1 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
CAE Based Strategies to Improve
Reliability of Variable Oil Pumps
Ric...
2 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Key Vehicle Systems Are Undergoing Drastic
Changes To Reduce Carbon F...
3 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Warranty Expenses Due to Increasingly Complex
And Interdependent Auto...
4 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Pump Design Process
4
Performance
Pump
Characterization
Pump
Optimiza...
5 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Advantage
5
 Reduction of the energy consumption...
6 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump – Conventional Type
6
• Features:
– Vane pump.
– Di...
7 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump – Genesis of the
Product
7
Customer SOR
• Oil Flow ...
8 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump – Design Loop
8
VOP design
1 2 3 4 5 6 7 8 Suggeste...
9 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Performance
9
Lumped Parameters
Simulation
Equiva...
10 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Performance
10
Output result: prediction of the ...
11 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Reliability
11
12 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Multi-Body Dynamic Analyses
Variable Oil Pump - Reliability
12
Outpu...
13 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Structural Analyses
Variable Oil Pump - Reliability
13
Deformations
...
14 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Structural Analyses
Variable Oil Pump - Reliability
14
Coarse Model
...
15 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Lifetime Prediction
Variable Oil Pump - Reliability
15
Real Crack
 ...
16 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Multi-axial Fatigue Analyses
Variable Oil Pump - Reliability
16
The ...
17 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Sealing Analyses
Variable Oil Pump - Reliability
17
 Full 3D approa...
18 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Sealing Analyses
Variable Oil Pump - Reliability
18
 Mono-dimension...
19 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Output results:
 Contact pressure
 Bending stress on teeth
Gear De...
20 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Reliability
20
Structural Resonance
Experimental...
21 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Reliability
21
Structural Resonance
Optimization...
22 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Variable Oil Pump - Reliability
22
FEA Dynamic Analyses
Spectrum & P...
23 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Acoustic Simulations
Variable Oil Pump - Reliability
23
FEM Modal An...
24 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
The increased “know how” gained in different simulation areas like t...
25 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Dynamic analysis was run in order to evaluate contact forces between...
26 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Calculated loads on shaft has been used to evaluate the lifetime of ...
27 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
• The present work has shown some possible numerical analyses which
...
28 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
• Simulation Driven Design and Development
of a Variable Vane Pump h...
29 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
Thank You!
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CAE-Based Strategies to Improve Reliability of Variable Oil Pumps

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http://bit.ly/TxMdSB Find out how pump manufacturers are using simulation to improve the reliability of their designs and bringing the cost and turnaround time drastically.

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CAE-Based Strategies to Improve Reliability of Variable Oil Pumps

  1. 1. 1 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential CAE Based Strategies to Improve Reliability of Variable Oil Pumps Riccardo Maccherini Pierburg Pump Technology, KSPG Automotive Riccardo.Maccherini@it.kspg.com Padmesh Mandloi ANSYS Padmesh.Mandloi@ansys.com
  2. 2. 2 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Key Vehicle Systems Are Undergoing Drastic Changes To Reduce Carbon Footprints Reduce Carbon Footprint Aerodynamics Road Resistance Powertrain HEV/EV Thermal Management Energy Leightweight Design Energy Recovery
  3. 3. 3 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Warranty Expenses Due to Increasingly Complex And Interdependent Automotive Systems Warranty Reduction KBI Early introduction of quality and reliability prediction system Innovative manufacturing processes Insights into system level interdependencies Courtesy of Pierburg Pump Technology Italy SpA
  4. 4. 4 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Pump Design Process 4 Performance Pump Characterization Pump Optimization Reliability Structural Integrity Fatigue Life Vibrational Behavior Dynamic Behavior Sealing Verification Noise Aeroacoustics Vibroacoustics 1D & 3DCFD FEA Multiphysics
  5. 5. 5 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Advantage 5  Reduction of the energy consumption: this is also valid for engines’ accessories!  VOP: an innovative concept of oil pump Up to 3% CO2 saving in the NEDC cycle
  6. 6. 6 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump – Conventional Type 6 • Features: – Vane pump. – Displacement controlled by the linear (or pivoting) movement of the control ring driven by the pressure signal. – Continuous control of the volume of the working chamber. – Simple design, few components. – Pressure working directly on the volume control system.
  7. 7. 7 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump – Genesis of the Product 7 Customer SOR • Oil Flow Rate Requirement • Oil Pressure Requirement • The Minimum Absorbed Energy
  8. 8. 8 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump – Design Loop 8 VOP design 1 2 3 4 5 6 7 8 Suggested Shaft diameter d [mm] 10.00 10.00 10.00 10.00 10.00 12.00 12.00 10.00 >10 Max eccentricity e [mm] 3.00 3.00 3.00 3.00 3.00 2.70 2.37 3.00 Vane inside rotor i [mm] 3.60 6.00 6.00 6.00 6.00 5.00 5.34 6.00 Rotor - hub thickness s [mm] 3.00 4.00 4.00 4.00 4.00 3.70 3.70 4.00 Rotor collar max thickness p [mm] 3.10 3.00 3.00 3.00 3.00 0.30 0.64 3.00 >3,0 "Small" ring thickness b [mm] 2.50 2.50 2.50 2.50 2.50 0.30 0.64 2.50 >2,5 Vane - rotor slot f [mm] 0.50 0.30 0.30 0.30 0.30 0.30 0.64 0.30 >0,3 Rotor - control ring g [mm] 0.50 0.30 0.30 0.30 0.30 0.30 0.64 0.30 >0,3 "Small" ring - shaft n [mm] 1.00 1.80 1.80 1.80 1.80 3.70 3.70 1.80 >0,3 "Small" ring - rotor m [mm] 0.50 3.00 3.00 3.00 3.00 4.70 4.70 3.00 >0,3 Rotor external diameter dr [mm] 36.200 42.600 42.600 42.600 42.600 40.800 40.800 42.600 Control ring internal diameter da [mm] 43.200 49.200 49.200 49.200 49.200 46.800 46.800 49.200 Vane length h [mm] 10.100 12.300 12.300 12.300 12.300 10.700 10.700 12.300 Vane length outside rotor slot a [mm] 6.500 6.300 6.300 6.300 6.300 5.700 5.365 6.300 Percentage of length outside rotor slot % 64.4 51.2 51.2 51.2 51.2 53.3 50.1 51.2 <55% "Small" ring diameter c [mm] 23.000 24.600 24.600 24.600 24.600 25.400 25.400 24.600 Ratio e/D e/D [adim] 0.0694 0.0610 0.0610 0.0610 0.0610 0.0577 0.0505 0.0610 <0,055 Required displacement C [cc/rev] 20.17 20.00 20.00 20.00 20.00 20.00 20.00 20.00 Vane number N [adim] 7 7 7 7 7 7 7 7 Vane thickness w [mm] 2 2 2 2 2 2 2 2 Max head radius for vane rmax [mm] 5.40 6.15 6.15 6.15 6.15 6.32 6.95 6.15 Max area Amax [mm2 ] 109.749 123.572 123.572 123.572 123.572 105.818 98.950 123.572 Min area Amin [mm2 ] 8.166 6.361 6.361 6.361 6.361 5.943 11.458 6.361 N*(Amax-Amin) [mm2 ] 711.081 820.477 820.477 820.477 820.477 699.124 612.446 820.477 Pump height 28.365 24.376 24.376 24.376 24.376 28.607 32.656 24.376 Pump height (rounded) 28.4 24.4 24.4 24.4 24.4 28.6 32.7 24.4 < 35 Delivery pressure Pd [bar] 5.00 5.00 5.00 5.00 5.00 5.00 5.00 5.00 Area of vane outside rotor slot A [mm2 ] 184.600 153.720 153.720 153.720 153.720 163.020 175.436 153.720 Total force on vane outside rotor slot F [N] 92.30 76.86 76.86 76.86 76.86 81.51 87.72 76.86 Unit pressure on vane punit [N/mm] 3.250 3.150 3.150 3.150 3.150 2.850 2.683 3.150 ---Input data ---Output data Data - Main geometric parameters Data - Displacement Results - Height H [mm] Data & Results - Clearances Results - Main geometric dimensions Preliminary verifications Optimization of the geometry best design Best Pump!
  9. 9. 9 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Performance 9 Lumped Parameters Simulation Equivalent hydraulic circuit build with custom & standard sub-models. Output results: instantaneous pressure - flow - torque values in different pump areas
  10. 10. 10 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Performance 10 Output result: prediction of the cavitation CFD Analyses
  11. 11. 11 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Reliability 11
  12. 12. 12 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Multi-Body Dynamic Analyses Variable Oil Pump - Reliability 12 Output results:  Exchanged Forces  Components Velocity  Components Accelerations
  13. 13. 13 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Structural Analyses Variable Oil Pump - Reliability 13 Deformations Stresses  Linear analyses  Non-linear analyses (contacts, material plasticity, large strain)
  14. 14. 14 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Structural Analyses Variable Oil Pump - Reliability 14 Coarse Model Sub-Model Sub modelling (detail analyses)
  15. 15. 15 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Lifetime Prediction Variable Oil Pump - Reliability 15 Real Crack  Classical theoretical approach (Goodman, Haigh, Soderberg, …)  Advanced theoretical approach (Sines, Critical plane, Dang Van, …)  Miner’s cumulative damage ratio Virtual Crack
  16. 16. 16 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Multi-axial Fatigue Analyses Variable Oil Pump - Reliability 16 The PPT F – Code Tool Dynamic Loads Sampling Results Data Multi Body Simulation Structural Analyses Equivalency Criterion Choice Rainflow Algorithm Palmgren – Miner Hypothesis Are Stress Principal Directions Varyimg? ANSYS Plot of μ Parameter No Yes Life in Every Node Proportional Fatigue? Material Data Import Data MatLab/SCILAB  Proportional and not proportional fatigue evaluation  Total load cycles by means of Rainflow algorithm
  17. 17. 17 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Sealing Analyses Variable Oil Pump - Reliability 17  Full 3D approach  Pre-stress effects  Mesh rezoning
  18. 18. 18 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Sealing Analyses Variable Oil Pump - Reliability 18  Mono-dimensional approach  “Bed” of springs  Linear or not linear springs gasket 3D model load – crush curve spring elements modelling the gasket resulting sealing force
  19. 19. 19 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Output results:  Contact pressure  Bending stress on teeth Gear Design Optimization Variable Oil Pump - Reliability 19
  20. 20. 20 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Reliability 20 Structural Resonance Experimental/Numerical Correlation Modal Analyses 1st Frequency
  21. 21. 21 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Reliability 21 Structural Resonance Optimization of the pump structure Modal Analyses 1st Frequency (New)
  22. 22. 22 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Variable Oil Pump - Reliability 22 FEA Dynamic Analyses Spectrum & PSD Analyses Transient Analyses
  23. 23. 23 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Acoustic Simulations Variable Oil Pump - Reliability 23 FEM Modal Analysis Vibrational Modes CFD Results INPUT SIGNAL Output results  dB Sound Power  Emission Type  Noise Radiation
  24. 24. 24 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential The increased “know how” gained in different simulation areas like the FEM, CFD and MBA has allowed to run complex combined simulations. These skills gives the possibility to manage difficult situation during the product development.  fluid dynamics analysis (CFD) internal pressure peaks  dynamical analysis (MBA) contact forces crankshaft-rotor  structural analysis (FEM) lifetime prediction or PROBLEM: crack on a VOP rotor. Cause of the failure ? Variable Oil Pump – Example of a Successfully Solved Problem 24 weak design engine conditions
  25. 25. 25 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Dynamic analysis was run in order to evaluate contact forces between crankshaft and rotor under crankshaft torsional vibration (measured directly on the engine). Clear effect of high unexpected vibration of the new engine against an existing application were highlighted. Crankshaft mounted camera New engine Old engine Variable Oil Pump – Example of a Successfully Solved Problem 25
  26. 26. 26 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Calculated loads on shaft has been used to evaluate the lifetime of the component. mesh internal stresses submodeling fatigue life At the end of this activity it was shown that the problem was engine related (excessive crankshaft torsional vibrations). Variable Oil Pump – Example of a Successfully Solved Problem 26 Customer worked to reduce the amplitude of torsional vibrations by tuning the engine (crankshaft modifications, new damper, etc). No re-design of the pump was necessary. No additional costs for PPT.
  27. 27. 27 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential • The present work has shown some possible numerical analyses which can be performed to design, optimize and verify a generic variable oil pump, in order to have a successful product with a reasonable cost. • Thanks to CAE software, all of the numerical evaluations are executed without the building of any prototype, with a great economy in terms of materials and money. • Thanks to the virtual prototyping it’s possible to explore “unusual” working loads, not reachable with experimental tests, in order to verify the pump also outside from the nominal conditions. • Finally, it is worth noting the great flexibility of the current CAE software, like ANSYS, which permit a complete multidisciplinary approach in designing and verifying whatever mechanical component, providing reliable results in short time Conclusions
  28. 28. 28 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential • Simulation Driven Design and Development of a Variable Vane Pump has been presented • ANSYS provides simulation based solutions for every aspect of pump analysis • Concepts discussed here can be applied to all types of positive displacement and centrifugal pumps Summary
  29. 29. 29 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential Thank You!
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