A numerical model for the evaluation of gerotor torque considering multiple contact points and fluid-structure interactions

This paper presents a numerical model for the evaluation of the actual torque in Gerotor units. The model consists of two major modules: the pre-processor module and the HYGESim module. The preprocessor module consists of the geometric and the mechanical module. The geometric pre-processor module considers the CAD geometry of Gerotor with tolerances as input and it provides as output the geometric features needed to evaluate the rotor loading and the flow features. The mechanical preprocessor module evaluates the forces of interaction at the contact points between the rotors. The flow displaced by the unit is evaluated using a lumped parameter model whereas the lubricating gaps are evaluated by solving the Reynolds Equation. The main novel aspects consist of the evaluation of the frictional losses at various interfaces. An Elasto-Hydrodynamic Lubrication (EHL) approach is used to evaluate the frictional losses at the contact points between the rotors. Tests on a prototype Gerotor unit are performed for the model validation, particularly as pertains to the features of the shaft torque. Additionally, the paper comments on the distribution of the different torque loss contributions associated with the operation of the unit taken as reference