Search Results (6)

The development of electric gerotor pumps is a complex multiphysical optimization problem. To develop optimal systems, accurate simulation models are required to increase digital reliability. An important challenge is the accurate prediction of the pump behavior for extreme temperatures in automotive applications from $-40$ °C to 110 °C, where the viscosity of the fluid changes significantly. Therefore, simulation-based methods (numerical methods for calculating viscous friction) were developed and validated by measurements, including climatic chamber tests. The results show a strong correlation between simulated and measured performance characteristics, especially in terms of volumetric flow rate ($<5\%$), pump torque and efficiency ($<7\%$) at different temperature and viscosity conditions over a wide speed range (1000–5000 rpm) and different system pressures (0.5–5 bar). A novel method for simulating the cold start behavior of pumps (journal bearing approach for outer gear in pump housing) was introduced and validated by measurements. The methods presented significantly reduce the need for physical testing and accelerate the development process, as the pump behavior at each operating point can be accurately predicted before a hardware prototype is built. This improves the understanding of gerotor pump characteristics and provides insights to further improve the model-based development of electric oil pumps for the automotive industry. Full article

Using the RNG k-ε turbulence model and a full cavitation model, this study numerically simulated cavitating flow-induced pressure fluctuations in a gerotor pump and analyzed the relationship between cavitating flow and pressure fluctuations. The results demonstrate that, as the inlet pressure decreases, the cavitation phenomenon in the gerotor pump intensifies, and the cavitation range in the rotor increases. Some of the vapor even spreads into the oil inlet groove, leading to high vapor content in the chamber that is in contact with the oil inlet groove. The pressure fluctuation characteristics of the flow field in the pump exhibit evident periodic changes. Under different cavitation conditions, the pressure fluctuation amplitude at the monitoring point decreases with increasing inlet pressure, whereas the main frequency of pressure fluctuation remains unaffected by cavitation conditions. The pressure fluctuation amplitude is the strongest at point O₁ of demarcation between the low-pressure and high-pressure zones in the chamber, and the volume between the oil inlet groove and the oil outlet groove serves as the main vibration source in the rotor pump. To ensure the stable and efficient operation of the gerotor pump, it is recommended to operate it at a larger NPSH. Full article

Electric continuously variable transmission (E-CVT) is a vital part of the automobile in order to enhance the power coupling. The oil pump is an important power source component in the hybrid transmission system. Its efficiency exerts a significant impact on the efficiency of the oil supply system and even the hybrid transmission system. In this study, a gerotor pump is designed in line with the requirements of a certain type of hybrid electric vehicle. A Non-dominated Sorting Genetic Algorithm II (NSGA-II) genetic algorithm was employed to optimize the rotor tooth profile. The proportional-derivative (PD) control of the oil supply system was realized to lower the functional error of the oil supply system based on the AMESim simulation platform. In addition, the prototype test was performed to verify the rationality of the design. Full article

The paper investigates hydraulic wave propagation phenomena through hydraulic circuits of power transmission systems by means of numerical approaches. The actuation circuit of a Dual-Clutch Transmission (DCT) power transmission system supplied by a Gerotor pump is analyzed. A steady state approach is adopted to detect resonance phenomena due to Gerotor design parameters and circuit lengths, while one-dimensional numerical models are implemented to predict the pressure oscillations through the hydraulic ducts for the whole pump operating domain. CFD-1D pipelines are adopted to address the pressure oscillation behavior through the hydraulic pipeline, while spectral maps and order tracking techniques are used to evaluate their fluctuation intensity in function of the pump speed rate. The numerical models are validated with experimental tests performed on an ad hoc test rig for power transmission systems and a good match is found between the numerical and the experimental results. Pump design parameters as well as hydraulic accumulators and resonators are numerically investigated to quantitatively evaluate their improvement on the circuits’ hydro-dynamic behavior. Furthermore, simplified numerical models are implemented to investigate the frequency response behavior of the hydraulic circuits by means of linear analysis. This approach resulted to be particularly effective for the prediction of the resonance frequencies location, and it can be adopted as an optimization tool since significant simulation time can be saved. Finally, the performance of the circuits operating with an eco-friendly fluid is evaluated numerically and the results are compared with the ones obtained with a traditional petroleum-based oil. Full article

Gerotor pump technology is being increasingly employed in innovative application fields, such as engines and as the hydraulic source of automatic transmissions. The most important issues in the automobile industry in recent years are improvement of fuel efficiency and noise reduction, so the existing studies relating to design of the gerotor profiles and the port in gerotor oil pumps have been conducted to ensure high flow rates and low irregularity. This study proposes a new gerotor lobe shape with 2-expanded cardioids to reduce the noise of the oil pump used in the automatic transmissions of automobiles. Theoretical equations to generate the tooth profile with 2-expanded cardioids was established, and then the gerotor profile to reduce noise was proposed using an automatic program. A design method for generation of a port shape suitable for the proposed gerotor was introduced, and performance tests (2000 rpm~3000 rpm) of the new oil pump with the suggested gerotor and port shape were implemented. The test results showed that the flow rate was improved by 7.3%~1.5% and the noise was reduced by 2.8 dB~4.8dB compared to those of the existing oil pump, so it was demonstrated that the design methods for the gerotor with 2-expanded cardioids and the port shape were validated. It is expected that the new lobe shape with 2-expanded cardioids and the port shape design method could be adopted in various fields, and will contribute to improving the performance of oil pumps. Full article

Gerotor pumps are widely used for fuel and lubricating oil distribution, since they provide an economic and compact solution for low-pressure fluid systems. Made of two internally coupled gears, their behavioral and operative performances are strictly tied to their geometrical designs. Traditionally, the external gear features circular lobes that give origin to a cycloidal profile for the internal rotor. In this paper, the use of profiles based on asymmetric lobes made of elliptic arcs is further explored and expanded. At first, a complete mathematical framework describing the pump geometry and its dynamic behavior is provided, while algorithms used to compute a selected number of performance indexes are presented and when possible, verified. Hence, a single-objective optimization procedure is applied to the traditional cycloidal profile, in order to minimize each of the following quantities: the flow rate irregularity, the expected wear rate, and the estimated rotor mass. Finally, a multi-objective optimization process based on evolutionary strategy is employed, to obtain several asymmetric profiles minimizing the combination of two or more performance indexes. The results are hence compared, and the merits associated with the use of asymmetric lobes are presented. Full article