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Accelerating the design of gerotor pumps using interactive tools and fast simulation

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Abstract

Gerotors are a family of mechanical pumps used for cooling, lubrication and fuel transfer in aerospace, medicine, etc. Modern industry demands to shorten the development time of products. This means further integration between the different design stages. As in any hydraulic machinery, an important bottleneck in the design process is the simulation time to validate designs. This is due mainly to the fact that Computational Fluid Dynamics (CFD) remains the go-to tool to perform simulations of hydraulic phenomena. One way to reduce this bottleneck is to adopt approximate yet fast simulation routines to refine the design before entering a precise simulation stage. This manuscript presents an interactive design tool that estimates the efficiency response of gerotor pumps using fast simulation routines. The presented tool intends to shorten and accelerate the design cycles of Gerotor pumps by providing the engineer with an estimation of the effect of geometry changes in the pump’s efficiencies in real time. The software tool integrates 2D and 3D design capabilities with real-time simulation response. The resulting efficiency estimations differ from the CFD models in maximum 8% in the case of volumetric efficiency. For mechanical efficiency the error ranges between around 20% and 45%, but the pump’s internal forces is estimated within a 1% accuracy. Future work focuses on refining the accuracy of the efficiency estimations and further integration of the design tool with physical data.

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Abbreviations

\(\textbf{Z}\) :

Number of teeth in the external gear

\(\mathbf {R_2}\) :

Distance to the center of the generator circumference

\(\textbf{e}\) :

Eccentricity, distance between the centers of rotation of internal and external gears

\(\mathbf {r_2}\) :

Radius of rolling roulette

\(\mathbf {r_1}\) :

Radius of fixed roulette

\(\mathbf {Q_{th}}\) :

Theoretical flowrate of the pump

\(\mathbf {Q_r}\) :

Real flowrate of the pump

\(\mathbf {V_i}(\theta )\) :

Volume of chamber i for angular position \(\theta \)

\(\mathbf {P_{in}}\) :

Pressure at the inlet

\(\mathbf {P_{out}}\) :

Pressure at the outlet

\(\mathbf {Q_{ip}}\) :

Inter-profile leakage

\(\mathbf {Q_{vc}}\) :

Flow through the vena contracta

\(\mathbf {j_p}\) :

Gap between the profiles at contact points

\(\mathbf {H_p}\) :

Area reduction due to energy losses at vena contracta

\(\textbf{b}\) :

Width of the axial cover flow

\(\textbf{l}\) :

Length of the axial cover flow

\(\mathbf {j_c}\) :

Axial gap between the rotors and the pump’s cover

\(\mathbf {\mu }\) :

Viscosity of the fluid

\(\eta _{\textbf{vol}}\) :

Volumetric efficiency of the pump

\(\mathbf {W_{hyd}}\) :

Power transmitted to the fluid

\(\mathbf {W_{vt}}\) :

Power loss due to viscous effects

\(\mathbf {M_v}\) :

Viscous torque

\(\mathbf {F_v}\) :

Viscous force

\(\omega _{\textbf{int}}\) :

Angular speed of internal gear

\(\mathbf {r_{er}}\) :

Radius of the equivalent ring simplification

\(\mathbf {W_p}\) :

Power loss due to pressure effects

\(\mathbf {M_p}\) :

Viscous torque

\(\mathbf {F_i}\) :

Pressure force applied by the fluid to the walls of volume chamber i

\(\mathbf {r_i}\) :

Vector from center of rotation to virtual point where force \(F_i\) is applied

\(\eta _{\textbf{mec}}\) :

Mechanical efficiency of the pump

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Funding

This work was funded by the Basque Government/Eusko Jarlitza Grant Number ZL-2020/00190.

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Authors and Affiliations

  1. Industry and Advanced Manufacturing, Vicomtech Foundation, Mikeletegi 57, 20850, Donostia, Gipuzkoa, Spain

    Juan Pareja-Corcho, Aitor Moreno, Jorge Posada & Oscar Ruiz-Salguero

  2. Egile Innovative Solutions, Kurutz-Gain Pol. 12, 20850, Mendaro, Gipuzkoa, Spain

    Asier Pedrera-Busselo & John Ciarrusta

  3. Laboratory of CAD CAM CAE, Universidad EAFIT, Kr. 49 Cl. 7S 50, Medellin, 050022, Antioquia, Colombia

    Oscar Ruiz-Salguero

  4. Faculty of Informatics, University of the Basque Country (UPV/EHU), Manuel Lardizabal 1, 20018, Donostia-San Sebastian, Gipuzkoa, Spain

    Juan Pareja-Corcho

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  1. Juan Pareja-Corcho
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Correspondence to Juan Pareja-Corcho.

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Pareja-Corcho, J., Pedrera-Busselo, A., Ciarrusta, J. et al. Accelerating the design of gerotor pumps using interactive tools and fast simulation. Int J Interact Des Manuf (2024). https://doi.org/10.1007/s12008-024-01814-1

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