Optimization of a spool-geometry for jet force compensation in a pressure control valve

Transcription

1 Optimizatin f a spl-gemetry fr jet frce cmpensatin in a pressure cntrl valve C. Hugel (M. Eng.) Hilite Germany GmbH Mtranwendungen Getriebeanwendungen 0

2 Inhaltsübersicht 1. What is Hilite Internatinal GmbH? 2. What had t be slved? 3. Slving the prblem with OptiSLang & ANSYS CFX 1. Methds and tls 2. Sensitivity and CP 3. Optimizatin (Calculatin) 4. Optimal gemetry 4. Summary 1

3 What is Hilite Internatinal GmbH? Everything imprtant abut us

4 Infrmatin Hilite Internatinal GmbH Key facts abut Hilite Fundatin f Hilite (Heller Hydraulik) in 1930 Prducts fr the autmtive industry divided int tw fields: Transmissin (AT valves, DCT valves, ) Unit Engine (VVT, engine valves, ) Apprx emplyees 3

5 Infrmatin Hilite Internatinal GmbH Headquarters: Marktheidenfeld 8 Lcatins n 3 cntinents 4

6 What had t be slved? Intrductin t the prduct and its prblem

7 Intrductin respnse time Pressure cntrl valve fr DCT 3/2 prprtinal valve Regulatin f the inflatin f the clutch Lw hysteresis and leakage Cntrl pressure: 0 15bar Supply pressure up t 20bar 6

8 Intrductin Respnse time Current rise Respnse time T=-30 c jet frce magnetic frce Dead time Filling time Actuatin f the clutch with pressure cntrl valve Respnse time: Time between current rise (actuatin) and achieving the target pressure (till 90% f target pressure) Dead time: Time between current rise (actuatin and pressure rise (<10%) Filling time: Time between pressure rise and achieving 90% f the target pressure Current rise Respnse time Dead time Filling time T=60 c 7

9 Intrductin Results reference system max. step respnse at 20bar supply pressure f 420ms pressure dependence within a band f ms Slw respnse times lead t cgging during gear change Reference gemetry Reference step respnse Reductin f the step respnse by ptimizing jet frce 8

10 Slving the prblem! Optimizatin with OptiSLang and ANSYS CFX

11 Slving the prblem Methds and tls CFD: Cmputatinal Fluid Dynamics (simplified) Numerical apprximatin f fluid dynamic prblem (Mainly used Navier-Stkes r Euler-equatins) Methd: Finite Vlume Separate the area int discrete elements (mesh) Slve the mdel equatins fr every element ver all surfaces Simulatin f the il flw thrugh the valve with ANSYS CFX 10

12 Slving the prblem Methds and tls Parametric System Basic System t build sensitivity and ptimizatin Cnnectin with Wrkbench and ANSYS CFX Sensitivity analysis Advanced Latin Hypercube Sampling (DE) with 200 designs Analysis f the imprtant parameters Start designs fr ptimizatin Optimizatin Multidisciplinary ptimizatin with tw bjectives Evlutinary algrithm with paret ranking (start size 20, archive size 20, number f parents 10) 11

13 Hehe Mittelsteg PVer Slving the prblem Mdel infrmatin Density: 816.5kg/m³ Viscsity: Pa s Pressure: 20bar Edited CFD-Mdel t fit jet frce calculatin with ptislang 7 adjustable spl gemetry parameters (see figure) Different spl psitins (mving the lwer part f the mdel t the right, with A- and P- Prt staying in place; figure rifice 0.1mm) A-Prt AbstandSekBlckSteuer PWinkel P-Prt Winkel_Innen Winkel Mittelsteg VInnen C. Hugel Hilite Germany GmbH 6/28/

14 Slving the prblem Parameters, cnstraints and bjectives Variatin f all imprtant gemetry parameters within a defined range Input pressure 20bar at P-Prt Different cnstraints t ensure crrect gemetries (nt listed) Calculated spl psitins (rifice at P-Prt): 0.025mm, 0.05mm, 0.15mm, 0.40mm Objectives (ptimizatin targets): 1. Reductin f the spls jet frce (Obj_FrceMIN) 2. Increase f the valves flw rate (Obj_FlwMAX) Imprve f the respnse time t ensure, that the clutch is filled with an acceptable speed. 13

15 Results - Sensitivity CP Imprtant fr jet frce and flw rate: AbstandSBS HeheMittelsteg Imprtant fr jet frce VInnen Winkel_Innen Imprtant fr flw rate PVer PWinkel C. Hugel Hilite Germany GmbH 6/28/

16 Results Optimizatin Calculatin Three designs with majr reductin f jet frce: #8, #43 and #48 #08 lwest jet frce #48 highest flw rate #43 lwest jet frce at small rifice; gd characteristics f the curve Optimal design fr the given requirements is #43 15

17 Results - Optimizatin Gemetry Reference Design A-Prt P-Prt Ref. CAD T A P Optimized Design A-Prt P-Prt Opti. CAD T A P 16

18 Results - Optimizatin Changes f the spl spl armature jet frce cmpensatin at spl snut ple cap Jet Frce reductin up t 50% & flw rate decrease f nly 7% snut P-Prt cntrl edge P A T A-Prt Density: 816.5kg/m³; Viscsity: Pa s; Pressure: 20bar; gap: 0.2mm spl P-Prt cntrl edge ledge at P-Prt chamfer at P-Prt cntrl edge chamfer at Mittelsteg Mittelsteg C. Hugel Hilite Germany GmbH 6/28/

19 jet frce [N] Results - Optimizatin Jet frce 3,50 3,00 2,50 Strömungskraft - Vergleich 2,00 1,50 1,00 0,50 0,00-0,50-1,00 0 0,1 0,2 0,3 0,4 0,5 0,6 rifice [mm] DP#43-5bar DP#43-10bar DP#43-20bar Ref-5bar Ref-20bar Ref-10bar Ref-10bar Ref-20bar Ref-20bar Detailed verificatin cmputatin t shw the behavir f the jet frce vs. spl psitin (P-Prt gap) fr a pressure jump f 5bar, 10bar and 20bar Cmparisn f the ptimized design and the reference design f the spl Reductin f the jet frce f 50% arund the peak value Shift f the maximum psitin t a smaller gap 18

20 Flw rate [l/min] Results - Optimizatin Flw rate Flw rate - cmparisn DP#43-5bar DP#43-10bar DP#43-20bar Ref-5bar Ref-20bar Ref-10bar Ref-10bar Ref-20bar Ref-20bar 0 0 0,1 0,2 0,3 0,4 0,5 0,6 rifice [mm] Detailed verificatin cmputatin t shw the behavir f the flw rate vs. spl psitin (P-Prt gap) fr a pressure jump f 5bar, 10bar and 20bar Cmparisn f the valve between the ptimized and the reference spl N increase f the flw rate with a reduced jet frce pssible Lw decrease f the flw rate (maximum at 7%) with a significant reductin f the jet frce (50%) 19

21 Results - Optimizatin Respnse time p-t-curve withut jet frce cmpensated spl (reference) p-t-curve with jet frce cmpensated spl (ptimized) Max. respnse time at 20bar (90% pressure target): 550 ms Max. respnse time at 20bar (90% pressure target): 170 ms 20

22 Results - Optimizatin Step respnse max. step respnse at 20bar supply pressure f 280ms (reference 420ms) P A T ptimized valve pressure dependence within a band f <200ms (reference ms) Reference valve Optimized valve 21

23 Summary Using the given parameters, a reductin f the jet frce at small gaps is very difficult Due t the ptimized spl the maximum jet frce decreased by 50% The critical peak f the jet frce (reference design) was remved Reductin f the flw rate decreased by 7% at maximum gap Tests with the real ptimized design shw the imprvement f the valve`s respnse time N cgging during gear change with the ptimized valve Optimizatin target f a faster valve fulfilled 22

24 Danke für Ihre Aufmerksamkeit.» 23