Hydraulic Pumps
Pumps – High Potential to Reduce CO
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 applications. The target is to develop more efficient 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 efficient 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" manufacturing 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 finding solutions for lubrication or actuation challenges like in engines or transmissions. Even applications that could be electrically actuated 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 inefficient engine oil pump needs up to 2kW more than a properly designed 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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O2 Emissions
Material:
The GKN powder mix for hydraulic parts is standardized to create best-in-class production cost and process effectiveness.
Nevertheless non-standard-powders can easily be used in order 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 process steps remove material they not only lead to higher piece
cost, but also negatively influence the LCA (life cycle assessment) 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 equipment – 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 volume parts with the highest demand on accuracy, reproducibility, cleanliness and quality – qualifying itself for applications within and outside the automotive industry.
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Pumps – Non Automotive
Applications
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 environments are different to the automotive sector and based on alternate standards in terms of technical
demand, perspective, hydraulic parameters, packaging, material and life time.
Burner Pumps
Fuel oil burner pumps are most often standardized and work with either external gear sets, G-Rotor or crescent (internal gear) rotor sets.
Household
Pump applications in household vary by a large extent, but most often are
identified with water as the working medium –e.g. circulation pumps for
heating installation (impeller type), wet-pit pumps, pumps for washing machines 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 harvesters, but also in the area of lawn & garden. Identified 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 flow logistics. It can be assumed that most of
application use external / internal gears, vane- and piston type pumps.
...that in a typical household an average of up to five
pumps can be found?
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Pumps – Automotive
Applications
Today, it is typical for each vehicle to contain up to 10 pumps with different purposes, examples include:
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 special vacuum pumps.
Power Steering
High pressure vane pumps with net shape geometry; substitution of profile
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 – GKN Products
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
specifications. 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.
Gear Pump
Different tooth profiles such as involute, cycloidal or helical are possible for NVH optimization. The tooth profiles
also have direct influence on the efficiency. 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 densification).
Size
ØA [mm]
H [mm]
cm3/u
Large
60
60
14
Normal
35
10
4
Minimum
10
5
1
Size
ØA [mm]
H [mm]
cm3/u
Large
102
20
25
Normal
70
12
5
Minimum
20
4
0.5
G-Rotor / Crescent Pump
G-Rotor sets and crescent pump parts can have the same
tooth profiles as found with gear pumps (involute, cycloidal or helical). Their influence on NVH, performance and
efficiency is equally high and should be optimized according to individual application.
...that a finished 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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Within the first 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 validation on fully owned hydraulic test rigs.
Vane Pump
Size
ØA [mm]
H [mm]
cm3/u
Large
90
20
25
Normal
60
25
15
Minimum
30
10
4
Sintered cam rings on which the inner bore is precision
sized offer a cost advantage on fully machined parts. Nevertheless they still need to be grinded to hold tight tolerances on height. In addition the apparent hardness can
be adjusted either directly during the sintering process
(altering rapid cooling conditions) or by special secondary heat treatment options.
P-Rotor Pump
Size
ØA [mm]
H [mm]
cm3/u
Large
130
25
20
Normal
74
15
14
Minimum
20
4
0.15
The P-Rotor-Pump represents a sophisticated and highly
efficient new pump concept - self sealing micro gear design to avoid tip clearance losses during high pressure
phases. The design is based upon the conventional GRotor 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 first mass production for an
automotive application was launched in 2008.
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Pumps – GKN Customer Support
Project Start
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 defined toothing. Depending on requirements
and P/M material properties, some housing components
like covers or housing rings - that operate with the calculated 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 levels at critical points.
Calculation / Layout
Due to the highly skilled engineering team it is not necessary for GKN customers to provide a proper drawing for
calculation – although this can be handled as well. If the
specifications and thus areas of application are well defined, GKN is able to drive the development and come up
with either ball park prices for a first shot or with detailed
quotations for final decisions.
Design
...that the packaging demand for an electric drive is roughly 26 times larger compared to a hydraulically actuated drive
(based upon torque)?
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FEA Analysis
Design Frames
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 properties and are sintered under the same mass production
conditions as they are defined on the print.
Evaluation
Machining operation like outer/ inner diameter grinding,
tooth profile 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 production is successfully finished. On customer demand, preproduction 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.
Testing
Last but least the installed equipment is able to simulate special load cycles defined by the customers that go
along with individual applications.
Prototyping
Prototyping
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Pumps - GKN Tech-Center
GKN - Innovation by Research and Development
The idea of a centrally located European Centre for Research 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 floor of 1500 m² accommodates among others a 800 t high tonnage multiaxial compaction press with a 7 level tool adapter for
training tool setting personnel, for testing various die fill
techniques, or for the initial determination of press parameters 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 flow behavior of various waxes.
A range of sintering furnaces such as continuous furnaces, batch furnaces as well as a vacuum furnace for temperatures between 400 °C and 1400 °C are installed and
operating.
For our gear rolling project we provide surface rolling machines for process development of surface finish rolling
and densification rolling. Our primary goal is the development 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 calculations for process simulation, stress and fatigue analysis.
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A materials testing laboratory with full metallographic
equipment like SEM and light microscopes allow specialists 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 purposes 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 floor space, including workshop and office.
Pumps - Questionnaire Technical Concept
Date:
Company:
Name:
Phone, Fax, Email:
Component:
Operation purpose /
application:
Market segment:
Annual volume:
Reason for inquiery:
Development:
Cost-benefi
b
t-analysis:
l
Design study:
Offer:
Production:
Distribution:
TECHNICAL DATA
Characteristic
operating points:
Effective flow measured /
required by system
Rotational speed
Pressure
Min.
[rpm]
[l/min]
[MPa]
Average
[rpm]
[l/min]
[MPa]
Max.
[rpm]
[l/min]
[MPa]
Fluid:
Type:
Viscosity [mm2/s]:
Operating temp.:
Minimum [°C]:
Maximum [°C]:
Dimensions:
Outside diameter [mm]:
at [°C]
Inside diameter (shaft) [mm]:
Height [mm]:
Material:
Rotor:
Housing:
ADDITIONAL INFORMATION
Pump to substitute:
Displacement [cm3/rev]:
Driving torque: [Nm]:
Required values for pump to substitute
Rotational speed
[rpm]
Effective
displacement
[l/min]
Pressure
Power
[MPa]
[kW]
Mechanical
efficiency
[%]
Volumetrical
efficiency
[%]
Total
efficiency
[%]
Remarks:
Reason for new design:
Other important information:
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About GKN Sinter Metals
Production Plants
Argentina
GKN Sinter Metals – a wholly owned
subsidiary of U.K.-based GKN plc,
a global industrial company – is the
world’s largest producer of precision
powder metal products. With a focus
on superior delivery, quality and total
solutions, the company offers
extensive technical expertise in
design, testing and various process
technologies. GKN Sinter Metals
offers a full range of more than
10,000 complex shape, highstrength
products for the automotive,
commercial vehicle, home
appliance, lawn and garden, office
equipment, power tool, recreational
vehicle and process industry markets.
The company’s global footprint
spans more than 13 countries
across five continents. GKN Sinter
Metals is in close proximity to its
customers with more than 30 global
locations and a workforce of
approximately 5,500 employees.
For more information about GKN’s
world of solutions visit
www.gknsintermetals.com
India
GKN Sinter Metals de Argentina S.A.
Ruta Nac. 5 Km. 159,5
(B6622GKA) Chivilcoy – Bs. As.
Argentina
GKN Sinter Metals Ltd.
146, Mumbai Pune Road
Pimpri, Pune 411 018
Maharashtra, India
Phone:
E-mail:
Phone:
E-mail:
*54-11-5368-3700
infoargentina@gknsintermetals.com
*91-20-2742-6261, 6262, 6263
infoindia@gknsintermetals.com
Italy
Brazil
GKN Sinter Metals Ltda.
Av. Emancipacão, 4.500 - Santa Esmeralada
CEP 13186-542
Hortolandia – SP – Brazil
GKN Sinter Metals SpA
Fabrikstraße 5
39 031 Bruneck (BZ)
Italy
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E-Mail:
Phone.
E-mail:
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North America
Canada
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7 Michigan Boulevard
St. Thomas, Ontario
Canada N5P 1H1
GKN Sinter Metals
3300 University Drive
Auburn Hills, Michigan 48326-2362
USA
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E-mail:
Phone:
E-mail:
*1-519-631-4880
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South Africa
China
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Number 7 Mechanical Industry Park
Danyang Development Zone
Danyang,
China
GKN Sinter Metals – Cape Town
P.O.Box 156
Sacks Circle
Bellville, 7530
South Africa
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Germany
GKN Sinter Metals Engineering GmbH
Krebsöge 10
42 477 Radevormwald
Germany
Phone :
E-mail :
*49 2191-693-0
infogermany@gknsintermetals.com
GKN Sinter Metals Sales Offices Worldwide
China
E-mail:
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E-mail:
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Dahlienstraße 43
P.O.Box 1520
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Germany
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feedback@gkn-filters.com
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