Comparative efficiency and performance analysis of spur gear and non-circular (square) gear hydraulic pumps

This study addresses the comparative energy consumption performance of hydraulic spur gear pumps, whose technical features and efficiency are well-known, and non-circular (square) gear pumps, whose technical features and efficiency have not been sufficiently investigated, under the same operating conditions. The study encompasses both theoretical and experimental analyses. In the theoretical section, the design process of the square gear pump, the creation of gear geometry, its operating principles, and potential advantages are explained in detail. At this stage, physical prototypes were developed using CAD models and rapid manufacturing techniques, and their functionality was verified. Thus, the volumetric flow rate, operating pressure, hydraulic oil temperature variations, and power consumption at different speeds of the gear pumps were experimentally analyzed and evaluated in detail. The findings indicate that, at the same speed and within the same time unit, the square gear pump consumed approximately 0.59 %–33.94 % less power (kW) per unit flow rate and 8.08 %–74.33 % less power per unit pressure compared to the spur gear pump. These results reveal that the square gear pump consumes less power than the spur gear pump. Furthermore, the square gear pump demonstrated higher fluid transport capacity and operating pressure during operation. These results indicate that the square gear pump offers a promising alternative for industrial applications, combining high efficiency with low power consumption.