New Development Methods Of Lubrication System Of Engine And Applications

This paper describes the development process and methods ofengine lubrication system based on engineering practices with thelubrication system development process as the primary clue.Firstly, some new methods and ideas adopted in this paper areintroduced, which includes the BENCHMARKING, system design, CAEapplication, development process and mechanical development.Secondly, methods and elements of system development arediscussed according to the development process of lubrication system,which mainly include the following,1) Definition of the lubrication system, confirmation of systemtarget and cost target according to system definition.2) Concept design. BENCHMARKING of key parameters.BENCHMARKING methods are introduced taking examples formain gallery pressure and main gallery oil flow. CAE analysis Calculation analysis platform of lubrication system and how to setup the calculation model are mainly described, illustrating theparameters input methods of oil pump and main bearing, introducing theprinciples and methods of system analysis and optimization, calculationresult output and evaluation contents, system analysis targets which aretreated as the input boundary condition of assembly design. Technical scheme of key assembly Taking the example of oil filter technical scheme definition, thedesign basis, schemes selection process and evaluation elements ofassembly scheme are discussed, the analysis and evaluation of FMEA(Failure Modes and Effects Analysis) are introduced, and risk analysisand criteria are also introduced.Thirdly, key assembly designing and second developmentproduction is discussed with the combination of engineering practice.1) Key assembly designingKey process of oil pan design is discussed taking the example of oilpan design, which includes the following,3-D space layout design.Primary boundary condition of oil pan in 3-D space is definedaccording to the engine and layout of engine in the vehicle.Function design.Inclination ability should consider installation angle of engine in thevehicle, vehicle acceleration and working environment. Oil storage isdefined according to oil circulation rate of lubrication system and oilpump supplying performance curve got from CAE analysis.Material selectionVarious kinds of material can be used as the oil pan materialconsidering production volume, working environment, characteristicrequirement, such as common steel plate, sandwich steel plate, plastic,gray cast iron, cast aluminum, and so on. Generally, the materialselection is defined from the aspects of cost, light weight and NVH.Structure design.Structure design should satisfy the requirement of function, formingtechnology and assembly technology.CAE optimization of forming technologyOil pan CAE simulation forming is introduced, disfigurementoccurred in the forming is analyzed and improvement is also putforward.CAE optimization of NVHNoise analysis is performing using structure model andacoustics boundary element.2) Second developmentSecond development includes not only technical control, but alsosupplier control, quality control, purchasing control and management.Design task paperDesign task paper is provided to second development supplier bysystem development engineers as the design input and basis, whichincludes production introduction, production description, functiondefinition, technical requirement, installation adjustment, maindimension, test attestation program and quality assurance.Design reviewAfter supplier finish scheme design and preliminary technical design,supplier should apply to R&D Center for design review which includeconcept design, structure design and test scheme design.Technology attestationThis task should be done by both quality assurance department anddesign engineer, which is based on the PFMEA and includingcomponents producing technology, assembly technology, test onproduction line, packaging and transportation.Production attestationAfter the supplier finish all development tasks and own providing CSamples, FAW will attest their production according to test criterion andstandard provided by FAW which mainly include performance testattestation and reliability test attestation.Finally, the mechanical development methods and process oflubrication system are discussed, which is the function attestation oflubrication system and improving development stages, and it is also avery important key stage in the lubrication system development process.