Development of a Small-Working-Volume Plunger Hydraulic Pump with Improved Performance Characteristics

Current trends in the development of technology are linked inextricably to the increasing level of automation in technological processes and production systems. In this regard, the development of systems for supplying working fluids with adjustable pumps that have high performance characteristics, an increased service life and low operating costs is an important scientific and technical task. A primary challenge in the development of such systems lies in achieving low fluid flow rates while maintaining stable operating characteristics. This challenge stems from the fact that currently available controlled hydraulic pumps exhibit either a high cost or suboptimal life and efficiency parameters. This work focuses on the development of a plunger hydraulic pump with a small working volume. A mathematical model has been developed to investigate the characteristics, optimize the design of this pump and further expand the size range of such pumps. The solution was implemented on a computer using the dynamic modelling environment MATLAB/Simulink. In order to verify the mathematical model’s adequacy, a plunger pump prototype was built and integrated with a test bench featuring a measurement system. The test results showed higher pump efficiency and a significant reduction in hydraulic losses. An analysis of the obtained data shows that the pump is characterized by increased efficiency due to optimal flow distribution and reduced internal leakage, which makes it promising for use in hydraulic systems requiring improved operating characteristics. The developed pump has more rational characteristics compared to existing alternatives for use in water supply systems for induction superheaters. The experimental external characteristics of the developed pump are 10% higher than the external characteristics of the ULKA EX5 pump selected as an analogue, and the pressure characteristics are 65% higher. It offers production costs that are several times lower compared to existing cam-type plunger or diaphragm pumps with oil sumps and precision valve mechanisms. Additionally, it has significantly better operating characteristics and a longer service life compared to vibrating plunger pumps.