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Simulation-Based Prediction of the Cold Start Behavior of Gerotor Pumps for Precise Design of Electric Oil Pumps

Authors :
Sven Schumacher
Ralf Stetter
Markus Till
Nicolas Laviolette
Benoît Algret
Stephan Rudolph
Source :
Applied Sciences, Vol 14, Iss 15, p 6723 (2024)
Publication Year :
2024
Publisher :
MDPI AG, 2024.

Abstract

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.

Details

Language :
English
ISSN :
20763417
Volume :
14
Issue :
15
Database :
Directory of Open Access Journals
Journal :
Applied Sciences
Publication Type :
Academic Journal
Accession number :
edsdoj.8626185b0b84594a212bc3d2a3ab983
Document Type :
article
Full Text :
https://doi.org/10.3390/app14156723