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G. Armenio
Pierburg SpA
Copyright 2004 SAE International
ABSTRACT ring and the pump cover. Vanes are exposed at their roots
to delivery pressure via a narrow duct manufactured in the
The paper presents geometric, kinematic and fluid-dynamic case and are held in place by an inner ring to avoid possi-
modelling of variable displacement vane pumps for low ble stitching especially in cold start operating conditions.
pressure applications in internal combustion engines lubri-
cation. All these fundamental aspects are integrated in a
simulation environment and form the core of a design tool
leading to the assessment of performance, critical issues,
related influences and possible solutions in a well
grounded engineering support to decision.
INTRODUCTION
1
K = 2 + 5U = 2 & + UY 5U (5)
VECTOR RAY
r = 2 & + U Y + 2 &U Y FRV d (1)
H +r 5
y = DFRV ----------------------------V- (2) Figure 4: control volume
Hr
In consequence of an infinitesimal shaft rotation dj, con-
tact points move in A and, respectively, in B while vector
rays rotate of an angle dy.
A volume variation dVi,j is observed in the control volume
that can be written as follows:
G9 L, M = --- +r M + Gy M + --- +r M Gy M (6)
being H the axial depth (vane thickness).
The variation in length that vector rays undergo as conse-
quence of this rotation is an infinitesimal of higher order
and can therefore be neglected. Let us consider the contact
point A as being integral with the vane; after rotation it
moves to A that does not coincide with the actual contact
point A (Fig. 5). An analogous reasoning is valid for point
B. For this reason the vane volume contained in the control
volume is varied due to rotation: to the right a portion
Figure 3: vector ray (referred to with 1 in Fig. 5) seen from the angle
Gg M = Gy M Gj leaves, while at left a portion seen from
the length of the CO segment and the angle d can be
angle Gg M + = Gy M + Gj enters. An additional variation
obtained solving the OOC triangle:
stems from the fact that vanes height is changed by the
quantity dh; more specifically, if the vane moves inward
2 & = H + ( 5 V U Y ) + H ( 5 V U Y ) FRV ( j + d ) (3) towards the centre of the rotor (negative dh) a portion of its
volume referenced as 2 in Fig. 5 leaves the control volume.
H VLQ j The angular extension g of the vane portion of height dh
d = DVLQ --------------- (4)
5 V U Y
varies of dg as consequence of the rotation dj, however,
Vane lift can be expressed as: this variation appears as a higher order infinitesimal and is
therefore neglected.
2
It is then possible to express the vane volume variation CHAMBER VOLUME
where: H VLQ j
9 M = --- + [ H FRV j VLQ j + 5 V DVLQ -------------- +
5V
H VLQ j
H ( 5 V U Y ) ( H FRV j + % ) VLQ j + DWDQ --------------
(16)
j + Dj
dK %
= ------------------------------------------------------------------------------------------------------------------------------------ (10) + H VLQ j 5V ( H VLQ j ) + --- + ( 5 V 5 U )Dj
dj j
H VLQ j
% H ( 5 V U Y ) FRV j + DWDQ -------------- + H + ( 5 V U Y )
% To a reasonable accuracy, the volume occupied by half a
vane can be evaluated as sum of the trapeze and circular
with sector hatched in Fig. 7:
% = ( 5 V U Y ) H VLQ j (11) E E d PD[
9 Y, M = ( K M U Y ) -----Y + U Y FRV d PD[ -----Y + U Y ---------- + (17)
With reference to Fig. 5 angles g are so written:
The volume of the j-th chamber (delimited by vanes j and
Dg j+1) becomes:
gM = ------ + [ j + ( M )Dj y M ]
(12)
Dg 9 M = 9 M 9 Y, M 9 Y, M + (18)
g'' M = ------ [ j + ( M )Dj y M ]
FLOW PASSAGE AREAS
with
EY To evaluate flow passage areas towards delivery consider
Dg = DVLQ -------- (13) chamber 1 delimited by vanes 1 and 2 (Fig. 8); on a prelim-
5 U
inary basis we define the following rotor angular positions
3
Figure 7: volume occupied by half a vane
4
The centrifugal force acting on a vane of mass mY is:
O
) FY, M = P Y w K M + 5 U ---Y
(25)
Figure 10: forces acting on the ring The centrifugal force acting on the mass of oil in each
chamber is:
) FR, M = r9 R, M w U *, M (27)
The exchanged force will be perpendicular to segment LM, The pump model accounts for the following leakage flows
will be applied at the mid point of LM with modulus towards chambers (Fig. 12):
1. between a chamber and the adjacent ones due to the
) S, M = / M S M + where pM is the chamber pressure. In addition
clearance between the vane tip and the stator ring
since the internal ring profile is a circle, the line of action (QI)
must go through O.
2. between a chamber and the adjacent ones due to the
The angle xM with the x-axis is: axial clearance hDY between the vane and the pump
case (QI)
[M + [M
x M = -------------------
- + Dp (22) 3. between chambers and vane roots due to axial clear-
\M \M +
ance hDU between rotor and pump case (QI)
where a is so expressed: 4. between chambers and volumes underneath vane
roots due to the clearance hYU between vanes and slots
LI \M \M + $1' [M + [M
in the rotor (QI)
D = LI \M + < \M (23) The leakage flow at the tip of the j-th vane is evaluated
LI \M \M + $1' [M + < [M through a flow equation in a laminar passage with variable
height:
Components of force FS along x and y are:
+ , YV ( SM SM )
4 I, M = ---- --------
- ------------------------- (30)
1 1 , m
) S, [ = ) S, M FRV ( xM ) ) S, \ = ) S, M VLQ ( xM ) (24)
where I and I are written as integrals of the reciprocal of
M= M=
respectively the second and third power of the gaps height
5
K M K DY
4 I, M = ---------------- ( S M S M ) (34)
mE Y
E I K DU
4 I, M = ------------------ ( S L S M ) (35)
mE URW
where E I 5 U Dj .
Flow going in the j-th chamber from the volume inside the
rotor through the clearance hYU between the vane and the
slot is:
E I K YU
4 I, M = ------------------ ( S SM ) (36)
mE URW L
Figure 12: leakage flows into chambers
where E I + .
(Fig. 13). Both definite integrals are taken with limit values
-a and a sufficiently far from the minimum height point hPLQ: The net flow into the chamber due to leakage contributions
is:
D D
4 I, M = 4 I, M + 4 I, M + 4 I, M + 4 I, M + 4 I, M + 4 I, M (37)
, = ------------- G[ , = K------------
- G[
(31)
K([ ) ([)
D D
SIMULATION
while vV is the sliding velocity of the vane tip on the internal
ring profile and m is dynamic viscosity. In Fig. 14 the simulation model in AMESim environment
The variation of gaps height with position x is: is shown; it is constituted by the following components [3]:
a fixed restrictor OR000-2: associated with the inlet
duct;
K ( [ ) = K PLQ + 5 V [ 5 V ( U Y [ U Y ) (32)
the supercomponent SVANE: simulates the pump core;
The vane tip clearance hPLQ is evaluated applying the equi- a variable restrictor VOR00: load;
surface areas BAP11 and BAP12: supply the force on
librium equation of the j-th vane:
the ring due to the pilot and delivery pressure
P Y \ + F\ ) FY + ( S M E Y + S M E Y S L E Y )+ = (33) spring BAP55; force on the ring due to the spring
fixed capacities BHC11: associated with the pilot and
Flow through clearance hDY at the j-th vane side is: spring chambers
laminar restrictors MLA51-1 and MLA51-2: simulate
the leakage flows from the delivery volume to the
spring chamber through the clearance between the
ring and the casing
laminar restrictor MLA51-3: simulates the leakage flow
from pilot chamber to the inlet volume through the
clearance between the ring and the casing
pump parameters PA510: supplies the main geometric
parameters to the components requiring them
PX53: supplies the shaft speed and the load
In Fig. 15 the structure of the supercomponent SVANE is
shown: the following components are identified:
fixed capacities HC00-3 and HC00-1: associated
respectively with the inlet and delivery volume
variable multiple restrictors (VOR52): evaluate the flow
rates to/from each chamber through the passage areas
AC100: calculates the passage areas with respect to
the shaft angular position and the ring eccentricity
variable volume chambers (VO59): associated with the
N chambers;
Figure 13: gap geometry at vane tip VC101: calculates the volumes and the volume deriva-
6
state and dynamic operating conditions. Fig. 16 and Fig. 17
show the prototype with the locations of pressure and dis-
placement transducers: delivery and pilot pressures are
monitored by piezoresistive Kistler 4045-A20 units with 20
bar end-of-scale reading, the inlet pressure is measured
with a similar Kistler 4045-A5 module with 5 bar end-of-
scale. The stator ring position is detected by an inductive
HBM W20 displacement transducer. Flow rate was mea-
sured with a volumetric HELIX flowmeter featuring a mea-
suring range of 0,5-190 L/min. with an accuracy of 0,5%.
Tests were performed @40 C with HYDROBAK 10 (ISO
VG10) oil. Data acquisition in dynamic conditions was per-
formed with a NI DAQCard-6062E (12 bit resolution and
500 ksample/s rate), interfaced with a LabVIEW software
program.
Figure 14: the simulation model
inlet
tives of each chamber with respect to the shaft angular pressure
position and the ring eccentricity: it also evaluates the
absorbed torque and the internal forces on the ring
a fixed capacity HC00-2: associated with the volume
below the vanes: the volume is connected with the
delivery volume through a fixed restrictor OR00-1
vanes VAN53: simulate the leakage flow through the
vanes
laminar restrictor MEA105: simulates the leakage flow
between the volume below the vanes and the inlet vol-
ume through the rotor-casing axial clearance delivery
annular orifice BAF13-1: evaluates the leakage flow pressure
through the shaft-sleeve clearance
stator STA54: calculates the position of the ring
pilot
pressure
ring
displacement
7
80
70
60
flow rate [L/min]
50
40
30
2000 rpm
20 3000 rpm
4000 rpm
10
0
0 1 2 3 4 5 6 7
pilot pressure [bar]
Figure 20: internal pressure distribution
Figure 18: flow rate - pressure characteristics
80
12 16
experimental simulated
70
10 14
60
delivery pressure [bar]
pilot pressure [bar]
8 12
flow rate [L/min]
50
6 10 40
4 8 30
20 displacement 50%
2 6
displacement 75%
10 displacement 100%
0 4
0 60 120 180 240 300 360 0
angular position [deg] 0 1000 2000 3000 4000 5000 6000
0.9
incomplete filling index
pressure [bar]
Figure 22: incomplete filling index
5
to delivery
trapped
to inlet
ten degrees and, therefore, the component of force Fi along
the x-axis can become comparable with the spring preload. 3
50 1
45
-1 0 20 40 60 80 100
angular position [deg]
40
Figure 25: pressure in the trapped volume
35 simulated
experimental
)
S = ------------------------------------------------
- (39)
30 ( E E G + 5 V VLQ z )+
[]
9
flow may be inadequate in fulfilling lubrication circuit vV sliding velocity tip vane - ring
demand owing to excessive displacement reduction. V volume
As already evidenced in previous studies [2], it is physically
impossible to significantly improve pump filling. A viable greek letters
compromise solution is to change the direct acting dis- dj infinitesimal rotation of the rotor
placement control with a piloted one. In this circumstance
the validated mathematical model is a very effective and
Dj angular pitch
powerful tool for dimensioning, predicting and comparing g angular extension of a vane portion
new possible solutions in terms of their individual perfor- d angular position of the contact point on the vane tip
mance. z angle bound to extent of incomplete filling
m dynamic viscosity
NOMENCLATURE x phase of the force FS
AL internal surface of influence r vector ray modulus
b witdh of the ring prismatic protusion spring side j rotor angular position
b witdh of the ring prismatic protusion pilot side
y vector ray phase
w angural velocity of the rotor
bG see Fig. 10
bURW see Fig. 12 ACKNOWLEDGMENT
bVWDW radial thickness of the stator
bY thickness of the vane The present work has been performed under a research
c viscous friction coefficient contract with Pierburg SpA. Authors acknowledge permis-
e eccentricity sion of publishing the present material.
e maximum eccentricity
CONTACT
e* eccentricity for complete filling achievement
FFY centrifugal force on the vane N. Nervegna: nicola.nervegna@polito.it
FFR centrifugal force on the oil within chambers S. Manc: salvatore.manco@polito.it
FL internal force M. Rundo: massimo.rundo@polito.it
FS force due the chambers pressures Web address: www.polito.it/fluidpower
h vane lift REFERENCES
hDY axial crearance between vane and pump case
hDU axial crearance between rotor and pump case 1. Fabiani, M., Manc, S., Nervegna, N., Rundo, M.: "Modelling
hYU clearance between vane and slot in the rotor and Simulation of Gerotor Gearing in Lubricating Oil Pumps",
SAE paper 1999-01-0626; 1999 SAE International Congress
H vane thickness and Exposition, Detroit, March 1-4, 1999. SAE Transactions,
k spring stiffness Journal of Engines, 1999.
lY lenght of the vane
L distance between two consecutives contact points 2. Manc, S., Nervegna, N., Rundo, M.: Effects of timing and
mV mass of the stator odd/even number of teeth on noise generation of gerotor
lubricating pumps for IC engines. SAE paper 2000-01-2630,
mY mass of the vane also in SAE Special Publication, Topics in Hydraulics (SP-
p pressure for initial displacement reduction 1554) ISBN 0-7680-0649-X; 2000 SAE International Off-
p* pressure for effective displacement reduction Highway & Powerplant Congress and Exposition, Milwaukee,
p pressure in the chamber of the spring WI, USA, September 11-13, 2000. SAE Transactions 2000 -
Journal of Commercial Vehicles ISBN: 0-7680-0841-7
p pressure in the pilot chamber
pG delivery pressure 3. Manc, S., Nervegna, N., Rundo, M.:A Contribution to the
pL pressure in the volume underneath vanes Design of Hydraulic Lube Pumps, The International Journal
of Fluid Power, vol. 3- Number 1, ISSN 1439 9776, pp. 21-31,
pM pressure in the j-th chamber
April 2002.
QI leakage flow at the tip of the vane
QI leakage through the clearance hDY
QI leakage through the clearance hDU
QI leakage through the clearance hYU
RU radius of the rotor
RV radius of the ring
rY radius of the vane tip
10