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Hydraulic Pumps
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Hydraulic Pumps
PumpsPumps – High Potential to Reduce CO– High Potential to Reduce CO2 Emissions
The growing concern to protect our planet from further environmental damage has made it a necessity to reduce overall pollutant emissions (primarily CO2) from industrial applications. Growing challenges from the Automotive Industry to optimize vehicle fuel economy and thus CO2 emission is forcing the supply-chain to re-think and re-design hydraulic vehicle applica-tions. The target is to develop more effi cient hydraulic components that integrate into the major structural vehicle components and create intelligent solutions for combustion engines, transmission and body/chassis applications.
With regards to this, a clear trend is the accelerating demand for variable displacement pumps, for highly effi cient constant pumps and for other hydraulic components. What these trends mean to the supply-base are the need for new production processes with optimized machinery and new equipment to produce components with the higher accuracies required by these applications. What is often overlooked though, is these "Best in Class" manufac-turing can also contribute to reduce CO2 emissions - a little bit with the production of every part.
Hydraulic pumps are playing a key role in every moving system when it comes to fi nding solutions for lubrica-tion or actuation challenges like in engines or transmissions. Even applications that could be electrically actu-ated and thus would not need hydraulic support still require lubrication. This situation often leads to the fact that - if a pump is needed anyhow on a system - the actuation is then hydraulically supported as well. Pumps thus remain in many cases the superior choice to drive actuation.
Today's discussions about emission reduction most often only takes into account the amount of CO2 that is emitted from a moving vehicle. The pollution and the waste that is related to the manufacturing process is rarely considered and therefore not well publicized. Hydraulic parts made by the powder metallurgy process can offer another advantage in this cause - due to net shape geometry they truly have advantages in a regard to life cycle assessments (LCA).
...that an ineffi cient engine oil pump needs up to 2kW more than a properly de-signed one? Such waste has a negative impact on a car’s agility and drive performance – and thus deteriorates fuel consumption and increases CO2 emission.
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Pumps – High Potential to Reduce COO22 Emissions Emissions
Material:
The GKN powder mix for hydraulic parts is standardized to cre-ate best-in-class production cost and process effectiveness. Nevertheless non-standard-powders can easily be used in or-der to cope with any superior customer’s demand – e.g. for higher strength, hardness, density or other requirements. The properties of some materials even allow a hardening within the sintering furnace. Integrating secondary process steps (here: hardening) into the core powder metal process not only supports cutting manufacturing cost but also helps to save energy and thus lowers CO2 emission.
Net Shape:
A primary target for GKN is to design and to produce parts near net shape to avoid any secondary machining operations - such as turning, grinding or milling. As these additional pro-cess steps remove material they not only lead to higher piece cost, but also negatively infl uence the LCA (life cycle assess-ment) by increasing energy consumption on the part during production. To get as close as possible to ready-to-assemble parts, GKN is dedicated to work with state of the art equip-ment – complex multi-level tooling, hydraulically controlled closed loop presses and computer controlled furnaces.
Cost:
GKN’s powder metal manufacturing of hydraulic components is worth to be named best-in-class net shape processing. It offers one of the most cost effective ways to produce high vol-ume parts with the highest demand on accuracy, reproduc-ibility, cleanliness and quality – qualifying itself for applica-tions within and outside the automotive industry.
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PumpsPumps – Non Automotive – Non Automotive ApplicationsApplications
Burner Pumps
Fuel oil burner pumps are most often standardized and work with either ex-ternal gear sets, G-Rotor or crescent (internal gear) rotor sets.
Household
Pump applications in household vary by a large extent, but most often are identifi ed with water as the working medium –e.g. circulation pumps for heating installation (impeller type), wet-pit pumps, pumps for washing ma-chines and dish washers, but also high pressure water pumps for cleaning devices (piston type).
Off-Highway / Offshore
Typical applications are in boats (off-shore), tractors, foresters and harvest-ers, but also in the area of lawn & garden. Identifi ed pump types are external or internal gear pumps, vane- and piston type pumps.
Others
To name just a few there are pumps in mobile hydraulic units for heavy duty equipment (e.g. construction machines) in fork lifts and other vehicles used by companies for internal work fl ow logistics. It can be assumed that most of application use external / internal gears, vane- and piston type pumps.
Non-Automotive hydraulic components can be found globally in countless applications in private households, off-highway / offshore engines and industrial areas. The requirements in these environ-ments are different to the automotive sector and based on alternate standards in terms of technical demand, perspective, hydraulic parameters, packaging, material and life time.
...that in a typical household an average of up to fi ve pumps can be found?
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PumpsPumps – Automotive – Automotive ApplicationsApplications
Today, it is typical for each vehicle to contain up to 10 pumps with different purposes, examples in-clude:
Engine Lubrication
Typical oil pumps such as G-Rotor, gear pumps, variable vane pumps, special variable pumps (e.g. pendulum slide pumps).
Break Assistance
Vacuum pumps (rotors) with slots and vanes; stainless P/M material for spe-cial vacuum pumps.
Power Steering
High pressure vane pumps with net shape geometry; substitution of profi le grinding by precision sizing P/M processing.
Coolant
Coolant water pumps.
Transmission
Pumps for actuation and lubrication etc.; gear shifting in a double clutch transmission (DCT) and lubrication of the clutch at the same time.
Fuel
Intank feeder pumps; pre-feeder pumps in combination with high pressure pumps (e.g. common rail diesel - G-Rotor for feeding the high pressure stage such as piston type pumps).
Comfort Systems
Pumps e.g. for windshield or headlight cleaning.
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Pumps Pumps – GKN Products– GKN Products
Gear Pump
G-Rotor / Crescent Pump
Size ØA [mm] H [mm] cm3/u
Large 60 60 14
Normal 35 10 4
Minimum 10 5 1
The information on diameter and height given in the below printed charts are examples from GKN’s current production portfolio. They represent typical sizes for demonstration purpose only. Any other dimension sets can be individually created according to customer demands and based upon agreed specifi cations. The limit regarding production feasibility of the sizes is mainly determined by the press force (diameter press area) and the possible travel of the compaction tools.
Different tooth profi les such as involute, cycloidal or heli-cal are possible for NVH optimization. The tooth profi les also have direct infl uence on the effi ciency. Their design and optimization need special and profound knowledge, experience and a good understanding of the individual application.In high performance environments like heavy trucks GKN is able to offer gears with improved properties realized by state of the art transverse rolling (surface & massive den-sifi cation).
G-Rotor sets and crescent pump parts can have the same tooth profi les as found with gear pumps (involute, cycloi-dal or helical). Their infl uence on NVH, performance and effi ciency is equally high and should be optimized ac-cording to individual application.
Size ØA [mm] H [mm] cm3/u
Large 102 20 25
Normal 70 12 5
Minimum 20 4 0.5
...that a fi nished P/M hydraulic pump part still contains up to 98 % of it’s originally compacted raw material powder? In other words: the ability of net shape production requires a wastage of only 2 % of the material due mechanical operation!!!
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Vane Pump
P-Rotor Pump
Sintered cam rings on which the inner bore is precision sized offer a cost advantage on fully machined parts. Nev-ertheless they still need to be grinded to hold tight toler-ances on height. In addition the apparent hardness can be adjusted either directly during the sintering process (altering rapid cooling conditions) or by special second-ary heat treatment options.
The P-Rotor-Pump represents a sophisticated and highly effi cient new pump concept - self sealing micro gear de-sign to avoid tip clearance losses during high pressure phases. The design is based upon the conventional G-Rotor geometry but consequently improves it’s areas of weakness. All parts are produced net shape and only require height grinding like any other pump parts. The idea for the P-Rotor was born by GKN internal hydraulic specialists and represent a good example not only of the level of understanding for customer needs but also on the development abilities: rotor set and calculation software are fully owned by GKN. The fi rst mass production for an automotive application was launched in 2008.
Within the fi rst steps of each project GKN product engineers evaluates the manufacturing feasibility of sintered (hydraulic) parts according to customer’s requirements and develops a dedicated design for function. However the data given below can be used as a general guideline and represent the current GKN sinter metal product range on pump components. If a project advances further in realisation, the GKN support can contain the calculation, design, optimization, FEA and - if requested - partially valida-tion on fully owned hydraulic test rigs.
Size ØA [mm] H [mm] cm3/u
Large 90 20 25
Normal 60 25 15
Minimum 30 10 4
Size ØA [mm] H [mm] cm3/u
Large 130 25 20
Normal 74 15 14
Minimum 20 4 0.15
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PumpsPumps –– GKN Customer Support
In most cases the GKN Engineering support starts with the calculation of the rotor set toothing. The layout /design of the porting geometry can then directly be derived from the before defi ned toothing. Depending on requirements and P/M material properties, some housing components like covers or housing rings - that operate with the calcu-lated rotor - can be designed as well. In case of highly stressed hydraulic components GKN is able to perform internally an FEA analysis that can help to optimize geometries with the target to reduce stress lev-els at critical points.
Due to the highly skilled engineering team it is not neces-sary for GKN customers to provide a proper drawing for calculation – although this can be handled as well. If the specifi cations and thus areas of application are well de-fi ned, GKN is able to drive the development and come up with either ball park prices for a fi rst shot or with detailed quotations for fi nal decisions.
...that the packaging demand for an elec-tric drive is roughly 26 times larger com-pared to a hydraulically actuated drive (based upon torque)?
Calculation / Layout
Project Start
Design
FEA Analysis
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Pumps – GKN Customer Support
During the prototyping phase all housing components can be made by a GKN fully owned rapid prototyping centre (5 axis milling machine). In the majority of cases the rotor sets themselves are made by wire erosion from sintered blanks. These blanks contain the correct material prop-erties and are sintered under the same mass production conditions as they are defi ned on the print.
Machining operation like outer/ inner diameter grinding, tooth profi le grinding, height grinding or key-way honing can be completely made within the GKN in-house tool shops. These tool shops are extremely skilled because they produce the highly complex tools for all compaction and sizing operation as well.
GKN support continues even after the prototype produc-tion is successfully fi nished. On customer demand, pre-production validation of parts - or even complete pumps - can be performed on one of the three existing hydraulic test rigs based at the European Technology Centre. Test pressures up to 350 bar for all different types of pumps and a test temperature from -40 °C up to 120 °C can be provided.
Last but least the installed equipment is able to simu-late special load cycles defi ned by the customers that go along with individual applications.Testing
Prototyping
Evaluation
Design Frames
Prototyping
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PumpsPumps - GKN Tech-Center- GKN Tech-Center
The idea of a centrally located European Centre for Re-search and Development was realized in 2006 - the new GKN Technology Center in Radevormwald, Germany.Covering an area of 3500 m² the new R&D facility was built for the investigation of all aspects of powder metallurgy.
From powder development to pilot production runs it is possible here to test and realize a great variety of options offered by powder metallurgy for the all-round service and support of our production plants and our customers.
The engineering hall with a ground fl oor of 1500 m² ac-commodates among others a 800 t high tonnage mul-tiaxial compaction press with a 7 level tool adapter for training tool setting personnel, for testing various die fi ll techniques, or for the initial determination of press pa-rameters prior to large volume production in one of the GKN plants.In addition to the high tonnage press, smaller presses are available, too. From 200 t presses for the development of aluminium technology to the most simple 10 t presses for testing the fl ow behavior of various waxes.A range of sintering furnaces such as continuous furna-ces, batch furnaces as well as a vacuum furnace for tem-peratures between 400 °C and 1400 °C are installed and operating.For our gear rolling project we provide surface rolling ma-chines for process development of surface fi nish rolling and densifi cation rolling. Our primary goal is the develop-ment of gear prototypes.An air conditioned room for precision measurements equipped with a Klingelnberg gear toothing measurement center is available for characterizing gear geometries and testing other geometries too.
The FEM analysis sector of the TechCenter carries out cal-culations for process simulation, stress and fatigue analy-sis.
GKN - Innovation by Research and Development
A materials testing laboratory with full metallographic equipment like SEM and light microscopes allow special-ists to investigate surfaces and microstructures and to determine mechanical characteristics as well as chemical analysis.Corrosion testing is performed using a climate and a salt spray test chamber. A great variety of test procedures are thus available for investigation; ranging from materials development to failure analysis. Either for our own pur-poses or for our customers.Hydraulic pulsers, resonance pulsers and cracktronics are available for fatigue testing. A Gammatec Densitometer of the latest generation is used for determination of the density.A separate section with three pump test rigs (11, 20 & 55 kW installed power), for testing and further development of our hydraulic pumps has been installed on roughly 200 m² fl oor space, including workshop and offi ce.
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PumpsPumps - Questionnaire Technical Concept- Questionnaire Technical ConceptDate:
Company:
Name:
Phone, Fax, Email:
Component:
Operation purpose /application:
Market segment:
Annual volume:
Reason for inquiery: Development: Cost-benefi t-analysis: Design study:
Offer: Production: Distribution:
TECHNICAL DATA
Rotational speedEffective fl ow measured /
required by systemPressure
Min. [rpm] [l/min] [MPa]
Average [rpm] [l/min] [MPa]
Max. [rpm] [l/min] [MPa]
Characteristic operating points:
Dimensions:
Material:
Type: Viscosity [mm2/s]: at [°C]
Minimum [°C]: Maximum [°C]:
Outside diameter [mm]: Inside diameter (shaft) [mm]:
Height [mm]:
Pump to substitute:
Displacement [cm3/rev]:
Driving torque: [Nm]:
ADDITIONAL INFORMATION
Required values for pump to substitute
Rotational speed
[rpm]
Effective displacement
[l/min]
Pressure
[MPa]
Power
[kW]
Mechanical effi ciency
[%]
Volumetrical effi ciency
[%]
Total effi ciency
[%]
Remarks:
Reason for new design:
Other important information:
Rotor: Housing:
b l
Fluid:
Operating temp.:
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About GKN Sinter Metals
GKN Sinter Metals – a wholly ownedsubsidiary of U.K.-based GKN plc,a global industrial company – is theworld’s largest producer of precisionpowder metal products. With a focuson superior delivery, quality and totalsolutions, the company offersextensive technical expertise indesign, testing and various processtechnologies. GKN Sinter Metalsoffers a full range of more than10,000 complex shape, highstrengthproducts for the automotive,commercial vehicle, homeappliance, lawn and garden, offi ceequipment, power tool, recreationalvehicle and process industry markets.The company’s global footprintspans more than 13 countriesacross fi ve continents. GKN SinterMetals is in close proximity to itscustomers with more than 30 globallocations and a workforce ofapproximately 5,500 employees.
For more information about GKN’sworld of solutions visit www.gknsintermetals.com
Production Plants
ArgentinaGKN Sinter Metals de Argentina S.A.Ruta Nac. 5 Km. 159,5(B6622GKA) Chivilcoy – Bs. As.Argentina
Phone: *54-11-5368-3700E-mail: [email protected]
BrazilGKN Sinter Metals Ltda.Av. Emancipacão, 4.500 - Santa EsmeraladaCEP 13186-542Hortolandia – SP – Brazil
Phone: *55-19-2118-9400E-Mail: [email protected]
CanadaGKN Sinter Metals – St. Thomas Ltd.7 Michigan BoulevardSt. Thomas, OntarioCanada N5P 1H1
Phone: *1-519-631-4880E-mail: [email protected]
ChinaGKN Sinter Metals – DanyangNumber 7 Mechanical Industry ParkDanyang Development ZoneDanyang, China
Phone: *86-511-86-885-556E-mail: [email protected]
GermanyGKN Sinter Metals Engineering GmbHKrebsöge 1042 477 RadevormwaldGermany
Phone : *49 2191-693-0E-mail : [email protected]
GKN Sinter Metals Filters GmbHDahlienstraße 43P.O.Box 152042 477 RadevormwaldGermany
Phone: *49 2195-609-27E-Mail: feedback@gkn-fi lters.com
IndiaGKN Sinter Metals Ltd.146, Mumbai Pune RoadPimpri, Pune 411 018 Maharashtra, India
Phone: *91-20-2742-6261, 6262, 6263E-mail: [email protected]
ItalyGKN Sinter Metals SpAFabrikstraße 539 031 Bruneck (BZ)Italy
Phone. *39-0474-570211E-mail: [email protected]
North AmericaGKN Sinter Metals3300 University DriveAuburn Hills, Michigan 48326-2362 USA
Phone: *1-248-371-0800E-mail: [email protected]
South AfricaGKN Sinter Metals – Cape TownP.O.Box 156Sacks CircleBellville, 7530South Africa
Phone: *27-21-950-6200E-mail: [email protected]
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KoreaE-mail: [email protected]
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