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A 20-year experience with LMS Amesim: the simulation of positive displacement pumps
1. A 20-year experience with LMS Amesim:
the simulation of positive displacement pumps
Naples, June 27, 2016
Massimo Rundo
Politecnico di Torino – Dipartimento Energia
Fluid Power Research Laboratory
New Trends in Fluid Power
Design & Simulation Symposium
2. 2/25
FPRL at a glance
- 1st course of Fluid Power in Italy (1979)
- 1979 - 2016: about 9500 students
- From 2014: 2 courses in English at M.Sc.
- More than 100 M.Sc. theses
- About 100 scientific papers
- Development of simulation models of
positive displacement machines and valves
Research
Didactics
Laboratory
- 1985: construction of the 1st Lab
- 2005: completion of the new Lab
www.fprl.polito.it
5. 5/25
The experience with LMS Amesim
‐ Users since 1995 with v0.3
‐ 1998: 1st international publication on gerotor pump
‐ 2000: presentation at the 1st AMESim Users’ Conference in Paris
‐ Since 2006 used by the students in didactic laboratories
‐ Several customized libraries created in Ameset
6. 6/25
Systems/components studied with Amesim
Detailed 1D modelling of positive displacement machines (with customized libraries)
• 1997: Gerotor pumps
• 1999: External gear pumps
• 2000: Swash plate and bent axis pumps, also in cosimulation with MSC Adams (2006)
• 2001: Vane pumps, also in cosimulation with MSC Adams (2008)
• 2005: Crescent pumps ‐ Swash plate motors
• 2012: Single vane vacuum pumps
Vehicle systems
• 1999: Variable Valve Actuation ‐ Electro hydraulic braking system
• 2002: Lubrication circuit, also aeronautical (2001)
• 2004: Clutch actuation ‐ Steering units
Mobile hydraulics
• 2001: Hydrostatic transmissions
• 2006: Load sensing proportional valves
• 2011: Excavator and telehandler hydraulic circuits (coupled simulation with LMS Virtual Lab)
Industrial hydraulics
• 2001: Hydraulic power unit for hydroforming system
7. 7/257/
Equivalent hydraulic circuit
Need to evaluate
the geometric
features
N variable
chambers
Delivery
volume
Suction
volume
Flow areas Flow areas
drainInternal
leakages
J
J+1
Gerotor
machine
Variable
chambers
The simulation of a positive displacement machine
Flow area
volume
areaarea
j‐th chamber
• Hydraulic volume: continuity equation
• Hydraulic resistance: flow equation
11. 11/25
inlet
outlet
A B
Variable flow gerotor pump2000
Early Closing
Inlet Port
Delayed Closing
Delivery Port
Timing can be varied with respect to the gearing
DCDP
The end of the delivery phase is progressively delayed
The flow area is also function of the sector position
Flow rate vs. sector position
NERVEGNA N., MANCO' S., RUNDO M.: “Variable Flow Internal Gear Pump”,
ASME International Mechanical Engineering Congress and Exposition, New York, 11‐16 November, 2001
Piston linked
to the sector
15. 15/25
Interaction between bodies (analytic approach)
Contact vane‐stator in a vane pump (detachment analysis)
2001
Force equilibrium on each vane:
MANCO' S., NERVEGNA N., RUNDO M., ARMENIO G., “Modelling and Simulation of Variable Displacement
Vane Pumps for IC Engine Lubrication”, SAE World Congress, 8‐11 Mar. 2004, Detroit, USA
Fr = reaction forces
Fp = pressure forces
Ff = friction forces
Fc = centrifugal force
x
( ) ( ) ....mx j cx j
Endstops management (contact with stator track)
If contact evaluation of contact force on the stator contribution to the stator equilibrium
If detachment evaluation of the leakage on vane tip influence on the chamber pressures
Small movements of mechanical parts influence on leakages
16. 16/25
Multibody simulation (fuel pump)
fluid viscosity ≈ 2‐3 cSt
The issue: the current positions of the gears
axes is critical for the leakages evaluation
x
y
Model in MSC Adams
with all clearances:
• inner gear – outer gear
• inner gear ‐ shaft
• outer gear ‐ housing
Forces on gears
calculated with Amesim
2005
Theoretical eccentricity (not in scale)
Amesim output Adams output
RIELLO Research Contract, 2006
23. 23/25
1D simulation of lubricating circuit
lubrication of each cylinder:
• main bearing
• piston cooling jet
• crankshaft drilled holes
• conrod bearing
SINGLE OVERHEAD CAMSHAFT DIESEL ENGINE
2003
Circuit layout
Load on the
bearings
(supplied as
data file)
FURNO F., RUNDO M.: “Simulazione del sistema di lubrificazione di un motore a combustione interna”,
58° Congresso Nazionale ATI, Padova ‐ S. Martino di Castrozza, Italy, 9‐12 September, 2003
25. 25/25
Some final remarks / curiosities
• First model of gerotor pump in 1997 ran on a Sun SparcStation 10 @ 50 MHz ‐ 96 Mb RAM
About 2‐3 minutes to simulate a shaft revolution
Now about 2 seconds : 2 orders of magnitude smaller !!
• In 1997 an entire month spent for the development of the model of a simple relief valve
(at that time the Hydraulic Component Design Library in Amesim did not exist !)
Now the same valve is built in 30 min by the students of the Fluid Power courses
• The nightmare :
When you realize that
your model no longer runs
on the new release of a software !!