Since many studies on axial piston pumps aim at enhancing their high power-weight ratio, many researchers have focused on the generated mechanical losses by the three friction pairs in such pumps and attempted to diminish them through abundant and new structural designs of the pump’s components. In this paper, a high-speed 2D piston pump is introduced and its architecture is specifically described. Afterward, a mathematical model is established to study the pump’s mechanical efficiency, including the mechanical losses caused by the viscosity and stirring oil. Additionally, in this study the influences of the rotational speed, the different load pressures, and the rolling friction coefficient between the cone roller and the guiding rail are considered and discussed. By building a test rig, a series of experiments were carried out to prove that the mechanical efficiency was accurately predicted by this model at low load pressures. However, there was an increasing difference between the test results and the analytical outcomes at high pressures. Nevertheless, it is still reasonable to conclude that the rolling friction coefficient changes as the load pressure increases, which leads to a major decrease in the mechanical efficiency in experiments.

This paper first introduces the structure and working principle of a 2D piston pump invented by the research team that the authors are involved with. Afterward, the mechanism of the churning losses caused by the pump’s moving parts, which are rotating in oil, is carefully studied by building up mathematical models and using CFD simulations. A test rig is set up to estimate the churning losses of the moving parts by monitoring the torque at different rotational speeds. The analytical results indicated that the torque of the churning losses increased with the increase of the rotational speed. In addition, the experimental data of the churning losses were consistent with the solutions from both the conducted mathematical models and CFD simulations before the rotational speed reached 8000 rpm. However, when the rotational speed exceeded 8000 rpm, the experimental data showed an apparent difference from the calculated ones. Based on the changes in the oil temperature and noise, this difference might be due to cavitation or turbulence. As a result, the churning losses that took place in the 2D high-speed piston pump need to be further studied, especially when the pump is driven by a high-speed motor.

Axial piston pumps with high rotational speeds are required in many fields to increase the power-to-weight ratio. However, three main sliding friction pairs in the pump restrict the increase in rotational speed. To solve this problem, we propose a 2D piston pump with a balanced force that contains a sliding friction pair. Firstly, the mechanical structure and working principle of the pump are described. Then, the pump volumetric efficiency is studied by mathematical modeling, and volumetric losses containing backflow and leakage are analyzed and discussed from the perspectives of load pressure and rotational speed. A test bench that verifies the mathematical model is built to measure the volumetric efficiency of the tested pump. We have found that the increase in rotational speed can help to increase the pump volumetric efficiency, and the mathematical model is consistent with the tested data for 1000 rpm but demonstrates a remarkable difference from the tested data for 3000 rpm. Thus, the temperature field of the pump and the viscosity-temperature characteristics of the oil must be taken into account to increase volumetric efficiency further.

Flowmeters play a critical role in hydraulic systems. Following a review of positive displacement flowmeters, we hereby introduce a novel positive displacement flowmeter with parallel two-dimensional pistons as metering units. The working principle involves simultaneously utilizing both the rotational and reciprocation movements of a two-dimensional piston and paralleling two two-dimensional pistons to prevent flow rate fluctuations. Consequently, we established a mathematical model to describe the cam track curves and the displacement of the flowmeter. Meanwhile, the pressure loss is analyzed and the leakage flow rate is estimated to compensate the relative error. Finally, we designed and fabricated a prototype to measure the flow rate with ranges of 1 – 25 L/min. The experimental results show that the prototype has a reading uncertainty of less than 2%, a linearity of around ±3.8% and relative errors of less than ±2.9%. The pressure loss for the prototype increases linearly with the total flow rate and reaches 3 bar at 25 L/min. These characteristics are acceptable considering that this prototype is the first set of two-dimensional piston flowmeters. The shortcomings of this first-generation flowmeter are discussed in the conclusion part to provide guidance to enhance the performance of next-generation prototypes.

In order to improve the volumetric efficiency of the axial piston pump, this paper proposes a novel stacked roller 2D piston pump. It utilizes the alternate communication between the distribution cylinder and the oil intake and discharge ports of the housing to realize the flow distribution. While removing the independent flow distribution mechanism of the traditional piston pump, the leakage loss at the distribution friction pair can be reduced to improve the volumetric efficiency. Based on the flow distribution principle, an analytical model of the volumetric efficiency of the stacked roller 2D piston pump was established. Then, a co-simulation model of the whole pump was built using both the Simulink and AMESim software. The variation curve of output flow and leakage flow under different load pressures and rotational speeds was obtained, as well as the influence of backflow, axial leakage, and circumferential leakage on the volumetric efficiency. On this basis, a prototype of the stacked roller 2D pump was designed and manufactured in order to measure the output flow under different load pressures and rotational speeds, and a dedicated test bench was established. The experimental results are consistent with the simulation results; when the rotational speed is 6000 rpm and the load pressure is 5 MPa, the volumetric efficiency of the prototype pump can reach 98.6%. The research work validates that the novel stacked roller 2D piston pump has high volumetric efficiency.

A new type of two-dimensional (2D) piston pump with a stacked cone roller set was introduced to eliminate the influence of the gap between the guiding rail and the cone roller. First, the structure and working principle of the 2D piston pump were studied; then, a corresponding mathematical model which considered the oil viscosity and oil churning loss caused by the rotation of the guiding rail in the enclosed chamber was established to examine the volumetric and mechanical efficiency of the 2D piston pump. The effects of different speeds, load pressures, and rolling friction coefficients between the guiding rail and the cone rollers on the efficiency were considered. During the test, when the speed was 6000 r/min and the load pressure was 6 MPa and 8 MPa, the volumetric efficiency reached 98.3% and 96.8%, respectively, basically consistent with the theoretical analysis. Because the temperature rise of the tested pump caused the oil viscosity and the eccentricity of the piston and piston rings increased the leakage, the test result was slightly lower than that of the theoretical analysis. When the speed was 1000 r/min and the load pressure was 5 MPa, the mechanical efficiency was 69.3%, and the mechanical efficiency model was consistent with the test results. However, with the increase in speed and load pressure, the difference between the test results and theoretical analysis results increased because the supporting force of the cone roller on the guiding rail increased, increasing the rolling frictional losses.