Patent Application
20140255235
The disclosure is generally related to the field of gear pumps, and more particularly to a self-adjusting gear pump having enhanced efficiency at low and high speeds, and which minimizes the impact of tolerance stack-ups and machining variances on pump performance.
In the diesel engine market it is common for fuel pumps (primarily rotary gear pumps) pumping low viscosity fluid (as low as 0.9 centistokes (cst)) to be required to run from very low speeds (below 100 RPM) and moderate pressures to relatively high speeds (in excess of 3000 RPM) at increasingly higher pressures. A problem with this is that gear pumps that are capable of running at higher speeds are typically not efficient at low speed operating points and gears pumps that have excellent low speed efficiencies are not typically capable of operating at elevated speeds. This creates a circular problem for the end user because in order for the pump to meet required flow rates at the lower speeds, it must be grossly oversized at the high speed conditions. This causes the end user to have a system that may produce two to three times more flow than they actually need at elevated speeds, requiring all of the excess flow to be dumped back to the system as unusable energy. With increasing demand for cleaner burning engines and more efficient systems, this is a large hurdle that needs to be overcome.
In addition, another problem that affects the performance and repeatability of one pump of the same type when compared to another is the problem of tolerance stack and machining variance from one pump to another. Due to cost and standard machining practices utilized when building and assembling pumps of this type, pump dimensions can vary (within tolerance) from part to part. These variances when added together can cause pump performance to be inconsistent between two pumps of the same design. These inconsistencies can also push pump efficiencies out of the acceptable range. The intent of this invention is to also minimize the effect of these machining variances and to create a more efficient and repeatable pump.
In the past others have tried several methods of improving the low speed efficiency of rotary pumps. Two of the most common methods include reducing mechanical clearances in the pump, and the addition of pressure biased or pressure balanced side plates. Both approaches have issues at low viscosities with elevated speeds and pressures.
When pumping low viscosity fluid, if the clearances in the pump are simply reduced there is a fine balancing act between good efficiency at low speed and enough clearance to keep the pump from seizing as it heats up and thermal expansion takes place. If the clearances are too wide the pump is not efficient. If the clearances are too tight the pump will have a mechanical failure, thus this method is very application specific and usually requires multiple iterations to get a compromised solution. This solution rarely provides an optimum pump sizing for both the low speed and high speed operating points.
The approach of using pressure biased side plates is a common and effective solution especially for low speed and low pressure applications with higher viscosity fluids. With this solution as pressure of the pump increases, the pressure behind the side plate increases, forcing the side plate tighter against the gears, thus closing the clearances in the pump tighter and tighter as pressure increases. This works well for high viscosity, low speed and moderate pressure applications and efficiencies have been shown to increase dramatically. However, with this concept as pressure increases greatly or speed increases greatly there is a large amount of heat generated due to friction. This heat eventually causes the side plates to fail and often seizes the pump.
The same is true with pressure balanced side plate designs. With this type of design the side plate is sized so that the pressure closing the side faces is nearly perfectly balanced so that the side plate does not rub as hard on the rotating gears as pressure increases. This concept works great for high viscosity and low to high pressure ranges, but is limited again to lower speeds operations. As speed increases, even though the side plates are balanced, the clearances remain the same thus heat is generated and the pump eventually fails.
In view of the above, there is a need for an improved gear pump design that improves both the low speed efficiency of the pump as well as creates a design that can still operate at the elevated speeds for extended periods.
A self-adjusting gear pump is disclosed. The pump may include a gear housing with first and second gears disposed therein. A side plate housing may be coupled to the gear housing. A side plate may be positioned within the side plate housing, the side plate having first and second opposing faces. An end plate may be coupled to the side plate housing. A shim member may be coupled between the side plate housing and the end plate. The side plate may be axially movable between a first position in which the first face contacts respective faces of the pinion gear, ring gear and gear housing, and a second position in which the second face contacts the end plate. The first face of the side plate may be biased toward the first position via a biasing member positioned between the side plate and the end plate.
A method is disclosed for manufacturing a gear pump assembly. The method may include assembling a crescent plate and a gear housing together, the crescent plate having a plate portion and a crescent portion, the gear housing having a pinion gear and a ring gear disposed therein, the crescent portion disposed between a portion of the pinion gear and the ring gear, and grinding respective faces of the gear housing, crescent portion, pinion gear and ring gear as a single unit to provide a finished flat gear assembly surface. The method may also include assembling a side plate housing and a side plate together, and grinding respective faces of the side plate housing and the side plate as a single unit to provide a finished flat side plate assembly surface. The method may further include coupling the crescent plate, gear housing, pinion gear and ring gear with the side plate housing and the side plate so that the finished flat gear assembly surface contacts the finished flat side plate assembly surface.
A method is disclosed for assembling a gear pump. The method may include: engaging a crescent plate with a pump housing, the pump housing having first and second projections received within first and second elongated openings in the crescent plate; engaging a pinion gear with a pump shaft so that the pinion gear is positioned adjacent to a crescent portion of the crescent plate; engaging a gear housing with the crescent plate; engaging a ring gear with the gear housing so that the ring gear is positioned adjacent to the crescent portion and so that teeth of the ring gear mesh with corresponding teeth of the pinion gear; and moving the gear housing with respect to the pump housing so that the teeth of the ring gear contact an outer surface of the crescent portion and the teeth of the pinion gear contact an inner surface of the crescent portion.
A method is disclosed for assembling a gear pump. The method may comprise: engaging a gear housing with a pump housing; engaging first and second gears with the gear housing; and providing a side plate in a side plate housing. The gear housing, the pinion gear and the ring gear may be match ground as a single unit to provide a uniform gear housing assembly surface. The side plate and side plate housing may be match ground to provide a uniform side plate assembly surface. The method may further comprise engaging the side plate and side plate housing with the gear housing and the first and second gears such that the side plate assembly surface contacts the gear housing assembly surface.
By way of example, a specific embodiment of the disclosed device will now be described, with reference to the accompanying drawings:
In certain applications the pressure profile for pump operation starts at a low pressure (e.g., 30-100 psi) and at extremely low speed (e.g., less than about 100 RPM), often referred to as a “startup condition”) then ramps up to a stable higher pressure (e.g., above 100 psi) at some intermediate speed (e.g., between 300-4000 RPM) This same elevated pressure is then maintained for all operating speeds above the low speed idle condition. Standard crescent internal gear pumps have excellent efficiency on low viscosity fluids, such as diesel fuel, at typical diesel fuel pressures, where pump speed is at or above low speed idle. Thus standard clearances are preferred at these operating points since the pumps have been proven to have very long life with these established clearances. The same may not be said about operating at low speed and low pressure (i.e., startup conditions) with such standard clearances.
To improve pump performance at low speed and low pressure operating conditions, a gear pump design is disclosed in which a side plate of the pump is spring biased into engagement with the gears when the pump pressure is between the startup pressure and the normal operating pressure of the pump. This arrangement causes the pump clearances to be tight when needed during startup but allows the clearances to open up once the startup condition is surpassed (i.e., when pump pressure exceeds the pressure exerted by the spring). This solves both the low speed efficiency issue and the longevity issue at elevated speeds and pressures. Thus, the long term effect is a pump that is sized appropriately to a particular system, and which also minimizes or eliminates energy waste associated with pumping unused fluid. It will be appreciated that the aforementioned pressure and speed ranges are merely exemplary, and the disclosed pump is not limited to operating within such ranges.
In one embodiment, shown in
Referring to
The disclosed spring-loaded side plate is advantageous as compared to prior designs in that it only acts to close the pump side face clearances over the low speed low pressure range of operation (e.g., startup speeds). This improves the efficiency of the pump in the operating range where prior designs are often inadequate. Once the “startup” conditions and pressures are exceeded, the side plate moves to normal proven clearances allowing the pump to operate at high pressures and low viscosities with minimal reliability issues.
It will be appreciated that the shim thickness “ST” can be selected to provide a desired clearance “CG” between the side plate 2 and the pinion and ring gears 4, 6 and the gear housing 8 at higher pressure conditions. In non-limiting exemplary embodiments, the shim thickness “ST” can be from about 0.0001-inches to about 0.020 inches, depending upon the application.
It will also be appreciated that although the spring 10 is illustrated as being a coil spring, other types of biasing elements could be used, a non-limiting list including wave springs, Belleville washers, conical springs, magazine springs, air springs, leaf springs, volute springs, spring washers, wave washers, elastomers as springs, and tapered springs.
The disclosed self-adjusting side plate design has the advantage over previous side plate attempts in that it only attempts to reduce clearances through the operating range that it is needed. The self-adjusting plate only closes clearances at “cranking” conditions where pressure and speed are relatively low. Once these conditions are exceeded the side plate relieves and the pump opens itself up to normal proven clearances that can operate at high pressure and high speed. This is an advantage over previous technology that either tries to balance the pressure on both sides of the side plate or pressure bias the side plate always to close clearances. These designs cannot operate at low viscosities and high speeds for extended amounts of time without failure due to heat generation or thermal expansion.
In addition to the self-adjusting side plates, the pump 1 may be manufactured and assembled in a manner that minimizes or eliminates tolerance stack-up issues and attendant pump performance issues. For example, as can be seen in
The two piece crescent plate 24 and gear housing 8 has another distinct advantage in that it allows the radial gap between the crescent 36 and pinion gear 4, and the radial gap between the crescent and the ring gear 6, to be minimized during assembly. The two pieces are independent of each other and are allowed to “free float” or slide against each other in one dimension. The other axes of free motion are confined, thus maintaining orientation of the pieces in a desired position. During assembly this allows the gear housing 8 to be loaded into the ring gear 6, which is in turn is loaded into the crescent plate 24, which in turn is loaded into the pinion gear 4 during assembly. This eliminates all radial tolerance stack-up during assembly, which not only makes the pump more efficient, but it also allows the tolerancing of the parts to be more liberal and reduces manufacturing expense.
Referring now to
The match grinding process also eliminates variations caused by tolerance stack-up between the independently machined components. Typically when the operator attempts to set the side face clearances there is a variation from one side of the part to the other, even if all parts are within tolerance. With the disclosed method this variation can be minimized or eliminated, and performance repeatability will greatly improve.
Moreover, the disclosed manufacturing method eliminates the need for costly adjustments while the pump is being assembled. It also allows for easier less costly machining options to improve pump efficiency. The individual manufacturing steps will be described in greater detail.
In similar fashion,
An exemplary assembly process according to the disclosure will now be described in relation to
The exemplary gerotor pump 58 may include some or all of the features of side plate adjustability as described in relation to the previously described embodiment. Thus, the spring 72 may be selected so that it acts to close the pump side face clearances over a low speed low pressure (i.e., startup) range of operation. This improves the efficiency of the pump in the operating range where prior designs are often inadequate. Once the startup conditions and pressures are exceeded, the side plate 68 moves to normal proven clearances (controlled by the shim 74 thickness) allowing the pump to operate at high pressures and low viscosities at elevated speeds with minimal reliability issues.
The exemplary external gear pump 78 may include some or all of the features of side plate adjustability as described in relation to the previously described embodiments. Thus, the spring 94 may be selected so that it acts to close the pump side face clearances over a low speed low pressure (i.e., startup) range of operation, thus improving the efficiency of the pump in the operating range where prior designs are often inadequate. Once the startup conditions and pressures are exceeded, the side plate 90 moves to normal proven clearances (controlled by the thickness of shim 92) allowing the pump 78 to operate at high pressures and low viscosities at elevated speeds with minimal reliability issues.
It will also be appreciated that the manufacturing methods described in relation to
As previously noted, this process has several distinct advantages over conventional methods. It eliminates the labor intensive task of setting side face clearances at assembly where the operator has to manually lap either the gears or housings and then repeatedly check the clearances of three parts with a gage until they are correct. With the pre match ground components the operator simply inserts the shim 74, 92 between the end cover 76, 96 and side plate housing 70, 88 and bolts the pump together. The shim 74, 92 precisely sets the side plate 68, 90 clearances and does so without variation from one side to the other.
The disclosed design can provide improved efficiency and reliability as compared to prior designs. The disclosed design can be applied to any viscous pumping application where a pressure profile that increases with speed is known. This is true of many if not most positive displacement pumping applications.
Based on the foregoing information, it will be readily understood by those persons skilled in the art that the present invention is susceptible of broad utility and application. Many embodiments and adaptations of the present invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing descriptions thereof, without departing from the substance or scope of the present invention. Accordingly, while the present invention has been described herein in detail in relation to its preferred embodiment, it is to be understood that this disclosure is only illustrative and exemplary of the present invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the present invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements; the present invention being limited only by the claims appended hereto and the equivalents thereof. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purpose of limitation.
