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Pierburg
Vane oil pump analysis with GT-Suite
Gaia Volandri
R&D Department - Livorno Plant +39 0586 255634
Matteo Gasperini
R&D Department - Livorno Plant +39 0586 255698
26th October 2015
Raffaele Squarcini
R&D Calc./Sim. & Testing
Department Manager +39 0586 255661
Steigenberger Airport Hotel Frankfurt
Frankfurt am Main, Germany
© KSPG AG 2014 | www.kspg.com 2
European GT conference 2015 – VOP analysis
Outline
A variable displacement vane oil pump (VOP)
The GT-ISE model of a VOP:
1. inputs
2. development
3. outputs:
3.1 speed sweep test results
3.2 (transient) stability analysis results
3.3 priming analysis results
© KSPG AG 2014 | www.kspg.com 3
European GT conference 2015 – VOP analysis
Outline
A variable displacement vane oil pump (VOP)
The GT-ISE model of a VOP:
1. inputs
2. development
3. outputs:
3.1 speed sweep test results
3.2 (transient) stability analysis results
3.3 priming analysis results
© KSPG AG 2014 | www.kspg.com 4
European GT conference 2015 – VOP analysis
Outline
A variable displacement vane oil pump (VOP)
The GT-ISE model of a VOP:
1. inputs
2. development
3. outputs:
3.1 speed sweep test results
3.2 (transient) stability analysis results
3.3 priming analysis results
© KSPG AG 2014 | www.kspg.com 5
European GT conference 2015 – VOP analysis
Outline
A variable displacement vane oil pump (VOP)
The GT-ISE model of a VOP:
1. inputs
2. development
3. outputs:
3.1 speed sweep test results
3.2 (transient) stability analysis results
3.3 priming analysis results
© KSPG AG 2014 | www.kspg.com 6
European GT conference 2015 – VOP analysis
A sliding VOP
Pump inlet
(suction pipe
omitted) Pump outlet
Cover
Housing
© KSPG AG 2014 | www.kspg.com 7
European GT conference 2015 – VOP analysis
A sliding VOP
Outlet volume of the pump
Inlet volume of the pump
Spring chamber
of the pump
Pilot chamber of
the pump Control ring
Rotor
Vanes
Small ring
© KSPG AG 2014 | www.kspg.com 8
European GT conference 2015 – VOP analysis
Sliding regulation mechanism
Maximum eccentricity, maximum pump displacement
Pump eccentricity reduces at increasing pump speed
1.5%-3.5% energy saving (fuel and CO2) of a VD VOP
with respect to a traditional pump
Eccentricity
© KSPG AG 2014 | www.kspg.com 9
European GT conference 2015 – VOP analysis
9
Hydraulic control system
OMITTED FOR INTERNAL POLICIES.
It will be shown during the
presentation
© KSPG AG 2014 | www.kspg.com 10
European GT conference 2015 – VOP analysis
1. Model inputs
© KSPG AG 2014 | www.kspg.com 11
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
© KSPG AG 2014 | www.kspg.com 12
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
© KSPG AG 2014 | www.kspg.com 13
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
Preliminary dimensioning (Excel file)
da
i a e
s h
d
dr
g
w
c
© KSPG AG 2014 | www.kspg.com 14
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
Preliminary dimensioning (Excel file)
Preliminary CAD model
© KSPG AG 2014 | www.kspg.com 15
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
Preliminary dimensioning (Excel file)
Preliminary CAD model
Standard design tolerances (to estimate clearences)
© KSPG AG 2014 | www.kspg.com 16
European GT conference 2015 – VOP analysis
GT-ISE model: input data
Pump type (e.g. sliding or pivoting)
Preliminary dimensioning (Excel file)
Preliminary CAD model
Standard design tolerances (to estimate clearences)
Components features:
• springs
• seals
• ball valves
• control logic: valve type, assembly and (when available) model
© KSPG AG 2014 | www.kspg.com 17
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Engine basement CAD model: to measure pipes dimensions from pump outlet interface
and to feedback pressure interface with pump
© KSPG AG 2014 | www.kspg.com 18
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Engine basement CAD model: to measure pipes dimensions from pump outlet interface
and to feedback pressure interface with pump
Engine pulley / sprocket to define transmission ratio
Belt load and direction referred to engine CAD model
© KSPG AG 2014 | www.kspg.com 19
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Engine basement CAD model: to measure pipes dimensions from pump outlet interface
and to feedback pressure interface with pump
Engine pulley / sprocket to define transmission ratio
Belt load and direction referred to engine CAD model
Suction CAD and suction mesh Q/P curves
© KSPG AG 2014 | www.kspg.com 20
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Working conditions:
oil type
temperature T[°C] range
aeration level vs. engine speed and temperature
© KSPG AG 2014 | www.kspg.com 21
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Working conditions:
oil type
temperature T[°C] range
aeration level vs. engine speed and temperature
Engine speed n[RPM] range
Accepted feedback pressure range in regulation
© KSPG AG 2014 | www.kspg.com 22
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Working conditions:
oil type
temperature T[°C] range
aeration level vs. engine speed and temperature
Engine speed n[RPM] range
Accepted feedback pressure range in regulation
Engine permeability curves: pump outlet flow rate/pressure curves and outlet-feedback
pressure drop
© KSPG AG 2014 | www.kspg.com 23
European GT conference 2015 – VOP analysis
GT-ISE model: input data from the engine manufacturer
Working conditions:
oil type
temperature T[°C] range
aeration level vs. engine speed and temperature
Engine speed n[RPM] range
Accepted feedback pressure range in regulation
Engine permeability curves: pump outlet flow rate/pressure curves and outlet-feedback
pressure drop
Design point
Outlet flow rate
[L/min] Feedback pressure
[Bar]
oil type @ T [°C]
Outlet pressure
[Bar]
© KSPG AG 2014 | www.kspg.com 24
European GT conference 2015 – VOP analysis
2. Model development
© KSPG AG 2014 | www.kspg.com 25
European GT conference 2015 – VOP analysis
Housing and cover porting plates
BEGIN
V-GROOVE END
DELIVERY
ANGLE
BEGIN INLET
ANGLE
END INLET
ANGLE
Eccentricity direction
BEGIN
DELIVERY
© KSPG AG 2014 | www.kspg.com 26
European GT conference 2015 – VOP analysis
Port areas vs angle estimation
In-house developed Matlab® (MathWorks) routine
Cover/housing up/down and lateral ports (control ring slots)
Accounting for:
actual eccentricity
porting plates angles and shape
begin delivery shape (standard, V-groove, slot)
deg
© KSPG AG 2014 | www.kspg.com 27
European GT conference 2015 – VOP analysis
Reference system
x
z
y
Outlet
Inlet
© KSPG AG 2014 | www.kspg.com 28
European GT conference 2015 – VOP analysis
Geometry
© KSPG AG 2014 | www.kspg.com 29
European GT conference 2015 – VOP analysis
Geometry
© KSPG AG 2014 | www.kspg.com 30
European GT conference 2015 – VOP analysis
Geometry and volumes
© KSPG AG 2014 | www.kspg.com 31
European GT conference 2015 – VOP analysis
Geometry and volumes
© KSPG AG 2014 | www.kspg.com 32
European GT conference 2015 – VOP analysis
Shape to component conversion in GEM3D environment
Components Mesh shapes
© KSPG AG 2014 | www.kspg.com 33
European GT conference 2015 – VOP analysis
Shape to component conversion in GEM3D environment
Imported mesh shape Port clipping and identification Component
Flowsplit
Pipe
© KSPG AG 2014 | www.kspg.com 34
European GT conference 2015 – VOP analysis
GEM component to GT-ISE model conversion
Preliminary
GT-ISE model
Components GEM vane pump
template
© KSPG AG 2014 | www.kspg.com 35
European GT conference 2015 – VOP analysis
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 36
European GT conference 2015 – VOP analysis
Sliding pump
7 rotor chambers
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 37
European GT conference 2015 – VOP analysis
Suction pipe Suction mesh not included
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 38
European GT conference 2015 – VOP analysis
Inlet volume
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 39
European GT conference 2015 – VOP analysis
Outlet volumes
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 40
European GT conference 2015 – VOP analysis
Spring chamber
Pilot chamber
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 41
European GT conference 2015 – VOP analysis
Control channels
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 42
European GT conference 2015 – VOP analysis
Leakages:
between rotor chambers
towards rotor center
from/to control chambers
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 43
European GT conference 2015 – VOP analysis
Clearance estimation
In-house developed Excel routines
Leakage type:
axial rectangular gap
annular gap
chamfers
Depending on:
tolerances
temperature
material
Classified as:
• Min
• Mean
• Max
Leakages:
between rotor chambers
towards rotor center
from/to control chambers
© KSPG AG 2014 | www.kspg.com 44
European GT conference 2015 – VOP analysis
Bearings
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 45
European GT conference 2015 – VOP analysis
Pump load
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 46
European GT conference 2015 – VOP analysis
Hydraulic spool valve
GT-ISE model
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 47
European GT conference 2015 – VOP analysis
GT-ISE model
ON-OFF Valve
(equivalent orifice approach)
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 48
European GT conference 2015 – VOP analysis
Based on the Henry-Dalton law
First order dynamics of gas transition
GT-ISE aeration modeling
Bar
PBVV liqssdgas
1,
*
,,,, )()(
disgasssdisgasdisgas mm
dt
md
Liquid volume available to
dissolve gas
τ*=time constant:
τfd = free-> dissolved (if mgas,dis > mgas,dis,ss)
τdf = dissolved ->free(if mgas,dis < mgas,dis,ss)
Max gas volume (free state @1 Bar,
273 K) dissolvable in the liquid at
steady-state
Pressure in the
volume
Actual mass of dissolved gas
Bunsen coefficient
Mass of
dissolved gas at
steady state
© KSPG AG 2014 | www.kspg.com 49
European GT conference 2015 – VOP analysis
GT-ISE fluid definition
On-line aeration
measurement
© KSPG AG 2014 | www.kspg.com 50
European GT conference 2015 – VOP analysis
Model validation
Through in-house experimental activities on test benches
Real time free air content measurement with Air-X® (DSI)
Compared outputs:
pressure
volumetric flow
adsorbed torque
0.1%
aeration level
16%
aeration level
© KSPG AG 2014 | www.kspg.com 51
European GT conference 2015 – VOP analysis
Adsorbed torque estimation
In-house developed relations and Matlab®
(MathWorks) routine (by Politecnico of Turin)
TCLA WWWW
Power loss for Coulombian friction (dependent on
delivery pressure and rotation speed): due to the contact between surfaces with relative motion
function of rotational speed n (vanes centrifugal force)
Power loss for viscous friction: due to fluid shear stresses inside lubricated clearances in the pump
function of rotational speed, viscosity and clearance size and shape
historically, Wilson model has been used for preliminary evaluations
Theoretical hydraulic power: due to real pressure present
in pump chambers
Adsorbed
torque
© KSPG AG 2014 | www.kspg.com 52
European GT conference 2015 – VOP analysis
3. Model outputs
© KSPG AG 2014 | www.kspg.com 53
European GT conference 2015 – VOP analysis
3.1 Speed sweep test results
© KSPG AG 2014 | www.kspg.com 54
European GT conference 2015 – VOP analysis
Results
Delivery pressure
Delivery flow rate
Main gallery pressure
Eccentricity
7% aeration - OFF state 1% aeration - ON state
© KSPG AG 2014 | www.kspg.com 55
European GT conference 2015 – VOP analysis
Results
Pilot chamber pressure
Internal pump force along eccentricity
Spring chamber pressure
7% aeration - OFF state 1% aeration - ON state
© KSPG AG 2014 | www.kspg.com 56
European GT conference 2015 – VOP analysis
Results
Hydraulic spool valve position
ON hole discharged flow rate
OFF hole discharged flow rate
7% aeration - OFF state 1% aeration - ON state
© KSPG AG 2014 | www.kspg.com 57
European GT conference 2015 – VOP analysis
3.2 Stability analysis results
© KSPG AG 2014 | www.kspg.com 58
European GT conference 2015 – VOP analysis
Results
Less detailed "standard" model
of pump in GT-Suite environment
Transient speed ramps (30 - 40 s
realistic speed ramps as in tests)
simulated in feasible time
No VOPs specific models in GT-
Suite
No porting plate
No clearances
No rotor chamber dynamics
No internal pump forces due to
hydraulics
OMITTED FOR
INTERNAL POLICIES
© KSPG AG 2014 | www.kspg.com 59
European GT conference 2015 – VOP analysis
Results
Actual design
30 s speed ramp in 5W30 @ 100°C from 0 rpm till 7000 rpm
Stable actual pump configuration: no oscillation visible in the time pressure signals
The map plot shows the pump speed at which oscillation begins
© KSPG AG 2014 | www.kspg.com 60
European GT conference 2015 – VOP analysis
Results
Oscillation appears at a certain pump speed during speed sweep test when some
parameters of the pump are changed (e.g. control ring slideways widths in the example)
Simulated design
© KSPG AG 2014 | www.kspg.com 61
European GT conference 2015 – VOP analysis
3.3 Priming analysis results
© KSPG AG 2014 | www.kspg.com 62
European GT conference 2015 – VOP analysis
Results
Internal force [N] along eccentricity
Eccentricity [mm]
Gas volume fraction @outlet
Average pressure [Bar] @outlet
0-1500 RPM 20 s ramp
Fi
x
© KSPG AG 2014 | www.kspg.com 63
European GT conference 2015 – VOP analysis
Simplified model (to be compared with Simerics PumpLinx® 3D analysis)
No regulation mechanics: fixed eccentricity (emax)
Only axial rotor clearences considered
No ball valve
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 64
European GT conference 2015 – VOP analysis
Simplified model (to be compared with Simerics PumpLinx® 3D analysis)
No regulation mechanics: fixed eccentricity (emax)
Only axial rotor clearences considered
No ball valve
50 mm long, Ø13.42 mm outlet pipe
Ø 6mm outlet orifice (cd=0.7, 0 Bar (rel.)
environment pressure)
OMITTED FOR
INTERNAL
POLICIES
OMITTED FOR
INTERNAL
POLICIES
© KSPG AG 2014 | www.kspg.com 65
European GT conference 2015 – VOP analysis
Pump (self) priming
designed to lift oil without filling the pump with liquid
partial vacuum creation at pump suction
OMITTED FOR
INTERNAL POLICIES
Oil volume fraction [-] Pressure [Pa]
Isosurface (oil 5%)
OMITTED FOR
INTERNAL POLICIES
OMITTED FOR
INTERNAL POLICIES
© KSPG AG 2014 | www.kspg.com 66
European GT conference 2015 – VOP analysis
Conclusions
The GT model has proved to be an efficient tool for simulating a sliding vane variable oil
pump in constant speed, dynamics and priming conditions
In-house developed routines integrated the GT potentialities
In-house experimental validation allowed to validate sweep speed and transient
simulation results
1D CFD priming simulations in GT environment were satisfactorily compared with the 3D
CFD model in Simerics PumpLinx® environment
67
Thank you for your attention!
© KSPG AG 2014 | www.kspg.com 68
© KSPG AG 2014 | www.kspg.com 69
Disclaimer
This presentation contains “forward-looking statements”. Forward-looking statements are sometimes, but
not always, identified by their use of a date in the future or such words as “will”, “anticipates”, “aims”, “could”,
“may”, “should”, “expects”, “believes”, “intends”, “plans” or “targets”. By their nature, forward-looking
statements are inherently predictive, speculative and involve risk and uncertainty because they relate to
events and depend on circumstances that will occur in the future. There are a number of factors that could
cause actual results and developments to differ materially from those expressed or implied by these
forward-looking statements. In particular, such factors may have a material adverse effect on the costs
and revenue development of the KSPG group.
All written or oral forward-looking statements attributable to KSPG AG or any group company of KSPG AG
or any persons acting on their behalf contained in or made in connection with this presentation are expressly
qualified in their entirety by factors of the kind referred to above. No assurances can be given that the
forward-looking statements in this presentation will be realized. Except as otherwise stated herein and as
may be required to comply with applicable law and regulations, KSPG AG does not intend to update these
forward-looking statements and does not undertake any obligation to do so.