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
1 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
 Key Vehicle Systems Are Undergoing Drastic
Changes To Reduce Carbon Footprints
Leightweight
Powertrain Energy Recovery
Design

Road Resistance

Reduce Carbon
Footprint
Aerodynamics

Thermal
Energy HEV/EV
Management

2 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential

 Warranty Expenses Due to Increasingly Complex
And Interdependent Automotive Systems
Early introduction of quality and
reliability prediction system

Courtesy of Pierburg Pump Technology Italy SpA

KBI

Insights into system

level interdependencies

Warranty
Reduction

Innovative manufacturing
processes

3 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential

 1D & 3DCFD
Pump Design Process FEA
Multiphysics

Performance Reliability
Pump Pump Structural Vibrational Dynamic Sealing
Fatigue Life
Characterization Optimization Integrity Behavior Behavior Verification

Noise
Aeroacoustics Vibroacoustics

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 Variable Oil Pump - Advantage
 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

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 Variable Oil Pump – Conventional Type

• 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.

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 Variable Oil Pump – Genesis of the
Product

Customer SOR

• Oil Flow Rate Requirement

• Oil Pressure Requirement
• The Minimum Absorbed Energy

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 Variable Oil Pump – Design Loop
VOP design
Data - Main geometric parameters 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
Data & Results - Clearances
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
Results - Main geometric dimensions
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
Data - Displacement
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
Results - Height
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 [mm 2] 109.749 123.572 123.572 123.572 123.572 105.818 98.950 123.572
Min area Amin [mm 2] 8.166 6.361 6.361 6.361 6.361 5.943 11.458 6.361
N*(Amax-Amin) [mm 2] 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
H [mm]
Pump height (rounded) 28.4 24.4 24.4 24.4 24.4 28.6 32.7 24.4 < 35
Preliminary verifications
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 [mm 2] 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

Best Pump!

Optimization of the geometry best design

8 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
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 Variable Oil Pump - Performance

Lumped Parameters
Simulation

Equivalent hydraulic circuit build with Output results: instantaneous pressure -

custom & standard sub-models. flow - torque values in different pump areas
9 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
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 Variable Oil Pump - Performance

CFD Analyses

Output result: prediction of the cavitation

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 Variable Oil Pump - Reliability

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 Variable Oil Pump - Reliability
Multi-Body Dynamic Analyses

Output results:
 Exchanged Forces
 Components Velocity
 Components Accelerations

12 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential 12

 Variable Oil Pump - Reliability

Deformations
Structural Analyses

Stresses

 Linear analyses
 Non-linear analyses (contacts,
material plasticity, large strain)

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 Variable Oil Pump - Reliability

Coarse Model
Structural Analyses

Sub-Model

Sub modelling (detail analyses)

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 Variable Oil Pump - Reliability

Real Crack
Lifetime Prediction

Virtual Crack

 Classical theoretical approach

(Goodman, Haigh, Soderberg, …)
 Advanced theoretical approach
(Sines, Critical plane, Dang Van, …)
 Miner’s cumulative damage ratio

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 Variable Oil Pump - Reliability
Multi-axial Fatigue Analyses

Material Data
The PPT F – Code Tool
Proportional
Multi Body
Import Data Fatigue? ANSYS Plot of μ
Simulation
MatLab/SCILAB Parameter

Dynamic Loads
Equivalency Are Stress Principal
Results Data Criterion Choice Directions Varyimg?
Sampling Structural Analyses

Rainflow
Algorithm
 Proportional and not proportional No Yes
fatigue evaluation Palmgren – Miner
Hypothesis
 Total load cycles by means of
Rainflow algorithm

Life in Every Node

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 Variable Oil Pump - Reliability

Sealing Analyses

 Full 3D approach
 Pre-stress effects
 Mesh rezoning

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 Variable Oil Pump - Reliability

Sealing Analyses

gasket 3D
model

springsealing
resulting elements
force
load – crush modelling the
curve gasket
 Mono-dimensional approach
 “Bed” of springs
 Linear or not linear springs
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 Variable Oil Pump - Reliability

Gear Design Optimization

Output results:
 Contact pressure
 Bending stress on teeth
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 Variable Oil Pump - Reliability

Modal Analyses

Structural Resonance

1st Frequency

Experimental/Numerical Correlation

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 Variable Oil Pump - Reliability

Modal Analyses

Structural Resonance

1st Frequency (New)

Optimization of the pump structure

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 Variable Oil Pump - Reliability

FEA Dynamic Analyses

Transient Analyses

Spectrum & PSD

Analyses

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 Variable Oil Pump - Reliability

Acoustic Simulations

CFD Results INPUT SIGNAL

Output results
 dB Sound Power
 Emission Type
FEM Modal Analysis Vibrational Modes  Noise Radiation
23 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
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 Variable Oil Pump – Example of a
Successfully Solved Problem
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.
PROBLEM: crack on a VOP rotor.

Cause of the failure ?

weak design or engine conditions

 fluid dynamics analysis (CFD) internal pressure peaks

 dynamical analysis (MBA) contact forces crankshaft-rotor
 structural analysis (FEM) lifetime prediction
24 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential
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 Variable Oil Pump – Example of a
Successfully Solved Problem
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.

New engine Old engine

Crankshaft
mounted
camera

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 Variable Oil Pump – Example of a
Successfully Solved Problem
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).
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.
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 Conclusions

• 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

27 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential

 Summary

• 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

28 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential

 Thank You!

29 © 2014 ANSYS, Inc. May 20, 2014 ANSYS Confidential