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07/11/2014
KISSsoft AG
Rosengartenstrasse 4
8608 Bubikon
Switzerland
To finish this tutorial it will be expected the user has already basic knowledge of the KISSsoft Gearpair and
Shaft calculation.
Part I
shows how to start KISSsys.
Part II
illustrates the use of an existing KISSsys model. Furthermore, basic functions and data manipulation
are described which will later be used in part III.
Part III
explains techniques how to build a KISSsys model of a two stage gearbox.
During the study of this tutorial, questions may arise or problems may occur. The KISSsoft customer support
can be reached through the address and phone number given above.
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Contents
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Part I, Start KISSsys
1 Start KISSsys
1.1 Start program
Start KISSsys through Windows-Start Programs KISSsoft 03-2014 KISSsys.
If there is no Project folder defined everything will be saved in the default folder. E.g. Users KISSsoft.
In the following figure it is shown the project folder for this tutorial. In this case the folder is
C:\Programme\KISSsoft 03-2014\KISSsys\Tutorial. After the selection, this is confirmed and KISSsys opens.
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1.3 Open a KISSsys model
After having selected the project, the KISSsys models available in this project can be opened through the
menu using File/Open. The message whether the current file should be saved or not can be answered
negatively since KISSsys starts with an empty file. Now, the KISSsys model KISSsys-Tutorial-001.ks is
opened, and KISSsys should look as follows:
Note that models should be opened only from the current project folder.
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Part II, Using an Existing Model
2 Toolbars and views
2.1 Views in KISSsys
The Classes, the Model (tree structure) the Templates, the Messages, the KISSsoft (Messages from the
KISSsoft calculations) and the Diagram can be shown or hidden by using the menu View:
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The tables, user interfaces and 3D view can be minimised, restored and closed. Using the menu „Window“,
navigating between the windows is possible. A closed window can be shown by a right mouse click on its
corresponding element in the tree structure and then selecting “Show”.
Another way to reopen the window is to double click on the element in the tree structure.
If an element is selected in the schematic, it is highlighted in the tree structure and in the 3D view.
When moving the cursor over the elements of the schematic, the name of the respective element is shown.
With a right mouse click, the element can be modified if you are in Administrator mode (see after).
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2.1.3 Using the 3D-View
In the 3D view, the gearbox can be rotated, moved and zoomed (left, centre, right mouse buttons
respectively).
Data and graphics are updated when the „Refresh All“ button is pressed.
This command results in an update of for example the 3D view after having changed some parameters such
as the tip diameter of a gear or that the power flow is highlighted in the schematic after the calculation of the
kinematics.
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3 Use of the model „001-KISSsysTutorial“
3.1 Calculate kinematics
The kinematic analysis is started through double click on the function „Kinematic“. All speeds, torques and
bearing forces are calculated. Based on the input speed, the gear data and the output torque, the resulting
reduction „i tot“, the input torque and the output speed are calculated and shown:
The speed at the input and the torque at the output can be defined directly. Note that the sign of the torque
defines the direction of the power flow.
After having changed the values for input speed and output torque, the kinematics should be analysed again
by executing the function „Kinematic“ in order to get the corresponding results.
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If the analysis is to be performed for a different lifetime, the required lifetime should be changed in KISSsoft.
Using the function „GP1“, access to KISSsoft is available where the lifetime can be changed from 20 000h to
e.g. 30 000h (repeat for second stage). In order to have the new value accepted, „Calculate” or „F5” has
to be pressed, then exit KISSsoft:
After that, the calculation of the safety factors can be repeated by double click on „Strength“.
Note that elements (gears, bearings, couplings, …) shown in the graphical shaft editor
must not be removed or added since the number of elements on a shaft is defined
in the tree structure within KISSsys.
The number of elements to be arranged on a shaft may only be changed in KISSsys directly.
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Part III, Building a model
4 Task
In KISSsys, a model of for the strength analysis of a two stage helical gearbox with analysis of the gears,
bearings and shafts is to be built. This model is to be used for analysis or dimensioning such systems.
In the end, the model built will correspond to the model „KISSsys-Tutorial-001”.
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Figure 12. Change to Administrator mode
If the option „Administrator“ is not available, the respective license is missing. Contact KISSsoft AG.
After having imported the templates, the model can now be assembled.
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4.5 Principles
Folder
Analysis modules for the respective machine element (light blue)
Machine elements (grey symbols)
Connections (constraint elements in grey)
Graphics
Tables
They are available from a library, called the templates. The templates may be modified by the user
(recommended for experienced users only).
The template is based on the classes. The User or the Administrator has no permission to change the classes.
Usually it will not use.
The user can switch between the elements arranged in the tree structure and the templates using the tabs as
shown below, or for easier use tabs can be arranged to be seen simultaneously:
Note: Renaming an element will result in the connections to this element being invalid.
Renaming elements is hence not recommended.
4.5.3 Insert
In this menu are 4 assistants and it is only available from KISSsoft 03-2014.
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The menu Insert „Parallel shafts assistant“ is an assistant to build a helical stage gearbox. It will guide the
user step by step through the whole model. The tables are not part of this assistant.
As explained in the previous chapter, the Template which is loaded will be used to add elements to the tree
structure. With the third assistant “Element-Box”, the most common elements from the templates will be find
in here.
The user has to define the starting position in the element tree, to add elements from the two assistants to
the model. This will happen by clicking the element in the assistant.
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4.6 Insert machine elements
The modelling of this tutorial will be used with the „Parallel shafts assistant“. All elements will be add to a
group. The element kSysGroup will placed on the root directory (_O.). During the insert procedure the name
can be changed e.g. to „GB“.
5
Figure 17. Add a kSysGroup
4
2
The „Parallel shafts assistant“ will guide the user step by step to the finished model. Now add a new shaft to
the group „GB”. Additionally under the group the new shaft will be shown. This element is necessary for the
gears, bearings and couplings.
The use of this assistant is to finish shaft by shaft. The configuration for the shaft looks as follow.
1. Add shaft shaft1 machine element can be add to the new shaft
2. Add machine element to the shaft1 with following element
a. 1 x Coupling (kSysCoupling)
b. 2 x Bearing (kSysRollerBearing)
c. 1 x Gear (kSysHelicalGear)
The order of the elements will be displayed as it adds to the shaft. The order can be set in the shaft
calculation later to the origin position.
3. Add the kSoftShaft calculation to shaft1
4. Go one level up to the main assistant
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Figure 18. Figure 4.6-1 Configuration shaft 1
„shaft2“
1. Add shaft shaft2 machine element can be add to the new shaft
2. Add machine element to the shaft2 with following element
a. 2 x Bearings (kSysRollerBearing)
b. 2 x Gears (kSysHelicalGear)
3. Add the kSoftShaft calculation to shaft2
4. Go one level up to the main assistant
„shaft3“
1. Add shaft shaft3 machine element can be add to the new shaft
2. Add machine element to the shaft3 with following element
a. 2 x Bearings (kSysRollerBearing)
b. 1 x Gear (kSysGear)
c. 1 x Force (kSysCentricalLoad)
d. 1 x Coupling (kSysCoupling)
The order of the elements will be displayed as it adds to the shaft. The order can be set in the shaft
calculation later to the origin position.
3. Add the kSoftShaft calculation to shaft3
4. Go one level up to the main assistant
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Figure 19. Shaft definition
2 4
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4.8 Add external elements
To finish the model it is necessary to add input and output elements. In KISSsys this element represent by
kSysSpeedOrForce. This element will be placed at the same level as the group „GB“. The group itself is the
gearbox, which is connected for example with a motor and generator. In this tutorial the input speed and
output torque are given.
One level up, before adding the external elements.
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Input element:
Output element:
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Figure 24. Two stage helical gearbox before and after the kinematic calculation
To see the power flow in your schematic run the kinematic calculation. In this step you can check the
functionality of the power flow.
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Figure 25. Rough sizing for helical gear pair
Modification for the gears will be done in the KISSsoft interface. This steps give the user the first dimension
about the gears.
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4.9.2 Definition of the shaft geometry
With double click on the KISSsoft shaft analysis modules „Shaft1_calc“, „Shaft2_calc“ and „Shaft3_calc“ the
KISSsoft shaft analysis is started. Here, in the graphical shaft editor, the shaft can be modelled in detail.
When opening the shaft editor, no shaft is visible, only the elements positioned on the shafts are present. To
keep it simple, a cylindrical element of diameter D=30mm and length 200mm is defined for all three shafts,
shown here for the first shaft:
The end position and geometry form of the other machine elements, bearings and coupling will be defined
later. The shaft can now be detailed in the usual way. You can also adapt the bearings and the couplings
according to the shaft diameter. It is also possible to define bearings in shaft module including the axial
supporting. After definition press „Calculate F5“ in order to start the shaft analysis. This is necessary to get
reaction forces on the bearings which are in turn necessary for the bearing definition/analysis.
Repeat this step for all other shafts (in this example all shafts have the same length of 200mm, and the
diameter are 30mm, 40mm and 60mm for shaft1, 2 and 3).
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Double click on the kSys3DView element in the element tree and a new tab of the 3D will be shown. Or use
the submenu with the right mouse button and click show to open the graphic tab.
All shaft are overlaying each other, because the positioning of the shafts is not yet defined.
The shaft „shaft1“ will use the function „Parallel to Shaft/Group“. As already mentioned the “shaft1” will be
fixed in the space. When the shaft „shaft1” has to be positioned at a certain position, then this can be defined
in the interface mask. In this example it will stays at the current position (0/0/0).
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Second the intermediate shaft will be placed relatively to the input shaft. Under the dialog the function
„According to gear pair“ will be chosen:
Choose the Gear pairs and let the definition according to Formulas. With this definition every change in the
gear pair calculation will take into account and shown in the 3D-View too.
Repeat this step for shaft „shaft3“.
4.10.2 3D-View
Once the positioning is done, update the 3D-View by clicking the „Refresh“ button.
Following picture will be shown:
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5 User Interface
5.1 Table with information on gear and bearing data
Choose the two predefined table from kSysTable from „Elements-Box“: „GearPairCalulations“ and
„HelicalGears“:
The table names can be renamed and has no influence to the table.
With the right mouse button on the table and click on show or double click on the predefine table to show:
Those tables show the important result from the calculation in KISSsys.
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5.2 User Interfaces
Click and keep on the variable Torque with the left mouse button, place over the cell, then click and maintain
the right mouse button while maintaining the left mouse button, and release the left mouse button. Then a
selection menu will be shown where Text, Reference and Expression can be chosen.
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Text is defined as String, Reference is an expression, where the value can be changed in the table (e.g. input
speed) and Expression return a value.
Now add all the Expression to cell which has a grey background. The finish step looks like the next table.
Next step is to add reference values into the UserInterface. The grey cells have to be filled with the correct
reference value. The inserted values are in red, tis indicates to the user, that this is changeable. At the
beginning it is difficult to know what the name of the required variable is. This will comes with the experience.
Here are the list with the name of the variable which are in use.
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Figure 40. UserInterface with Reference values
Similarly input and output powers can be shown. Furthermore, the total gear ratio shall be shown. Again, right
mouse click on the desired field, „insert real“ and defining the following expression:
Figure 41. Calculation of the total reduction from input and output speed
Expression is extended to have a condition (IF…THEN and ELSE) to check that Output speed is not zero to
be able to evaluate the formula. It can be calculated from power difference between input and output. With
right mouse click, „Insert string“, in desired field, the following dialog is shown. In „Expression“ the formula for
efficiency can be given. Again condition is first checked and then CADH_ValToSrt() converts value to a string
and CADH_Round(value, nof digits) will round the value to desired number of digits. After the conversion also
“%” mark is shown. Press “Ok” to accept and the result is shown in the user interface. Be careful to type
expression correctly not to lose it if there is typing mistakes.
Figure 42. Condition and formula to calculate efficiency of the system and convert the value to a text
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Figure 43. Defining calculation in UserInterface
Functions can also be defined within a field of the user interface (right mouse click, „Insert function“). A name
for the function is to be given and the commands to be executed have to be listed.
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For the function „GP 1“ and „GP 2“:
Now the UserInterface has 4 function tab integrated, to activate the functions double click on it:
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6 Completing the model
6.1 Setting 3D-View
Use function “System specific settings from menu to set 3DView colours and appearance (First click on the
kSys3DView window or tab to activate the button)
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