Design and Function of ZF Vane Pumps

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1 and Function of ZF Vane Pumps The construction principle of the ZF vane pumps is based on a pumping element which is usually in a light-alloy housing (1) and consists basically of a shaft (2), the rotor (3), ten vanes (4), acam ring (5) and the pressure plate (6). Depending on the model range, a second pressure plate or control plate is used. The axial end is formed by acover (9) which is also made of light alloy The shaft is guided in the housing by a ball bearing or plain bearing system depending on the type of drive and connected free of play with the rotor (3) seated on it. The vanes (4) are located in the ten radially arranged slots of the rotor. The cam ring (5), which is fixed in the housing or cover against rotation, surrounds the rotor together with the lateral pressure/control plate or cover, respectively. The two crescent-shaped pump chambers are situated between the cylindrical circumferential surface of the rotor and the ellipsoidal bore in the cam ring. The volume of the chambers results from the largest possible Functional scheme of ZF vane pump FP 4. 1 Housing 2 Shaft 3 Rotor 4 Vane 5 Cam ring 6 Pressure plate 7 Suction chamber 8 Pressure chamber 9 Cover 10 Pressure relief and flow limiting valve 4 and Function

2 crescent segment between two vanes and the width of the rotor or vanes, respectively. Due to the design, the oil flow generated in the crescent-shaped pressure chambers is directed to the valves for pressure relief and flow limitation (10) positioned longitudinally or transverse to the shaft, limited to the values set and passed on to the hydraulic power steering via a hose connected to it. The performance ranges of the vane pump model ranges as well as the different equipment variants in respect of mounting, type of drive, energy saving and attachment of an oil reservoir can be seen from the Technical Summary on page 19/20. Function Rotation of the input shaft (2) and, with it, the rotor (3) results in the vanes (4) located in the rotor being forced radially by centrifugal force on to the track of the fixed cam ring (5). This movement is assisted by the pressurized oil which flows from the pressure chamber (8) via connections to the internal faces of the vanes. Between the ten vanes, ten self-contained pump cells are formed which draw oil into the two crescent-shaped pump chambers when the volume is increasing and expel it into the pressure chamber when the volume is decreasing. Since the shape of the cam ring means that two suction zones and two pressure zones always lie opposite each other, each of the ten pump cells delivers twice its own volume with every rotation of the input shaft. In addition, owing to this double-action arrangement of the suction and pressure zones, the hydraulic radial forces acting upon the rotor cancel each other out. characteristic of the ZF vane pumps can optionally be set at a flow rate which is constant, falling or falling in steps. In the pump design offering a constant flow rate (see figure below; variant A) an almost constant oil flow is fed to the power steering gear throughout the speed range of the vehicle engine. The ZF vane pump with falling control characteristic (variant B) is designed such that the required flow rate is achieved at a determined speed, e.g rpm, and that from this point the flow rate continuously falls while the speed continues to rise. The reduced flow rate remains, however, sufficient to allow for the maximum hydraulic assistance to be built up at any time. This characteristic is influenced by a control system in the pressure region specifically developed by ZFLS, which results in a reduction of hydraulic assistance in the steering gear at higher speeds and, thus, in a distinct improvement of the contact between the steering wheel and the road surface. For special applications, it is alternatively possible to provide the pumps with a control characteristic falling in steps (variant C). In this design, the flow rate is reduced in a pronounced transition area already in the medium speed range. This shorter phase of transition from maximum to minimum flow rate can be adjusted individually by a special valve system. Figure at top: ZF Vane pump FN 4. Flow rate [dm 3 /min] A B C Figure at bottom: Basic diagram of control characteristics with constant and falling flow rate as well as flow rate falling in steps. Pump speed [rpm] and Function 5

3 ZF Vane Pump CP 14 On this pump type, the pressure relief and flow limiting valve is installed transverse to the input shaft. The mounting is standardized and meets the specifications of the Association of the German Motor Industry (VDA). This allows easy exchange of competitors' products. As arule, the ZF vane pump CP 14 on passenger cars is driven from the vehicle engine via a pulley. characteristic of this vane pump can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable energy saving improvements can be achieved in this model range by using the ECO (Electronically Controlled Orifice) valve described on pages 11/12. ZF Vane pump CP 14 with pressed-in suction connector. 6 ZFVane Pump CP 14

4 ZF Vane Pump CP 1 The CP 1 model range with its modular design system allows mounting in many ways, thus ensuring optimum adaptation of the pump to the vehicle conditions. In addition to the specific CP 1 mounting longitudinally to the input shaft, it is also possible to make use of transverse bolt connection directly to the combustion engine. Also, it is possible to redesign the pump cover to allow individual variants of mounting, e.g. as a multifunctional bracket, besides the standard design. Again, this pump is usually driven by belt from the vehicle engine. characteristic of the vane pump CP 1can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Figure at bottom: ZF Vane pump CP 1 with a multi-functional bracket connected with the cover. Figure at top: ZF Vane pump CP 1with pressed-in suction connector. ZF Vane Pump CP 1 7

5 ZF Vane Pump FP 2 The pump type FP 2 was designed specifically for the pressure oil supply of hydraulic power steering gears on small passenger cars of the Asian market. Both the compact design with the pressure port moved towards to the center and the reduction of hydraulic capacity and belt pull are adapted to match on a high degree the requirements of these subcompact cars. An optionally fitted pressure switch, tuned to the electronics of the engine management, prevents stopping the vehicle engine at low speed. The ZF vane pump FP 2 is provided with the standardized mounting according to the specifications of the Association of the German Motor Industry (VDA). Depending on the application, other possibilities of attachment are feasible. The pump is belt driven from the vehicle engine. characteristic of this vane pump can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). ZF Vane pump FP 2with pressed-in suction connector. 8 ZFVane Pump FP 2

6 ZF Vane Pump FP 4 As a result of the standardized mounting which meets the specifications of the Association of the German Motor Industry (VDA), this proven pump type, of which millions have been made, ensures easy exchange of competitors products. Also, it allows to mount the oil reservoir directly on top of the pump. This saves a hose line and assembly costs. Drive is preferably by belt driven from the vehicle engine. characteristic of the vane pump FP 4 can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable improvements for energy saving can be achieved in this model range too by adapting the ECO (Electronically Controlled Orifice) valve described on pages 11/12. ZF Vane pump FP 4with pressed-in suction connector. ZF Vane Pump FP 4 9

7 ZF Vane Pump FP 6 The development of the FP 6 model range achieves in particular the new target, set by the automotive industry, of steering pumps of higher hydraulic capacity, for its performance potential comprises a controlled flow rate up to 15 dm 3 /min. and a maximum pressure of 150 bar. The function of the pumping element and the external dimensions of this pump are for the most part identical to the vane pump FP 4. Again, the mounting is standardized and meets the specifications of the Association of the German Motor Industry (VDA). This allows easy exchange of competitors' products. If required, a plastic oil reservoir can be mounted in order to save ahose line and thus assembly costs. characteristic of the vane pump FP 6 can optionally be set at a flow rate which is constant, falling or falling in steps (see description on page 5). Energy saving Remarkable improvements for energy saving can be achieved in this model range, too by using the ECO (Electronically Controlled Orifice) valve described on pages 11/12. ZF Vane pump FP 6with oil reservoir mounted on top. 10 ZF Vane Pump FP 6

8 Energy Saving by ZF Vane Pumps 6 5 Advantages: Fuel reduction by 20 to 40% on average 15to20 Cdecrease in temperature approx. 35% less power input reduction of neutral pressure drop by about 4to6bar 10 (Values depend on duty cycles and system design) Energy saving by ECO Another important step towards energy saving is the adaption of an ECO valve (4) (ECO = Electronically Controlled Orifice) on the vane pump (1). Due to control dependent on steering wheel turning rate and vehicle speed, this hydraulic control unit generates a flow rate as needed for the hydraulic steering system, thus extending significantly the functionality of the base pump. The oil flow not needed by the pump system is controlled chiefly during straight ahead driving. The necessary electronic control can be integrated into the existing vehicle electronics. Figure at bottom: Pump comparison for average power input in the driving and ECE cycles (test method for measuring pollutant emissions). Power input [W] Driving cycle ECE cycle Standard vane pump Vane pump with ECO Figure at top: Schematic representation of a hydraulic steering system with a ZF vane pump with ECO valve. 1 ZF vane pump 2 Steering gear (basic unit) 3 Steering valve 4 ECO valve 5 Oil cooler (if required) 6 Oil reservoir 7 Electronic control unit 8 Anti-vibration hose 9 CAN 10 Battery 11 Speed sensor 12 Steering wheel turning rate sensor Energy Saving 11

9 Schematic representation of a ZF steering pump with ECO together with a ZF Active Steering on the basis of a ZF Servotronic 2. 1 ZFVane pump FP 6with ECO 2 ZF Servotronic 2(basic unit) 3 Servotronic 2 rotary valve 4 Electric motor 5 Superposition gear system 6 Oil reservoir with fine filter 7 Electronic control unit 8 Hoses, anti-vibration hose 9 Cables to power supply, CAN, ignition, vehicle sensors Servotronic is aregistered trademark of ZF Lenksysteme GmbH. 12 Energy Saving

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