Design and testing of pistons and cups for large hydrostatic pumps and motors

A new transmission is being designed for a next generation of large, offshore wind turbines, based on floating cup pumps and motors. The machines have a fixed displacement of around five liter per revolution. The objective of this study is to design, manufacture and test the pistons and cups of these machines. To this end, a new test bench has been designed and build, to measure the leakage and friction of the pistons up to a pressure level of 350 bar. Several sets of pistons and cups have been tested against a reference set which was proven to have very little friction at rated and peak operating conditions. The leakage between the pistons and cups was measured at different piston positions at stationary conditions. The friction between the piston and the cup has been measured continuously. From the tests it can be concluded that the friction force is below 0,01% of the piston force. The leakage losses are less than 0,5% of the total effective flow output.