The improvement of the overall performance of hydraulic pumps is the basis of intelligent hydraulics. Taking the straight line conjugate internal meshing gear pump as the research object, the theoretical flow rate and the geometric flow pulsation rate equations are established in this study through the volume change method. The change laws of the gear pair’s geometric parameters on the theoretical flow rate and the geometric flow pulsation rate are studied. The simulation model of the internal flow channel is established, and the influence factors and the influence degree of the flow pulsation and average flow rate are analyzed. The high-pressure positive displacement pump test system is also designed and built. The performance evaluations are conducted, and the experimental results are analyzed. The results show that the periodic change of the meshing point position is the root cause of the geometric flow pulsation. The theoretical flow rate and the geometric flow pulsation rate are 103.71 L/min and 1.76%, respectively. To increase the theoretical flow rate whilst decreasing the geometric flow pulsation rate, the tip circle radius of the external gear should be increased as much as possible within the allowable range of the design calculation. Amongst the three influencing factors that produce flow pulsation, the oil compressibility has no effect on the flow pulsation. The uneven internal leakage is the main factor, and the geometric flow pulsation only accounts for a small proportion. The internal leakage reduces the simulated flow rate by 3.59 L/min. The difference between the experimental and simulated flow rates is less than 2%. Within the allowable speed range, the rotation speed of the external gear should be increased as much as possible to increase the average flow rate and the volumetric efficiency.

As a medium and low pressure gear machine without automatic compensation structure for axial and radial clearances, the friction pairs in the straight conjugate internal gear pumps (SCIGPs) depend on the fixed small clearances to seal, lubricate and transfer the force. The oil film design of the friction pairs has become an important part of gear pump design. However, there has never been a publicly published research on the oil film design of the SCIGP in past literature. This paper applies orthogonal test to the oil film design of the SCIGP for the first time to determine the best working clearances. With this goal, the paper first provides the mathematical models for analyzing the internal leakage flow and the viscous friction loss, which elucidate the relationships between the leakage and the friction loss with working conditions. After that, the orthogonal test scheme for numerical simulation was designed on the basis of determining the range of oil film thickness. The paper also propounds the viewpoints of using the range-method to estimate the primary and secondary relationship of factors and determining the optimal combination according to the test target. Based on this concept, the main factors affecting the target are procured and the optimal working clearances of the friction pairs are determined. For the purpose of verifying the model, the redesigned prototype was tested and compared with the simulation results. The results validate the applicability of the simulation model and the correctness of the simulation method. Finally, the paper summarizes the ways to improve the total efficiency and the working conditions at the highest efficiency.

In oil–gas mixed transportation using spiral-vane-type multiphase pumps, high sand content often causes wear on flow-passing components. To reveal the motion patterns of particles, a three-stage spiral-vane-type multiphase pump was selected as the research subject. A visualization test bench was constructed, and the pump’s performance curve was obtained by experimental measurements. High-speed photography was used to capture the flow process of a single particle within the pump, and CFD-DEM was used to study the motion characteristics of four particle sizes (0.5 mm, 1 mm, 1.5 mm, and 2 mm). The results showed that 0.5 mm and 1 mm particles had smaller trajectory angles in the guide vanes, while 1.5 mm and 2 mm particles had larger angles, with wall collisions observed. Velocity changes were similar: When they just enter the impeller, the circumferential velocity increases sharply and then stabilizes around 15 m/s. After entering the guide vane passage, the circumferential velocity exhibits an initial abrupt decrease followed by a gradual reduction. The axial velocity increases gradually along the impeller passage, reaches the highest value at the impeller outlet, and begins to decrease gradually after entering the guide vane. The particles had higher volume fractions in the guide vane and collided more with impeller walls. Collisions with guide vane walls increased with particle size.

Blade wear is the critical problem in the operation of multiphase pump. This paper presents a numerical study of the multiphase flow of multiphase pump. The trajectory of particles in the pump is calculated by the discrete phase model. Then, the simulation results are compared with the model test results of the pump to verify the correctness of the simulation method. The results show that the particles in the impeller domain are mainly near the hub, and the particles in the diffuser domain form a agglomerated area in the middle of the flow channel. The average wear rate of the impeller is more affected by the particle size than that of the diffuser. The maximum wear rate of blade surface increases first and then decreases with the increase of particle size. According to the wear data under different particle sizes, the regression model between particle size and wear rate is fitted to predict the wear of mixed transport pump in actual operation. The research results have important reference value for the prediction of the wear performance of the multiphase pump.

The working conditions (i.e., gas content, working pressure, and working temperature) of oil in the actual hydraulic system are always in a dynamic process, which will cause the basic properties of oil (i.e., density, absolute viscosity, and effective bulk modulus) to change and further generate changes of the flow characteristics in the straight conjugate crescent gear pump (SCCGP). However, no clear explanation has been given for the variation of the flow characteristics of the SCCGP with the working conditions in previous studies. This paper first expounds the gear pair profile equations used to draw the tooth profile curves and the equation applicable to the calculation of the geometric displacement at the given geometric parameters. Subsequently, the mathematical models of the oil’s basic properties are analyzed, and it is explained how the changing working conditions affect the changes in oil properties. After that, the paper designs an orthogonal test scheme and applies it to the study of the flow characteristics of the SCCGP for the first time to optimize its working conditions. Then, the paper performs simulations in commercial CFD numerical software, and the change laws of the internal flow field, flow pulsation, pressure pulsation, volumetric efficiency, and total efficiency of the SCCGP at different working conditions are analyzed in detail. The working conditions for decreasing pulse rate and improving total efficiency are summarized. Finally, for model validation purposes, the paper elucidates the construction process of a high-pressure positive displacement pump test system and carried out experimental research. The simulation and actual measurement results are compared under the same working conditions. The results validate the accuracy of the simulation model and the potential for future analytical studies.