Regulating Pumps For Open Loop
Regulating Pumps For Open Loop
Regulating Pumps For Open Loop
REGULATING PUMPS
for open loop
We move the world.
Construction Equipment
Agricultural Machinery
Forestry Equipment
Municipal Vehicles
Material Handling
with hydrostatic drives and working systems. The use of these systems
in our own fork lift trucks has made Linde the world market leader!
Electronics also play an important role in those applications.
Linde products have been leaders in the field of mobile hydraulics for
many years. Our customers can rely on our systems expertise and our
know-how.
Linde engineers are masters of their field whether it involves better
power utilization, the best possible interaction among the total-system
components, ease of operation or safety.
CONTENTS Page
1. Pump Design 4
3. Technical Data 7
5. Regulator Versions
5.1 LS with Electrical Override (E1L) 10
5.2 LS with Power Limiter (TL) 12
5.3 LS with Pressure Cut-off (LP) 13
= low pressure
= high pressure
= drain and vent pressure
Pressure areas
= low pressure
= high pressure
= drain and vent pressure
= LS modulation pressure
Regulator mechanism
4
21O
Response Times
Swashing from maximum displacement (Vmax) to minimum displacement (Vmin).
Response times are for swashing from high pressure (HD) to stand-by-pressure.
5
2. CHARACTERISTICS, FEATURES, SIZES
= low pressure
= high pressure
HPR-02 E1L
6
3. TECHNICAL DATA
*) at max. operating pressure and max. displacement Vmax, all values are theoretical
1,2 1,4
1,1 1,2
1,05 1,1
1 1
0,95 0,9
0,9 0,8
0,5 0,55 0,6 0,65 0,7 0,75 0,8 0,85 0,9 0,95 1
rel. displacement V / Vmax
The data on which this brochure is based correspond to the current state of development. We reserve the right to make changes in case
of technical progress. The dimensions and technical data of the individual installation drawings are prevailing.
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4. LOAD SENSING (LS) TECHNOLOGY
4.1 Basics
The main feature of Load Sensing control is: Further advantages of an LS system:
Continuous detection of the load and thus pump
pressure in the hydraulic system, with constant Longer pump service life due to lower overall
adjustment of the pump delivery volume according to working load
the requirements of the moment. This control method Fast, accurate control of the pump flow, irrespective
is also referred to as flow on demand control. of load at any given time
Less heat generated, so a smaller oil cooler is
The technical solution to this task is answered sufficient
as follows: Overall system noise reduction thanks to lower
working pressures
The load signal (pressure) is measured between an ad-
justable orifice and the consumer (hydraulic motor or Load Sensing pumps and systems are used very suc-
cylinder) (see figure / circuit diagram). The signal acti- cessfully in large numbers of working hydraulic circuits
vates the LS controller of the pump, which adjusts the (open loop) e.g.: construction and agricultural machin-
pump flow such that the pressure differential (p) ery, transport vehicles, materials handling, industrial
across the orifice remains constant at all times. Pump and marine equipment.
flow Q obeys the equation Q ~ A x p. With a con-
stant p pressure differential, the pump flow Q is there- Common to all LS applications are the significant ener-
fore solely dependent on the open cross-sectional area gy saving and better utilisation of the prime mover (die-
A of the valve: Q ~ A. This system relieves the opera- sel engine, electric motor) compared to conventional
tors workload considerably, as there is no need for systems.
ongoing adjustment when the load changes since the
system, being independent of load, compensates In addition to reduced environmental impact, in some
automatically. For example, the orifice might be a pro- applications this means that a prime mover (diesel en-
portional valve or a fully hydraulic controller with an LS gine, electric motor) of the next rating class down can
signal connection. be used.
The most striking advantage of a Load Sensing The advantages for both equipment manufacturer and
System is the significant energy saving, compared to operator are obvious.
conventional hydraulic systems.
compensator
VW valves with compensator
orifice inside
valve
orifice inside
valve
Primary valve
regul.
pump PCO
LS-regulator HPR-pump with LS-regulator
HPR
regul.
pump LS-regul.
HPR
LS-Signal
8
4.2 LS Pump Realization
This is the most favourable pump design in terms of The only loss arises from maintaining a pressure diffe-
energy utilisation. Compared to the power-regulated rential p of about 20 bar. This relatively small excess
variable displacement pump, this model represents a pressure over system pressure makes the pump highly
further substantial improvement. The additional impro- responsive.
vement in energy consumption produced by flow on
demand control applies not just to the pump but to the In addition, the pressure supports the swivel action of
entire system (reduced power consumption, lower heat the pump once started up, because it swashes back
generation, lower noise level). towards zero on low stand-by pressure when there is
no flow requirement.
Unlike a power-regulated variable displacement pump,
a hydraulic pump with an LS regulator can operate at
any point below the power hyperbola, i.e. the pump is
not bound to the power hyperbola. It delivers exactly
the flow demanded by the system without producing
any excess flow which then has to be dissipated by
means of high pressure valves resulting in wasteful
heat generation. To ensure this strikingly economic
operation the LS pump controller constantly measures
the load pressure at the LS valves.
power loss
p
max. power available
actual
power requirement
of system
flow
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5. REGULATOR VERSIONS
5.1 Load Sensing with Electrical Override Control (E1L)
The LS regulator is designed so that external LS pres- The control solenoid and the pressure-reducing valve it
sure signals arriving from the consumer are conducted actuates are integrated in the pump regulator, so that
to a spring chamber, where they act against the pump the transmitted signal is direct and instantaneous. The
pressure. The LS regulator spring is preloaded to circa regulator design caters for solenoid voltages of 12 or
20 bar (standard setting) and therefore the pressure 24 V from the vehicle electrical systems (in the case of
generated by the pump is above the system pressure mobile applications) or from an external supply (mostly
by this amount. stationary applications).
The regulator concept described here is an ingenious
The basic design of the HPR-02 hydraulic pump solution for
makes it eminently suitable to supplement this power limit regulation (reduction control) and
regulator concept by adding an electrical override to mode switching (mode selection)
the LS regulating signal.
The power limit regulator detects speed reductions in
A pressure-reducing valve operated by a control sole- the prime mover (e.g. diesel engine), caused by overlo-
noid produces a proportional pressure, which acts ad. As a result, the pump delivery volume (and conse-
against the 20 bar spring and thereby reduces its ef- quently the power demanded by the pump) is reduced,
fect. The pump thus receives a modulated p LS value and the prime mover then recovers so that it is availa-
and as a result, reduces its flow output. ble with full power (speed) for other consumers.
10
The relationship between the proportional current (I) to In principle, the p LS acting on the LS pilot can be
the solenoid and p LS is shown in the graph below decreased to a value of 0 bar if required, although in
(p LS = f (I) ). this case it should be noted that at low values of
p LS, pump system response times can be slower.
The LS regulator spring provides a basic setting range
for Linde HPR-02 pumps (test rig setting) of between
p LS = 16 bar and 30 bar. The standard Linde factory
setting is p LS = 20 bar.
p LS-Modulation
35
max. p-Setting 30 bar
30
Pressure p LS (bar)
25
p-Setting 20 bar
20
min. p-Setting 16 bar
15
10
0
0 100 200 300 400 500 600
Control Current I (mA) at 24 V
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5.2 Load Sensing with Power Limiter (TL)
HPR 75-02 TL, SPU HPR 75-02 TL, SPU with pilot pump
For applications where the input power for a hydraulic If the power consumption of the system remains below
system is limited but where optimum use must never- the set value of the power limiter the LS regulator alone
theless be made of the available power, the power limi- controls the pump. This enables the pump/valve
ter can be used as a regulating device. system to operate at any point below the power cha-
It limits the mathematical product of flow volume racteristic. The overall working range is only limited up-
Q (working velocity) and pressure p (force) according to wards by reaching the set power, as the power limiter
an approximated characteristic curve. overrides the LS regulator and thereby prevents the
When the set value of the adjusted power limiter is rea- prime mover from being overloaded.
ched it reduces the flow volume (i.e. the displacement
of the HPR pump), such that product p x Q corres-
ponds to the set value. The approximated exponential
regulator characteristic is implemented by a spring
system incorporated in the controller.
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5.3 Load Sensing with Pressure Cut-off (LP)
One advantage of hydraulic systems is their simple flow to make up system leakage in order to maintain
protection against overloads. Nonetheless, relying on the system pressure. The pump can stay at this opera-
the response of high pressure-relief valves during over- ting point for considerable periods thus demanding mi-
load is inefficient because the fluid power dissipated is nimal power, which is highly advantageous for the
uncontrolled and generates excessive heat. The fast overall energy consumption of the system.
response of the pressure cut-off valve in an HPR pump
means that there are no power losses due to the slow Similar to the situation described under Section 5.2, in
response by pressure relief valves. The pump displace- this mode the pump is also controlled solely by the LS
ment is limited by the maximum pressure regulator regulator characteristic. Here as well the pump/valve
whilst, at the same time, maintaining the operating system can operate at any point below the power
pressure. hyperbola. The LS regulator is not overridden until the
pressure set on the maximum pressure regulator is re-
The pump displacement can be reduced to near zero ached, when the pump is reduced to near zero displa-
during this operating period, only delivering sufficient cement.
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6. NOISE OPTIMISATION WITH SPU SILENCER
The noise characteristics of a hydraulic pump have be- The task of the designer is to minimise noise where it
come a major quality feature, not least because of in- occurs and to check or prevent its propagation as
creased environmental awareness. Linde have taken much as possible. Linde designers, together with an
account of this and developed an appropriate technical experienced research team, have come up with an op-
solution. timal solution to this problem for the HPR-02 open
loop pump.
In principle, every hydraulic system will inevitably deve-
lop noise, regardless of which components are Noise is now reduced as soon as it occurs. The meas-
coupled together (pumps, motors, valves, orifices, re- ures taken are primary measures, which are always
strictors, piping). These noises are ultimately transmit- more effective than measures introduced subsequently
ted to the human ear as airborne noise. This airborne into an existing system (secondary measures).
noise is the result mainly of structure-borne noise Secondary measures are always time-consuming and
(caused by the inevitable pressure changes), that in costly.
turn is largely fed by fluid noise (caused by the equally
inevitable pressure pulsation due to the number of wor- Pressure pulsating is disadvantageous, not only in
king pistons, the compressibility of the pressure fluid terms of noise development but also because of the
and valve operation). Every hydraulic circuit is inescap- mechanical load on all the components and parts of
ably associated with this unwanted noise sequence. the overall hydraulic circuit. The main cause of pressure
pressure pulsation
speed speed
(rpm) system pressure (bar) (rpm) system pressure (bar)
14
pulsation is the finite number of working pistons in This new concept of a silencer chamber enables major
conjunction with the high pressure produced by the practical requirements to be met and these are:
pump, and the pump speed. a reduction in volume fluctuations over a wide
operating range
The volume flow and pressure pulsations are both sig- a reduction in pressure pulsation over a wide
nificantly reduced by a self-compensating silencer. This operating range
results in a major reduction in the fluid and structure- no decrease in efficiency
borne noise emitted from the pump and consequently simple, maintenance-free design
in a considerable reduction of the overall system noise. acceptable weight and volume increases
self-compensating, so no adjustment necessary
The fact that the technical solution realised keeps pul-
sation at a low level over the entire operating range Figure (page 14) shows a comparison of the pressure
(pressure, speed, temperature), is highly advantageous pulsation as a function of high pressure and speed in a
and in turn leads to a balanced noise characteristic of standard unit and in a unit optimised with a silencer.
the system over the whole operating cycle. However, it The reduction in pressure pulsating, resulting directly in
should not be forgotten that by far the largest noise a marked reduction in noise is clear.
component is generated, not by the pump, but by vi-
bration of the mechanical elements of the whole Figure (page 15) shows a comparison of the noise level
system (sheet metal parts, floors, walls, girders, moun- of a standard unit and of a unit optimised with a silen-
tings, etc.). cer as a function of the prime mover (e.g. diesel engi-
ne) speed. The significantly reduced noise level of the
The solution found to produce a substantial reduction SPU variable capacity pump is striking. Not only does
in noise emissions is the the noise reduction apply over the entire speed range
Linde SPU Silencer both inside and outside the cabin, but also the peaks
are smoother than those occurring with the standard
which consists of an optimised arrangement of an
unit.
additional chamber (silencer chamber) immediately
adjacent to the valve (timing) plate and therefore to the
prime source.
noise level
in 2 dB(A) steps
conventional
with SPU
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7. DOUBLE AND MULTIPLE PUMPS
Double Pump HPR 105D-02 E1L, SPU Multiple Pump with SAE3 bell housing
HPR 135-02 LP, SPU + HPV 105-02 E1
Double and multiple pumps consist of single units Multiple Pump: HPR regulated pump coupled to an
arranged in series. HPV variable displacement pump
Double Pump: 2 equal-sized pump bodies arranged
The swash plate design is highly advantageous for this. back-to-back, 1 common suction
manifold, 2 pressure manifolds
Option: 1-circuit pump or 2-circuit
pump
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Multiple pumps may consist of only open circuit pumps Knowledge of each pumps load cycle is, therefore, the
or only closed circuit pumps but it is also possible to key to the unit assembly order and thus ensuring relia-
combine both types and the order of their assembly ble and trouble-free operation.
(i.e. 1st pump/2nd pump + further pumps) is, in essen-
ce, completely free. Similarly, their orientation to each The Tandem Pump is, by definition, a special multiple
other (e.g. respective positions of controls, regulators pump usually comprising two equal size units of the
and/or pressure and suction ports) is flexible and de- same type and orientation of controls/regulators and
termined only by installation limitations. The critical fac- porting.
tor ruling the order of the individual units is primarily the
admissible shaft torque that can be transmitted from Otherwise, the individual units in a Multiple Pump as-
one to the other. The timing of their respective work sembly may be of differing sizes, types and orienta-
cycles is predominant when considering this. tions.
Possible Combinations
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8. POWER TAKE-OFF (PTO)
HPR 105-02 LP, SPU with PTO-connection SAE A HPR 75-02 TL, SPU with pilot pump added
Technical description
Ancillary drives, e.g. for further working pumps, drive
pumps, cooling pumps, power steering pumps or ser-
vo pumps, can be connected via the spline on the end
of the pump through-drive shaft.
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9. PRESSURE FLUIDS AND FILTRATION
Permitted Pressure Fluids
Mineral oil HLP to DIN 51524
Biodegradeable fluids upon request
Other pressure fluids upon request
Technical Data
Viscosity Recommendations
Filtration
In order to guarantee proper functions and efficiency of
the hydraulic pumps the purity of the pressure fluid
over the entire operating period, must comply to at le-
ast class 18/13 according to ISO 4406. With modern
filtration technology, however, much better values can
be achieved which contributes significantly to exten-
ding the life and durability of the hydraulic pumps and
complete system.
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10. MAIN DIMENSIONS
*HPR 210-02 with square 4-hole-mounting-flange (not shown in schematics of page 21)
20
Flange F
Shaft W
Shaft W
Shaft W
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11. APPLICATIONS We move
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the world.
How to reach us
e-mail [email protected]
internet www.linde-hydraulik.de
www.linde-hydraulics.com
mail Linde AG
Linde Material Handling Division
P.O. Box 10 01 36
D-63701 Aschaffenburg
LMH-HPR-02 12/02E
Linde AG
Linde Material Handling Division
Schweinheimer Strasse 34 D-63743 Aschaffenburg