Project e Objectives

A company that produces hydraulic systems and components was in the final stages of designing a vane pump for lubrication applications. One of the objectives was to assess the robustness of the design and its integration into a lubrication system that involved multiple users with different flow rate requirements. This assessment was to be conducted before the construction of a prototype, in order to eliminate potential issues related to volumetric efficiency and flow rate distribution.

System Modeling Process:

For this purpose, the company turned to BSIM, entrusting it with the task of conducting lumped parameter analysis to validate the pump design and accurately size the system in which it would be installed. Using the geometric information of the pumping element, BSIM provided a detailed study of the vane pump’s behavior to evaluate its volumetric efficiency and propose any modifications to improve its performance. Subsequently, the optimized model was integrated into the hydraulic network that would house the pump, in order to predictively assess its resistive contribution and correctly balance the flow rates.

Step 1: Optimization of the Volumetric Efficiency of the Vane Pump

Detailed Model of the Pump

To first evaluate and then optimize the volumetric efficiency of the vane pump, BSIM developed a detailed model of the pump that included both internal and external leakage models. This model allowed for the identification of critical areas where interventions could be made to reduce leakage losses.

Leakage Analysis

The analysis revealed that the clearance between the rotor and the housing was one of the main sources of leakage. By adjusting these design tolerances through a sensitivity study, it was possible to significantly reduce the losses and improve the overall volumetric efficiency of the pump while keeping production costs sustainable.

Step 2: Integration of the Pump Component into the Lubrication System

Lubrication System Analysis

The lubrication system featured multiple distribution branches, each dedicated to specific users. The analysis needed to ensure that each user received the appropriate flow rate for the proper functioning of the system.

Sizing of Ducts and Calibrated Orifices

To ensure optimal flow distribution, BSIM developed a resistive hydraulic model, using predefined models for bends, constrictions, and branches. After a preliminary analysis, several optimization studies were conducted to determine the ideal sizes of ducts or calibrated orifices for the various users to correctly distribute the flow as per the design specifications. The system’s operation was then simulated using commercially available duct sections and calibrated orifices, selecting the best solution to ensure that the flow balance was still maintained.

Optimization Study

The optimization involved parametric simulations that evaluated various combinations of duct and orifice sizes to ensure that the distributed flow rates met the required specifications. Different operational scenarios were analyzed to verify the robustness of the design under various operating conditions.

Conclusion

Thanks to the methodical approach and detailed analysis conducted by BSIM, the manufacturer was able to:

• Improve the volumetric efficiency of the vane pump through a detailed model that allowed for the identification and reduction of leakage losses. The adjustments made to the tolerances between the rotor and the housing demonstrated how small modifications can lead to significant improvements in the component’s performance.

• Ensure that the lubrication system distributed flow rates optimally to all users through the proper sizing of ducts and calibrated orifices. The optimization analysis ensured that the selected commercial sections were suitable for maintaining the correct system operation under various operating conditions.

Reliability and Next Steps

The data collected and the results obtained have demonstrated the reliability of the proposed solutions. The next phase involves the construction and testing of a prototype based on the optimized design, with the goal of further confirming the simulation results and making any additional improvements.

Benefits for the Manufacturer

Cost Reduction
By avoiding the need to build non-optimized prototypes, the company was able to significantly reduce development costs.

Performance Improvement
The optimization resulted in a more efficient and reliable design, enhancing the overall performance of the lubrication system.

Development Speed
The simulation approach accelerated the development process, allowing the product to reach the market more quickly.

Thanks to the collaboration with BSIM, the manufacturer was able to move confidently into the production phase, assured of the quality of the design and the efficiency of the system.