Synthetic Approach to the Design, Manufacturing and Examination of Gerotor and Orbital Hydraulic Machines

Gerotor technology is an important research area in the field of hydraulics which attracts the attention of both academic scientists and industry. Despite the numerous publications announced by academics, as well as a considerable number of projects made by industry, the subject has not been exhausted. This paper presents a new approach to gerotor technology which has been formed by gathering the authors’ knowledge of gerotors in a synthetic form. The following scientific and technical results have been obtained: (1) A uniform system of parameters and basic concepts regarding toothing and cycloidal gearing (z, m, λ, v, g) which is consistently used to describe the geometry, kinematics, hydraulics and manufacture of those elements; (2) description of the geometry and kinematics of the epicycloidal and hypocycloidal gears with the use of the adopted system of parameters. Additionally, the epicycloidal/hypocycloidal double gearing is presented, which is an original idea of the authors; (3) description of the hydraulics of the gerotor and orbital machines, and in particular: (i) determination of equations for delivery (capacity) q and irregularity of delivery (capacity) δ using the above-mentioned system of basic parameters; (ii) formulation of the principles of designing internal channels and clearances in the gerotor machines and presentation of the original disc distributor in the epicycloidal/hypocycloidal orbital motor; (iii) presentation of the methods of manufacturing the epicycloidal and hypocycloidal gearings with 12 examples of the systems implemented in practice; (4) presentation of the research methods applied for the examination of the gerotor machines, combining computer simulation and experimental research into a coherent and cohesive whole which results in the effect of research synergy. Such a synthesis of knowledge may serve the improvement, creation and investigation of gerotor and orbital machines carried out by academics and industry.