gerotor pumps for automotive drivetrain applications: a ...– pump design and concept...
TRANSCRIPT
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Gerotor Pumps for Automotive Drivetrain Applications: A Multi Domain Simulation Approach
Wolfgang Schweiger, MAGNA Powertrain, Austria
Andrea Vacca, Purdue University, IN, USA
September 2011
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GRPs in AWD-Powertrain Systems
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Absolute speed driven
GRPs
Differential speed
sensing GRPs
Electric motor driven
GRPs
500 … 9000 rpm - 500 … + 500 rpm 0 … 6000 rpm
max. operating pressure ≤ 30 bar
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GRPs in AWD-Powertrain Systems
Absolute speed driven GRPs
Differential speedsensing GRPs
Electric motor driven GRPs
500 … 9000 rpm - 500 … + 500 rpm 0 … 6000 rpm
max. operating pressure ≤ 30 bar
September 2011 3
Absolute speed driven
GRPs
Differential speed sensig
GRPs
Electric motor driven
GRPs
500 … 9000 rpm - 500 … + 500 rpm 0 … 6000 rpm
max. operating pressure < 30 bar
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Problem Statement
• A lot of experience and knowledge is required by the pump designer
• Interactions of different pump tolerance combinations requires extensive test runs
• A trial and error design process is very expensive and time consuming and optimizations are difficult
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• Not every parameter can be measured directly
A new approach in computational methods is required
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Research Goal
• Development of a multi-domain simulation methodology for GRPs suitable for
– Pump design and concept considerations in an early stage of
development
– Simultaneous consideration of mechanical and hydraulic
effects
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– Consideration of geometrical pump tolerances and their
interactions
– Accurate prediction of the system behavior in the course of a
complete system simulation
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Literature Overview
Gear profile generation / optimization
• Litvin F. L., Feng P.-H., 1996
• Hsieh C.-F., Hwang Y.-W., 2007-2009
• Bonandrini G., Mimmi G.,
Rottenbacher C., 2009-2010
Geometric and kinematic modeling
• Fabiani M., Mancò S., Nervegna N.,
Analysis of forces and moments
• Ivanovic L. et al, 2006-2010
Lumped parameter simulation approach (AMESim)
• Mancò S., Nervegna N., Rundo, M. et al, 2004-2009
• Neyrat S. et al, 2005 Axial piston machines
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• Fabiani M., Mancò S., Nervegna N., Rundo M. et al., "Modeling and Simulation of Gerotor Gearing in Lubricating Oil Pumps", SAE Paper 1999-01-0626, March 1999
• Wieczorek, U. and Ivantysynova, M. 2002
• Furno F., Vasile L., Andersson D., 2009
• Vacca A., Guidetti M., 2011
An overall approach for the complete system simulation of GRPs and its
dynamical interactions with a particular system has never been studied with
high level of detail.
… several others
Vane pumps
External gear pumps
machines
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GRP Operating Principle
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GRP Operating Principle
Delivery port
Cover plate Mid plate Base plate
Inner rotor
Outer rotor
Delivery port
Suction port
Inner rotor
Outer rotor
e
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Suction port
Lateral sealing gaps Hydrodynamic
lubricated bearing
Inner rotorOuter rotor
Mid plate
Base plate
Cover plate
Delivery
port
Suction
port
e
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Modeling Approach
Parametric
geometry generation
CAD geometry model
Numerical calculation
of geometry data Lumped parameter
fluid dynamic
model
FEM Model1)
Graphical user interface (GUI) MATLAB/Simulink
CATIA V5
ANSYS CFX
AMESim
1) Coupling under
development
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CAD geometry model
Pump database
Geometry import /
Export facility
Dynamic
System
Simulation
FEM Model
CFD Model Hydrodynamic
bearing model
1)
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Modeling Approach Parametric Geometry Generation
• Geometric model for generation of rotor gear profiles based on trochoidal curves
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Geometrical Parameters
r1 Radius circle 1 (rolling circle)
r2 Radius circle 2 (fixed circle)
e Excentricity
a Trochoide generating radius
ρ Envelope radius
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Modeling ApproachFluid Dynamic Model
• Evaluation of flow through the pumpdue to the displacement action
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Modeling Approach Numerical Calculation of Geometry Data
• Geometric Model for calculation of characteristic geometry data
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Modeling Approach Fluid Dynamic Model: Implementation in AMESim
• Evaluation of flow through the pump
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Graphical User Interface (GUI)
Design
Parameter
Simulation
ParameterPump Layout
Window
CAD/FEM
Interface
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Pump
Library
Geometry
Import
Geometry
Export
Result
Windows
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Reference Pump 1 Reference Pump 2
Model Validation
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Differential speed sensing GRP
qv = 42.5cc
zi = 5
Do = 94mm
B = 17mm
pmax = 50bar
nmax = 500rpm
Electric motor driven GRP
qv = 0.25cc
zi = 12
Do = 19mm
B = 7.5mm
pmax = 30bar
nmax = 6000rpm
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ResultsReference Pump 1
Steady State Pump Operation
T=50°C, p=20bar
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Pump Tolerance MIN NOM MAX
Tip Clearance [mm] 0.025 0.050 0.075
Lateral Clearance [mm] 0.015 0.020 0.025
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Comparison with Test Results Reference Pump 2
MIN clearance pump
T=60°C, n=40rpm
MAX clearance pump
T=60°C, n=40rpm
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Pump Tolerance MIN NOM MAX
Tip Clearance 0.020 0.025 0.030
Lateral Clearance 0.019 0.024 0.029
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System SimulationReference Pump 1
• Complete system simulation
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Re
vo
lutio
ns [-]
System SimulationReference Pump 1
• Complete system simulation
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Time [s]Toil=50°C
Coll. # Pump # Pump Tol. Revs [-] p_eff [bar] U_eff [V] I_eff [A]
1 AMIN 6072 5.75 2.00 3.09
MAX 7069 5.81 2.12 3.15
2 BMIN 3799 4.73 1.54 2.57
MAX 12330 5.01 2.15 1.80
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Numerical Model for Lateral Sealing Gaps
• Evaluation of lateral leakage flow
Fluid Domain 1
Fluid Domain 2
Qleak,ext
Qleak,int
Qleak,int
Lateral leakage path
Gap height s
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Qeff,Bearing
Qeff,Shaft
Qleak,int
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Finite Element Model
Max. Principal Stress Min. Principal Stress
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Radial Sealing Gaps
1st. rev. 2nd. rev. 3rd. rev. 4th. rev. 5th. rev. 6th. rev.
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Conclusion
• Based on current stage of development the model is already useful for concept considerations in an early phase of product development
• All essential pre- and post-processing operations can be performed out of a central and easy to handle GUI
• The presented modeling approach is general suitable for all possible GRP geometries
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all possible GRP geometries
• The model can easily be integrated into a complete hydraulic systems
• The modeling approach shows great potentials for a comprehensive and bi-directional coupling of the specific models
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Future Work
• CFD Model to consider leakage flow paths and viscous torque losses in the lateral sealing gaps
• Bi-directional coupling of the FEM and CFD model with the lumped parameter fluid dynamic model
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Contact
Wolfgang Schweiger Dr. Andrea Vacca
Assistant Professor
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Magna Powertrain
Defining CAE
MAGNA Powertrain AG & Co KG, Plant Lannach
Industriestraße 35, 8502 Lannach, Austria
phone.: +43(0)664-80444-4765
web: www.magnapowertrain.com
email: [email protected]
Assistant Professor
Maha Fluid Power Research Center
Purdue University (IN, USA)
Maha Fluid Power Research Center
1500 Kepner Dr., Lafayette, IN, 47905
phone: +1 765 430 0081
web: https://engineering.purdue.edu/Maha/
email: [email protected]
*) Corresponding author