<p>Despite the increasing demand for the hydraulic pump noise reduction, there is yet to be an established straightforward solution to reduce noise emissions. This is primarily due to a lack of understanding of the complete mechanism underlying noise generation and propagation, which involves complex interactions between three domains. Study of the physical phenomena of the hydraulic pump noise is typically separated into three categories, namely fluid-borne noise (FBN), structure-borne noise (SBN), and air-borne noise (ABN). In this light, this study examines the noise generation and propagation of hydraulic pumps in all three domains numerically and experimentally, taking external gear pumps (EGPs) as a reference. </p> <p>In conventional pump noise studies, the outlet pressure ripple in the fluid domain, which typically refers to has been the key focus to minimize, and FBN typically refers to the outlet pressure ripple. Fortunately, attempts to minimize ripples have resulted in some promising solutions that are now on the market (e.g., dual-flank gear pumps). However, since the noise generated by gear pumps involves several other significant and coherent noise sources, this approach has some limitations. In view of this, the current study describes FBN in a wider context to include all potential noise sources in the fluid domain, and their mutual effects on noise are investigated.</p> <p>Another aspect of the vibration and noise of the pump that is not often investigated is its “field” behaviors. Many significant works in vibroacoustic analysis or noise solutions rely on the simple measurements of acceleration or sound pressure at a single or few local points. Since vibration and noise are functions of not only time but also "space", this practice has also served as one of the obstacles to a comprehensive understanding of noise generation. Therefore, this study contributes to topic of the vibroacoustic field behaviors.</p> <p>Furthermore, when prototyping or designing new pumps, inefficient trial-and-error methods are often used, and it demonstrates the necessity of the acoustic model of the pumps for virtual prototyping. The major limiting factor towards the development of this type of models is high computational costs. Another technical challenge is that most of vibroacoustic analysis commercial software usually requires the user’s manual works for the simulation setup. In this regard, another aim of this study is to develop a computationally inexpensive and automated acoustic model that does not need manual inputs of users, so that the model can be used as a virtual prototyping tool with various design parameters.</p> <p>To sum up, the primary goal of this research is to numerically and experimentally investigate the vibroacoustic field behaviors and formulate the acoustic model to be used as a virtual prototyping tool with the experimental validation. To achieve these objectives, this research employs the well-established computational and experimental methods of vibro-acoustic analysis.</p> <p>The analysis of FBN makes use of the HYGESim tool, which has been developed to study EGMs at Maha Fluid Power Research Center. This tool solves the main flow based on the lumped parameter approach in conjunction with different solution schemes for lubricating interfaces and body dynamics. From the HYGESim results, all potential noise sources within the working fluid, such as inlet and outlet pressure ripple and dynamic pressure at the tooth space volumes, hydrodynamic journal bearings, and the lateral lubricating interface, are properly mapped to the structure using appropriate simplifications. </p> <p>When it comes to SBN, the modal superposition approach is exploited for the fast prediction of vibration fields. Therefore, considerable efforts are expended both numerically and experimentally to obtain accurate modal information. Particular attention is paid to the modeling of the mechanical connections between components and modeling of constraints in numerical modal analysis using the finite element method (FEM). Moreover, the vibration mode shapes are categorized according to the dominant motions that the pump body exhibits. Then, two different approaches, namely the full numerical model and the hybrid model, are introduced for the estimation of the vibration field during the operation; for the modal expansion, the former uses numerical modal information, while the latter uses experimentally determined modal information. Finally, the numerical model results are compared to the operational deflection shape (ODS) measured during pump operation, and a good agreement is observed.</p> <p>For the ABN prediction, the boundary element method (BEM) is used by taking the predicted vibration information as an input. The BEM solver development is elaborated to numerically replicate the acoustic environments where the noise measurement is conducted. With the developed BEM solver, two units that have the different gear and groove designs that fit into the same casing are tested, and as the key outcome, their sound power level, sound power spectrum, sound pressure distributions are presented. For model validation, the noise measurements are performed according to the ISO standard in the semi-anechoic chamber at Maha using a custom-designed robot arm. These validations demonstrate the ability of the developed model to predict the overall sound power levels with an averaged error of 1.87 dB and capture the general trends of measured sound power spectrum and sound pressure level distribution under various operating conditions. Furthermore, the developed model provides the reasonably fast computation time.</p> <p>Finally, using the developed acoustic model, a parametric study is performed with the backflow groove as a design variable. It is discussed how the volumetric efficiency and noise performance vary with the design changes, which demonstrates the model potential as a virtual prototyping tool.</p>

Detta arbete har genomförts på uppdrag av SCA Munksund, för att undersöka möjligheten att tillståndsövervaka hydraulpumpar med hjälp av smarta sensorer som mäter vibrationer och temperatur. Hydraulpumpar är svåra att tillståndsövervaka, och möjligheten att prediktera ett haveri i ett tidigt skede är väldigt svårt. Haverier på hydraulpumpar sker oftast inte direkt efter att ett fel har uppstått, utan efter en längre period, med däremot sker haverier på hydraulpumpar oftast utan förvarning och är mycket kostsamma för processindustrin, där materialkostnaden utgör en liten del jämfört med kostnaden som följd av produktionsförlusten. En möjlighet för bättre och effektivare tillståndsövervakning är att använda vibrationssensorer som i ett tidigt skede indikerar när pumpen avviker från sitt normaltillstånd, och på så sätt planera in underhållsarbete vid exempelvis nästkommande underhållsstopp, utan att behöva stoppa produktionen. Just därför har det valts att undersöka olika sensorparametrar för att identifiera hydraulpumparnas normaltillstånd, och utifrån det bestämma lämpliga larmgränser. Vibrationsmätningarna har genomförts under ca en månad på två hydraulpumpar, en som är relativt ny och en som är äldre. Huvudfokuset har varit att övervaka vibration och temperatur under varierande pumpbelastning/effekt och även att övervaka kolvslitage och lagertillstånd. Med användning av smarta vibrationssensorer har larmgränser kunnat identifierats för båda pumparna. Däremot måste fler mätningar utföras för att säkerställaatt de larmgränser som presenteras i denna rapport är korrekta och kan användas i framtiden. SCA Munksund har nu tillgång till alla mätningar och dokumentation som har utförts för båda hydraulpumparna, och kan nu arbeta vidare för att på sikt tillhandhålla mer specifika larmgränser. / This work has been carried out on behalf of SCA Munksund, to investigate the possibility of condition monitoring hydraulic pumps using smart sensors that measure vibrations and temperature. Hydraulic pumps are difficult to condition monitor, and the ability to predict a failure at an early stage is very difficult. Breakdowns on hydraulic pumps usually do not happen immediately after a fault has occurred, but after a longer period, but on the other hand, breakdowns on hydraulic pumps usually happen without warning and are very costly for the process industry, where the cost of materials constitutes a small part compared to the cost resulting from the loss of production. One possibility for better and more efficient condition monitoring is to use vibration sensors that indicate at an early stage when the pump deviates from its normal state, and in this way plan maintenance work at, for example, the next maintenance stop, without having to stop the production. Precisely for this reason, it has been chosen to investigate various sensor parameters to identify the normal state of the hydraulic pumps and based on that to determine suitable thresholds. Vibration measurements have been carried out for about a month on two hydraulic pumps, one that is relatively new and one that is older. The main focus has been on monitoring vibration and temperature under varying pump load/effect and also to monitor piston wear and bearing condition. With the use of smart vibration sensors, thresholds have been identified for both pumps. However, more measurements must be performed to ensure that the thresholds presented in this report are correct and can be used in the future. SCA Munksund now has access to all measurements and documentation that have been carried out for both hydraulic pumps and can now work further to provide more specific thresholds.

In hydraulic pumps, typically in axial piston pumps, reduction of pressure and flow ripples was attempted by providing relief grooves and pre-compression for noise reduction. Pre-compression is normally achieved by using the dead space between pump ports in the valve plate. Also valve plate profile modification is required, if system operating conditions such as pump output pressure and flowrate change, to maintain optimum operating conditions for reduced pressure/flow ripple. An earlier simulation study confirmed effectiveness of varying dead centre position to reduce pressure and flow ripples. A specifically designed mechanism, outlined in the earlier work, achieves this goal by varying the dead centre position of the pump swash plate. This study reports on the findings of the effect of varying dead centre position and groove configurations on forces and moments acting on the swash plate for various operating conditions. The simulation model cited in the earlier work was used in this study. This information is vital for the design of an actuating mechanism to vary dead centre position of a pump valve plate. These simulations were run using MATLAB/Simulink and S-functions. Results of this study are promising.

A Pipeline Analytical Program and Dredging Knowledge{Base Expert{System (DKBES) determines a pipeline dredge's production and resulting cost and schedule. Pipeline dredge engineering presents a complex and dynamic process necessary to maintain navigable waterways. Dredge engineers use pipeline engineering and slurry transport principles to determine the production rate of a pipeline dredge system. Engineers then use cost engineering factors to determine the expense of the dredge project. Previous work in engineering incorporated an object{oriented expert{system to determine cost and scheduling of mid{rise building construction where data objects represent the fundamental elements of the construction process within the program execution. A previously developed dredge cost estimating spreadsheet program which uses hydraulic engineering and slurry transport principles determines the performance metrics of a dredge pump and pipeline system. This study focuses on combining hydraulic analysis with the functionality of an expert{system to determine the performance metrics of a dredge pump and pipeline system and its resulting schedule. Field data from the U.S. Army Corps of Engineers pipeline dredge, Goetz, and several contract daily dredge reports show how accurately the DKBES can predict pipeline dredge production. Real{time dredge instrumentation data from the Goetz compares the accuracy of the Pipeline Analytical Program to actual dredge operation. Comparison of the Pipeline Analytical Program to pipeline daily dredge reports shows how accurately the Pipeline Analytical Program can predict a dredge project's schedule over several months. Both of these comparisons determine the accuracy and validity of the Pipeline Analytical Program and DKBES as they calculate the performance metrics of the pipeline dredge project. The results of the study determined that the Pipeline Analytical Program compared closely to the Goetz eld data where only pump and pipeline hydraulics a ected the dredge production. Results from the dredge projects determined the Pipeline Analytical Program underestimated actual long{term dredge production. Study results identi ed key similarities and di erences between the DKBES and spreadsheet program in terms of cost and scheduling. The study then draws conclusions based on these ndings and o ers recommendations for further use.