Numerical and experimental study of performance of a hydraulic motor

Abstract: The aim of this study was to develop an understanding of the fluid properties that influence the efficiency of hydraulic systems in a steady-state, especially components in hydrostatic transmission systems under different running conditions. The aim has also been to investigate and model the sources of losses in hydraulic machines, in order to estimate the losses, taking fluid properties into account. Finally, the technique of optimization has been introduced in order to improve the efficiency of a distributor valve in a radial piston hydraulic motor, Marathon M200. From an experimental field-test, which was performed on a belt conveyer using a hydrostatic transmission system, the overall efficiency of the hydrostatic transmission was compared when using a mineral oil, Shell Tellus TX 68, a synthetic fluid, Mobil SHC 526, and a vegetable fluid, Binol Hydrap II. The experimental field-test showed that vegetable and synthetic fluids improve the efficiency compared to mineral oil. The three fluids have the same viscosity but experimental tests showed that the temperature ()- and pressure() -viscosity coefficient differs between them. It was also found that the pressure-viscosity coefficient () of mineral oil was higher compared to vegetable and synthetic fluids. The proposed steady-state model gives greater accuracy regarding overall efficiency than the Wilson model, when examining fluid properties that differ in other aspects than their viscosity. The study has focused on losses in lubricated sliding contacts within a radial piston hydraulic motor, Marathon M200, and an analysis of the losses has been made using the finite element method (FEM). A FEM software package, Solvia, which takes into account fluid properties, such as temperature- and pressure- viscosity coefficient, heat conduction and specific heat, has been used to simulate the behaviour and to estimate the losses in tribological contact. This approach of simulation has been applied to two different tribological contact within the hydraulic motor: to a journal bearing contact and to a hydrostatic annular multi-recess plane thrust bearing. By using an FEM software package linked to an optimization algorithm, the losses in the tribological contact in a distributor valve were reduced significantly. The study shows that the optimized geometry of the distributor valve in the motor can successfully be improved, with regard to losses, by small changes in the geometry. Combining an FEM software package with the optimization routine offers an effective tool for designers to simulate and improve the efficiency of a hydraulic unit.