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Application Examples

Maruyama Mfg. Co., Inc.
Development of Fluid Control Equipment using
Computer Simulation and Quality Engineering

Maruyama Mfg has long been designing and manufacturing agricultural tools and industrial pumps. They use SC/Tetra fluid thermal simulation software for pump analyses to understand how the fluid can be more effectively controlled. Combined with quality engineering, they have improved the efficiency and effectiveness of their development process so they require less prototyping.

Maruyama Mfg, Chiba Factory

Figure 1: The first fire extinguisher developed in Japan (left), and high clearance boom sprayer, the first and one of the most innovative sprayer vehicles in Japanese industry (right). Click to enlarge.

 Since being founded in 1895 in Niigata, Japan, Maruyama Mfg has been manufacturing agricultural machinery, disaster-proof equipment, industrial tools, and water cleaning devices. The range of Maruyama Mfg agricultural machinery products include power sprayers for spraying chemicals for spraying fields, stereo sprayers for orchards, and high clearance boom sprayers used in paddy and soil fields (Figure 1). Their industrial pumps are not only used in factories but also for desalination. Their misting system is used in amusement parks.

 Maruyama Mfg first started out as a fire extinguisher manufacturer. They developed Japan's first mass production fire extinguisher. Their first product produced carbon dioxide by breaking a glass bottle that contains highly concentrated sulfuric acid and sodium bicarbonate, which generated an extinguishing agent (Figure 1).

  High-speed power sprayers (with uniflow design technology) were first developed in 1956. This sprayer, called Hope, significantly reduced the weight of the pump and increased processing speed. This was followed by development of industrial pumps, high clearance boom sprayers, mowing machines, and stereo sprayers. In 1991, Maruyama Mfg founded an engine manufacturing firm, and released a 2-cycle engine. In 2004, they launched a new quintuplex piston design pump, and two layers of pistons to successfully dampen the pulse dynamics of the chemical agent. In 2010 they developed their own chainsaw. In 2013 they facilitated the solar energy generation system in the Chiba factory. And in 2015, Maruyama Mfg celebrates their 120th anniversary. They hope to expand their business around the world using a network of overseas offices. Development of disaster-proof equipment, pumps, and engines has become their core strength. In addition Maruyama Mfg has integrated Software Cradle SC/Tetra fluid analysis tool into their pump product design processes.

​Figure 2: The evaluation on piston geometry on
pressure control valve. ​Click to enlarge.

 

Figure 3: Simulation results of water velocity distribution around the valve. Click to enlarge.

Evaluation of Pump Internal Component Geometry

 The pressure control valve regulates the spray pressure in a pump. One of the examples of computational fluid dynamics (CFD) analyses using SC/Tetra is the evaluation of how the pump piston geometry affects the pressure control valve. The control valve is designed to adjust the channel gap by the spring load, which changes the spray pressure (Figure 2). Controlling the pressure means controlling the gap opening. “Ideally, the water velocity should be kept uniform when passing through the narrow end,” says Nobuhiro Yuhashi from Designing Section No.2, Engineering Department. Mr. Yuhashi recalls the time he was asked to evaluate the piston geometry, which was when he started considering the use of a fluid analysis tool. He conducted an analysis using Geometry A and B as shown in Figure 3, and found that the flow moved too fast towards the outlet with Geometry A. Based on the results, he decided to employ Geometry B. Experimental tests verified that the flow was too strong and unevenly distributed with Geometry A. No such problem was found with Geometry B.


Figure 4: Structure of a pump with uniflow design. Click to enlarge.

 Maruyama Mfg also evaluated valves in the uniflow pumps designed for high-speed agricultural power sprayers. The valve incorporates Maruyama patented uniflow design structure (Figure 4), which makes the pump behave like a bicycle pump. As a result, the valve is lighter and rotates much faster than conventional valves.

​ To increase the efficiency of the uniflow design, Maruyama Mfg evaluated the internal geometry using CFD analyses. This enabled them to visualize the phenomena. The geometry of the piston retainer was originally triangular (Geometry A) as shown in Figure 5. The fluid trails towards the discharge end due to leakage through the gap around the triangle (gray area). Although this geometry has been used for many years, Maruyama Mfg decided to conduct a CFD analysis to determine if they could further improve the efficiency.

Mr. Ichiro Matsuda, Director, Engineering Department, Production Division, Chiba Factory (middle)
Mr. Nobuhiro Yuhashi from Designing Section No.2, Engineering Department, Chiba Factory (right)
Mr. Takashi Ichikawa from Quality and Manufacturing Control Department, Quality and Manufacturing Control Section (left)

Figure 5: Examining two different geometries for the water suction seal within a pump. Click to enlarge.

Figure 6: CFD analysis results (velocity distribution). Click to enlarge.

 The results from the CFD analyses showed that the local maximum water flow velocity would be halved for Geometry B compared to Geometry A. The flow distribution is also improved. This is due to using the round shape and four inner holes (Figure 6). “The improved flow means less noise and higher pump efficiency,” says Mr. Ichiro Matsuda, Director of Engineering Department, Production Division, Chiba Factory. The visual outputs of the analyses were effective for demonstrating how changing the geometry of the water suction seal can boost the performance. This would have been almost impossible to determine from only pump experiments.

 

 

​​*All product and service names mentioned are registered trademarks or trademarks of their respective companies.
*Contents and specifications of products are as of November 31, 2014 and subject to change without notice. We shall not be held liable for any errors in figures and pictures, or any typographical errors in this brochure.

Company Details






 

Maruyama Mfg. Co., Inc.
Founded 1895
Businesses Design and manufacturing of agricultural machinery (including pest control and forest machines), industrial and fire equipment, and farm vehicles.
Company President Masanobu Ogashira
URL http://www.maruyama.co.jp/english/index.html/

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