Patent Application
20130118346
This invention relates to rotary axial piston pumps and, more specifically, to rotary axial piston pumps that are specifically engineered to operate in plain water applications in a manner that provides improved service life and more robust operation criteria when compared to conventional rotary axial piston pumps.
Rotary axial piston pumps (RAPPs) are known in the art and can be constructed for a number of different end-use applications. One category of RAPPs are configured for use in applications, e.g., oil hydraulic transport, that permit the internal components that are subjected to friction to be oil lubricated, thereby helping to reduce the unwanted effects of friction to provide a desired service life.
Another category of RAPPs are configured for use in applications, e.g., water hydraulic transport, that do not permit the internal components subjection to friction to be oil lubricated. In such applications, the RAPPs are configured to use plain water without additives or aides as the only friction lubricating medium.
Conventional RAPPs configured for water hydraulic transport service use internal parts, subjected to friction during use, that are specifically configured to include a polymeric low-friction surface feature. Such a conventional RAPPs comprise metallic piston slippers that include a polymeric surface feature that projects outwardly a small distance from the slipper body metal interface surface. As the piston rotates against a metallic swash plate during RAPP operation, and the polymeric surface feature operates to prevent metal-to-metal contact, thereby reducing friction.
While such RAPPs are configured to address frictional wear effects between adjacent metallic parts during water hydraulic transport use, the use of such RAPPs configured in the manner described require that the water entering the pump be filtered to very high level to remove particulate matter. If unfiltered, the particulate matter in the water can otherwise wear and/or damage polymeric surface feature resulting in metal-to-metal contact, thereby reducing the effective service life of the RAPP. The need to filter the water transported by the RAPPs to protect against unwanted damage and/or reduced service life involves using filtration equipment that adds labor and material costs to the overall cost of operating such RAPPs.
Thus, while RAPPs configured for water transport service are constructed to provide some degree of low friction operation under certain operating conditions, e.g., ultra-clean conditions, it is desired that an RAPP be constructed in a manner that permits a more robust operating parameters in water transport services in terms of both improved service life and in terms of reduced water pretreatment requirements. Specifically, it is desired that an RAPP be constructed in a manner comprising internal parts specially developed and engineered to provide an improved degree of friction reduction performance, thereby extending service life when compared to conventional water transport RAPPs.
It is further desired that such RAPPs comprising such construction provide the improved degree of friction reduction performance in a manner that avoids the need to filter the incoming water to ultra-fine standards, thereby reducing the overall equipment and labor costs associated with RAPP operation. Finally, it is desired that such RAPP be constructed in a manner avoiding the use of exotic materials and/or nonconventional manufacturing techniques, thereby minimizing any such impact on material and manufacturing costs.
RAPPs as disclosed herein comprise a housing, a swash plate that includes an inclined surface, and a rotor assembly that is positioned adjacent the swash plate. In an example embodiment, the inclined surface can be formed from a ceramic material and/or the entire swash plate can be formed from a ceramic material. The rotor assembly comprises a rotor-drum that has at least one cylinder bore disposed therein, and that has piston(s) disposed within the respective cylinder bore(s). The pistons are constructed having a ball-shaped end that extends from the cylinder bore(s).
Such RAAPs further comprise at least one slipper that is interposed between the swash plate and the rotor-drum. The slipper(s) comprises socket joints for accommodating the piston ball-shaped end(s) therein. The socket joint may comprise a plastic material disposed therein that is in contact with the piston ball-shaped end. The slipper(s) further include a swash plate interface surface that is in contact with the swash plate inclined surface and that is formed from a ceramic material. In an example embodiment, the slipper may be formed from a ceramic material. In an example embodiment, the slipper and socket joint are configured in the form of a molded together construction.
The RAAPs also includes a stator plate that is positioned adjacent an end block that is disposed in the housing open end, and a rotor plate that is interposed between the stator plate and the rotor-drum. In an example embodiment, the stator plate comprises an interface surface that is in contact with the rotor plate, and that is formed from ceramic material. In an example embodiment, the rotor plate comprises an interface surface that is in contact with the stator plate, and that is formed from a ceramic material. In an example embodiment, the stator plate and/or the rotor plate may be formed entirely from a ceramic material.
In an example embodiment, the RAAPs comprise a pressure plate that is in contact with the slippers. A spring may be in contact with the pressure plate, and the spring may be disposed within a central cavity in the rotor-drum interposed between a closed end of the cavity and the pressure plate. In an example embodiment, the RAAPs may further comprise a plurality of retainers disposed on top of respective slippers and interposed between the slippers and the pressure plate.
The above and further objects, features and advantages of RAPPs as disclosed herein will be more fully understood and appreciated from the following description taken in conjunction with reference to the accompanying drawings in which:
RAPPs as disclosed herein are specially engineered to provide an improved service life in water hydraulic transport service without the need for ultra-fine filtration requirements. RAPPs as disclosed herein include one or more internal parts that are formed from a ceramic material for the purpose of reducing and controlling unwanted frictional effects between dynamically engaged surfaces. Depending on the particular internal part, the entire part can be formed from a ceramic material, or only a portion of the part can be formed from a ceramic material.
A stator plate 16 is disposed within the housing 12 and is positioned adjacent an inside surface of the end block 14. The stator plate is a metallic stationary member that does not rotate relative to the housing. A swash plate 18 is disposed within the housing and positioned adjacent an inside surface of the housing closed end 13. The swash plate is also a metallic stationary member that does not rotate relative to the housing and provides a smooth flat inclined surface that extends towards the stator plate.
A rotor assembly is disposed within the housing and comprises a cylindrical rotor-drum 20 that is interposed between the stator plate and the swash plate. The rotor-drum is configured to rotate within the housing and comprises an array of axial cylinder bores, each fitted with an axial piston 22. Each axial piston comprises a ball-shaped end in swivel engagement with a slider shoe or slipper 24 held against the inclined surface of swash-plate 18. The slipper comprises a metallic body and swash plate interface surface.
Slider shoes 24 are supported in a uniform array and held against swash-plate 18 by a shoe pressure plate 26, which bears against the central region of rotor-drum 20 via a hemispherical swivel member 28. At the other end of rotor-drum 20, an attached rotor plate 30 interfaces kidney plate 16 at a sliding interface to serve as a sliding valve control system. The rotor plate rotates with the rotor-drum assembly within the housing.
The rotor plate 30 is configured having a number of openings therethrough (not shown) that align with respective openings in the cylinder bores. The stator plate 16 also comprises openings (not shown) that are in alignment with inlet and outlet ports (not shown) extending through the end block. As the rotor-drum 20 rotates within the housing, the rotor plate openings align with the stator openings to facilitate fluid inlet and outlet in a manner corresponding to the piston inlet and outlet strokes to provide the desired fluid transport by the pump.
Generally speaking, the internal components or parts of such RAPPs that are subjected to frictional forces during pump operation include the interface surfaces between the stator plate 16 and the rotor plate 30, the metallic interface surfaces between the swash plate 18 and the piston slippers 24, and the interface between the piston ball and the slipper As noted earlier, when the RAPP is configured for use in oil hydraulic transport service, such metallic interface surfaces are lubricated by the oil being transported, which operates to reduce the frictional forces existing at the metallic interfacing surfaces.
Design of RAPPs is complex and involves tradeoffs between an inherent set of problems arising from the liquid pressures and the moving interface surfaces described above, and these have given rise to many different approaches. Assuming the capability requirement to be a well-defined constant (essentially input/output pressures, flow rate and RPM), efficiency and reliability become of main concern in meeting the usual requirements of overall (initial, operating, long-term) cost effectiveness and reliability. Since efficiency depends heavily upon sealing and lubrication, and these two tend to be mutually exclusive in the design of practical RAPPs, the unsatisfactory extent and nature of tradeoff and compromise that must be accepted in the present state of the art in this field of endeavor indicate an unfulfilled need for further improvement.
RAPPs as disclosed herein are specially designed and engineered to function in water hydraulic transport service, where lubrication within the pump is provided by water rather than oil or any additives. The challenges associated with this type of service application relate primarily to addressing the friction forces that develop within the pump at the noted interfacing surfaces during use.
Past approaches at designing RAPPs for such surface have focused on using a combination of plastic and metal for all bearing or interface surfaces, e.g., by placing a polymeric surface or surface feature on one or more of the interface surfaces. While this approach has had some effect, the polymeric surface features are very sensitive to and are subject to being damaged or worn away during operation by the presence of particulate matter in the water. In the presence of even fine particulates, the plastic material can prematurely wear out and result in catastrophic failure of the RRAP. Therefore, such RAPPs configured in this manner require that the water entering the pump be prefiltered to a high degree, e.g., be ultra-fine, to provide a desired service life.
RAPPs as disclosed herein are specially designed and engineered having a more robust design, enabling such RAPPs to provide an improved service life in water hydraulic transport service without the need for fine prefiltration of the water, thereby permitting a broader spectrum of use in a manner that is also less costly.
In an example embodiment, the stator plate 52 comprises a ceramic surface that interfaces with the rotor plate 56. The stator plate 52 can be made entirely from a ceramic material or can be a composite construction comprising a metal body and having a ceramic layer (e.g., in the form of a veneer or the like) covering all or a portion of the interface surface with the rotor plate and/or covering all or a portion of the interface surface with the end block. If desired, the layer can be provided in the form of a continuous surface or can be provided in the form of one or more surface features projecting outwardly a distance from the surface to contact the rotor plate. In a preferred embodiment, the stator plate is entirely formed from a ceramic material.
In an alternative embodiment, the stator plate is formed from a metallic material and comprises a ceramic layer disposed over all or part of at least the rotor place interface surface. In stator plate embodiments comprising a ceramic layer, i.e., when the entire stator plate is not formed from a ceramic material, it is desired that such layer have a thickness that is sufficient to provide a desired degree of low-friction service to provide a desired effective service life without unnecessarily adding to the material costs. In an example embodiment, it is desired that the ceramic layer or ceramic surface feature have a thickness of at least 0.03 inches, and preferably in the range of from about 0.03 to 0.1 inches.
The stator plate comprises inlet and outlet ports to facilitate the flow of fluid into and out of the RAPP by cooperation and alignment with fluid openings in the rotor plate during operation of the RAPP. Ceramic materials useful for forming the stator plate or being used to form a ceramic layer on the one or more surfaces of the stator plate include metal oxides and metal carbides. Examples of preferred ceramic materials include but are not limited to aluminum oxide, silicon carbide, tungsten carbide and combinations thereof.
The rotor plate 56 can be formed from a metallic material. In an example embodiment, the rotor plate may have a metallic body comprising a ceramic layer along a stator rotor interface surface. In such embodiment, the rotor-drum interface surface may be metallic. In a preferred embodiment, the rotor plate 56 comprises a stator interface surface comprising a ceramic layer. Such layer can be continuous or can be provided in the form of surface features projecting outwardly from the rotor plate surface. Thus, a preferred RAPP embodiment comprises bearing surfaces formed between the stator plate and rotor plate that are both made from ceramic material.
Like the stator plate, the rotor plate 56 can alternatively be formed entirely from ceramic material, i.e., a monolithic ceramic construction. As noted above, the rotor plate can have a composite construction comprising a metal body and having a ceramic layer (e.g., in the form of a veneer or the like) covering all or a portion of the interface surface with the stator plate. In embodiments where the rotor plate comprises a ceramic layer or surface feature, the thickness of such layer or surface feature is the same as that disclosed above for the stator plate. In a preferred embodiment, the rotor plate is entirely formed from a ceramic material. The ceramic materials used to form all or part of the rotor plate are selected from the same group of ceramic materials disclosed above for the stator plate.
The rotor plate 56 includes a number of openings that are configured to accommodate respective nipples 60 therein that are interposed between adjacent cylinder bores and rotor plate openings. The nipples are preferably cylindrical annular members that may be formed from a metallic material, and that have an outer diameter sized to fit inside a portion of the adjacent cylinder bore and rotor plate opening to facilitate the passage of fluid therebetween. The nipples include seals that are positioned around the outside diameter to form a leak-sight connection with the adjacent inside surfaces of the rotor plate opening and cylinder bore.
The RAPP comprises a shaft 61 that extends from a position outside of the RAPP axially through the end block 54, through the stator plate 52 and through the rotor plate 56. The shaft 61 is used to rotate the rotor-drum and includes a reduced diameter section that projects axially from the rotor plate and is securely disposed within a central cavity of the rotor-drum. The rotor plate 56 is fitted to the shaft to rotate with the rotor-drum during shaft rotation. Configured in this manner, the rotor plate 56 does not move axially within the RAPP during operation.
The rotor-drum 58 is formed from a metallic material and comprises a number of cylinder bores 62 disposed axially therein. Pistons 64 are disposed within respective cylinder bores 62. In an example embodiment the pistons are formed from a metallic material, preferably stainless steel. The nipples 60 are configured having a length that does not impair the stroke of the pistons within the respective cylinder bores. The pistons include ball-shaped ends 64 that project outwardly from respective cylinder bores 62.
The piston ball-shaped ends 64 are each disposed within a respective socket joint 66 of a slipper 68. Referring to
In an example embodiment, the slipper and the socket joint polymeric material can be molded together at the same time. In another embodiment, the slipper and socket joint plastic material can be formed separately and assembled together for use within the RAPP.
The slipper body includes a swash plate interface element 72 in the form of a dish-shaped member positioned at the end of the upper cylindrical wall portion 70. In an example embodiment, the swash plate interface element 72 is formed from a ceramic material. In a preferred embodiment, the slipper body is a one-piece ceramic construction comprising the upper cylindrical portion and the swash plate interface element. Configured in this manner, the slipper comprises a swash plate interface element having a ceramic surface for interacting with a swash 73 plate. If desired, the swash plate interface surface can be configured having one or more surface features projecting therefrom. Such surface features can be configured to provide to further reduce the friction forces that occur during RAPP operation.
In an example embodiment, the swash plate interface surface comprises a surface feature in the form of a circular ridge 85 (best shown in
While a slipper comprising a one-piece ceramic construction has been disclosed, in an alternative embodiment, the slipper may be configured having a composite construction or more than one material, wherein the swash plate interface surface is formed from a ceramic layer, e.g., a veneer, that is provided in a continuous layer or in the form of one or more surface features. For example, the slipper may comprise a metallic upper cylindrical wall construction, and the swash plate interface element may be formed from a metallic material having a ceramic swash plate interface surface, or the swash plate interface element may be formed entirely from a ceramic material.
In the example embodiment illustrated in
Alternatively, and as illustrated in
As illustrated in
A feature of the RRAP disclosed herein is that spring providing the biasing force does not contact the rotor plate. Rather, the spring 80 is interposed between and in contact with the rotor-drum and the pressure plate. These construction features enables the rotor plate to be made from a ceramic material or comprise a ceramic layer to provide the desired degree of friction force reduction between the bearing surfaces, rather than having to make the rotor-drum itself out of a ceramic material. Thus, this construction features provides an RAPP having a more cost effective replacement element if damaged or worn, i.e., the rotor plate rather than the entire rotor-drum.
Referring to
Referring to
A feature of RAPPs as disclosed herein is that the internal bearing surfaces, existing between the stator and rotor plates, and the slippers and swash plate, are all characterized by having ceramic-to-ceramic surfaces. The selective use such ceramic materials, to either entirely form these internal components or form only the interfacing surfaces between these internal components, provides a desired improved reduction of friction forces between such internal components that not only permit use of such RAPPs in water hydraulic transport applications, but that enables such use without the need for high levels of entering fluid pretreatment, i.e., ultra-fine levels of filtration.
Thus, RAPPs designed and constructed in this manner enable more robust RAPP service in water hydraulic transport applications with improved service life and without pretreatment, thereby avoiding the costs and expenses associated with purchasing, operating, and maintaining such pretreatment equipment.
RAPPs as disclosed herein may be embodied and practiced in other specific forms without departing from the spirit and essential characteristics thereof. The present embodiments disclosed and illustrated herein are therefore to be considered in all respects as illustrative and not restrictive.
