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This paper describes how to use the thermal analysis calculation in KISSsys, to be able to calculate the power
losses, efficiency, and heat dissipations of a given gearbox.
Several different methods are implemented in order to let the user select how the calculation should be
performed, according to the ISO/TR 14179 standard, part 1 and part 2 (combined with AGMA 6123-B06).
In some cases, results have to be treated with special care, because calculation methods used may not fully
support the type of geometry.
Additionally to these calculation methods, some extensions and combinations of them are introduced.
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Contents
1 Introduction ............................................................................................................................. 4
1.1 Thermal analysis ..................................................................................................................................... 4
1.1.1 Power losses ....................................................................................................................................... 4
1.1.2 Heat dissipations ................................................................................................................................. 4
1.2 Possible calculations ............................................................................................................................... 4
1.3 Flow chart................................................................................................................................................ 5
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1 Introduction
1.1 Thermal analysis
The thermal analysis can be defined in two sections: power losses and heat dissipations. Additionally, an
external cooler can be taken into account. Power losses as well as heat dissipations can be separated in several
sections to consider the effect of all the different transmission components.
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1.3 Flow chart
The efficiency template should be only added in an existing KISSsys model, because it is a calculation extension
for a “complete” model. The template is included in the default templates.
The administrator mode needs to be activated using “Extras/Administrator” as shown below to be able to add
new elements like this template in the model.
Then the template can be loaded on the root of the tree structure by using the corresponding default templates
button. The template contains a table element (standard name: “Efficiency”), which includes all the functionalities,
a two sub tab called “Losses” and “TemperatureSpectrum”.
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Figure 2. Importing "EfficiencyTemplate.ks"
If the user already have a model with the efficiency template integrated, to be able run the calculation using the
corresponding button, the administrator mode doesn’t need to be activated anymore, but the specific license right
k11h is mandatory. For any request concerning this feature, please contact info@kisssoft.ag.
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2.2.3 Bearing losses
For the roller bearing losses, some elements are created, type “kSysPowerLoss”, and called
“Losses+name_of_the_bearing”. For connection roller bearings, one element is created on each shaft to which
the bearing is connected (to get the relative speed for the calculation).
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Figure 3. Interface for thermal rating calculations in KISSsys
* For these calculations, the user will get the requested result in the corresponding field, section “Results
summary”. When the user runs the calculation with one of these selections, all the other results (losses,
efficiency …) will be displayed by taking into account this request result as an input. But for the input power
selection, the original value will be set back to the model input directly after the calculation.
3.2 Housing
To be able to consider heat dissipations through the housing, some settings regarding its geometry, material,
surface treatment must be done. The user can first select if the housing can be approximated by a rectangular or
cylindrical shape. Then he can define its wall thickness, material, extensions in every direction (value between
the extreme element in this direction and the inside of the housing). And finally he can integrate the coupling in
the housing or not (for the calculation of the minimum housing size required after).
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Figure 4. Dialog for housing dimensions
Then, depending on the shape selection, the user has a display of the external dimensions of the housing, taking
into account the extensions and wall thickness previously defined. Here it is possible to give some dimensions
and calculate the total surface area, or to input it directly (selection “Calculated” or “Own input”). It is also
possible to set a total surface and some dimensions in maximum two directions to get the other one(s). It is also
possible to switch back to the default (and minimum) values calculated by the template (button Sizing). After the
housing size definition, the surface treatment must be defined. It will have an influence on the heat emissivity (but
the value can be changed anyway afterwards), and it is dependent on the previous material selection.
In this dialog he will find also the input for the automatic creation of the seal losses elements. If the user select
“Yes”, or if he has created a user defined seal loss element with a variable “seal”, then he will have a third dialog
with the selection of the seal type for all these elements using the loss calculation from the standard.
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Figure 6. Seal type selection
If the user selects “Yes” for the fields “Draw housing” and “Draw oil level”, he will get the following display (if he
has at least one gear calculation with an oil bath lubrication, otherwise without oil level): display of the housing
with the wall thickness and the oil level in the 3DView (also the foundations if the user defined it).
Important note: The housing shapes (meant to be an approximation of an industrial gearbox housing) are really
simple because they are just used mainly to calculate, with the material and surface treatment, the main heat
transfer coefficient of the gearbox. If the user wants, he can anyway define it manually after.
3.3 Settings
With this button, the user will be able to give all the general inputs needed, depending on the calculation method
selected: ISO TR 14179 part 1 or part 2.
With this calculation method, the heat dissipated will be calculated by taking into account these general
assumptions:
• Lubricant temperature of 95 °C
• Ambient temperature of 25 °C
• Air velocity smaller than 1.4 m/s
• Air density at sea level
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• Continuous operation
The user will then have to select the real operating conditions to apply some correction factors and get the
effective heat dissipation calculation.
If thermal fining should be considered in heat dissipation, the geometry for these needs to be set using the
following dialog.
If the foundations should be considered in heat dissipation, the geometry for these needs to be set using the
following dialog.
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If output shafts should be considered in heat dissipation, the geometry for these need to be set using the
following dialog.
In this dialog will appear all the shafts outcoming from the defined housing. Below the shaft inputs will appear the
coupling inputs if there is an outcoming coupling as well. For these elements, the output length, mean output
diameter as well as the thermal (or heat conduction) coefficient must be set. If the user press the button “Init all
values”, all the different values will be calculated and filled out automatically (for the thermal coefficient for both
shafts and couplings, the value is taken form the shaft material). If the user doesn’t want to consider a shaft or a
coupling, he can simply enter “0” in the field “Output length”.
Important note: all these different dialogs have some restrictions, and the user can’t input “0” in some fields. The
dialog will simply re-open if a field is not correctly defined.
3.4 Ventilation
With this button, the user will be able to give all the ventilation inputs needed, depending on the calculation
method selected, and on the “Ventilation method” selected in the “Settings” for ISO TR 14179-1.
With “Own input”, he can define his own heat transfer coefficient, and apply or not an external ventilation
(auxiliary cooling) with a certain speed (with no ventilation, the speed can be different to zero, but must be inferior
or equal to 1.4 m/s). Ventilated air temperature is grayed out if no external ventilation is considered.
With “With auxiliary cooling”, he can define an air speed (this time it must be at least superior to 1.4 m/s), and the
different temperatures. The heat transfer coefficient is then calculated internally.
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Figure 14. With auxiliary cooling
With “Without auxiliary cooling”, he can select the space around the gearbox, and the speed, respecting the
restrictions indicated in the selection. The heat transfer coefficient will then be depending on this selection. And
no ventilated air temperature can be defined as there is no auxiliary cooling.
3.5 Lubrication
For the lubrication setup, the user will have different dialogs, depending on the lubrication type for the gears.
The first important thing to know is that only oil bath and oil injection lubrications are considered in the standard.
For other types, no solution is provided for the churning losses of the gears.
In every dialog the user will have the possibility to connect the oil temperature to all the different KISSsoft
calculations in the model. This will be mandatory to use the different calculations possible with the template
expected “Efficiency” where you can input a different oil temperature for every different element if needed.
The oil type and lubrication types are to be defined separately, in each calculation or using a general external
table like the “Settings” one available in the “templates.ks”.
If the user has only oil bath lubrications defined he will get the following dialog. He can then select to calculate
(middle of the lowest tooth or roller from the highest gear or bearing) or input the oil level (defined in the global
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coordinate system of the gearbox). He can then connect the oil temperature and set the value. He can also
connect the oil level which will then be transferred locally to each shaft calculation for the bearing losses.
If the user has also oil injection lubrications defined he will get an additional selection in the dialog to define the
oil injection properties. He can then select to define a global oil injection input or do it separately for each different
gear calculation.
For the global oil injection input or for each gear calculation with oil injection lubrication, he will get the following
dialog, where he has to define the injection volume and velocity, and the point of injection.
Important note: for the bearings, the user can also define a separated oil level (the previous one will then only
be used to calculate the churning losses of the gears) in each shaft calculation, in the “Module specific settings”.
He can define there as well the calculation method (be careful, SKF 1994 doesn’t take into account the oil level),
lubrication type, and seals torque loss (for the bearings only). The user can also connect all this variables with
the latest version of the “Settings” template.
3.6 Cooler
For the cooler definition, the user will have to define the cooler needed cooler power and the temperature drop of
the oil over the cooler from the starting point to the end.
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Figure 20. Cooler power setup
The first one will be the general correction factors input available from the main interface of the template.
In this dialog, he will be able to apply a general correction factor for each group of losses (default value is “1”).
Each time he opens this dialog, if he selects “Yes” for a specific losses group, the factor below is applied. If he
already defined one before and/or defined individual corrections (see after), and he opens again this dialog, by
pressing “OK”, he will overwrite all the values where “Yes” is selected. He should then select “No” if he doesn’t
want it overwritten. This dialog is in fact just created to spare time when you have a lot of different individual losses
to correct.
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Figure 23. Individual losses and correction factors
In this table, the user can first have an overview of all the different losses from the model. He can then define
individually all the different correction factors for each loss by doing a “right clic – Edit” on the “Correction factor”
column.
For the user defined loss elements, he can’t apply the general correction factors unless it is modified as a seal with
the variable “seal” inside. But in any case it will appear in the individual losses sub table. If it is defined as a seal,
it will have the “Calculated value” filled out, otherwise not as it is a user input (then “0” is set, but he can apply a
correction factor anyway).
3.8 Report
The user will finally be able to print out a general report gathering all the inputs and outputs of his calculation.
The report file will be saved in the KISSsys project folder. After writing the report it will be automatically shown in
the editor.
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Figure 25. Definition dialog of the temperature spectrum
Then the user can define the sequence. If you use some steps with a big duration, they are anyway cut in several
steps to be able to calculate properly the temperature evolution. The user can then modify the maximum number
of iteration and the maximum temperature variation from one step to the other by changing the default values in
the variables below. In the variables TotalEfficiency, TotalHeat…,… he will get the actual results for each virtual
step calculated (can then be 10 even if the user has only 2 steps defined in the temperature spectrum).
The temperature start need then to be defined in the lubrication button. It can be set for example to the ambient
temperature.
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Then when the user presses the calculation button, a dialog pops up to enter mass and specific heat capacity for
the various elements which are dissipating heat. Depending on the selected calculation method and user
definitions the dialog changes dynamically.
These values can be calculated by pressing the update button, or each time the geometry is modified and the
calculation is launched when setting the auto update selection to “yes”.
Figure 28. Definition of the mass and specific heat capacity of heat dissipating elements
When the calculation is finished, the user gets the results in the temperature spectrum tab, with additional columns
for the temperature, efficiency, heat generated and heat dissipated for each step.
A good first approach is to use the nominal load on each step as on the example above, with a duration of 0.03h
for each. Then you can see quite well the exponential increase of the temperature until the reach of the thermal
balance.
When exporting the result from the table (or the virtual steps) in Excel, the user can then get a good overview of
the temperature evolution.
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Figure 30. Results for nominal load
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