Efficiency of radial piston hydraulic motors

Abstract: In a world with high energy cost, the efficiency of motors becomes increasingly important. Thereby, the understanding of loss mechanics is of great significance and having accurate simulation models for the efficiency of motors is crucial.    Bosch Rexroth Mellansel has developed a new radial piston hydraulic motor with high power, capable of operating at high torque and speed. In this master thesis the newly developed motor will be examined and undergo a lab test to determine its efficiency. The results from this will then be used to improve the current simulation model and aim for a physical model that align with the efficiency results. Furthermore, the loss mechanics of the motor is important and will be studied during this thesis. The loss mechanics in a motor can be split into two parts, hydro-mechanical and volumetric losses. Hydro-mechanical losses refer to the losses due to both friction and hydraulic flow. The losses in the fluid flow are in turn divided into two parts, the major losses and the minor losses which are the friction losses in the fluid and the losses due to geometric changes in the channels respectively. The volumetric losses are on the other hand the losses from internal and external leakage of the hydraulic fluid, and compression flow which is the extra flow that occurs when the fluid changes density.  In order to determine efficiency values from a radial piston hydraulic motor, a test specification was written containing the information needed to perform the test, including two different methods, the pressure and torque method, and the sensors needed to measure the different parameters. For the hydro-mechanical efficiency the uncertainty is 0.1% for the pressure method and 0.15% for the torque method. The test was performed for several different rotational speeds and different pressure points. An improved model was developed from the test results by testing and optimization, and it was found that having the losses due to geometric changes in the channels, depend on Reynolds number agreed better with the test result. However, the improved simulation model does not align as well with the test result for all measured points. Hence a further investigation on the friction model and the dependence on pressure might improve the model further. However, it was found that for a specific sub test, the new model had a mean difference from the pressure method test result of 10^-3. While the mean difference for the unaltered simulation model was 10^-2, hence the new simulation model is an improvement. Therefore, the outcome of this master thesis is an improved simulation model for the newly developed radial piston hydraulic motor QMp 560-560 but also for future motors to come.