Hydrostatic Pump Wear Detection via Flow Comparison
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Solution Overview
Problem
Hydrostatic pumps, particularly radial piston pumps, suffer from wear-out leading to increased leakage and reduced performance, making it difficult to accurately assess current performance and wear level due to dependencies on system variables like viscosity, pressure, and temperature, which complicates maintenance and system reliability in precise hydraulic systems.
Innovation Solution
A method to determine current wear in hydrostatic pumps by measuring actual volume flow and comparing it to computed volume flow using a mathematical model based on system variables, allowing for the calculation of a quantitative wear value through a computational method that accounts for rotational speed, pressure, viscosity, and temperature, enabling wear-optimized maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the pump operates for an extended period, then the volume flow is maintained, but wear increases leading to reduced performance
Solution Approach 1:
The system performs preliminary measurements of system variables (pressure, temperature, rotational speed) and uses a computational model to predict the original volume flow before wear occurs. This preliminary computation establishes a baseline against which actual performance can be compared, enabling early detection of wear-induced performance degradation.
Solution Approach 2:
The system continuously measures the actual volume flow and compares it with the computed original volume flow from the mathematical model. This feedback mechanism calculates a wear indicator that quantifies performance degradation, allowing operators to monitor wear progression in real-time and schedule maintenance before significant productivity loss occurs.
2Measurement precision
If traditional measurement methods are used, then the actual volume flow can be measured, but the wear condition cannot be accurately determined due to dependencies on system variables
Solution Approach 1:
The mathematical model acts as an intermediary that translates measurements of system variables (pressure, temperature, rotational speed) into a computed volume flow value. This intermediary computation accounts for the complex dependencies between system variables and pump performance, enabling accurate determination of wear condition by comparing the computed value with the actual measured volume flow.
Solution Approach 2:
The system replaces direct mechanical wear measurement (which would require disassembly and physical inspection) with a computational approach. By substituting mechanical measurement with a mathematical model-based computation and comparison method, the system can accurately determine wear condition through non-invasive measurements of operating parameters and volume flow.
3Ease of operation
If the pump wear is not monitored, then operational simplicity is maintained, but system reliability decreases due to unrecognized malfunctions
Solution Approach 1:
The system performs self-diagnosis by automatically measuring operating parameters, computing the expected volume flow using the mathematical model, comparing it with actual measurements, and calculating a wear indicator. This self-service capability eliminates the need for manual wear assessment while providing continuous monitoring of pump condition, thereby maintaining operational simplicity while enhancing system reliability.
Data Source
AI summary
A method for determining a current wear (w) of a hydrostatic pump, particularly of a radial piston pump, with a variable-speed drive, where the pump is connected to a fluid passage, in which a fluid is pumped by the pump to create a current actual volume flow in the fluid passage. A current actual volume flow (Qact) is determined, by measuring the volume flow in the fluid passage at a predetermined drive-vector, a computed volume flow (Qcomp) is determined, by a first computational method, at the predetermined drive-vector, and the current wear (w) of the pump is determined, by a second computational method, which relates the current actual volume flow (Qact) to the computed volume flow (Qcomp).