a new tribological test bench for lightweight hydraulic
TRANSCRIPT
1 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
www.kit.edu
IPEK – Institute of Product Engineering
KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
A New Tribological Test Bench for Lightweight Hydraulic Components IPROD-Meeting 15.-19.09.2015, Nis, Serbia
M. Sc. Markus Blust
2 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Introduction and Motivation
Test Bench Model / Test Bench Design
Measurement Results
Conclusion and Outlook
T op i cs
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
3 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Reducing masses in motion becomes increasingly relevant. Lightweight design
Hydraulic drive trains tend to be oversized High masses High costs
Main component: Axial piston variable pump Cooperation with Bosch-Rexroth
Introduction and Motivation
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Figures: Bosch-Rexroth
4 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Approach: Replacing steel with polymeric material or hybrid design components Consequence: Changed tribology of the system Lack of knowledge regarding tribological behavior of polymeric or hybrid design components Objective:
Introduction and Motivation
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Gain insights into tribological effects in pump made of lightweight material components
5 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Analysis of tribology between cylinder and control plate of the pump made of lightweight materials Modeling of tribological conditions
Research approach: Test bench RPR
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Tribological Contact
Control Plate
Cylinder
6 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
TFluid
Test Bench Model
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
ØD
FD
nDisk
Disk 1
Disk 2
Similar to real pump: Disk´s surface design Disk´s surface roughness
Source: youtube.de
7 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
TFluid
Test Bench Model
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
ØD
FD
nDisk
Disk 1
Disk 2
Friction force measurement system Indirect wear measurement Possibility for testing 8 tribological contacts at the same time
Characterisics Range
Diameter of the test disks D 50 – 100mm
Pressure Load FD 0,5 - 6kN
Maximum rotating speed nDisk 4000 1/min
Lubricant Temperature TFluid 20 – 120°C Friction Force (Wear)
TFluid
1
2
3 4
5
6
7
8
8 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Test Bench Model
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
ØD
FD
nDisk
Disk 1
Disk 2
Assumptions: Oil-bath lubrication Minimum temperature: 20°C
(only heating is possible, a cooling system is planed) Constant pressure load
TFluid
1
2
3 4
5
6
7
8
9 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Electrical drive
Test Bench Design – Main Components
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Mounts for test components Table
Test chamber
Belt transmission
Mounts for test components with friction force measurement system
10 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Test Bench Design – Test Chamber
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Rotating test component (green)
Non-rotating test component (blue)
11 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Test Bench Design – Test Chamber
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Input shaft
Gear drive Rotating test component shaft
12 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Test Bench Design – Test Chamber
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Hydraulic cylinder
Torque sensor
13 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Test Bench Design – Test Chamber
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Test-fluid
Oil-bath gear drive
Sealing
14 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Validation Test Procedure
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
Validation Parameters Material rotating disk brass
Material non-rotating disk modular cast iron
Lubricant H-LP 32 (DIN 51524)
Number of test 6
Common materials are used Fixed test component
Rotating test component Validation test procedure
15 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
A test bench for the analysis of the tribological behavior of the contact between cylinder and control plate in the axial piston variable pump was developed.
Main aim testing of the tribological behavior of lightweight materials
Measurement results for validation reproducible test results according to literature
There will be further tests with different lightweight materials in the future
Conclusion and Outlook
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
16 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
Thanks to the German Federal Ministry of Education and Research for the financial support within the framework of the research project „LHYDIA – Leichtbauhydraulik im Automobil“
Acknowledgements
M.Sc. Markus Blust – A New Tribological Test Bench for Lightweight Hydraulic Components
17 19.09.2015
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
www.kit.edu
IPEK – Institute of Product Engineering
KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association
a t K a r l s r u h e I n s t i t u t e o f Te c h n o l o g yInstitute of Product Engineering
A New Tribological Test Bench for Lightweight Hydraulic Components IPROD-Meeting 15.-19.09.2015, Nis, Serbia
M. Sc. Markus Blust