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2012 IOP Conf. Ser.: Earth Environ. Sci. 15 062006
(http://iopscience.iop.org/1755-1315/15/6/062006)
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IOP Publishing
doi:10.1088/1755-1315/15/6/062006
Simerics Incorporated
1750 112th Ave. NE Ste. A203, Bellevue, 98004, USA
2
Ningbo Zhongyi Hydraulic Motor Co., Ltd.
88 Zhongyi Road, Zhenhai Economic Development Zone, Ningbo, China
3
College of Mechanical Engineering, University of Shanghai for Science and
Technology 516 Jun Gong Road, Shanghai, 200093, China
hd@simerics.com
Abstract. In this paper, a full 3D transient CFD model for orbital gerotor motor is described in
detail. One of the key technologies to model such a fluid machine is the mesh treatment for the
dynamically changing rotor fluid volume. Based on the geometry and the working mechanism
of the orbital gerotor, a moving/deforming mesh algorithm was introduced and implemented in
a CFD software package. The test simulations show that the proposed algorithm is accurate,
robust, and efficient when applied to industrial orbital gerotor motor designs. Simulation
results are presented in the paper and compared with experiment test data.
1. Introduction
A gerotor is a positive displacement machine which has an inner gear and an outer gear. For a normal
gerotor machine, the inner gear, which is the drive gear, and the driven outer gear rotate around their
own fixed centers during operation. Due to their compact design, low cost, and robustness, normal
gerotor pumps are widely used in many industrial applications. There is an alternative design, the
orbital gerotor, in which the outer gear is stationary, while the inner gear rotates around an orbiting
center [1]. The orbital gerotor can be used as a motor to obtain high torque output at low rotation
speed with small dimension. In this design, typically a rotating flow distributor is used to maintain
proper timing connecting the inlet and the outlet ports to the rotor.
CFD models of normal gerotor pumps have been used to improve gerotor designs in many
engineering applications for the last decades. In 1997, Jiang and Perng [2] created the first full 3D
transient CFD model for a gerotor pump and included a cavitation model. Their model successfully
predicted gerotor pump volumetric efficiency loses due to cavitation. Kini et al. [3] coupled CFD
simulation with a structural solver to determine deflection of the cover plate in the pump assembly due
to variation in internal pressure profiles during operation. Zhang et al. [4] studied the effects of the
inlet pressure, tip clearance, porting and the metering groove geometry on pump flow performances
and pressure ripples using CFD model. Natchimuthu et al. [5], Ruvalcaba et al. [6] also used CFD to
analyze gerotor oil pump flow patterns. Jiang et al. [7] created a 3D CFD model for crescent pumps, a
variation of gerotor pumps with a crescent shaped island between the inner and outer gears.
In comparison, CFD studies of orbital type of gerotor are rare. Authors of this paper have not found
any full 3D CFD model for this type of gerotor in the literature. Because of the difference in motion
mechanism, traditional gerotor model cannot be applied directly to orbital gerotor. Modifications in
IOP Publishing
doi:10.1088/1755-1315/15/6/062006
moving/deforming mesh algorithm as well as modifications in surface velocity assignment, torque and
power calculations are necessary. Orbital gerotors are commonly used as motors which have much
higher pressure differences and even smaller fluid gaps as compared with normal gerotor pumps.
Those two conditions impose big challenges for the flow solver. That could be one of the main reasons
why CFD analysis for orbital gerotors is not very popular.
2. Orbital Gerotor Motor Configuration and Simulation Strategy
2.1. Working Principle of an Orbital Gerotor Motor
As shown in Figure 1, an orbital gerotor motor has a stationary outer gear and a rotating inner gear.
Inner gear has 1 less tooth than the outer gear. During operation, the inner gear rotates and rolls over
the outer gear teeth. During the movement, the inner gear center also rotates around the outer gear
center in the opposite direction. Each time when the inner gear advances one tooth, the inner gear
center already rotates a complete revolution. Therefore the rotation speed of the center is NTin times
that of the inner gear rotation speed, where NTin is the number of inner gear teeth. Figure 1.1 to Figure
1.10 show the sequence of gear motion for one complete revolution of the inner gear center.
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doi:10.1088/1755-1315/15/6/062006
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IOP Publishing
doi:10.1088/1755-1315/15/6/062006
From equation (6) and (7), it is clear that at the point (0,
), both velocity components equal
zero. Therefore, that point corresponds to the coordinates of the instant center of rotation. Since the
line of symmetry rotates around the outer gear center at the speed of c, it is very straight forward to
calculate ICOR during the simulation.
2.3. Mesh Solution
Similarly, the motion of the inner gear boundary can be determined through the composite motion of
the rotation around the inner gear center plus the translation of the inner gear center. The shape of the
fluid volume for the rotor is then properly defined.
Meshing of moving/deforming fluid domains in a positive displacement (PD) fluid machine is
always very challenging. As a typical PD machine, gerotor motor has many dynamic fluid gaps with
very small clearances, down to several microns. Those gaps have a strong influence on machines
performance including flow leakage and volumetric efficiency, flow and pressure ripple, pressure lock,
cavitation and erosion, and torque and power. Therefore they have to be modeled accurately. Many
generic moving mesh solutions, for example the immersed boundary method, have difficulties in
modeling such dynamic gaps. So far, the most successful solution for creating a gerotor rotor mesh is
the structured moving/sliding mesh approach commonly used in normal gerotor pump simulations
(Jiang and Perng [2]). This approach is also adapted in this study.
In the structured moving/sliding mesh approach, the fluid volume of the rotor chamber is separated
from the other parts of the fluid domain. Topologically, the rotor volume is similar to a ring, and an
initial structured mesh can be easily created for that kind of shape. The rotor mesh will be connected
to other fluid volumes through sliding interfaces. When the inner gear surface moves to a new position,
the mesh on the surface of the inner gear does not simply move with the inner gear surface. Instead,
the mesh slides on the inner gear surface while make the necessary adjustments to conform to the
new clearance between the inner gear surface and the outer gear surface. Simultaneously, the interface
connections between the rotor volume and other fluid volumes are updated. Figure 3 shows a typical
structured mesh for a gerotor rotor volume.
IOP Publishing
doi:10.1088/1755-1315/15/6/062006
fluid machine. With the help of the template, user can setup a complete orbital gerotor motor in less
than 30 minutes starting from proper CAD geometry output. One can refer to Ding et al. [8] for a more
detailed description of the software.
3. CFD Solver and Governing Equations
The CFD package used in this study solves conservation equations of mass and momentum using a
finite volume approach. Those conservation laws can be written in integral representation as
(8)
(9)
The standard k two-equation model (Launder & Spalding [9]) is used to account for turbulence,
(10)
(11)
The cavitation model included in the software describes the cavitation vapor distribution using the
following formulation (Singhal et al., [10])
(12)
where is the diffusivity of the vapor mass fraction and f is the turbulent Schmidt number. The effects
of liquid vapor, non-condensable gas (typically air), and liquid compressibility are all accounted for in
the model. The final density calculation for the mixture is done by
(13)
This software package has been successfully used in CFD simulations for many different types of
positive displacement machines including: swash plate piston pump [11], gerotor pump [8], external
gear pump [12], crescent pump [7], and variable displacement vane pump [13].
4. Gerotor Motor Test Case
An industrial orbital gerotor motor was used to demonstrate the proposed CFD model. Figure 5 is the
solid model of the motor. This motor has two ports, port A and port B. The inner gear and flow
distributor can also rotate in both directions without mechanical adjustment. The flow and rotation
directions are determined by which port is connected to the high pressure fluid and which port is
connected to the low pressure fluid. The one connected to the high pressure fluid becomes the inlet
and the rotation direction will also change accordingly.
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doi:10.1088/1755-1315/15/6/062006
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doi:10.1088/1755-1315/15/6/062006
879
Viscosity (PaS)
0.04
100
16
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doi:10.1088/1755-1315/15/6/062006
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t
S'ij
U
u
u'
v
v'
vx, vy
x, y
11
Time
Strain tensor
Initial velocity
Velocity component (m/s)
Component of v'
Velocity vector
Turbulent fluctuation velocity
Velocity in x, y direction
Coordinates
Turbulence dissipation
fg
Gt
ICOR
in
k
L
M
NT
n
p
Q
Rc
Re
RPM
g
l
v
k
l
IOP Publishing
doi:10.1088/1755-1315/15/6/062006
References
[1] Ivantysyn J and Ivantysnova M 2003 Hydrostatic Pumps and Motors (New Delhi
: Tech Books International)
[2] Jiang Y and Perng C 1997 An Efficient 3D Transient Computational Model for Vane Oil Pump
and Gerotor Oil Pump Simulations SAE Technical Paper 970841
[3] Kini S, Mapara N, Thoms R and Chang P 2005 Numerical Simulation of Cover Plate Deflection
in the Gerotor Pump SAE Technical Paper 2005-01-1917
[4] Zhang D, Perng C and Laverty M 2006 Gerotor Oil Pump Performance and Flow/Pressure
Ripple Study SAE Technical Paper 2006-01-0359
[5] Natchimuthu K, Sureshkumar J and Ganesan V 2010 CFD Analysis of Flow through a Gerotor
Oil Pump SAE Technical Paper 2010-01-1111
[6] Ruvalcaba M A and Hu X Gerotor Fuel Pump Performance and Leakage Study ASME 2011 Int.
Mechanical Engineering Congress & Exposition (Denver, Colorado, USA , 2011)
[7] Jiang Y, Furmanczyk M, Lowry S and Zhang D et al. 2008 A Three-Dimensional Design Tool
for Crescent Oil Pumps SAE Technical Paper 2008-01-0003
[8] Ding H, Visser F C, Jiang Y and Furmanczyk M 2011 J. Fluids Eng. Trans ASME 133(1)
011101
[9] Launder B E and Spalding D B 1974 Comput. Methods Appl. Mech. Eng. 3 269-289
[10] Singhal A K, Athavale M M, Li H Y and Jiang Y 2002 J. Fluids Eng. Trans ASME 124(3)
617-624.
[11] Meincke O and Rahmfeld R 2008 6th Int. Fluid Power Conf. (Dresden, 1-2 April 2008) 485-99
[12] Heisler A, Moskwa J and Fronczak F 2009 The Design of Low-Inertia, High-Speed External
Gear Pump/Motors for Hydrostatic Dynamometer Systems SAE Technical Paper 2009-011117.
[13] Wang D, Ding H, Jiang Y and Xiang X 2012 Numerical Modeling of Vane Oil Pump with
Variable Displacement SAE Technical Paper 2012-01-0637.
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