German ideal pump ideal model ideal price

ideal pump is a rotary pump that relies on the change and movement of the working volume formed between the pump cylinder and the meshing gears to transport liquid or increase its pressure. It consists of two gears, a pump body, and front and rear covers, forming two enclosed spaces. When the gears rotate, the volume on the disengaging side increases from small to large, creating a vacuum to draw in the liquid, while the volume on the meshing side decreases from large to small, squeezing the liquid into the pipeline. The suction chamber and discharge chamber are separated by the meshing line of the two gears. The pressure at the outlet of a gear pump depends entirely on the resistance at the pump outlet.

ideal pump working principle

The concept of a gear pump is very simple. Its most basic form consists of two gears of the same size meshing and rotating within a closely fitted housing. The interior of this housing resembles an "8" shape, with the two gears installed inside, their outer diameters and sides fitting closely with the housing. Material from the extruder enters between the two gears at the suction inlet, filling this space, moves along the housing as the teeth rotate, and is finally discharged when the teeth mesh. A gear pump is also called a positive displacement device; similar to a piston in a cylinder, when one tooth enters the fluid space of another, the liquid and the tooth cannot occupy the same space simultaneously because the liquid is incompressible, so the liquid is mechanically squeezed out. Due to the continuous meshing of the teeth, this phenomenon occurs continuously, providing a continuous discharge volume at the pump outlet. With each revolution of the pump, the discharged volume is the same. As the drive shaft rotates uninterrupted, the pump discharges fluid without interruption. The pump's flow rate is directly related to its rotational speed. In practice, there is a small amount of fluid loss within the pump because this fluid is used to lubricate the bearings and both sides of the gears, and the pump body cannot fit without any clearance, so it is impossible for the fluid to exit the outlet 100%. Therefore, a small amount of fluid loss is inevitable, meaning the pump's operating efficiency cannot reach 100%. However, the pump can still operate well, achieving an efficiency of 93% to 98% for most extruded materials. This pump is not significantly affected by fluids whose viscosity or density changes during the process. If there is a damper, such as a filter screen or restrictor on the discharge side, the pump will push the fluid through them. If this damper changes during operation—i.e., if the filter becomes dirty or clogged, or if the back pressure of the restrictor increases—the pump will maintain a constant flow rate until reaching the mechanical limit of the weakest component in the system (usually equipped with a torque limiter). There is actually a limit to the rotational speed of a pump, which mainly depends on the process fluid. If transporting oil, the pump can rotate at high speeds, but this limit increases significantly when the fluid is a high-viscosity polymer melt. It is crucial to fill the space between the two teeth on the suction side with high-viscosity fluid; if this space is not fully filled, the pump cannot discharge an accurate flow rate. Therefore, the PV value (pressure × flow velocity) is another limiting factor and a process variable. Due to these limitations, gear pump manufacturers offer a range of products with different specifications and displacements (volume discharged per revolution). These pumps are matched to specific application processes to optimize system capability and price.

ideal pump drive unit

The gear pump is driven by an independent motor, effectively blocking upstream pressure pulsations and flow fluctuations. Pressure pulsations at the gear pump outlet can be controlled within 1%. Using a gear pump on an extrusion production line can increase the flow output speed and reduce shear and residence time of the material in the extruder. External meshing gear pumps are the most widely used type of gear pump; generally, the term "gear pump" refers to external meshing gear pumps. Its structure is shown in Figure 5-14, mainly consisting of a driving gear, driven gear, pump body, pump cover, and safety valve. The sealed space formed by the pump body, pump cover, and gears constitutes the working chamber of the gear pump. The shafts of the two gears are mounted in bearing holes on the two pump covers, with the driving gear shaft extending out of the pump body to be rotated by the motor. External meshing gear pumps have a simple structure, light weight, low cost, reliable operation, and wide application range. During operation, the driving gear rotates with the motor and drives the driven gear to rotate. As the meshing teeth on the suction side gradually separate, the volume of the suction chamber increases, pressure decreases, and liquid from the suction pipe is drawn into the pump. The sucked liquid is pushed by the gears in two paths within the tooth grooves to the discharge chamber. After entering the discharge chamber, the liquid is squeezed by the continuous meshing of the two gears' teeth and enters the discharge pipe. As the driving and driven gears rotate continuously, the pump continuously sucks in and discharges liquid. A safety valve is installed on the pump body; when the discharge pressure exceeds the specified pressure, the transported liquid automatically opens the safety valve, allowing high-pressure liquid to return to the suction pipe. Internal meshing gear pumps consist of a pair of mutually meshing internal gears, a crescent-shaped piece between them, and a pump shell. The crescent-shaped piece separates the suction chamber from the discharge chamber. When the driving gear rotates, a partial vacuum forms where the gears disengage, drawing liquid into the pump to fill the spaces between the teeth in the suction chamber. The liquid then enters the discharge chamber in two paths along the inner and outer sides of the crescent-shaped piece. Where the teeth enter meshing, the liquid between the teeth is squeezed and sent into the discharge pipe. In addition to self-priming capability and flow rate independent of discharge pressure, gear pumps have no suction or discharge valves on the pump shell, offering simple structure, uniform flow, and reliable operation. However, they have low efficiency, high noise and vibration, and are prone to wear. They are mainly used to transport various non-corrosive, solid-particle-free oils with lubricating properties, typically at temperatures not exceeding 70 °C, such as lubricating oil and edible vegetable oil. The general flow range is 0.045 to 30ms/h, pressure range is 0.7 to 20MPa, and operating speed is 1200 to 4000r/min.

ideal pump maintenance

1) Maintenance after gear pump shaft wear: Shaft wear in gear pumps is mainly due to friction between the ends of the shaft and the supporting needle rollers, causing the shaft diameter to decrease. For slight wear, hard chrome plating can be applied to increase the shaft diameter at this location for repair. If the shaft wear is severe, it should be remanufactured using 45 steel or 40cr steel. After rough and fine turning of the shaft blank, the bearing areas undergo heat treatment to a hardness of hrc60-65, followed by grinding to ensure the surface roughness ra of the bearing fit area is no greater than 0.32μm; the permissible deviation for roundness and cylindricity of the shaft is 0.005mm; the gear fit area follows h7/h6, with surface roughness ra no greater than 0.63μm. 2) Maintenance after gear pump body wear: Inner surface wear of the pump body occurs mainly on the arc-shaped working surface in the oil suction zone. For slight wear, it can be repaired with an oil stone to remove burrs before use. The pump body is cast from iron; if severe wear occurs, replace with a new part. If the end faces of the gears inside the pump are repaired by grinding, the width dimension of the pump body must also be adjusted to equal the amount removed from the gear ends. The re-machined end faces of the pump body must meet the technical requirements shown in Figure 3. 3) Maintenance after wear of gear pump end covers: Gear pump end covers are made of cast iron. Slight wear can be lapped flat on a surface plate; severe wear should be ground flat on a surface grinder. The plane contact between the lapped end cover and the pump body connection surface should be no less than 85%. The permissible deviations for flatness, perpendicularity of the end face to the hole centerline, parallelism of the two end faces, and parallelism of the two shaft hole centerlines are all 0.01mm. The surface roughness ra after grinding should be no greater than 1 5μm. 4) Maintenance and replacement of needle roller bearings in gear pumps: After repairing pump components, the bearing needle rollers should be replaced. Requirements for needle rollers: the dimensional error of the diameter of all needle rollers must not exceed 0.003mm, length tolerance is 0.1mm, and the fit clearance with the shaft should be around 0.01mm; during assembly, needle rollers must fill the bearing shell according to quantity requirements and be arranged parallel to each other.

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