A parameter matching method for “Shuttle” technology in piston pumps to enhance distribution performance across wide operating ranges

The distribution shock phenomenon of swashplate axial piston pumps can lead to flow and pressure fluctuations, reduce system efficiency, induce cavitation and erosion, increase vibration and noise, and severely affect system performance. In 2021, INNAS introduced a variable distribution technology based on the principle of chamber compensation, known as “Shuttle” technology. Simulations and tests have demonstrated that this technology can significantly reduce power loss and noise caused by the distribution process, indicating promising prospects for engineering applications. However, a systematic method for matching the structural parameters of the “Shuttle” technology is still lacking, and no investigation has been conducted on its application in large-displacement, high-pressure piston pumps. To address this issue, this paper develops a dynamic model of piston pumps that integrates “Shuttle” technology, proposes a parameter matching method for the “Shuttle” structure specifically oriented toward large-displacement piston pumps, and performs an improved design for a representative large-displacement piston pump. Dynamic simulations demonstrate that the redesigned pump reduces the average distribution power loss by 77 % under high-speed, high-load conditions and decreases the peak-to-peak flow pulsation by 50.6 % within the 20–50 MPa pressure range, thereby achieving a significant performance enhancement.