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Energy Procedia
Energy 12600
Procedia (201709) 1115–1122
(2017) 000–000
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72nd Conference of the Italian Thermal Machines Engineering Association, ATI2017, 6-8
72nd Conference of the ItalianSeptember 2017, Lecce,
Thermal Machines Italy
Engineering Association, ATI2017, 6-8
nd September 2017, Lecce, Italy
72 Conference of the Italian Thermal Machines Engineering Association, ATI2017, 6-8
DiagnosticTheProcess bySeptember
Using
15th International Vibrational
Symposium Sensors
on District
2017, Lecce, Italy forCooling
Heating and Monitoring
Diagnostic
Cavitation Process
Phenomena by Using Vibrational
in a Getoror PumpSensorsUsed for forAutomotive
Monitoring
Assessing
Diagnostic
Cavitation the feasibility
Process
Phenomena by Using of usingPump
Vibrational
in Applications
a Getoror the heat demand-outdoor
Sensors
Used forAutomotive
for Monitoring
temperature function forinaApplications
Cavitation Phenomena along-term
Getoror Pump districtUsed heatfor
demand forecast
Automotive
a b b
Daniela Siano *,Applications
Emmaa Frosina , Adolfo Senatore c
I. Andrića,b,c*, A. Pinaa, P. Ferrão
a
Daniela a
, J. Fournier
b
b
., B. Lacarrière
b , O. Le Corre
Siano *, Emma Frosina , Adolfo Senatore
c
CNR – Istituto Motori, Via Marconi – 80125, Naples, Italy
a Research b Técnico, b 1, Naples,
*,Motori,
a b
IN+ Center University
for Innovation, Daniela
Technology
of Naples
b
Siano
a and
Federico
CNR
II,Policy Emma
Department
– Istituto Via Frosina
of Industrial , Adolfo
- InstitutoEngineering,
Superior
Marconi – 80125, Naples,Senatore
Av. Rovisco
Via Claudio
Italy
Pais
21 – 80125, 1049-001 Lisbon, Portugal
Italy
b Veolia Recherche & Innovation, 291 Avenue Dreyfous Daniel, 78520 Limay, France
c University of Naples Federico II, Department of Industrial Engineering, Via Claudio 21 – 80125, Naples, Italy
Département Systèmes Énergétiques
a et Environnement
CNR – Istituto - IMT Atlantique,
Motori, Via Marconi 4 rue Alfred
– 80125, Naples, ItalyKastler, 44300 Nantes, France
b
University of Naples Federico II, Department of Industrial Engineering, Via Claudio 21 – 80125, Naples, Italy
Abstract
Abstract
AAbstract
full experimental investigation on a Gerotor pump used for the lubrication of engines is described in this paper. These pumps,
Abstract
as full
A wellexperimental
known, are widely used onon
investigation engines
a Gerotorfor all hydraulic
pump used for circuits and, for this
the lubrication of reason,
enginesoften they work
is described in some
in this paper.conditions (such
These pumps,
District
as at high heating
speeds networks
and pressure arevalue)
commonly which addressed
are very in the literature as one of the most effective solutions for decreasing the
challenging.
as well known, are widely used on engines for all hydraulic circuits and, for this reason, often they work in some conditions (such
Agreenhouse gas
oneemissions fromunwanted
the
on abuilding sector. These systems require high investments which are returned through the the
heat
as full
In this
at experimental
highpaper
speeds ofinvestigation
and the most
pressure value) Gerotor
which are pump
phenomena used
that for
very challenging. the occurs
often lubrication
during of engines
the pump is described
operation inhas
this paper.
been These pumps,
investigated:
sales.
as well Due to are
known,
cavitation. thewidely
changed used climate
on conditions
engines for all and building
hydraulic renovation
circuits and, for policies,
this reason, heat demand
often they in the
work in futureconditions
some could decrease,
(such
In this paper one of the most unwanted phenomena that often occurs during the pump operation has been investigated: the
prolonging
as
Theat cavitation
high speeds thecaninvestment
and
bepressure return
triggered byperiod.
value) manywhich are very
multiple challenging.
factors such as the sloshing in the tank (translational and rotational motions),
cavitation.
The
In main
this paper scope
one ofofthis
the paper
most isunwanted
to assess the feasibility
phenomena of too
that using
often theatheat demand – outdoor temperature function for heat demand
high percentage of gas dissolved in the
The cavitation can be triggered by many multiple factors suchfluid and pressure asoccurs
low thethe during
pump
sloshing the
thepump
suction
in port.
tank operation
Therefore,
(translational hasthe
andbeen investigated:
characterization
rotational thea
of
motions),
forecast.
cavitation.
Gerotor pumpTheindistrict
cavitationof Alvalade,
condition located
is really in Lisbon (Portugal), was used as a case study. The district is consisted of 665
interesting.
high percentage of gas dissolved in the fluid and pressure too low at the pump suction port. Therefore, the characterization of a
buildings
The
In order to that
cavitationreplay vary
can beincavitating
the both construction
triggered by many
conditions period
multiple
a pump and hastypology.
factors such
been asThree weather
the sloshing
installed on inscenarios
a dedicated the tank (low, medium,
(translational
test bench andhigh)
of the Department andofthree
rotational district
motions),
Industrial
Gerotor pump in cavitation condition is really interesting.
renovation
high percentage
Engineering scenarios
of
of thethe gas were
university developed
dissolved in
of Naples the (shallow,
fluid and
“Federico intermediate,
pressure too deep).
low at To
the estimate
pump the
suction error,
port. obtained
Therefore, heat
the demand values
characterization were
onofthea
In order to replay cavitating conditions a pumpII”. hasThebeenpump has been
installed on aforced
dedicated to cavitate by placing
test bench calibrated orifices
of the Department of Industrial
compared
Gerotor
suction pump
side with
of in results
thecavitation
pump. fromManya dynamic
condition is
decreasing heat demand
really diameters model,
interesting. have previously
been locateddeveloped
in an and validated
aluminum by the authors.
connection block, to measure all the
Engineering of the university of Naples “Federico II”. The pump has been forced to cavitate by placing calibrated orifices on the
The
In
working results
order to showed
replay
parameters the that
like when
cavitating
the only
flow-rate, weather
conditions a
pressure change
pump
(at is suction
has
the considered,
been installed
and theonmargin
deliverya of error
dedicated
ports), could
test
pump bench
speedsbe acceptable
of
andthe forripple.
Department
pressure someofapplications
Industrial
Cavitating
suction side of the pump. Many decreasing diameters have been located in an aluminum connection block, to measure all the
(theno-cavitating
and error inofannual
Engineering demandhave
theconditions
university was
of lowerinvestigated
Naples
been than 20%II”.
“Federico for
byThe all pump
using weather
anand scenarios
hasdelivery
been forced
accelerometer considered).
to pump
sensor cavitate However, of after
by placing
in proximity introducing
calibrated
the pump renovation
orifices
suction on the
chamber
working parameters like the flow-rate, pressure (at the suction ports), speeds and pressure ripple. Cavitating
scenarios,
suction side
withno-cavitatingthe
of error
the
the aim monitoring value
pump. increased
Many up
decreasing to 59.5% (depending
diameters have on
been the weather
located in anand renovation
aluminum scenarios
connection combination
block, to considered).
measure all the
and conditionsthehave phenomena in terms ofbyvibration
been investigated using anamplitude.
accelerometer sensor in proximity of the pump suction chamber
The
working
As value
afore of slopelike
parameters
mentioned, coefficient
thethepump increased
flow-rate,
under on average
pressure (at of
investigation thehaswithin
been the
suction and range
studied inofallports),
delivery 3.8% up
operative to conditions
pump 8% per and
speeds decade, that without
pressure
with and corresponds
ripple. Cavitatingto the
cavitation
with the aim of monitoring the phenomena in terms vibration amplitude.
decrease
and
phenomena inbythe
no-cavitating number
usingconditions
a of heating
have
non-intrusive beenhours
sensor of 22-139h
investigated
like by during
using
accelerometer theaccelerometer
an
in heating
order to season sensor
monitoring (depending
ifin on is
proximity
cavitation theof combination
the
present. pump of weather
suction chamber and
As afore mentioned, the pump under investigation has been studied in all operative conditions with and without cavitation
renovation
with
More the aim scenarios
of
precisely, monitoring
the considered).
the
accelerometer On
phenomena
sensor the in
other
hasterms hand,
been of function
vibration
located intercept
amplitude.
close to the increased
pump for 7.8-12.7%
suction chamber per the
and decade (depending
vibrations have on
beenthe
phenomena by using a non-intrusive sensor like accelerometer in order to monitoring if cavitation is present.
coupled
As afore
acquired scenarios). The
mentioned,
contemporarily the values
pump
with suggested
under
pressure signalscould
investigation be has
(intake used
and beento modify
studied
outgoing the
in function
all
discharge) operative
and parameters
conditions
properly for the
triggered with scenarios
withand considered,
without
tachometer cavitation
signal and
by
More precisely, the accelerometer sensor has been located close to the pump suction chamber and the vibrations have been
improve
phenomena
using thebyaccuracy
a multichannel of heat demand
using a non-intrusive
acquisition systemestimations.
sensor like(intake
accelerometer
(Siemens™). in order to monitoring if cavitation is present.
acquired contemporarily with pressure signals andAoutgoing
spectral vibration
discharge) analysis
and hastriggered
properly been usedwithastachometer
diagnostic signal
tool forby
More
using a multichannel acquisition system (Siemens™). A spectral vibration analysis has been used as diagnostic toolbeen
precisely, the accelerometer sensor has been located close to the pump suction chamber and the vibrations have for
© 2017 contemporarily
acquired The Authors. Published by Elsevier
with pressure signalsLtd.
(intake and outgoing discharge) and properly triggered with tachometer signal by
Peer-review
using under responsibility
a multichannel acquisition ofsystem the Scientific Committee
(Siemens™). of The 15th
A spectral International
vibration analysisSymposium
has been used on District Heating and
as diagnostic tool for
Cooling.
* Corresponding author. Tel.: +39 081 7177108; fax: +39 081 7177108.
E-mail address: d.siano@im.cnr.it
* Corresponding
Keywords: author. Tel.:
Heat demand; +39 081
Forecast; 7177108;
Climate fax: +39 081 7177108.
change
E-mail address: d.siano@im.cnr.it
1876-6102 © 2017 author.
* Corresponding The Authors. Published
Tel.: +39 by Elsevier
081 7177108; Ltd. 081 7177108.
fax: +39
Peer-review responsibility of the scientific committee of the 72nd Conference of the Italian Thermal Machines Engineering
underd.siano@im.cnr.it
E-mail address:
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Association.
Peer-review under responsibility of the scientific committee of the 72nd Conference of the Italian Thermal Machines Engineering
1876-6102
1876-6102©©2017
Association. 2017The
TheAuthors.
Authors.Published
PublishedbybyElsevier
ElsevierLtd.
Ltd.
Peer-review underresponsibility
Peer-review under responsibility of the
of the scientific
Scientific committee
Committee of15th
of The 72nd Conference
the International of the on
Symposium Italian Thermal
District HeatingMachines Engineering
and Cooling.
Association.
1876-6102 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review under responsibility of the scientific committee of the 72nd Conference of the Italian Thermal Machines Engineering Association
10.1016/j.egypro.2017.08.269
21116 D.Daniela
Siano etSiano
al./ Energy
et al. / Procedia 00 (2017)
Energy Procedia 126000–000
(201709) 1115–1122
2 D. Siano et al./ Energy Procedia 00 (2017) 000–000
accurately detecting pump degradation. The results coming from the analysis have shown that in presence of cavitation
accurately
phenomenadetecting pump degradation.
the non-intrusive The results
monitoring technique coming
represent fromdiagnostic
a good the analysis haveforshown
method thatpump
assessing in presence of cavitation
operability.
phenomena the non-intrusive monitoring technique represent a good diagnostic method for assessing pump operability.
© 2017 The Authors. Published by Elsevier Ltd.
© 2017
© 2017 The
The Authors.
Authors. Published
Published by
by Elsevier
Elsevier Ltd.
Ltd. committee of the 72nd
nd
Peer-review
Peer-review under
under responsibility
responsibility of
of the
the scientific
scientific committee Conference of
of the 72nd Conference of the
the Italian
Italian Thermal
Thermal Machines
Machines Engineering
Engineering
Peer-review under responsibility of the scientific committee of the 72 Conference of the Italian Thermal Machines Engineering
Association.
Association
Association.
Keywords: Gerotor pumps, Cavitation detection, FFT, Vibration.
Keywords: Gerotor pumps, Cavitation detection, FFT, Vibration.

Nomenclature fvan Passes Frequency originated on the inner

Nomenclature fvan Passes Frequency
rotor teeth originated on the inner
p Pressure Ninner teeth rotor teeth
Number of inner rotor teeth
ppv Pressure
Saturated vapour pressure Nouter
F innerteeth
teeth Number
Frequency of originated
inner rotoron teeth
the outer
pf0v Saturated
frequency vapour pressure F outer teeth Frequency
rotor teeth originated on the outer
fω0 RPM frequency
Pump shaft rotation Nouter teeth rotor teeth
Number of outer rotor teeth
ωRPM Pump shaft rotation Nouter teeth Number of outer rotor teeth
1. Introduction
1. Introduction
Mechanical systems that interact with liquids, such as pumps or propellers, may present an unwanted
Mechanicalcalled
phenomenon systems that interact
cavitation. with liquids,
The cavitation, such as
as well know, pumpsby or
depends propellers,
pressure In fact,may whenpresent
a liquidan at aunwanted
constant
phenomenon called cavitation. The cavitation, as well know, depends by pressure
temperature is subject to a decreasing pressure, p, which falls below the saturated vapor pressure pv cavitation In fact, when a liquid at a constant
may
temperature
occurs [8-11]. is subject
Therefore,to a the
decreasing
processpressure, p, which
of rupturing falls below
a liquid the saturated
by decrease vapor at
in pressure pressure
roughlypv constant
cavitationliquid
may
occurs [8-11]. Therefore, the process of rupturing a liquid by decrease
temperature is often called cavitation. Issues related to the cavitation are essentially the noise and the material in pressure at roughly constant liquid
temperature
damages thatiscan oftenbe called
causedcavitation.
by the high Issues related pressures
velocities, to the cavitation are essentially
and temperatures. the noise
In fact, when and the material
exposed to high
damages that can be caused by the high velocities, pressures and temperatures.
pressure, those voids tend to collapse, releasing a great amount of energy, usually in form of an acoustic shockwave, In fact, when exposed to high
pressure, those
or even as visible light. voids tend to collapse, releasing a great amount of energy, usually in form of an acoustic shockwave,
or even
Thoseasacoustic
visible light.
shockwaves can be easily detected by using a sensor such as an accelerometer positioned near the
Those acoustic
cavitation zone. One shockwaves
of the methods can betoeasilydetectdetected by using
the presence a sensor such
of cavitation, is byas processing
an accelerometerthe time positioned near the
history signal of
cavitation zone. One of the methods to detect the presence of cavitation, is
this sensor and performing a FFT (Fast Fourier transform) analysis, which will give an insightful point of view of by processing the time history signal of
this sensor and performing a FFT (Fast Fourier transform) analysis, which
the cavitation process. As will be discussed later, when cavitation is present, a lot of the energy of the sound will give an insightful point of view of
the cavitation
spectrum tendsprocess. As will abehigher
to shift towards discussed later, band,
frequency whenmaking
cavitation is present,
possible a lotthe
to identify of presence
the energy of the
of this sound
problem.
spectrum tends to shift towards a higher frequency band, making possible to
One disadvantage of this method, is that in practical situations, the accelerometer is subjected to secondary sources identify the presence of this problem.
One disadvantage
of vibration, making of the
thisdiagnose
method, of is the
thatcavitation
in practical situations,
problem very the accelerometer
complex [2]. is subjected to secondary sources
of vibration, making the diagnose of the cavitation problem very complex
In the case of this article, an experiment to detect cavitation was conducted in a Gerotor Pump, used for [2].
In the case
automotive of this article,
applications. The pump an experiment
in question to detect
is an cavitation
oil pump, which waswereconducted
subjectedintoarotation
Gerotorspeeds
Pump,ofused1000for to
automotive applications. The pump in question is an oil pump, which
6000 RPM in 1000 RPM steps, with three different sizes of orifice on the inlet side of the pump of 18mm, 5mmwere subjected to rotation speeds of 1000and to
6000 RPM in 1000 RPM steps, with three different sizes of orifice on the
3mm, to induce the cavitation phenomena [2]. An accelerometer was fixed on the pump, near the cavitation zone, inlet side of the pump of 18mm, 5mm and
3mm,
and two to instantaneous
induce the cavitation
pressurephenomena
transducers [2]. wereAn accelerometer
used to measure the wasinlet
fixedandondelivery
the pump, near the
pressure cavitation
of the zone,
pump, inside
and two instantaneous pressure transducers were used to measure the inlet
the chamber, near the rotor. The pump rotation was also measured. The present work will be a discussion about theand delivery pressure of the pump, inside
the chamber,
detection and near the rotor.of
identification Thethepump rotation
cavitation was also
problem measured.
on this GerotorThe pump.present work will be a discussion about the
detection and identification of the cavitation problem on this Gerotor pump.
2. Reference pump and experimental setup
2. Reference pump and experimental setup
The pump under investigation is an internal gear pump used for the lubrication system of internal combustion
The pump
engines. The pump underconsists
investigation is anrotor
of an outer internal
with15gearteeth
pump andused for the
an inner lubrication
with 14 teeth. system of internal combustion
engines.
The pump works in a rotation speed range of [1000 ÷ 7000] rpm and a14
The pump consists of an outer rotor with15 teeth and an inner with teeth. range of [0 ÷ 6] bar. A relief
pressure
The pump works in a rotation speed range
valve is included in the pump with an opening pressure of 4.5bar. of [1000 ÷ 7000] rpm and a pressure range of [0 ÷ 6] bar. A relief
valve is included in the pump with an opening pressure of 4.5bar.
As already said, the pump has been tested on a test bench of Department of Industrial Engineering of University
of As
Naplesalready said, theII”.
“Federico pump has been
In figure tested
1a the testonbench
a test layout
bench of Department
is shown. The of Industrial
bench Engineering
can drive the pump of in
University
the real
of Naples “Federico II”. In figure 1a the test bench layout is shown.
operation condition reaching a maximum shaft rotational speed of 8000 rpm. A hydraulic axial piston motor The bench can drive the pump in theofreal
12
operation
cm3/rev powers the pump, (see figure 1a). The variable displacement axial piston motor is driven by a PowerofUnit
3 condition reaching a maximum shaft rotational speed of 8000 rpm. A hydraulic axial piston motor 12
cm /rev powers the pump, (see figure 1a). The variable displacement axial piston
that consists of an oil tank with a nominal capacity of 100 l, an axial piston pump with theoretical displacement of motor is driven by a Power Unit
that
71 cm consists
3
/rev, aofthreean oil tank electric
phase with a nominal
motor with capacity
4 poles,of 100 l, anof
capable axial piston pump
delivering a maximumwith theoretical
power of displacement
18.5 kW andofa
71 cm3/rev, a three phase electric motor with 4 poles, capable of delivering a maximum power of 18.5 kW and a
 Daniela Siano et al. / Energy Procedia 126 (201709) 1115–1122 1117
D. Siano et al./ Energy Procedia 00 (2017) 000–000 3

heat exchanger air – oil. The pump shaft rotation speed has been varied, during the tests, through an electro-
hydraulic regulator handled by a dedicated card. A potentiometer gives the input signal to the card managing the
displacement of the axial piston pump of the Power Unit [3-7].
Looking at figure 1a, it is possible to locate all the transducers installed on the test bench. These sensors can
monitor and acquire the Gerotor operating parameters. In particular there is a flow-mater to measure the oil flow-
rate, two instantaneous pressure transducers (P1) (P2) located in the suction and delivery chamber volumes, a mean
pressure transducer (P3) on the pump delivery and a torque meter. The thermostatic tank, with an oil volume
capacity of 13 dm3, is enable to heat oil up to a temperature of 150°C. In the tank has been also installed a separation
baffle (figure 1c) to separate suction and delivery ports of the pump.

Fig. 1. (a) Test bench layout; (b) Test bench; (c) Suction and delivery view of the pump, (d) and (e) Calibrated
orefices.
As already mentioned, three pressure transducers (P1, P2, P3) are installed in the hydraulic circuit. (P1) and (P2)
are both instantaneous. These sensors are located inside two chambers (respectively suction and delivery chambers)
close to the rotors. Both of them are type AVL LP11D, in particular the measuring ranges are [0 ÷ 10] bar for P1 and
[0 ÷ 30] bar for P2. Thanks to the clock signal of an incremental optical encoder installed on the pump shaft, these
sensors can measure the pressure ripples in a pump shaft rotation. Both sensors have a frequency response of > 50
kHz. (P3) is a mean pressure transducer. It is located at the outlet side of the pump. It is a type Burkert 8314 with a
measuring range of [0 ÷ 10] bar and is based on ceramic technology measurement principle. The lamination valve
(R2) regulates the pressure at the delivery side of the pump. The valve is located at the delivery port of the pump
after the flow meter (Q). The flow meter (Q) works with a functional principle based on the controlled generation of
Coriolis forces. It is able to measure also the temperature and density of the oil. Different signals are acquired by the
hardware system NI PCI16-E1-MIO (12-bit ADC converter resolution). All the signals are routed to the board NI
PCI-MIO 16-E1 through a 68-pin shielded desktop connector block NI SCB-68. A finite - machine study, developed
with National Instruments LabVIEW® 2015 software, thus to control, manage and capture data.
As said, the goal of this analysis is the study of a Gerotor pump forced to cavitate. Cavitating conditions have
been achieved reducing the diameter of the suction port with three calibrated orifices (R1). These orifices are shown
in figures 1d and 1e, where the first one (18mm) corresponds to the regular diameter of the inlet port of the pump.
The second orifice has a diameter of 5 mm, while the last one is of 3mm. By reducing the diameter of the suction
port the performance of the pump changes as well.
The described test bench is able to perform three acquisition methodologies:
 Low sampling rate for main bench parameters (flow-rate, mean pressure, rpm);
 External clock variable sampling rate (instantaneous suction and delivery pressure);
 Time dependent sampling frequency (10 kHz) with a fixed time window (1 ÷ 10 s).
The experimentation has been done in all the pump operating condition with oil: PETRONAS SYNTIUM 7000
0W-20. In particular the pump has been tested varying the delivery pressure in the range [0 ÷ 6] bar and with an oil
temperature of 30°C, 60°C and 90°C.
In figure 2 experimental data are shown. In particular, figure 2a shows the pump characterization with no
restriction. Figure 2b presents the delivery varying the pump speed by changing the suction diameter with orifices of
18, 5 and 3mm. By the end, in figure 2c the measured pressure ripples are shown, the four spikes are due to
geometry of these four teeth.
1118 Daniela Siano et al. / Energy Procedia 126 (201709) 1115–1122
4 D. Siano et al./ Energy Procedia 00 (2017) 000–000

Fig. 2. Experimental data: (a) Pump caracterization, (b) Infuelce of restriction on the pump performance, (c)
Pressure ripples.
3. Experimental vibration analysis setup

As discussed before, the experiments were realized on a Gerotor automotive oil pump, settled on a custom test
bench. The pump was powered by an axial piston motor powered by an axial piston pump which was finally
powered by a three phase electric motor, capable of delivering 18.5 kW of power.
The Gerotor pump was equipped with two instantaneous pressure transducers inside the inlet and delivery regions
of the chamber, directly on the oil flow. The transducers used were the type AVL LP11DA, with the inlet one being
capable of measuring pressures in the range of [0 - 10] bar and the delivery one on the range of [0 - 30] bar. The
transducer accuracy is in the order of < 0.1% FSO, and it is capable of performing measurements at rate of 50 KHz.
A ceramic shear ICP® accelerometer PCB Piezotronics, 10 mV/g, 5 to 60 kHz, model 352A60 was placed outside
of the pump near the cavitation zone, as indicated on figure 3. Its sensitivity is low at very low and very high
frequencies, with a reasonably flat response ( ±3 dB variations) over the frequency range 5 Hz to 60 kHz.
Also, on the pump shaft was installed an incremental optical encoder, to measure the shaft speed rotation.
All signals were acquired by using an LMS SCADAS XS 12 channels scope, with the sampling frequency of
52.2 KHz for each channel. The complete experimental array used, is shown on the figure 3 below.

Fig. 3. Experimental Layout.

All the experiments were performed with a constant oil temperature of 40 ºC, for which 54 different conditions
with and without cavitation were tested, by mixing the following states:
 Daniela Siano et al. / Energy Procedia 126 (201709) 1115–1122 1119
D. Siano et al./ Energy Procedia 00 (2017) 000–000 5

 1000 to 6000 RPM with 1000 RPM steps

 0, 1 and 3 bar of delivery pressure
 18, 5 and 3 mm of diameter of the intake orifice
Those tests generated 216 data streams in total, composed by, tachometer, accelerometer, pressure-in and
pressure-out data. All of this data was post processed on the Siemens LMS.Lab Signal Acquisition software, mainly
by applying a FFT to obtain their FRF’s (Frequency response functions).

4. Results and Discussion

The results obtained by the experimental setup described in last section will be exposed here. They will be
classified in two classes: no cavitation and developed cavitation. One clue to identify if cavitation is present, is that
it will tend to shift most of the energy in the frequency spectrum into higher frequency bands, between 7 KHz and
14 KHz, when compared to low frequencies. On the low band of the frequency spectra, some important regions that
usually contains a lot of energy are located around the fundamental frequency - eq 1, that originates from the shaft
rotation, the van passes frequency – eq 2, that originates from the inner teeth’s of the rotor and the outer teeth
frequency – eq3, which, as the name implies, is originated on the outer teeth’s of the rotor. The theoretical value of
those frequencies can be calculated from the equations below.
�
�� = ����60 (1)
���� ������ = �� ∗ ������ ����� (2)
������ ����� = �� ∗ ������ ����� (3)
On the following figure 4, is possible to see the spectrum the response frequency of the accelerometer, for a first
essay realized at 2000 RPM, with an orifice size of 5mm, and various delivery pressures (0, 1 and 3 bar).

Fig. 4. Accelerometer response at 2000 RPM.

In this spectrum is noticeable that no cavitation is present, because of the lack of any important activity on the
high frequencies bands. Most of the energy is located on the lower end of the spectrum, meaning the system is being
mainly excited by conventional mechanic sources of vibration, such as misalignments and manufacturing defects,
which does not tend to present high frequency responses.
In next figure, the spectrum shows the frequency response of the accelerometer for a pump rotation of 3000
RPM, an orifice size of 5mm, and the same three delivery pressures from last case.

Fig. 5. Accelerometer response at 3000 RPM.

It is evident that, when the delivery pressure reaches around 3bar, an important amount of energy gets
concentrate on the frequency band between 7 KHz and 14 KHz, meaning the cavitation phenomena is starting to
develop. It is not possible to confirm surely that it is really present, because the lower frequency band also contains a
lot of energy, mainly around 1400 Hz, which represent two times the van passes frequency at 3000 RPM, and on
3500 Hz and 4500 Hz, which are caused by the fluid recirculation inside the pump chamber.
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6 D. Siano et al./ Energy Procedia 00 (2017) 000–000

In next figure, the spectrum shows the response of the accelerometer for a pump rotation of 4000 RPM, an
orifice size of 5mm, and two delivery pressures (1 and 3 bar). The delivery pressure of 0 bar cannot be achieved at
4000 RPM.

Fig. 6. Accelerometer response at 4000RPM.

Now it is possible to confirm that cavitation fully developed with 3bar of delivery pressure. It is explained,
mainly because the energy density of the spectrum, between 7 KHz and 14 KHz is much greater than the lower end
of the spectrum, which is usually excited by conventional mechanical sources. The peek of vibration amplitude of
around 3500Hz is caused by recirculation inside the pump chamber. In this case, the FRF method to detect
cavitation is perfectly suited.
In next figure, the spectrum shows the response of the accelerometer for a pump rotation of 5000 RPM, an
orifice size of 5mm, and various delivery pressures (1 and 3 bar). The delivery pressure of 0 bar cannot be achieved
at 5000 RPM.

Fig. 7. Accelerometer response at 5000RPM.

Fig. 8. Accelerometer response at 2000 RPM, in cavitation and no caviation conditions.

 Daniela Siano et al. / Energy Procedia 126 (201709) 1115–1122 1121
D. Siano et al./ Energy Procedia 00 (2017) 000–000 7

Notice that the main behaviour of this scenario at 5000 RPM is very similar to the scenario earlier described at
4000 RPM. The main differences that can be spotted are related to the overall amplitude of vibration in the
frequency bands around 3500 Hz and the cavitation zone between 7 kHz and 14 kHz. At 5000 RPM, those
amplitudes are much higher than at 4000 RPM, and one more time, as expected, cavitation is present.
In case in figure 9, the three spectres show the Gerotor pump at 2000 RPM in different discharge pressures
(0.1 and 3 bar), in cavitation and no cavitation conditions. Cavitation is induced by installing a 3mm orifice on the
oil inlet, as oppose to the no cavitation condition, in which the pump is operating normally, with it’s default 18mm
inlet orifice.
In all three spectrums, it is visible that there is a lot of energy on the lower band of the frequency spectrum.
Which is explained again by ordinary mechanical excitations, the van passes frequency and some recirculation,
mainly when the lamination valve is open at 0 bar. In all cases also, when cavitation is present, for the green curve,
the overall behavior is the same. The main variation that occurs from case to case is related to the overall amplitude
of the response of the accelerometer on the cavitation zone, which is bigger on the lower discharge pressure.
In the next case (figure 9), the two spectres show the Gerotor pump at 5000 RPM in different discharge
pressures (1 and 3 bar), in cavitation and no cavitation conditions. As on last case, cavitation is induced by installing
a 3mm orifice on the oil inlet. The pressure value of 0 bar on the pump discharge cannot be achieved at 5000 RPM,
for this reason this test was performed only in 1 and 3 bar of pressure.

Fig. 9. Accelerometer response at 5000RPM, in cavitation and no caviation conditions.

Notice that in all two spectrums when cavitation is present (green curve), the overall behavior is the same. It is
important to notice that the cavitation amplitude at 5000 RPM is much higher than at 2000RPM, at least 5 times as
high. In addition, it is noticeable, on the second spectrum, at a discharge pressure of 3bar that the pump starts to
cavitate even on the normal working condition, as can be seen on the red curve, on the frequency range between 7
KHz and 14 KHz.

5. Conclusion

In this paper a typical Gerotor pump used for the lubrication of Internal Combustion Engine has been studied
in cavitation conditions. The pump has been tested on a test bench installed in the Department of Industrial
Engineering of the University of Naples Federico II.
Cavitation has been forced by reducing the suction port of the pump with calibrated orifices with diameters of
18mm, 5mm and 3mm. For each diameters, the Gerotor has been characterized measuring the delivered flow-rate,
pressure in the suction and delivery chambers, the mean pressure at the delivery port the absorbed torque and noise
with an accelerometer. The detected cavitation is stronger with lower diameters and higher pressure. As discussed
earlier, there are some secondary sources of vibration and noise, other than the cavitation itself, like radial
misalignments, impeller pressure variations, manufacturing defects of seals, bearings and impellers, and even
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8 D. Siano et al./ Energy Procedia 00 (2017) 000–000

hydraulic sources of noise, such as transient and unstationary flow causes. All of those secondary vibration sources
add to the final measurement captured by the accelerometer, and their identification is important to the quality of the
final analysis of the pump. As the identification of some noise sources may be very difficult, such as the hydraulic
sources, the fault identification by using only the FRF of the accelerometer is not always obvious.
The main difficulty of implementing a method to detect fault (in this case cavitation) by using the FRF method
relies on the threshold that must be set to differentiate cavitation from normal operation. As can be seen on the
results section, mainly on figure 5 (3000 RPM-5mm orifice), is not always obvious when the cavitation problem is
present or not, and it gets even more difficult to make conclusions, because the response induced on the
accelerometer by cavitation, in g amplitude varies for each shaft rotation speed.
Future developments could regard in implementing an effective method to predict failure, some other
approaches may be used, mainly the ones that permit to set a constant threshold to determine if cavitation is present
or not. One possible approach is the use of the ARMA (Auto Regressive Moving Average), [12-14] mathematical
model that applies directly on the time history of the accelerometer signal, and permits to set a constant threshold, or
even the use of an ANN (Artificial neural network).

Acknowledgements

The authors would like to Gennaro Stingo, Giuseppe Iovino and Umberto Cesaro of University of Naples
“Federico II” for the technical support, and at last, but not least BADAN Joao Pedro de Campos student at Supmeca
(Public national engineering School of Paris) for technical support in editing the article and in preparing
experimental tests.

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