energies
Article
Design of Gerotor Pump and Influence on Oil Supply System
for Hybrid Transmission
Mingyu Huang, Chongshi Shi, Yu Zhu, Jiaqiao Zhang






Citation: Huang, M.; Shi, C.; Zhu, Y.;
Zhang, J.; Zhang, F. Design of Gerotor
Pump and Influence on Oil Supply
System for Hybrid Transmission.
Energies 2021, 14, 5649. https://
doi.org/10.3390/en14185649
Academic Editor: Susan Krumdieck
Received: 27 July 2021
Accepted: 5 September 2021
Published: 8 September 2021
Publisher’s Note: MDPI stays neutral
with regard to jurisdictional claims in
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iations.
Copyright: © 2021 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Energies 2021, 14, 5649. https://doi.org/10.3390/en14185649
and Fubao Zhang *
School of Mechanical Engineering, Nantong University, Nantong 226019, China; huang.my@ntu.edu.cn (M.H.);
shichongshi.ntu@gmail.com (C.S.); zhu.y@ntu.edu.cn (Y.Z.); 1810310038@stmail.ntu.edu.cn (J.Z.)
* Correspondence: zhang.fb@ntu.edu.cn; Tel.: +86-13646288919
Abstract: Electric continuously variable transmission (E-CVT) is a vital part of the automobile in
order to enhance the power coupling. The oil pump is an important power source component in
the hybrid transmission system. Its efficiency exerts a significant impact on the efficiency of the oil
supply system and even the hybrid transmission system. In this study, a gerotor pump is designed
in line with the requirements of a certain type of hybrid electric vehicle. A Non-dominated Sorting
Genetic Algorithm II (NSGA-II) genetic algorithm was employed to optimize the rotor tooth profile.
The proportional-derivative (PD) control of the oil supply system was realized to lower the functional
error of the oil supply system based on the AMESim simulation platform. In addition, the prototype
test was performed to verify the rationality of the design.
Keywords: E-CVT; gerotor pump; oil supply system; hybrid transmission
1. Introduction
In recent years, although the continuous increase in the number of passenger cars has
significantly promoted the development of the automotive industry, the corresponding en-
ergy shortages and environmental pollution problems have gradually entered the public’s
field of vision. To satisfy the current challenges and reduce oil consumption, researchers
have adjusted their goals to the R&D and manufacturing of energy-saving vehicles or
new energy vehicles [1–3]. Hybrid electric vehicles mainly refers to oil–electric hybrid
electric vehicles, whose power sources contain a traditional internal combustion engine and
electric motor. Its design goal is to make the engine always work at its highest efficiency
through the power coupling input of the two power sources, aiming to realize the effects
of energy saving and emission reduction. The hybrid transmission belongs to one of the
core components of a hybrid vehicle. The hydraulic system of the hybrid transmission
is designed to achieve the cooling and lubrication of the motor, lubrication of the gear
shaft components in the box, and lubrication of the shifting components, as well as the
shifting of various gears. The oil supply system is a critical part of the hydraulic system,
and a certain flow of hydraulic oil is supplied to the entire tank through the oil supply
system [4–7]. In the traditional continuously variable transmission (CVT), the power loss of
the hydraulic oil pump and its oil supply accounts for approximately 40% of the power loss
of the transmission, which also belongs to one of the important sources of the power loss of
the entire CVT. As a result, the question of how to improve the efficiency of the oil pump
and its oil supply dominates an essential role in increasing the power of the entire gearbox
and achieving the energy-saving and emission-reducing effects of the entire vehicle [8,9].
Traditional automatic transmission oil pumps are mechanical pumps which are driven
directly or indirectly by the engine. In pure electric mode, in addition to the necessary cool-
ing and lubrication requirements, high-pressure oil is also required to control the shift for
the design of a hybrid power system with shifting components. Therefore, the traditional
single engine-related mechanical pump oil supply method cannot satisfy the demand for
hybrid products [10,11]. This study designs the oil supply method of mechanical pump
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Energies 2021, 14, 5649 2 of 12

traditional single engine-related mechanical pump oil supply method cannot satisfy the
demand for hybrid products [10,11]. This study designs the oil supply method of mechan-
auxiliary electric pumps. When the pump is directly driven by the engine, the oil pump is
ical pump auxiliary electric pumps. When the pump is directly driven by the engine, the
associated with the input shaft. The proposed method requires a longer oil inlet passage.
oil pump is associated with the input shaft. The proposed method requires a longer oil
It significantly increases the design difficulty of the tank. In the meanwhile, the long oil
inlet passage. It significantly increases the design difficulty of the tank. In the meanwhile,
passage causes a certain degree of pressure to drop. In addition, with a direct connection
the long oil passage causes a certain degree of pressure to drop. In addition, with a direct
to the input shaft, a higher speed produces a higher shear rate, resulting in increased
connection to the input shaft, a higher speed produces a higher shear rate, resulting in
friction and reduced mechanical efficiency. Regarding low-pressure lubricant circuits,
increased friction and reduced mechanical efficiency. Regarding low-pressure lubricant
high-speed and low-pressure vehicles are prone to poor lubrication. When the engine
circuits, high-speed and low-pressure vehicles are prone to poor lubrication. When the
drives the oil pump indirectly, the system is installed flexibly, and the mechanical efficiency
engine drives the oil pump indirectly, the system is installed flexibly, and the mechanical
is higher compared with that of the direct drive solution. However, the mechanism of the
efficiency is higher
intermediate shaftcompared
needs to be with that of the
designed, anddirect drive solution.
the number However,
of components ofthe
themecha-
system
nism
becomeof the intermediate
large, leading to shaft needs in
an increase to the
be designed,
design cost andandthe number of
a decrease components
in the reliabilityofof
the
thesystem becomeAtlarge,
mechanism. leading
present, withtotheandevelopment
increase in the of design
electroniccostcontrol
and a decrease
technology in the
and
reliability of the mechanism. At present, with the development
the miniaturization of motors, an increasing number of motors are used to replaceof electronic control tech-
me-
nology
chanicalandor the miniaturization
hydraulic structures of motors, an increasing
in automobile number of motors
research. Electrification are used
can achieve to
greater
replace mechanical or hydraulic structures in automobile research.
maneuverability, which can save on cost to a certain extent. Based on the development Electrification can
achieve greater electrification,
of automobile maneuverability, andwhich can save
considering onthe
that cost to a certain
engine directlyextent. Based on
or indirectly the
drives
development of automobile electrification, and considering that the
the mechanical pump confronts numerous problems, this study only considers the design engine directly or in-
directly drives the mechanical pump confronts numerous problems,
of electric pumps [12,13]. For the electric pump system, the hydraulic system contains this study only con-
siders the designcooling
a low-pressure of electric pumpsand
oil circuit [12,13]. For the electric
a high-pressure shiftpump
brakesystem, the hydraulic
oil circuit. As shown
system contains a low-pressure cooling oil circuit and a high-pressure
in Figure 1, with this functional requirement, three integration modes of oil shift brake oil cir-
pump and
cuit.
motorAs are
shown in Figure
proposed, 1, with thissingle-motor
respectively: functional requirement,
single-pump, three integrationdual-pump,
single-motor modes of
oil
andpump and motordouble-pump.
double-motor are proposed, respectively: single-motorofsingle-pump,
The power transmission the oil pumpsingle-motor
and motor is
dual-pump,
illustrated in and double-motor
Figure double-pump.
2. By calculating the power The power
loss of thetransmission
three modes,of thethe oil pump
single-motor
and motor is illustrated in Figure 2.
dual-pump integrated mode is determined [14].By calculating the power loss of the three modes, the
single-motor dual-pump integrated mode is determined [14].

(a) (b)

(c)

Figure
Figure1.1.Three
Threeintegration
integrationmodes:
modes:(a)
(a)single-motor
single-motorsingle-pump,
single-pump,(b)
(b)single-motor
single-motordual-pump,
dual-pump, and
and (c) dual-motor dual-pump.
(c) dual-motor dual-pump.
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Figure2.
Figure Schematicdiagram
2.Schematic diagramof
ofthe
thetotal
totalsuccess
successrate
rateof
ofthe
theoil
oil pump.
pump.

Thehydraulic
The hydraulicsystem
system of
ofmass-produced
mass-produced cars
cars in
in the
the world
world includes
includes numerous
numerous modes
modes
such as Prius, Malibu, Lexus, and Trumpchi. The integration modes and the number
such as Prius, Malibu, Lexus, and Trumpchi. The integration modes and the number and and
types of pumps used in the hydraulic system vary from each
types of pumps used in the hydraulic system vary from each other.other.
(1) Hydraulic
(1) Hydraulic system
system in in Prius
Prius hybrid
hybrid system
system
The hybridsystem
The Prius hybrid systemis is based
based on on Toyota’s
Toyota’s hybrid
hybrid technology
technology “THS”“THS”
system,system,
which
is currently
which a mature
is currently hybridhybrid
a mature technology product
technology [15]. The
product [15].hydraulic system
The hydraulic of theof
system Prius
the
gearbox only adopts one mechanical pump, which is driven by the engine shaft
Prius gearbox only adopts one mechanical pump, which is driven by the engine shaft in in order to
achieve
order to the cooling
achieve theand lubrication.
cooling The structure
and lubrication. is simple while
The structure fulfilling
is simple whilethe functional
fulfilling the
requirements
functional in this wayin[16–20].
requirements this way [16–20].
(2)
(2) Hydraulic system
Hydraulic in in
system Malibu hybrid
Malibu system
hybrid system
The
The Malibu hybrid system
Malibu hybrid systemisisbased
basedononGeneral
General Motors’
Motors’ technology,
technology, which
which is dedi-
is dedicated
cated to the research of double-row and three-row planetary gear mechanisms.
to the research of double-row and three-row planetary gear mechanisms. In the oil supply In the oil
supply system, a single electric pump provides pressure and flow for realizing the
system, a single electric pump provides pressure and flow for realizing the electrification electri-
fication ofsupply
of the oil the oil system.
supply system. The oilispump
The oil pump is a gerotor
a gerotor pump [21,22].
pump [21,22].
(3)
(3) Hydraulic
Hydraulic system
systemin in
Lexus
Lexushybrid system
hybrid system
Based
Basedon onthe
theoriginal
original“THS”,
“THS”, the
theGS450h
GS450h hybrid
hybrid transmission
transmission mounted
mounted on
on the
the Lexus
Lexus
LS600h
LS600h isis aa “THS-II”
“THS-II” longitudinal
longitudinal two-stage
two-stage hybrid
hybrid transmission.
transmission. The
The hydraulic
hydraulic system
system
consists
consists of
of aa mechanical
mechanical pump
pump and
and anan electric
electric pump
pump [23].
[23].
(4) Hydraulic system in Trumpchi hybrid system
(4) Hydraulic system in Trumpchi hybrid system
The GAC Mechatronic Coupling hybrid power system equipped with Trumpchi
The GAC Mechatronic Coupling hybrid power system equipped with Trumpchi
GA3S is a set of electromechanical coupling systems with a simple structure but superior
GA3S is a set of electromechanical coupling systems with a simple structure but superior
performance. The hydraulic system is composed of a mechanical pump and an electric
performance. The hydraulic system is composed of a mechanical pump and an electric
pump, and the mechanical pump assists the electric pump for cooling and lubricating [24].
pump, and the mechanical pump assists the electric pump for cooling and lubricating [24].
In the present study, based on a certain type of hybrid transmission, the oil pump is
In the present study, based on a certain type of hybrid transmission, the oil pump is
designed in line with the needs of the hydraulic system, and the influence of the pump on
designed in line with the needs of the hydraulic system, and the influence of the pump on
the oil supply system is further analyzed. Moreover, an experiment platform was built,
the oil supply system is further analyzed. Moreover, an experiment platform was built,
and the design and simulation results were verified.
and the design and simulation results were verified.
2.
2.Design
Designof ofGerotor
GerotorPumpPumpOil OilSupply
SupplySystem
System for for Hybrid
Hybrid Transmission
Transmission
The
The oil pump refers to the power source of the hydraulic system.
oil pump refers to the power source of the hydraulic system. Designing
Designing the the type
type
and structure of the oil pump satisfying the requirements of the
and structure of the oil pump satisfying the requirements of the hybrid transmission is one hybrid transmission is
one
of the of important
the importanttaskstasks
for thefordesign
the design
of theofhybrid
the hybrid transmission
transmission [25]. The [25].gerotor
The gerotor
pump
pump
has the has the advantages
advantages of havingof having few parts,
few parts, a compact
a compact structure,
structure, smallsmall pulsation,
pulsation, and andlow
low noise. Moreover, it has been extensively applied in aerospace,
noise. Moreover, it has been extensively applied in aerospace, aviation, and automobile aviation, and automo-
bile
fields.fields. As shown
As shown in Figure
in Figure 3, the3,base
the circle
base circle with radius
with radius r1 andr1theand the radius
radius circleradius
circle with with
radius
r2 roll rpurely
2 roll purely around
around the base
the base circle.
circle. In addition,
In addition, thethe connectionpoint
connection pointCCon on the circle
circle
isis formed
formed to to construct
construct aa short-circle
short-circle cycloid
cycloid C1C2.
C1C2. The The center
center of of the
the circle
circle andand aa certain
certain
radius
radius RR makemake aa series
series of of circles.
circles. The
The formed
formed innerinner envelope
envelope isis thethe tooth
tooth profile
profile ofof the
the
inner
inner rotor
rotor of
of the
the gerotor
gerotor pump,
pump, and and the
the arc
arc conjugate
conjugate with with the
the inner
inner rotor
rotor is is the
the outer
outer
rotor
rotor arc.
arc. In
Inaagerotor
gerotorpump,
pump,the therotation
rotationcenter
centerof of the
the outer
outer rotor
rotor is is the
the center,
center, andand the
the
circle
circle whose
whose radius
radius refers
refers toto the
the distance
distance (L)(L) between
between the the rotation
rotation center
center of of the
the outer
outer rotor
rotor
and
andthe thearc
arctooth
toothprofile
profilecenter
center of of
thethe
outer rotor
outer is defined
rotor is defined as the
as creation
the creation circle. The ratio
circle. The
ratio
of theofgenerative
the generative
circlecircle
radius L to L
radius to outer
the the outer
rotorrotor
pitch pitch circle
circle radius
radius r2 isr2determined
is determined as
as the
the generative
generative coefficient
coefficient k. The
k. The ratioratio
of theof outer
the outer
rotorrotor
toothtooth
profileprofile arc radius
arc radius R toRthe to
the outer rotor pitch circle radius r2 is described as the arc diameter coefficient h [26]. As
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outer rotor in
presented pitch circle3,radius
Figure r2 is described
the coordinate as the1 yarc
axis S0:xO is diameter
based oncoefficient h [26].OAs
the base circle 1 aspre-
the
coordinate
sented origin;
in Figure thecoordinate
3, the coordinateaxis axisS0:xO
S1:x11O
y 1isybased
1 withon thethe
inner
baserotor
circlerotation center
O1 as the O1
coordi-
as the
nate coordinate
origin; origin; and
the coordinate theS1:x
axis coordinate
1O1y1 with axistheS2:inner
x2 O2rotor
y2 with the outer
rotation rotor
center O1rotation
as the
center O2 as
coordinate the coordinate
origin; origin. Among
and the coordinate them,
axis S2: x2Othe fixedthe
2y2 with point C locates
outer on the abscissa
rotor rotation center
of the S2
O2 as the coordinate system. In the coordinate system, where the outer rotor
origin. Among them, the fixed point C locates on the abscissa of the is the center of
rotation,
S2 the outer
coordinate system.rotor
In tooth profile arcsystem,
the coordinate equation can be
where thewritten as: is the center of ro-
outer rotor
tation, the outer rotor tooth profile arc equation can be written as:
( x − L sin ϕ)2 + (y − L cos ϕ)2 = R2 (1)
(𝑥 − 𝐿 sin 𝜑) + (𝑦 − 𝐿 cos 𝜑) = 𝑅 (1)
According to the coordinate transformation, the inner rotor tooth profile curve equa-
According to the coordinate
tion can be expressed as [27]: transformation, the inner rotor tooth profile curve equa-
tion can be expressed as [27]:

𝑋X==𝐿Lcos(𝜓
cos(ψ2 − −𝜓ψ1 )) −
−R𝑅 cos
cos(𝜓(ψ2 ++θ𝜃−−ψ𝜓 −−e cos
1) ) 𝑒 cosψ1𝜓
(2)
(2)
Y = L sin ( ψ − ψ ) − R sin (
𝑌 = 𝐿 sin(𝜓 2 − 𝜓1 ) − 𝑅 sin(𝜓2 + 𝜃 − 𝜓ψ + θ − ψ ) + e sin
1 ) + 𝑒 sin1𝜓ψ

where, 𝜓
where, andψ𝜓
ψ1 and 2 satisfy: ψ1𝜓= =
satisfy: r2 ·𝑟ψ∙2 /r
𝜓 1/𝑟 𝜃 denotes
; θ ;denotes the angle
the angle between
between the straight
the straight line
line O 2C
Oand the normal
2C and PC of
the normal PCthe
of cycloid; ϴ satisfies:
θ satisfies:
the cycloid; 𝑟 /θsin
r2 / sin = 𝜃L/=sin
𝐿/(sin(
π − 𝜋ψ2−−𝜓θ )−
. 𝜃).

Rotortooth
Figure3.3.Rotor
Figure toothprofile.
profile.

The gerotor pump refers to the positive displacement pump, which pumps oil by
The gerotor pump refers to the positive displacement pump, which pumps oil by
changing the volume of the closed chamber. The instantaneous flow rate is characterized
changing the volume of the closed chamber. The instantaneous flow rate is characterized
by the volume change rate of the cavity, and the differential–integral method is adopted to
by the volume change rate of the cavity, and the differential–integral method is adopted
obtain the instantaneous discharge flow rate:
to obtain the instantaneous discharge flow rate:
𝑑𝑉i ≤ 0
𝑑𝑉 i , dψ
( dV dV
Z
qi = ⎧ dψ2 ,dV 2 ≤ 0 , Qin = ∑ qi (3)
𝑑𝜓0, 𝑑𝜓 i
𝑞 = dψ > 0
2 , 𝑄 = 𝑞
i =1 (3)
⎨ 0, 𝑑𝑉 > 0
⎩ 𝑑𝜓
Based on the mathematical model of the instantaneous flow of cycloidal rotor pump,
the numerical calculation and analysis of the instantaneous flow can be realized by writing
Based on the mathematical model of the instantaneous flow of cycloidal rotor pump,
a script file with open-source software [28,29].
the numerical calculation and analysis of the instantaneous flow can be realized by writ-
NSGA-II is one of the most popular multi-objective genetic algorithms, which lowers
ing
theacomplexity
script file with open-source
of non-inferior software
ranking [28,29].
genetic algorithms. It has the advantages of having
a fast running speed and good solution set convergence.genetic
NSGA-II is one of the most popular multi-objective algorithms,
Moreover, which
it has also lowers
become the
the complexity of non-inferior ranking genetic algorithms. It has the advantages
benchmark for the performance of other multi-objective optimization algorithms. Based on of having
athe
fastNSGA-II
runninggenetic
speed and good solution
algorithm, the rotorset convergence.
tooth Moreover,
design is carried it has
out. The also become
design the
parameters
benchmark for the performance of other multi-objective optimization algorithms.
of the tooth shape include the following four parameters, respectively: the number Z of Based
on the and
inner NSGA-II
outergenetic algorithm,
rotor teeth, the rotor tooth
the eccentricity e, the design is carried
radius of the createdout. circle
The design
L, andpa-
the
rameters of the tooth shape include the following four parameters, respectively:
radius R of the outer rotor arc [30–32]. Considering the range of the teeth of the commonly the num-
ber
usedZ hybrid
of inner and outer rotor
transmission teeth,
gerotor pump,the the
eccentricity
number ofe,teeth
the radius of therotor
of the outer created circle L,
is selected as
Energies 2021, 14, 5649 5 of 12

four sets of data containing 5, 7, 9, and 11. The remaining design parameters are determined
by the final design results. As a result, the design variables are determined as:

X = [ x1 , x2 , x3 ] T = [ L, e, R] T (4)

According to the main principles of compactness and pulsation that should be fol-
lowed in the design of the hybrid transmission oil pump, the design goals of OF1 and
OF2 are proposed in this study. The compactness is characterized by the smallest unit
displacement volume, and the pulsatility is the deviation of the instantaneous flow rate
from the average flow rate:

π · ( L − R + 2e)2 · H
OF1 : min( h i) (5)
πH ( L − R + e)2 − ( L − R−e)2
 Z ψ2 = π 
Z Z
2
OF2 : min Q − Q dψ2 (6)
π ψ2 =0

Constraints on design variables are proposed, aiming to simplify the complexity

of the design process. The optimization results have practical significance. The tooth
shape of the Equation (7) should not have the basic constraints of failure. In addition,
basic boundary conditions include: generative coefficient k value range: 1.1 to 1.8, an arc
diameter coefficient h value ranging from 0.2 to 0.8, and an eccentricity value ranging from:
1.5 to 3. The radius of the outer rotor tooth root circle is required to be greater than the
radius of the creation circle. Moreover, all design variables should be positive real numbers.
s
27( Z − 1)( L2 − e2 Z2 2 )
R< (7)
( Z + 1)3

The optimization calculation program of NSGA-II algorithm is written via MATLAB.

The initial population is designed to be 100. After several iteration calculations, it can be
found that the population of 100 individuals remains basically stable after 300 iterations.
Figure 4 displays the Pareto optimal solution when the number of teeth of the outer rotor
is 5, 7, 9, and 11 teeth. Obviously, the pulsation performance is more superior with an
increasing number of rotor teeth, while the compactness is more superior when the number
of teeth decreases. Based on the selection of a hybrid vehicle with small pulsation and
compact pumps, and the functional requirement that the pulsation performance weight is
greater than the compact weight, a rotor pair with an outer rotor of nine teeth is selected in
this study. The specific parameters include the number of teeth of the outer rotor (nine),
the number of teeth of the inner rotor (eight), the eccentricity (e: 1.8 mm), the radius of the
created circle (L: 19.5 mm), and the radius of the outer rotor arc (R: 3.8 mm). According to
the designed parameters, a curve is drawn in Creo, as shown in Figure 5. Then, a complete
gerotor pump drainage basin was formed through 3D modeling software [33,34]. At the
same time, the pressure cloud diagram was obtained based on the CFD simulation software
of professional motion machinery, as presented in Figure 6. The outlet pressure pulsation
curve is illustrated in Figure 7. The analysis illustrates that the pulsation rate is 0.9%.
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Figure4.
Figure 4. Pareto
Pareto optimal
optimal solution.
solution.
Figure
Figure 4.4.Pareto
Paretooptimal
optimalsolution.
solution.

Figure 5. Rotor tooth profile.

Figure Rotortooth
Figure5.5.Rotor
Rotor toothprofile.
tooth profile.

Figure 6. Pressure cloud diagram.

Figure 6. Pressure cloud diagram.
Figure6.6.Pressure
Figure Pressurecloud
clouddiagram.
diagram.
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Figure
Figure
Figure7. Pressure
7.7.Pressure pulsation.
Pressurepulsation.
pulsation.

Based on
Based on the known
known rotor tooth
tooth shape, the
the oil supply
supply pump that
that satisfies the
the flow
Based onthethe knownrotorrotor toothshape,
shape, theoil oil supplypump
pump thatsatisfies
satisfies theflow
flow
requirements and working conditions can be calculated. The prototype presented in
requirements
requirementsandandworking
workingconditions
conditionscan
canbebecalculated.
calculated.The
Theprototype
prototypepresented
presentedininFig-
Fig-
Figure 8 is made and tested for displacement, efficiency, starting performance and so on.
ure
ure88isismade
madeandandtested
testedfor
fordisplacement,
displacement,efficiency,
efficiency,starting
startingperformance
performanceandandsosoon.on.
Moreover, the rationality of the design is verified.
Moreover,
Moreover,thetherationality
rationalityofofthe
thedesign
designisisverified.
verified.

Figure
Figure8.
Figure 8.8.Prototype
Prototypefor
Prototype fortesting.
for testing.
testing.

3.3.Influence
InfluenceofofGerotor
Influence GerotorPump PumpParameters
Parameterson onOil OilSupply
SupplySystem System
The traditional automatic transmission oil pump is generallyaaquantitative
The traditional
traditional automatic
automatic transmission
transmission oil
oil pump is generally quantitativepump pump
which is driven directly or indirectly
which is driven directly or indirectly by the engine.The by the engine. The
The flow output ofthe
flow output of theoiloilpump
pumpisis
associated
associated
associatedwithwith the
withthe engine
theengine speed.
enginespeed. speed.In In order
Inorder
orderto totosatisfy
satisfy
satisfythethe pressure
thepressure
pressureand and flow
andflow requirements,
flowrequirements,
requirements,
the
thedisplacement
displacementdesign designofofthe theoiloilpump
pumpisisalso alsodetermined
determinedby bythe
theminimum
minimumspeed speedofofthe the
engine.
engine. During
engine.During normal
Duringnormal driving,
normaldriving,
driving,the the working
theworking
workingrange range
rangeof of the
ofthe engine
theengine speed
speedisisoften
enginespeed oftengreater
greater
than
thanthetheminimum
minimumspeed. Therefore,
speed.Therefore,
Therefore,the the supply
thesupply
supplyofofhydraulic
hydraulicpump pumpflow flowisisoften
oftengreater
greater
than
than the
thanthe demand
thedemand
demandflow, flow, as illustrated
flow,asasillustrated in Figure
illustratedininFigure 9.
Figure9.9.The The excess
Theexcess flow
excessflow generates
flowgenerates overflow
generatesoverflow
overflowloss,loss,
loss,
also
also causing
alsocausing
causingthe the entire
theentire transmission
entiretransmission to
transmissiontotodrive drive
drivethe the decrease
thedecrease in efficiency.
decreaseininefficiency.
efficiency.As As a result,
Asaaresult, only
result,only
only
improving
improving
improvingthe the efficiency
theefficiency
efficiencyof ofofthe
the oil
theoil pump
oilpump
pumpto totocontrol
control
controlthe theoutput
the outputflow
output flowof
flow ofofthe
theoil
the oilpump
oil pumpis
pump isisnot
not
not
enough
enough
enoughto totodecrease
decrease
decreasethe the power
thepower
powerloss loss ofofthe
lossof the oil
theoil supply
oilsupply system.
supplysystem.system.The The self-adaptive
Theself-adaptive performance
self-adaptiveperformance
performance
ofofthe
of the oil
theoil pump
oilpump refers
pumprefersreferstototothe
the control
thecontrol
controlof ofofthe
the oil
theoil pump
oilpump through
pumpthrough timely
throughtimely output
timelyoutput feedback
outputfeedback under
feedbackunder under
different
different working
differentworking conditions,
workingconditions,
conditions,whichwhich is of great
whichisisofofgreat importance
greatimportance
importancefor for the entire
forthe
theentireoil supply
entireoiloilsupply system.
supplysys- sys-
tem.Although the gerotor pump has good speed characteristics, high volumetric efficiency,
tem.
and aAlthough
simple structure,
Although the
thegerotor it still
gerotor has ahas
pump
pump large
hasgoodpressure
good speed
speed pulsation. Proportional
characteristics,
characteristics, high Integral
highvolumetric
volumetric Deriva-
effi-
effi-
tive
ciency,(PID)
ciency,and is an
andaasimple abbreviation
simplestructure, for
structure,ititstillproportional
stillhas
hasaalarge integral
largepressure differential
pressurepulsation. control,
pulsation.Proportional which
ProportionalIntegralrefers
Integral
toDerivative
a commonly
Derivative (PID)
(PID)used
isisancontrol
an algorithm.
abbreviation
abbreviation for The P in PIDintegral
forproportional
proportional control
integralis a proportional
differential
differential control,link.
control, The
which
which
proportional control is actually an adjustable gain amplifier. The proportional control can
Energies 2021, 14, x FOR PEER REVIEW 8 of 12
Energies 2021, 14, x FOR PEER REVIEW 8 of 12
Energies 2021, 14, 5649 8 of 12

refers to a commonly used control algorithm. The P in PID control is a proportional link.
refers
The to a commonly
proportional control used control an
is actually algorithm.
adjustable The gain P in PID control
amplifier. Theis a proportional
proportional link.
control
The
can proportional
reduce the size control is actually an adjustable gain amplifier. The proportional control
reduce the size of theoferror
the errorbut cannotbut cannot
eliminate eliminate the steady-state
the steady-state error. The error.
letterThe letter I
I indicates
can reduce
indicates the the size of the
integration link. error
The but of
use cannot
the eliminate link
integration the steady-state
can eliminate error.
the The letter I
steady-state
the integration link. The use of the integration link can eliminate the steady-state error, but
indicates
error, but the integration
increases the link. The
system use of the
overshoot and integration
even cause linkthe cansystem
eliminate the steady-state
toDoscillate. D is a
increases the system overshoot and even cause the system to oscillate. is a differential
link, which is also known as an inertial link. The output through the inertial link has aDtime
error, but
differential increases
link, which the is system
also overshoot
known as an and even
inertial cause
link. The the system
output to
through oscillate.
the inertialis a
differential
link
delayhasanda time link,
cannot which
delay is
and cannot
be changed also known as
be changed
in time an
with the in inertial
timeIn
input. link.
with The output
the input.
addition, through
it canInreduce the
addition, inertial
it can
overshoot,
eliminate system oscillation, and improve system stability. The construction of theitcon-
link
reduce has a time
overshoot, delay and
eliminate cannot
system be changed
oscillation, inand time with
improve the input.
system In addition,
stability. The can
pro-
reduce overshoot,
struction
portional oflinkthemodule eliminate
proportional
is employed system
link tooscillation,
module is employed
achieve errorandcontrol
improve [35].system
to achieve error
The stability.
control
inertial link The
[35].
modulecon-
The
struction
inertial link of the
module proportional
is built to link
controlmodule
the is
sudden employed change
is built to control the sudden change of error, and the output signal is delayed in time, to achieve
of error, error
and thecontrol
output [35]. The
signal
inertial
isthereby
delayed link in module
time, is
thereby built to control
decreasing the
the sudden
system change
adjustment
decreasing the system adjustment time. The oil pump speed control module shown of error,
time. and
The the
oil output
pump signal
speed
is delayed
control
in Figure 10inhas
module time,
shown
been thereby
in Figure
developed decreasing
10
to has the the
been
realize system
developed
stabilityadjustment
to oil
of realizetime.
supply. theThe oil
stability
The pump
controlof oil speed
sup-
module
control
ply. The module
includes control
a low-pressure shown inincludes
module Figure
flow 10 has been
a low-pressure
feedback control, developed
aflow to realize
feedback
high-pressure the stability
control,
load offeedback
oil sup-
a high-pressure
pressure
ply. pressure
load Theand
control, control an module
feedback
oil pump includes
control,
torque and aanlow-pressure
feedbackoil pumpcontrol. flow
torque Thefeedback
feedback
maximum control,
control.
working aThehigh-pressure
maximum
pressure of
load
working pressure
pressure feedback
of the control,
hydraulic and an
system oil pump
investigated torque
the hydraulic system investigated in the current work is 17 bar, and the demand flow of in feedback
the current control.
work The
is 17maximum
bar, and
working
the
the demand pressure
high-pressure flow ofoil ofthethe
circuithydraulic
high-pressure
is 7 L/min.system investigated
oilBesides,
circuit isthe 7 L/min.in the
demand current
Besides,
flow ofthework
the demandis 17 bar,
low-pressure flowand of
oil
the
the demand
low-pressure
circuit flow
is not lessoil of the
circuit
than high-pressure
14 L/min.is not less oil circuit
than 14 L/min.
Considering is
the pump 7 L/min.
Considering Besides,
displacement,the pumpthe demand
flowdisplacement, flow
demand, and of
the low-pressure
flow
pump demand,
volumetric andoil circuit
pump
efficiency, isthe
not
volumetric lessefficiency,
analysis than 14 L/min.
demonstrates Considering
the analysisthat, when the pump
demonstrates
the pumpthat, displacement,
speed when the
is about
flow r/min,
pump
1800 demand,
speed the and
is about pump
maximum volumetric
1800 r/min,demand theflow efficiency,
maximum the analysis
demand
of the hydraulic flow
system demonstrates
of can
the hydraulic that,
be satisfied. when
system
The can
giventhe
bepump speedThe
satisfied. is
ofabout
given1800
signal input
pump r/min,
isspeedther/min,
1800 maximum
of signal while demand
input theismaximum
1800flowr/min,
of the
speedhydraulic
while is limitedsystem
the maximum to 3500can
be satisfied.
r/min.
speed is The
limited Thetogiven
control model
3500 pump
r/min. speed
is equipped
The of
with
control signal
the input
model entire is 1800 r/min,
hydraulic
is equipped system
with while
the the hydraulic
simulation
entire maximummodel
speed is
simulate limited
and to 3500
control ther/min.
pump The
speedcontrol
in themodel
system simulation model to simulate and control the pump speed in the entire drivethe
to entire is equipped
drive cycle with
in the
order toentire
achievehydraulic
cycleoil
system
insupply simulation
order target
to achieve of the model
theoiloil
supplyto simulate
supply system
target and of control
[36]. the oil supplythe pump speed
system in the entire drive cycle
[36].
in order to achieve the oil supply target of the oil supply system [36].

Figure
Figure9.9.Diagram
Diagramofofoil
oilpump
pumpflow
flowrequires
requiresand
andsupply.
supply.
Figure 9. Diagram of oil pump flow requires and supply.

Figure 10. Speed control module: low_con is the control of flow; pres_con is the control of pres-
sure;
Figure 10. Speediscontrol
torque_con the control of torque
module: andisPum_speed_con
low_con flow; pres_con
is the
the control of flow; is
controlis
pres_con the
ofthe control
pump of pressure;
speed.
control of pres-
sure; torque_con
torque_con is the is the control
control of torque
of torque and Pum_speed_con
and Pum_speed_con is the is the control
control of pumpof pump
speed.speed.
Energies 2021, 14, 5649 9 of 12
Energies2021,
Energies
Energies 2021,14,
2021, 14,x
14, x xFOR
FORPEER
FOR PEERREVIEW
PEER REVIEW
REVIEW 9 9of
9 ofof12
1212

Figure
Figure11
Figure 11
11 presents
11presents
presentsthe
presents the
thecontrolling
the controllingspeed
controlling speed
speedof
speed ofofthe
of theoil
the oilpump.
oil pump.The
pump. TheThespeedspeedis
speed isisdynamically
dynamically
dynamically
Figure controlling the oil pump. The speed is dynamically
adjusted
adjusted according
according
adjusted according
according to totothe
to thethe output
output
the output feedback.
feedback.
output feedback. Simultaneously,
Simultaneously,
feedback. Simultaneously,
Simultaneously, it it is
it
it is limited
is limited
is limited
limited to to tothe
to the the speed range
speedrange
the speed
speed range
range
adjusted
required
requiredby by the
bythe pump.
thepump.
pump.When When parking,
Whenparking,
parking,the the signal
thesignal
signalcancan
canbebe received in time to reduce
reducethe
required
required by the pump. When parking, the signal can bebereceived
receivedin
received inintimetimeto
time totoreduce
reduce the
the
the
speed.
speed.
speed. Figure
Figure
Figure 12
1212 illustrates
illustrates
illustrates aaacomparison
comparison
comparison of
ofofthe
thethe simulation
simulation
simulation results
results
results of
of ofthe
the
the cooling
cooling
cooling oil
oil
oil flow
flow
flow
speed. Figure 12 illustrates a comparison of the simulation results of the cooling oil flow
without adding
withoutadding
without addingthe the speed
thespeed module
speedmodulemoduleand and
andthe the
thesimulation
simulationresults
simulation resultsafter
results afteradding
after addingthe
adding thecontrol
the control
control
without adding the speed module and the simulation results after adding the control
module.
module. Through
module. ThroughThrough
Through the the comparison,
the comparison,
the comparison,
comparison, it it is
it
it isfound
is
is foundfoundthat
found that there
that are
there
that there
there are aarewide
are aa wide a range
wide
wide range of
range
range of conditions
of that
conditions
of conditions
conditions
module.
do not
that
that do domeet
do not not the
meet
not meet flow
meet the therequirements
the flow flow
flow requirements before
requirements
requirements before the control.
before
before the the After
control.
the control. the
control. After addition
After
After the the of control
addition
the addition
addition of module,
of control
of control
control
that
the flow requirements
module,
module, the
the flow
flow can be basically
requirements
requirements can
can bebemet during
basically
basically mettheduring
met entire
during drive
thethe cycle.drive
entire
entire At the
drive sameAt
cycle.
cycle. time,
At the
the
module, the flow requirements can be basically met during the entire drive cycle. At the
the flow
same supply
time, the can
flow be quickly
supply reduced
can be during
quickly parking
reduced in order
during to avoid
parking waste.
in order Figure
to 13
avoid
same time, the flow supply can be quickly reduced
same time, the flow supply can be quickly reduced during parking in order to avoid during parking in order to avoid
displays a simulation
waste.Figure
Figure result aofsimulation
the main oilresult circuit pressure
mainbefore and after control, as well
waste.
waste. Figure 1313displays
13 displays
displays aa simulation
simulation result result of ofofthe
themain
the main oil
oiloilcircuit
circuit
circuit pressure
pressure
pressure before
before
before and
and
and
asafter
a comparison
control, as of the
well theoretical
as a comparisonpressure. of The
the simulation
theoretical proves
pressure. that
The the error
simulation between
proves
after control,
after control, as as well
well as as a comparison
comparison of of the
the theoretical
theoretical pressure.
pressure. The The simulation
simulation proves proves
the main
that pressure
theerror
errorbetweenand thea the
between theoretical
mainpressurepressure
pressure after the
and control is smaller.
theoretical Based on
pressure the control
after analysisis
that
that the
the error between the main
the main pressure and
and the theoretical
the theoretical pressure
pressure after
after control is
control is
ofsmaller.
the above simulation
Based on the results,
analysis the
of PD
the control
above of the oil pump
simulation results, speed the can
PD effectively
control ofreduce
the oil
smaller.
smaller. Based on
Basederror
on thethe analysis
analysis of the above
of thesystem, simulation
above simulation results,
results, the PD control
the PDconditions, of
control ofsuch the oil
the oil
the functional
pump speed can of the
effectively oil reduce
supply the especially
functional error under
of the extreme
oil supply system, especiallyas
pump
pump speed can effectively
speed can effectively reduce
reduce the the functional
functional error of the
error of the oil oil supply system, especially
low temperature and low pressure conditions. Additionally, thesupply system, especially
characteristics of the oil
underextreme
under
under extremeconditions,
extreme conditions,such
conditions, suchas
such asaslowlowtemperature
low temperatureand
temperature andlow
and lowlowpressure
pressureconditions.
pressure conditions.Addi-
conditions. Addi-
Addi-
pump are greatly affected by the environment. Moreover, the dynamic control of oil pump
tionally,
tionally, the
tionally, the characteristics
the characteristics
characteristics of of the
of the
the oil oil pump
oil pump
pump are are greatly
are greatly affected
greatly affected
affected by by
by the the environment.
the environment.
environment. More- More-
More-
speed is of great engineering significance.
over,the
over,
over, thedynamic
the dynamiccontrol
dynamic controlof
control ofofoil
oilpump
oil pumpspeed
pump speedis
speed isisof
ofofgreat
greatengineering
great engineeringsignificance.
engineering significance.
significance.

Figure11.
Figure
Figure 11.Oil
11. Oilpump
Oil
Oil pumpcontrol
pump
pump controlspeed.
control
control speed.
speed.

Figure12.
Figure
Figure 12.Comparison
12. Comparisonof
Comparison
Comparison ofofcooling
coolingand
cooling andlubrication
and lubricationflow
lubrication flowbefore
flow beforeand
before andafter
aftercontrol.
control.

Figure13.
Figure 13.Comparison
Comparisonofofmain
mainoiloilpressure
pressurebefore
beforeand
andafter
aftercontrol.
control.
Figure
Figure 13.
13. Comparison of main
Comparison of oil pressure
main oil pressure before and
before and after
after control.
control.

Anexperiment
An
An experimentplatform
experiment
experiment platformwas
platform
platform was
was built
built
wasbuilt
built according
according totothe
according
according to tothe
the design
design
the ofofthe
design
design of thegerotor
the
of gerotor
gerotor
the pump.
pump.
gerotor
pump. Dis-
Dis-
pump.
Dis-
placementis
placement isisregarded
Displacement
placement regarded
regarded asasthe
is regarded
as the
the important
important
asimportant
the datato
data
important
data tocheck
to check
check
data totodetermine
to check
to determine
determine whether
whether
to determine thehydraulic
the
whether
whether the hydraulic
hydraulic
the hy-
Energies 2021, 14, 5649 10 of 12

draulic pump is qualified. The evaluation standard refers to that when the temperature is
40 ◦ C ± 3 ◦ C and the deviation between the theoretical flow and the design flow cannot
exceed 5%. Table 1 presents the high-pressure pump displacement test data, and Table 2
indicates the low-pressure pump displacement test data.

Table 1. High-pressure pump displacement test data.

Test Conditions Pressure: 0 Bar Theoretical Displacement: 4 mL/r

Oil Pump Rotating Speed Flow Calculated Displacement Deviation
Number (r/min) (L/min) (mL/min) (%)
1000 3.85 3.85 3.75%
1#
1500 5.8 3.87 3.25%
1000 3.84 3.84 4%
2#
1500 5.8 3.87 3.25%

Table 2. Low-pressure pump displacement test data.

Test Conditions Pressure: 0 Bar Theoretical Displacement: 8 mL/r

Oil Pump Rotating Speed Flow Calculated Displacement Deviation
Number (r/min) (L/min) (mL/min) (%)
1000 7.9 7.90 1.25%
1#
1500 11.8 7.87 1.63%
1000 7.9 7.90 1.25%
2#
1500 11.8 7.87 1.63%

According to the test of the high- and low-pressure prototype pumps, respectively,
the deviation between the calculated displacement value and the theoretical displacement
value meets the requirements. As a result, the designed oil pump can satisfy the functional
requirements of a hybrid transmission.

4. Conclusions
(1) A gerotor pump was designed. The tooth profile was analyzed and designed in line
with the requirements of the hydraulic system for hybrid transmission;
(2) NSGA-II algorithm was employed to optimize the design of tooth profile parameters
according to the mathematical model of instantaneous flow. The parameters of the
gerotor pump can be determined;
(3) Based on the AMESim platform, a PD control strategy was employed to develop the
oil pump speed control model of the oil supply system. In addition, the influence
of the designed gerotor pump on the performance of the oil supply system was
simulated;
(4) Prototypes were made, an oil pump test platform was built, and oil pump unit tests
were conducted to confirm the rationality of the oil pump design and simulation
reliability. Besides, the designed oil pump can meet the functional requirements of a
hybrid transmission.

Author Contributions: Conceptualization, M.H. and F.Z.; methodology, M.H.; validation, C.S. and
Y.Z.; resources, M.H. and F.Z.; writing—original draft, C.S. and J.Z.; writing—review and editing, F.Z.
All authors have read and agreed to the published version of the manuscript.
Funding: This research was supported by A Priority Academic Program Development of Jiangsu
Higher Education Institutions (PAPD); Engineering Research Center for Harmless Treatment and
Resource Utilization of Aluminum Ash and Slag Solid Waste in Jiangsu Province; The Basic Scientific
Research Project of Nantong City (grant number: JC2021200).
Institutional Review Board Statement: Not applicable.
Energies 2021, 14, 5649 11 of 12

Informed Consent Statement: Not applicable.

Data Availability Statement: Not applicable.
Acknowledgments: Sincere thanks go to anonymous reviewers for their valuable comments and
great suggestions to improve this article. Thanks to Corun Hybrid Technology Co., Ltd. for providing
the experimental conditions and simulation platform.
Conflicts of Interest: The authors declare no conflict of interest.

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