Estimations of leakages through gaps at ‘transition’ contacts using computational fluid dynamics and photoimaging of core-flow cavitation features in Gerotor pumps

Chambers in the Gerotor pump units are separated by metal-to-metal geometrically form-closed higher pair active contacts in the lobes of star and ring components. With rotation when the chamber volumes expand and contract, the active contacts move on lobe profiles and are subjected to deformations due to contact stress caused by fluid pressure and transmitted torque. Evidently at two transition active contacts, which separate the high-pressure chambers from the low-pressure chambers, gaps are generated due to contact deformations. However, it is for a short period of time during operation and mostly not at the same time in the two transition contacts. From our experimental visual investigation by photoimaging technique on flow processes, we have visualized that at some angular positions of the star–ring, cavitation occurs inside the chamber. In an earlier work, in the estimation of gaps in transition contacts, we have first evaluated the stresses, deformations at all ideally form-closed active contacts in our chosen Gerotor pump using static structural analysis in the Ansys® environment. In the present work, to investigate the flow characteristics, including the formation of cavitations in the Gerotor pump, numerical analysis using the computational fluid dynamics tool in the Ansys® environment has been carried out. We analyze the flow process for the different angular positions of a star. Results obtained by the numerical analysis have good agreement with the flow patterns visualized experimentally.

Rotor Behavior and Friction Torque Characteristics of a Gerotor Pump Used for Automatic Transmissions

Rotor behavior may affect the torque characteristics of gerotor pumps, but the measurement of the behavior has received little attention. Thus, in this study, we measure the rotor behavior of a gerotor pump used for automatic transmissions under various operating conditions. The experiments revealed that the inner rotor rotated near the middle of the cover wall and casing sidewall, slightly tilted with respect to them. The outer rotor rotated in the vicinity of the casing sidewall and came closer to the sidewall with decreases in the dimensionless parameter ?N??P (where ? [Pa?s] is the oil viscosity, N [s^(-1) ] is the rotational speed, and ?P [Pa] is the pressure difference). In addition, the eccentricity of the outer rotor was observed to increase with decreases in ?N??P. The inclination of the inner rotor and the approximation of the outer rotor to the casing sidewall may increase the driving torque of the pump. Taking the measured results on rotor behavior into account, a clear physical meaning is given to an existing mathematical model of viscous friction torque.

Improving Gerotor Pump Performance Trough Design, Modeling and Simulation

Gerotor pumps are well known by a compact design, simple structure and low noise level, which makes them suitable for use in the automotive industry, and especially in hydraulic systems for engine lubrication. One of the main disadvantages of gerotor pumps is the inability to adjust to wear, which significantly reduces the pump efficiency. In order to mitigate the negative effect of the inevitable wear process, this paper presents a methodology for determining the optimal combination of trochoid gears design parameters for a defined aspect. An appropriate mathematical model has been developed to analyze the effect of changes in gear design parameters in relation to maximum contact stresses, pressure changes in gerotor pump chambers and wear rate proportional factor (WRPF). Verification of the developed models was performed by realizing physical pairs of gears and laboratory experiments with simulation of pump operating conditions. The results and conclusions presented in this paper, with an emphasis on the actual work processes, bring very important perspectives for the gerotor pumps design with improved performance.

A Virtual Prototype for Fast Design and Visualization of Gerotor Pumps

In the context of generation of lubrication flows, gear pumps are widely used, with gerotor-type pumps being specially popular, given their low cost, high compactness, and reliability. The design process of gerotor pumps requires the simulation of the fluid dynamics phenomena that characterize the fluid displacement by the pump. Designers and researchers mainly rely on these methods: (i) computational fluid dynamics (CFD) and (ii) lumped parameter models. CFD methods are accurate in predicting the behavior of the pump, at the expense of large computing resources and time. On the other hand, Lumped Parameter models are fast and they do not require CFD software, at the expense of diminished accuracy. Usually, Lumped Parameter fluid simulation is mounted on specialized black-box visual programming platforms. The resulting pressures and flow rates are then fed to the design software. In response to the current status, this manuscript reports a virtual prototype to be used in the context of a Digital Twin tool. Our approach: (1) integrates pump design, fast approximate simulation, and result visualization processes, (2) does not require an external numerical solver platforms for the approximate model, (3) allows for the fast simulation of gerotor performance using sensor data to feed the simulation model, and (4) compares simulated data vs. imported gerotor operational data. Our results show good agreement between our prediction and CFD-based simulations of the actual pump. Future work is required in predicting rotor micro-movements and cavitation effects, as well as further integration of the physical pump with the software tool.

PREDICTION OF OIL FILM THICKNESS IN TROCHOIDAL PUMP

A model for predicting the oil film thickness between the contact surfaces of the gerotor pump teeth is given in this paper. Gerotor pumps are rotary pumps with inner trochoidal gearing. The working process of the pump is followed by mechanical losses due to friction that occurs between the coupled surfaces. In order to reduce these losses and avoid wearing of the teeth’s active surfaces, it is necessary to provide a minimum thickness of the oil film between the contact surfaces. The minimum thickness of the oil film depends on a large number of different factors, but in this paper for its determination, the Hamrock and Dowson empirical equation is used. Previously, the mathematical model that follows the change of relative velocities in contact, sliding velocity, rolling velocity and contact force at the contact points of the coupled teeth profiles is developed. The influence of different parameters on the lubrication regime has been analyzed, and it has been shown that the trohydraulic pump operates most with the limit EHD lubrication regime. The most unfavorable period occurs when the resulting rolling velocity decreases significantly, and this period dominates during coupling. The results of this research provide guidelines for the design of the tooth profile’s shape and the choice of operating parameters of the pump with high reliability.

An Investigation of Tooth Tip Leakages in Gerotor Pumps: Modeling and Experimental Validation

Gerotors are inexpensive positive displacement pumps commonly used in hydrostatic transmissions, fuel injection, and automotive lubrication systems. In these pumps, leakages at the tooth tips of the gears are the major source of volumetric losses that prevents their usage in high pressure applications. However, due to the curvature of typical gear profiles, the flow relations available in the literature do not accurately model this leakage flow. In this paper, a novel tooth tip leakage flow model is developed based on dimensional analysis. Key geometric and flow parameters are identified and a set of computational fluid dynamics (CFD) simulations are conducted on the tooth tip geometry to establish the flow relationship. This relationship is first verified with the analytical formulation derived from Reynolds equation. Then, an experimental setup is designed to reproduce the flow conditions at the tooth tip of gerotors. Experiments are conducted for a range of geometric and flow parameters, and results from the experiments are used to validate the proposed leakage flow model. The tooth tip leakage flow model developed and validated in this work is valuable for pump designers in determining the impact of gear geometry and clearances on volumetric performance of the pump. Moreover, the model can be readily used in any lumped parameter based simulation tool permitting a fast and accurate prediction of the tooth tip leakage flow and hence the volumetric efficiency of the unit.

Modelling and Validation of Tooth Tip Leakages in Gerotor Pumps

Gerotor pumps are commonly used as charge pumps in hydrostatic transmission systems as well as in fuel injection and automotive lubrication systems. For high pressure applications, Gerotors suffer from internal leakages which are one of the main sources of volumetric loss. The curvature of typical gear profiles for Gerotors prevents the usage of simple analytical relations to describe this leakage flow. In this paper, a non-dimensional functional relationship is developed between geometric and flow parameters to model this leakage flow. A set of CFD simulations are conducted on the tooth tip geometry to establish this relationship. Then, an experimental setup is designed to reproduce the flow conditions at tooth tip of Gerotor. Experiments are conducted for a range of geometric and flow parameters and results from experiments are used to validate the proposed non-dimensional model. The tooth tip leakage model developed and validated in this work is valuable for pump designers in determining the impact of gear geometry and clearances on volumetric performance of the pump. Moreover, the model can be readily used in any lumped parameter based simulation tool permitting a fast and accurate prediction of the tooth tip leakage flow and hence the volumetric efficiency of the unit.

A Review of Gerotor Technology in Hydraulic Machines

Over the years, numerous investigations have established the gerotor fundamentals. This work aims to provide a complete review of the literature from the last decade, focusing on the articles published in the past five years on gerotor technology in hydraulic machines. The report gives a catalogue of guidelines based on the trochoidal-envelope definition, a background analysis, the worldwide distribution of articles in each continent and country and the most frequently used keywords in the field. The paper identifies state-of-the-art research, and reports on current mainstream ideas. From the historical background, this literature review reports the current approaches in gerotor pumps (geometry and performance approaches, modeling and numerical simulations), orbital motors and new concepts. The report will serve as a guide and a directory for novel engineers working with gerotor technology in hydraulic machines. Another intention of this paper is to disseminate the works of the researchers who use this technology around the world, and to provide a scenario for future international collaboration. The paper gives an account of the disparity between academia and engineering applications. There is currently very little published literature on design and production methodologies for gerotor pumps and orbital motors. Hence, the future goal is to collect recommendations that combine academia and industry expertise to make better use of these extensive studies in the field.