Quantifying the Efficiency Advantages of High Viscosity Index Hydraulic Fluids

By providing higher in-use viscosity at elevated operating temperatures,hydraulic fluids with high viscosity index improve the efficiency of the hydraulic system.For mobile hydraulic equipment this efficiency can be quantified as an increase in fuel economy.This paper reviews the research that demonstrates these efficiency advantages in gear,vane and piston pumps and presents a method for predicting the overall fuel economy for a fleet of hydraulic equipment in operation.Finally a `Maximum Efficiency Hydraulic Fluid’ performance definition is presented which will enable an equipment operator to easily improve the performance of the system and reduce fuel consumption.

Life prediction and test period optimization research based on small sample reliability test of hydraulic pumps

Hydraulic pumps belong to reliable long-life hydraulic components. The reliability evaluation includes characters such as long test period,high cost,and high power loss and so on. Based on the principle of energy-saving and power recovery,a small sample hydraulic pump reliability test rig is built,and the service life of hydraulic pump is predicted,and then the sampling period of reliability test is optimized. On the basis of considering the performance degradation mechanism of hydraulic pump,the feature information of degradation distribution of hydraulic pump volumetric efficiency during the test is collected,so an optimal degradation path model of feature information is selected from the aspect of fitting accuracy,and pseudo life data are obtained. Then a small sample reliability test of period constrained optimization search strategy for hydraulic pump is constructed to solve the optimization problem of the test sampling period and tightening end threshold,and it is verified that the accuracy of the minimum sampling period by the non-parametric hypothes is tested. Simulation result shows it could possess instructional significance and referenced value for hydraulic pump reliability life evaluation and the test's research and design.

Development of a Test Apparatus for Measurement of Hydraulic Fluid Efficiency

With increasing demand for nonrenewable resources,energy conservation is critical.Efficiency gains allow more work to be performed while maintaining or even decreasing the energy expended in the process.Reducing the energy consumed by a system results in favorable economic and environmental impact.An apparatus has been developed to measure hydraulic fluid efficiency in a stationary application.The system can be used to develop more efficient fluids,leading to increased work output or decreased energy consumption.

Investigation of the effects of radial clearance on the screw conveyor performances for different inclinations

Screw conveyors are widely used for bulk material transportation.This study investigates the critical role of radial clearance,the gap between the screw and the conveyor body,on performance across various inclination angles.The Discrete Element Method(DEM)is employed to analyze the effects of different radial clearances on conveyor performance for concrete aggregate and sand as bulk materials.Volumetric efficiencies and capacity losses serve as key performance indicators,quantitatively assessed for each radial clearance and inclination combination.Experimental validation is conducted to corroborate the findings.In the study,the optimal radial clearance was identified as 1.5 to 3 times of the particle size.This optimal clearance minimizes the material jamming and increases the performance for screw conveyors with different inclinations and bulk material types as a result.

Theoretical and experimental investigation on the efficiency of a novel roller piston pump

This study presents a novel roller piston pump,in which a cam guide-roller type rolling support is adopted to replace the sliding pair support of the swash plate-slipper pair to achieve the oil suction and discharge of the piston cavity.In addition,the shaft distribution is used to replace the original valve plate distribution and the driving shaft is used as the distribution shaft to remove the valve plate structure,which greatly simplifies the design of the axial piston pump.Such a configuration largely reduces the number of sliding friction pairs of the pump,and avoids the influence of the sliding friction pair on it under high-speed and variable-speed conditions.Firstly,mathematical models of the mechanical and volumetric efficiencies of the roller pump are deduced respectively through force analysis and the compressibility equation.Based on the numerical simulation of MATLAB and AMESim,the effects of load pressure and rotational speed on mechanical and volumetric efficiencies are studied respectively,and it is verified that the roller pump has no structural flow pulsation.The prototype pump is then designed and built,along with a special test rig.The outlet pressure,outlet flow,and torque of the pump under different load pressures and rotational speeds are measured,and the mechanical and volumetric efficiencies of the prototype pump under various load pressures and rotational speeds are obtained.The experimental results are in good agreement with the simulated analysis.When the load pressure is 8 MPa and the speed is 5000 r/min,the mechanical and the volumetric efficiencies are 85.5% and 96.8%,respectively.When the speed is increased to 10000 r/min,the mechanical and the volumetric efficiencies are 66.7% and 95.6%,respectively.The experimental results show that the proposed roller piston pump has excellent efficiency under wide-speed and high-speed conditions and can be a potential solution as a fuel pump in aerospace fuel systems.

螺旋缝隙泄漏双向流固耦合方法

针对螺杆泵泄漏机理,利用数值模拟加数据拟合方法,提出了一种针对螺杆泵螺旋微小缝隙泄漏的双向流固耦合模拟方法.利用此方法,对比了单向流固耦合和双向流固耦合方法在螺杆泵泄漏计算结果的偏差,计算结果表明,间隙越小偏差越大,间隙为0.500 mm时两结果相差20.3%,说明螺杆泵这种刚柔配合螺旋缝隙泄漏必须利用双向流固耦合求解才能获得准确结果.随后利用双向流固耦合方法对三维螺杆泵模型进行有限元分析求解,研究了初始间隙、流体介质黏度、螺杆泵单级腔室压差、进出口压力对螺杆泵泄漏的影响.结果显示:泄漏量随初始间隙的增大而增大,随流体介质黏度的增大而减少;进出口压力变化对螺杆泵泄漏影响很小,可以忽略;腔室间的压差造成橡胶定子变形形成间隙,间隙随着压差增大呈线性增大.最后利用双向流固耦合方法计算了不同举升压力螺杆泵的容积效率,与试验结果对比误差在±5%以内.

聚合物注入站注聚单耗影响因素分析及节能措施研究

聚合物驱油技术已经成为大庆油田持续稳产的主力技术,其中注聚系统能耗是注入过程中最主要的能耗点,而注聚单耗是衡量耗电量的重要指标。通过分析注聚泵容积效率、不同压力损失、回流比等对注聚单耗的影响,采取注聚泵结构优化、加装变频器等技术措施,并通过加强注聚泵日常维护、控制采暖温度等管理措施,实现了注入体系平稳、连续注入,进一步保证了开发效果,优化注聚泵结构后聚合物注入站注聚单耗由原来的2.36 kWh/m3降为1.44 kWh/m3。达到了降低注聚单耗的目的。

变工况条件下的齿轮泵容积效率特性研究

容积效率是反映液压泵性能的重要指标,针对某特种齿轮泵的容积效率影响因素进行分析和试验验证。建立数学模型并通过UG建立齿轮泵内流场仿真模型;导入Pumplinx中进行仿真模拟,分析不同工况条件下负载压力及转速与容积效率的关系。仿真结果表明:当负载压力较小时,油液脉动较小,产生泄漏量较小,负载压力增大时,由于齿轮腔齿间容积压力快速变化,油液产生剧烈波动,内泄漏加剧,导致齿轮泵容积效率降低;当转速较小时,出口处出现吸空,使容积效率降低,随着转速升高,单位时间内容积腔油液流量增大,容积效率随之升高。根据仿真条件进行实际试验,试验结果与仿真结果差值小于5%,表明了仿真分析的正确性。

新型近无泄漏立式柱塞泵的设计及效率研究

针对传统立式柱塞泵在特殊工况下的漏油问题,设计了一种新型立式柱塞泵结构,并对其效率进行研究。以传统凸轮驱动立式柱塞泵为研究对象,在其柱塞端加入直筒型弹性密封构件,泵体与柱塞位置采取倒置方式,凸轮通过滚子轴承与泵体接触作往复直线运动,利用橡胶密封套代替密封圈防止泄漏。在对立式柱塞泵结构和工作原理分析的基础上,计算柱塞泵容积效率及机械效率。计算结果表明,该设计容积效率为98.4%,机械效率为95.2%,性能及效率均有所提高,且无油液污染,可作为一种小型柱塞泵为医用仪器及设备提供动力。

超高压柱塞泵柱塞副的油膜温度特性研究

柱塞副油膜温度特性是影响超高压柱塞泵性能的重要因素,针对油膜温度导致超高压柱塞泵容积效率低和密封失效等问题,对柱塞副间隙油膜温度特性进行了分析,研究了不同因素对超高压柱塞泵柱塞副油膜温度特性的影响规律。首先,建立了超高压状态下油液的黏温黏压方程和柱塞泵工作过程中的柱塞运动方程;然后,分析了间隙中流体的流动状态,采用ANSYS-Fluent研究了柱塞副间隙油膜温度场分布情况和负载压力、主轴转速、间隙高度、密封长度等四种因素对油膜温度的影响规律;最后,通过四因素四水平正交试验,确定了各因素对油膜温度影响的主次顺序。研究结果表明:负载压力每增加10 MPa,油膜最高温度升高6℃左右;主轴转速每提高100 r/min,油膜最高温度增加0.76℃左右。间隙高度越大,间隙出口油膜温度波动越小;负载压力对油膜温度影响程度最大,密封长度影响最小。该研究结果可为超高压柱塞泵柱塞副的设计提供参考。

液压泵高低温试验系统设计与应用

针对某型航空齿轮泵在极端温度环境下的工作特性测试需求,设计了一套液压泵高低温性能测试方案,并搭建测试试验台架,完成齿轮泵高低温性能测试。结果表明,被试泵的流量-压力特性满足技术指标要求,液压泵的容积效率与工作温度及加载压力成反比。

端盘型螺杆泵测试装置的分析和优化设计

通过对端盘型螺杆泵在产品测试时效率较低的原因进行分析,提出用于端盘型螺杆泵产品测试装置的优化方案,将端盘型螺杆泵进、出口方向组合方式进行固定,在测试时固定端盘型螺杆泵进口的方向,通过在端盘型螺杆泵出口位置设置旋转接头以及平面支承等相关零部件,使测试装置能够满足端盘型螺杆泵多个进、出口方向组合方式的测试要求。通过优化方案,可对端盘型螺杆泵的测试过程进行简化,这样可以解决在端盘型螺杆泵产品测试中测试效率不高、测试调整过程繁琐等问题,实现通过一套测试装置能够快速满足不同规格端盘型螺杆泵各种进、出口方向组合方式的测试工作,提高测试效率,节约测试成本,更好地满足端盘型螺杆泵的高效产出。

不同转速下轴向柱塞泵效率分析与研究

应用相似原理,推导出几何相似的轴向柱塞泵容积效率和机械效率的无因次变量表达式,根据已有参数计算出不同转速下泵的效率,为液压系统节能控制提供数据支持。

一种双联内啮合齿轮泵的结构优化设计

针对一款变速箱的双联内啮合齿轮泵在实际运行过程中存在的泵容积效率低的问题,该文从泵的结构上进行了原因分析,在此基础上,通过增加后端盖、紧固螺钉等措施对泵进行了结构优化设计,同时对优化前、后的双联内啮合齿轮泵进行了试验对比测试,测试结果表明,优化后的双联内啮合齿轮泵的容积效率明显高于优化前的,说明此次结构优化设计改进能够减小泵的泄露,提高泵的容积效率,保证其工作的良好性能。

seeka节能增安型螺杆泵驱动设备的应用

老旧螺杆泵井普通驱动设备需要更新,为此应用了一种seeka节能增安型螺杆泵直驱驱动设备。分析螺杆泵井普通地面驱动装置现状与换新设备阶段成效,给出seeka直驱特点并通过应用总结其技术优势。seeka直驱设备的增安能力即反转机械控制装置,加装在电动机上端盖,通过光杆离心力获得棘爪启动能量,利用摩擦减速实现安全停机,增加了系统安全性。该设备采用三相异步电动机配合伺服控制器实现节能,通过传动效率室内实验,seeka异步直驱地面驱动工艺设备传动效率比异步普通驱动高20~30个百分点,满足节能的需要;3口现场试验井日节电45 kWh,预计年可节约电能1.64×10^(4)kWh,拥有较好的节电能力。

基于流体力学泄漏模型的螺杆泵泄漏机理分析

针对螺杆泵筒壁间隙、啮合间隙等决定螺杆泵性能的关键间隙设计问题,在研究螺杆各项间隙构成原理的基础上,运用流体力学间隙泄漏理论,建立泵腔间隙泄漏压差流和剪切流模型,分别分析螺杆泵筒壁间隙和啮合间隙的泄漏量,得到螺杆泵不同间隙泄漏的表达式。以主动螺杆2头、从动螺杆3头的双螺杆泵为例,通过理论计算与试验对比分析了螺杆转速、压差对泵泄露的作用机理,揭示了螺杆转速、泵进出口压差对螺杆泵流量特性及容积效率特性的影响规律,从而完善了螺杆泵转子设计理论,提升了螺杆泵输送性能。

基于啮合间隙的螺杆齿形设计与成形加工方法

针对螺杆泵关键部件螺杆转子设计过程复杂、加工难度高导致啮合间隙不均匀的问题,在分析螺杆啮合间隙形成机理基础上,运用空间解析几何基础理论,提出基于啮合间隙的螺杆齿形设计新方法,建立螺杆加工过程进刀轨迹-螺杆齿形-啮合间隙转换方程;结合微分几何等距曲面构型原理,得到预定加工间隙的螺杆端面齿形;研究螺杆与刀具在加工过程中的空间包络特性与几何特性,结合机床、螺杆、刀具协同运动所生成的接触线形状和空间位置参数,提出一种基于离散点齿形的螺杆加工成形刀具设计方法——形位几何法,该方法基于具有稳定接触的包络结构,将抽象的空间包络问题转化为平面解析几何问题,简化包络求解模型,克服传统啮合理论设计刀具时无法精确计算齿形曲线尖点的关键性技术难点,提高成形刀具齿形设计的精确性。

航天器用超低黏度齿轮泵轻量化设计

为追求航天器用超低黏度介质齿轮泵较好的容积率和较低的发射成本,该文在创建容积率和新重合度公式的基础上,采用最优化设计方法,通过泵的单位排量体积或单位排量质量最小化,实现了90%的最小容积率和质量最轻化,分析了结构参数对优化结果的影响。结果表明:采用齿顶重合度优化设计后的根切重合度为–0.3429,不能保证连续传动要求;压力角、轴半径、齿条刀具齿顶圆角半径和过渡区起始角对优化结果,分别有6.07%、7.8%、2.9%和6.4%的影响,总体上影响不大;径向、轴向间隙的影响很大,并具有0.04、0.07 mm的影响转折点,该转折点为径向、轴向间隙的取值上限提供了依据。初次针对航天用齿轮泵的优化设计尝试,阐明了超低黏度介质同样适用于齿轮泵。该研究可为提高其他行业用超低黏度液压泵的研发提供参考。

液压泵可靠性短时试验方法研究

液压泵属于高可靠长寿命产品,其可靠性对整机的可靠性和工作性能有着至关重要的影响,即使经过长时间的加速寿命试验仍可能出现无失效的情况,给液压泵可靠性评估带来了困难。针对传统的可靠性评估局限性,以容积效率退化数据为基础,应用非线性最小二乘法和最优化理论进行液压泵性能参数退化轨迹研究,提出了液压泵可靠性短时试验方法,将短时试验与可靠性寿命试验特征参数对比,证实了该方法的准确性和有效性。

螺杆泵井系统效率分析模型及应用

与其它机械采油方式相比,螺杆泵采油系统的突出特点是系统效率较高,对其进行研究意义重大。根据螺杆泵井各个部分运动特点及能量损失情况,建立了螺杆泵井系统效率分析模型。该模型在二连油田的应用表明,影响二连螺杆泵井系统效率的主要因素为抽汲参数偏小、供排不协调以及电动机配置过大等。针对该情况对不同的螺杆泵井提出了具体提高系统效率的措施,使得二连油田螺杆泵井的管理水平上了一个台阶。应用结果表明了该模型的有效性和准确性,对提高其他油田螺杆泵井系统效率具有一定的指导意义。