pump in which the pistons are
driven by a cam mounted on the drive shaft, Fig. 6. The
cam is designed such that the motion of the pistons
Figure
5 An example
of external
gear
pump flow
ripple
Figure
7 An example
predicted
of measured
and
ripple
"pounding" .
8 Effect
pump
of mean
suction
inlet
port flow
pressure
on gear
2.1.6
ripple
Water Hydraulic
Pumps
2.1.7
2.1.8
Motors
Figure
10 Example
of bent
axis
piston
motor flow
Valves
Transmission
of FBN
ripple
10
propagation
in "rigid pipe" hydraulic circuits is
summarised by, inter alias, Edge and Tilley [53]. The
term "rigid" pipe is not strictly correct because due
allowance for pipewall elasticity can be taken into
account by appropriate adjustment of the fluid
bulk
modulus.
However, the terminology
conveniently
distinguishes
such circuits from those containing
exible pipe (hose).
fl
In order to design quieter systems an understanding of
the factors influencing the transmission of pressure and
ow ripple in circuits is essential.
Because of flthe
complex nature of the interactions between components,
even in very simple circuits, it is usually necessary to
use computer simulations to evaluate the impact of
design changes.
Edge and Tilley [53] demonstrate that in a simple
(2)
where F and H are frequency-dependent
complex
coefficients which are both directly proportional to the
pump (source) flow ripple but also are functions of the
source impedance, the characteristic impedance of the
pipe and the impedance of the termination (loading
valve).
Impedance, in an FBN context, is the complex ratio of
the pressure ripple to the flow ripple. For a restrictor
valve, for example,
the impedance
is closely
approximated
by the slope of the pressure-flow
characteristic
of the valve at the operating point
(although there may be some deviation from this at
higher frequencies).
The impedance
of other
components is generally more complex and will be
discussed later.
The source impedance of a pump
describes the nature of the fluid
mechanics in the
discharge
passageway.
At low frequencies
the
behaviour is principally capacitive and can be described
by the equation:
Figure 11 Experimentally-determined
source impedance
of an external gear pump (numerically-smoothed)
The impedance of many designs of pump remains
largely independent of operating conditions since the
principal factors affecting behaviour are the geometry
and fluid
properties.
However, variable capacity
machines with a servo-actuation system fed from the
delivery
passageway
may exhibit
variations
in
impedance with operating condition [48].
Motor
impedance is very similar in nature to pump impedance
and again depends primarily on the passageway
geometry [48, 54].
In order to gain an appreciation of the factors affecting
FBN consider the case of the pump-pipe-valve system
previously mentioned. For a given pump, length of line,
and load valve setting, pressure ripple levels can be
reduced by increasing pipe diameter.
However, the
impact of this on SBN and ABN is not necessarily
beneficial since any unbalanced axial forces are the
product of pressure ripple and pipe cross-sectional area.
(3)
11
Prediction
of FBN
in circuits
(4)
For
given
the
"rigid
pipe"
case,
the
matrix
coefficients
are
by:
(5)
(6)
Boundary conditions are defined according to the FBN
characteristics of the components which are attached to
the transmission
line.
These may be lumped
impedances,
such as a restrictor
valve or an
accumulator, or distributed impedances
such as a
silencer or a flexible hose.
Various software packages have been developed for the
prediction of pressure pulsation levels in circuits:
Johnston and Edge in the UK [56]; Lecerf in France
[57]; Kojima et al in Japan [58] and Wacker in Germany
[59], for example. In order to use any of these packages
Figure
12 Predicted
characteristics
12
and measured
impedance
for an accumulator
dynamics
(CFD) to
13
Figure
Motors
and
other
components
14
2.4 Attenuation
(7)
Figure
15 Circuit
of a component
of FBN
15
2.5
Computational
circuits
the
tools
[e.g.56,
opportunity
stage
available).
for
58,
to
examine
Steps
in
However,
to
there
is
of
provide
the
FBN
for
can
response
prediction
59]
data
still
FBN
levels
at
the
to
review
outcome
of
simulation
to
in
with
design
components
taken
much
levels
designer
individual
be
the
issues
the
57,
(provided
design
Design
be
is
the
circuit
studies.
done
to
aid
this
process:
EIt
is
not
Low
simply
ABN
between
sufficient
is
the
FBN
to
focus
ultimate
and
ABN
is
solely
on
FBN.
target
and
the
complex
(as
discussed
of
prediction
link
later).
EThe visualisation
data
and
is difficult.
the
FBN
For
levels
need
locations
in
operating
parameter
levels.
the
How
over
a range
The
selection
largely
required
perhaps)
mind.
and
the
one
as
seems
to
than
in the
The
emergence
may
Cost
case
trade-offs
are
How
selection
of
the
time
3.
with
pump
although
and
after
it
is
is
be
possible
in
EQuietening
and
and
against
the
components
their
selection?
NOISE
deal
to
desig
difficult
with
separately
not
inserts).
here.
noise
to
low
construction
BORNE
important
play
balanced
involved
(other
valve
judge.
cost/lower
SBN
of
tuner
notoriously
this
effort
motor)
it
to
be
issue
with
to
in
for
functionality.
a general
role
STRUCTURE
FBN
(and
as
motors,
a component
systems
higher
is
is
performance
of a valve,
the
of
hoses
can
FBN
and
basic
difficult
can
low
Guidance
addressing
CFD
noisy
expensive.
its
important
commissioning
As
achieve
E pumps
function
an
unacceptably
and
to
process.
of flexible
have
FBN
behaviour
process.
of
be
of
one
the
trade-off
than
a secondary
many
just
conditions?
selection
a by-product
at
in
change
designer
error
is
condition
change
FBN
tool
the
(other
example,
No
examined
generally
components
trial
aid
be
A
operating
of
to
operating
to
will
does
Components
given
system.
of
interpretation
one
also be an
ABN. The
on the type
is given by
the
from
lose
issues
circuit
sight
of
their
of
issues
inter-
relationships.
3.1
This
section
considered
of
will
apply
the
casing
consequence
occur
secondary
Pumps
focus
of
of
on
equally
a
the
inherently
consideration
and
pumps
well
since
to
pump
rapid
in
Motors
arises,
changes
the
the
motors.
the
pressure
mechanism.
coupling
to
be
excitation
primarily,
in
pumping
is
factors
The
between
as
which
Figure
16a
Predicted
for a range
the
16
axial
piston
of swashplate
pump
piston
angles
forces
Gear pumps
17
Poaibon
Poaibon
Poaibbn
Sound
presaura
Figure 17 Calculated (-) and measured (- -) vibration and sound pressure of an axial piston pump
(reproduced from [107] with permission of Research Studies Press)
18
3.4 Measurement
At
Figure
power
18 Measured
spectral
density,
pipe acceleration,
time
there
are
no
Standard
test
best damping
present
procedures
for characterising
SBN generated
by
hydraulic fluid power machines. A useful summary of
some of the problems associated with quantifying SBN
is given by Hiibner [ 126]. Particular emphasis is given
to the problems of structures connected to the machine
under test and their impact on the vibration levels, and
the difficulty in selecting appropriate measurement
worst damping
the
of SBN
locations
locations
in terms of
19
20
REMARKS
software integration
optimisation
education
Figure
19 The
domain
generation
21
of hydraulic
and transmission
system
noise
ACKNOWLEDGEMENTS
13.
14.
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