Professional Documents
Culture Documents
07/11/2014
KISSsoft AG
Rosengartenstrasse 4
8608 Bubikon
Switzerland
Part I Introduction,
explains the most important points for this modeling task and introduces how to start KISSsys.
Part II Modelling,
shows techniques how to build a KISSsys model of a complex gearbox with several power path
possibilities.
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
1 Introduction .............................................................................................................................................. 4
1.1 Summary of the most important points ........................................................................................... 4
1.2 Systematic procedure ..................................................................................................................... 4
1.3 Errata and remarks ......................................................................................................................... 4
1.4 Modelling task................................................................................................................................. 5
1.5 Starting KISSsys............................................................................................................................. 6
1.6 Selection of the project directory .................................................................................................... 6
1.7 Use KISSsys in the administrator mode ......................................................................................... 7
1.8 Loading the templates .................................................................................................................... 7
2 Building a model....................................................................................................................................... 8
2.1 Tree structure ................................................................................................................................. 8
2.1.1 Shafts and shaft groups ............................................................................................................. 8
2.1.2 Machine elements ...................................................................................................................... 9
2.1.3 Connection of coaxial shafts .................................................................................................... 11
2.1.4 Connections of the gears ......................................................................................................... 12
2.1.4.1 Helical gearpair connections ............................................................................................ 12
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1 Introduction
1.1 Summary of the most important points
1. Where two or more shafts overlap (e.g. loose gear, ring and sun of the planetary stage), the shafts
(element “kSysCoaxialShaft”) must be positioned under the same element “kSysGroup”.
2. The calculation of a connection with three helical gears is calculated with KISSsoft calculation
“kSoft3HelicalGears”.
3. The speed at the two output shafts (front and rear axle) are placed with one to another in reference.
Therefore the speed at one output shaft has to be set as "Constraint=Yes" and an expression is set
to compute one speed (those of the front axle) from the other (the rear axle). In addition, an iteration
is necessary for the calculation of the relative speed.
4. "Iteration for torques” and “speed with damping" must be set to execute the iteration.
9. Tests, debugging
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2. The planetary differential used for this example in practice would be a double planet planetary where
the sun and the planet carrier have the same sense of rotation. However, to prevent the example
becoming too complex, a simple planetary train is used. Therefore both outputs rotate contrary to
each other.
3. The original idea for this tutorial had planned a differential lock between the annulus and the planet
carrier. This clutch is called c3. In reality it will be not used although in the tutorial it is described. It
is recommended to proceed exactly according to the tutorial instructions (i.e. the clutch c3 is to be
modeled although this is not used).
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Figure 1. Diagram of the gearbox to be modelled
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respective KISSsoft files are saved. Before a KISSsys model can be opened or created, the project / folder
where the model will be saved has to be defined.
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.
If the option "Administrator" can not be selected, then the KISSsys license is missing. In this case contact
KISSsoft AG.
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Figure 4. Element library after loading the templates
After having imported the templates, it can be started with building the model.
2 Building a model
It is up to the user which method is used to build the model. It is recommended to use the Elements box
The shaft group “planet” is placed under the shaft “s5”. This group characterizes the planet of the differential
Figure 6. The coaxial shafts “pin” and “planet” are copied into “Planet”. The shaft ”pin” (Planet pin) is fixed
with the planet carrier “s5” by a coupling.
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Figure 6. Adding the Shaft group “Planet”
2) The planet is supported by two bearings of the planet pin (shaft “pin”). The pin is fixed with
supports “support1”and “support2” and will be connected with the planet carrier through the
coupling constraint “carrier_pin” (element “kSysCouplingConstraint”).
3) The planet carrier needs a special coupling: ”kSysPlanetCarrierCoupling“. Do not mix up this
element with „kSysCoupling“. This special coupling should be named as „carriercoup“ and will be
positioned on the shaft s5. This element is necessary to rotate the planet in the world coordinate
system.
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Figure 7. Model with the machine elements
The settings for the connection „carrier_pin“ between the carrier and the planet pin are as followed:
Figure 8. Settings for the connection between carrier and planet pin
The connection of two coaxial shafts with clutches and bearings will be described in the next chapter.
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2.1.3 Connection of coaxial shafts
The coaxial shafts are connected with connection roller bearing elements “kSysconnectionRollerBearing”.
In all of the groups it is necessary to define the inner and the outer race. In the example, in group “Input” is
added a connection roller bearing between shaft “s1” and “s1a”.
Figure 9. Selection of the inner and outer race for the connecting roller bearings
All of the other coaxial shafts can be mounted in the same way together.
Figure 10. Model tree after adding the connection roller bearings
The clutches “c1”, ”c2” and “c3”are elements of the type “kSysConnectionBearing”. These can be used
for a connection between two coaxial shafts (synchronizers in gearboxes). The elements must be inserted
under each shaft group. In the following dialog the inner race (for “c1” use shaft s1) and outer race (for “c1”
use shaft ”s1a”) must be selected. In chapter 4 it will be explained how to activate or deactivate the clutches
through a function automatically. For getting a correct power flow it is necessary switching the clutch c1 first
manually. So select the coupling “c1” and set under properties the variable “stateRy” to “fixed”. The same
setting can also be done by clicking with the right mouse button on the element and selecting “Dialog”. As it
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is given in the information in section 1.3, the clutch c3 is modelled but not used in the Tutorial. Therefore the
rotation around the y-axis has to be free.
In the next step, the gear elements can be added to the Model tree.
Figure 12. Model tree after adding the connection bearings and gears
In the next step the gears are connected. For the spur gears, the type "kSysGearPairConstraint" is
necessary. The following connections need to be defined:
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Connection Element1 Element2
gp1 z1 z2
gp2 z3 z4
gp3 z4 z5
gp4 z6 z7
The planets need the type “kSysPlanetaryGearPairConstraint" two times. One where the sun wheel
meshes with the planet, the other for the mesh between planet and ring. The connections are copied from the
templates into the tree structure, below the group of "GB":
Figure 14. Left: Definiton of the connection “ps” Planet/Sun; right: Definition of the connection “pr” Planet/Ring.
The tree structure with the connections defined in the KISSsys sketch should look now as follows:
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2.1.5 Definition of the boundary conditions
The definition of the power flow in the gearbox is through the element „kSysSpeedOrForce“ . This element
has to be copied from the templates and pasted four times into the root directory (not under „GB“). According
to the Diagram in Figure 1, the following boundary conditions have to be defined:
Name Element Speed contraint Speed[1/min] Torque constraint Power/Torque input Torque [Nm]
Input CIn Yes 2000 Yes Torque with sign 100
PTO cPTO No Yes Torque with sign 10
OutR crOut No No
OutF cfOut Yes No
Figure 16. Table for the boundary conditons
During the power input "Input" speed and the torque are given. Both values are signed sizes. If the product
of the two signs is positive, then the power is positive, i.e. it concerns a positive input power.
The PTO torque is set to 10Nm (acceptance for this example). The direction of rotation is counter clockwise.
The number of revolutions is therefore negative. The torque has to be entered positively thereby the power
output becomes negative.
The condition for the front wheel drive (OutF) is defined as follows:
Front axle and rear axle turn with the same speed, but contrary. This condition will be still specified in section
6.2. Thus the number of revolutions at this output (the front axle) is the same as from the number of revolutions
of the output “OutR", therefore "speed of constrained=yes" must be set.
With the right mouse-click on the power output "OutF" and the choice in "Properties" of "speed", an expression
for the speed can be defined at this output. Enter in the field "Expression":
"-OutR.speed". This guarantees that the speed at the output is equal to the speed of the shaft s5, but in
opposite direction of rotation.
Now the kinematic calculation can be performed by clicking on . After a Refresh, the sketch looks as
follows:
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Figure 18. Diagram after the definition of the boundary conditions and the kinematic calculation
Figure 19. Settings for the three geair train calculation element
The planetary gear analyses are arranged directly below the appropriate connection with the same name.
It is necessary to select the “Planetary gear pair constraint” option which was used for the planetary stage
connections as well.
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Figure 20. Settings for the planetary stage calculation element
The shaft calculation elements have to be placed in the corresponding shaft group. Since only coaxial shafts
are used in this Tutorial, the coaxial shaft calculation element has to be added.
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2.2 Input of Gear, shaft, and bearing data
Figure 22. Input values for the gearpair calculation GP1 in KISSsoft
Figure 23. Input values for the gearpair calculation GP4 in KISSsoft
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Figure 24. Input data for the three gear train GP2_3 in KISSsoft
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Figure 25. Input data for the planetary stage in KISSsoft
All shafts of a shaft group will be built up in the appropriate shaft calculation module. There are used very
simple structure for shaft modeling. The effective diameter of the couplings should be entered in the shaft
editor, so that the clutch is visible in the 3D-view.
position couplings:
cIn: y = 5mm
c1: y = 50mm
c2: y = 120mm
position shafts s1a,s1b:
y = 40 mm
y = 110 mm
position bearings b1,b2:
y = 15 mm
y = 170 mm
position gears z1,z3 (resp. s1a,s1b):
y = 10mm
y = 10mm
position z6:
y = 190 mm
Figure 26. Input data for the shaft group “INPUT”
position gears:
z2 y = 50 mm
z4 y = 120 mm
position shaft s6:
y = 180 mm
position bearings b1,b2:
y = 15 mm
y = 170 mm
position z7, cPTO (resp. s6):
y = 10mm
y = 22.5mm
Figure 27. Input data for the shaft group “MIDDLE”
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position shaft planet:
y = 2.5mm
position zp:
y = 5 mm
b2 y = 58 mm
s5: b1 y = 10,5 mm
b2 y = 136 mm
position gears:
zs(resp.s4)y=190mm
zr(resp.s3) y=20mm
z5(resp.s3) y=10mm
3 3D View
3.1 Adding 3D view in the tree structure
From the templates or from the element box, the 3D view "kSys3Dview" is inserted into the highest level
of the tree structure. Select “show" after clicking with the right mouse button on the element. All mechanical
components are still in the same position because their position in the working sheet is not defined. Therefore,
the next step will be to arrange the positions of the shafts in the coordinate system.
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Figure 30. View of the model in 3D before positioning the shafts
The shaft group “Middle” is positioned over center distance a between z1 to z2 relative to shaft group “Input”.
For this select “Middle”, right mouse click and “Dialog”.
The shaft group “main” is positioned in r-direction over center distance from z4 to z5 relative to shaft group
“Middle”. The angle phi is set to –90. The position in y- direction must be chosen so that z4 and z5 are in
correct engagement. This is realized through the calculation: “position gear 4 - (position shaft 3 + position
gear 5)”. The input is: “GB.Middle.s2.z4.position-GB.Main.s3.position-GB.Main.s3.z5.position“.
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3.2.3 Positioning of the group „Planet“
The shaft group “Planet”, which characterizes the planet pin, is positioned in r-direction over center distance
sun-planet (center distance of epicyclic stage “PGS”) relative to shaft group “Main”. The angle phi is set to
–90. The position in y- direction must be chosen so that sun ”zs” and planet “zp” are in correct engagement.
This is realized through the calculation: “position sun - (position shaft planet + position planet)”. The input is:
„GB.Main.s4.zs.position-GB.Main.s5.Planet.planet.position-GB.Main.s5.Planet.planet.zp.position“.
Press “Refresh” button on menu to see all components places correctly in the space.
Figure 34. Expression for the variable “di”, which has to be defined for the gears
This supplies the outside diameter of the shaft at the place where the gear part is located, checking that the
input value is not superior to the root diameter.
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3.3.2 Color and transparency
By clicking on the user can change the color and transparency of the “3D-view” for gears, shafts,
bearings and couplings. Further all elements can be shown more detailed. For this it must be chosen “Solid
Elements” under “Representation mode”. For transparency: 0 means not transparent and 1 full transparent
(invisible).
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3.4 Insert data from CAD system
Depending upon version of KISSsys *.sat, *.iges or *.step data from any CAD system can be imported. In
addition, "kSysCasing" has to be copied from the templates into the tree structure. In this example, four
individual CAD data records are read in, and four KISSsys elements of type "kSysCasing" are created. They
are called in this example "Wheel1" to "Wheel4": The file attached in this example is called “tut-003-CAD-
data.igs”.
By clicking with the right mouse button on the Housing-element and selecting “Dialog” and changing “Type”
to ” Read file”, it can be defined that a file should be imported. In the field "file name" the complete file name
inclusive path has to be indicated if file is not located in the project folder.
There is always a refresh needed to see the graphical changes. Positioning of the wheels can be done
manually entering in the Properties and changing position values.
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Figure 39. 3D view after importing and positioning the CAD data
4 Changing of gears
4.1 Background Information about clutch elements
The variable “stateRy” of the clutches c1 and c2 is necessary for switching the gears. This variable can
be “free” (disconnected) or “fixed” (connected). The same can also be done by clicking with the right mouse
button on the element and selecting “Dialog”.
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Figure 41. Expression to be written in the function SetGear
The function "CADH_VarDialog" generates a dialogue in which can be defined whether the on- or off- road
gear is selected. The dialogue supplies an array of "res" as result. Zero elements into "res" is 1 (or TRUE) if
the dialogue is confirmed using "OK", 0 (or FALSE) if the dialogue is closed with "CANCEL". The first element
of the array corresponds to the selection made. If "on-Road" is selected then 0 is returned, otherwise "off
Road" is selected and 1 is set.
The first “IF” condition examines if the dialogue was closed with "OK". After this the selection is put into the
variable “Settings.OnOffRoad”. If "on-Road" was selected, the clutch “c1” is closed, “c2” is open. If "off Road"
was selected, the clutch “c2” is closed, and “c1” is open. Next, the kinematic calculation is called to calculate
new power flow. To see the clutches in 3D-view, the outer diameter “D”, the inner diameter “d” and the
thickness must be set under properties. The function can still be extended so that the open clutch in the 3D
diagram is translucently represented, the closed clutch obscurely:
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Figure 43. Input to call the function SetGear through the function SetSpeed
Through a double-click on the grey button "SetSpeed" the following dialogue is called:
Depending upon selection, either the on- or off road gear is activated and the current power flow is computed.
The path over which the power flows is marked red marked in the pattern.
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5 User Interface
The user interface table can be created in different ways. The method with copying the values to the right cell
was used in the previous tutorials. As an alternative, the method with inserting the values directly to the cell
is shown in this tutorial.
Input of text As a comment Clarifying text can be typed directly into a cell.
This text appears in black writing with white background.
Input of Display of Right mouse-click on the desired cell, select "Real insert". An input mask
numbers values of appears. Into “expression” the path of the variable has to be written, their
variable value should be displayed.
The value appears in black writing with white background.
See Figure 46.
Reference on For display Right mouse-click on the desired cell, select "Real insert". An input mask
numbers and input of appears left down "reference" must be pressed. After this, "reference up"
values of the path of the variable has to be written their value should be displayed
variables Note: the path must be located in quotation marks. The values are
indicated in red writing with white background. See Figure 48.
Insert execute Execute Right mouse-click on the desired cell, select "function insert". An input
buttons for functions mask appears. Under "name" the name can be inserted, where the
functions through function in the user interface has to be indicated with. In the field
double click "expression" are called those variable in those the functions is located
which will be required. The function is locked with an empty argument
called () and closed with a semicolon.
Functions are indicated with black writing on light blue background. See
Section 5.2
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The path of the variable has to be written into
“expression”, then their value is displayed. In
the example shown, this variable is the power
input calculated from the speed and torque.
(See below).
For the display of speed, torque and power at
the front- and rear axle the following variables
have to be used:
OutF.speed
OutF.torque
OutF.power
OutR.speed
OutR.torque
OutR.power
Now for the definition of the input torque and speed, a reference can be inserted for each:
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After “Reference” is selected, the “reference to” field is switch on to insert a text. The path of the desired
variable must be inserted now. (put it between the two semicolons “ “)
Here the example for Input.speed as the Input speed is shown.
For the input of the torque at the input shaft the following expression has to be insert accordantly:
„Input.torque“
Figure 49. Implementing the function “Kinematics” into the UserInterface table
Figure 50. Implementing the function “Strenght” into the UserInterface table
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With this instruction, a general report is generated in which
all individual KISSsoft reports are summarized.
Figure 51. Definition of the function “Report” to generate the KISSsoft calculation report
If user doesn’t want to create functions for “Kinematics”, “Strength” and “Report” it is possible to use buttons
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Figure 53. Creation of the variable “FrontRearRatio” in settings
The speed at the front axle is now equal to the number of revolutions at the rear axle multiplied by this ratio.
Also, under the element "OutF" (output at the front axle) in the tree structure the expression for "speed" is
extended as follows:
In the same dialogue where the gear is selected, the speed ratio can also be entered. For this purpose the
dialogue must be extended (input of a value, delivery of this value into the variable provided above). This is
possible through “edit", with a right mouse-click on "SetSpeed" in the characteristics of "Settings“. Again the
function editor appears:
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Figure 55. Update of the function “SetGear”
The dialogue now looks as follows. For instance, when the value 1.5 is entered for "Front to Rear”, the
numbers of revolutions result is as shown:
The efficiencies can be put in the connections either through the dialogue boxes or directly into the variable
"eta". Only the teeth efficiencies are to be entered.
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Figure 57. Setting for the kinematic calculation
7 Annex
7.1 Code [line numbers are not part of the code]
1 VAR res;
2 res=CADH_VarDialog( ["SetSpeed",250,250,0.4,1],
3 [[C:VDLG_StrCom],"Speed:",["On-Road","Off-Road"],[OnOffRoad],1],
4 [[C:VDLG_Real],"Front to Rear:",Settings.FrontRearRatio,Settings.FrontRearRatio]
5 );
6 IF res[0] THEN
7 OnOffRoad=res[1];
8 Settings.FrontRearRatio=res[2];
9 IF res[1]=0 THEN
10 GB.Input.c1.stateRy=1;
11 GB.Input.c2.stateRy=0;
12 GB.Input.c1.kSys_3DTransparency=0;
13 GB.Input.c2.kSys_3DTransparency=0.7;
14 ELSE
15 GB.Input.c1.stateRy=1;
16 GB.Input.c2.stateRy=0;
17 GB.Input.c1.kSys_3DTransparency=0;
18 GB.Input.c2.kSys_3DTransparency=0.7;
19 ENDIF
20 System.calcKinematic();
21 ENDIF
7.1.1 Clarification
VAR res;
A local variable of "res" is defined. The type of the variable does not have to be defined for the time being.
The type is equal to the type on the right side of the equal sign being located in the line 2. Since the instruction
“CADH_VarDialog” returns an array, "res" is likewise an array.
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CADH_VarDialog
"Set speed" is the name of the dialogue, 250 is the width (in pixels), 250 is the height (in pixels). Value 0.4
defines that 40% of the width is in the left part of the window, 60% in the right. The following expressions in
square brackets define in each case an input field. The square brackets are separate by comma. In the first
expression a selection list is generated, called "speed". Between "on Road" and "off Road" are selected. The
second line permits the input of a value. The pre-emption of the input mask becomes defined through [
Settings.OnOffRoad ] and Settings.FrontRearRatio.
The outside IF loop examines whether the dialogue with "ok" was locked or not. If this applies, then the zero
element is alike 1 in the array of "res". Thus returns res[0] 1 or TRUE and the IF condition is fulfilled.
Line 7: Into the variable "OnOffRoad" is written 1 or 0. 0 means on road gear is selected, 1 means off road
gear is selected.
Line 8: The entered ratio is written into the variable "FrontRearRatio".
Second IF loop: if the selection is zero, whether on-road or off-road gear is selected (res [1]), then the on-
road gear is set. The clutch c1 is closed and c2 open. In the ELSE loop (will be execute if the on-road gear is
selected) c2 is closed and c1 opened.
#
IF df > kSoft_RotCADDiameter(^.OBJ_GetMember("outerGeometry"),position) THEN
RETURN kSoft_RotCADDiameter(^.OBJ_GetMember("outerGeometry"),position);
ELSE
CADH_Message("The defined diameter in the shaft calculation is too big" + "\n" + "(" +
CADH_ValToStr(kSoft_RotCADDiameter(^.OBJ_GetMember("outerGeometry"),position)) + "mm)
following value will be set (" + CADH_ValToStr(CADH_Round(df - 2 * 3.5 * d / z, 3)) + "mm)");
RETURN df - 2 * 3.5 * d / z;
ENDIF
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