KISSsys Tutorial: Two Stage Helical Gearbox KISSsys Tutorial: Two Stage Helical Gearbox

Structure of the tutorial

The tutorial has three parts to be studied in this order. 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. Modifications Date 10.11.2006 23.10.2007 19.03.2008 Who A. Halter R. Kivel R. Kivel Changes Update program views and title of the machine elements Calculation method definition added New GUI

4. April 2008

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Table of content
1 Start KISSsys ...................................................................................................................................................................3 1.1 Start program...........................................................................................................................................................3 1.2 Definition of project folder .....................................................................................................................................3 1.3 Opening a KISSsys model.......................................................................................................................................3 Toolbars and views ..........................................................................................................................................................5 2.1 Views in KISSsys....................................................................................................................................................5 2.1.1 Views and windows ............................................................................................................................................5 2.1.2 Arranging elements in the schematic ..................................................................................................................6 2.1.3 Connection between 3D view, schematic and tree structure...............................................................................6 2.1.4 Using the 3D view ..............................................................................................................................................6 2.1.5 Refresh All..........................................................................................................................................................6 2.2 In- and output of data ..............................................................................................................................................7 2.3 Starting KISSsoft analysis.......................................................................................................................................7 Using the model 001-KISSsys-Tutorial .......................................................................................................................8 3.1 Calculate kinematics ...............................................................................................................................................8 3.2 Analysis of root and flank safety factors.................................................................................................................8 3.3 Changing gear data, bearing data and shaft geometry.............................................................................................9 Task................................................................................................................................................................................10 Structure of the system...................................................................................................................................................10 5.1 Start KISSsys ........................................................................................................................................................10 5.2 Loading the templates ...........................................................................................................................................10 5.3 Principles...............................................................................................................................................................11 5.3.1 Elements, templates ..........................................................................................................................................11 5.3.2 Drag/Drop, Copy/paste, rename, delete ............................................................................................................12 5.4 Insert machine elements ........................................................................................................................................12 5.5 Definition of the kinematics ..................................................................................................................................14 5.6 Adding KISSsoft analysis modules.......................................................................................................................16 5.6.1 KISSsoft shaft analysis .....................................................................................................................................16 5.6.2 Add KISSsoft gear analysis ..............................................................................................................................17 5.6.3 Adding bearing analysis....................................................................................................................................19 5.7 Positioning the elements........................................................................................................................................19 5.7.1 Preliminary positioning.....................................................................................................................................19 5.7.2 Positioning of the shafts....................................................................................................................................20 5.7.3 3D View............................................................................................................................................................21 5.8 Definition of the shaft geometry ...........................................................................................................................22 5.9 Definition of bearings............................................................................................................................................24 User Interfaces ...............................................................................................................................................................25 6.1 Table with information on gear and bearing data..................................................................................................25 6.2 User Interfaces ......................................................................................................................................................26 6.2.1 Introducing an user interface ............................................................................................................................26 6.2.2 Adding text .......................................................................................................................................................26 6.2.3 Display of results ..............................................................................................................................................26 6.2.4 Changing values using the UserInterface ......................................................................................................29 6.2.5 Changing calculation method from the UserInterface...................................................................................29 6.2.6 Further settings .................................................................................................................................................30 6.2.7 Execution of functions ......................................................................................................................................31 Completing the model....................................................................................................................................................33 7.1 Display of the coupling .........................................................................................................................................33 7.2 Definition of fixed and free bearings ....................................................................................................................33 7.3 Definition of the force acting on the output shaft..................................................................................................34

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PART I, Start KISSsys 1 Start KISSsys

1.1 Start program
Start KISSsys through Windows-Start/Programs/KISSsoft 03-2008/KISSsys.

1.2 Definition of project folder

KISSsys uses projects to manage the files. Project folder simply defines where KISSsys models and the respective KISSsoft files are saved. Before a KISSsys model can be opened or created, the project / folder where the model will be saved is to be defined. Using the button shown in the following figure, the project / folder selection is displayed, here C:\Programs\KISSsoft 03-2008\KISSsys\Tutorial. After having selected the project / folder, the selection is to be confirmed, press Open and KISSsys is launched.

Figure1.2-1 Selection of project / folder

1.3 Opening 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:

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Figure1.3-1 KISSsys after opening the model KISSsys-Tutorial-001.ks

Note that models should be opened only from the current project.

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PART II, Using the Existing Model 2 Toolbars and views

2.1 Views in KISSsys
2.1.1 Views and windows
KISSsys features the following views:

Tree structure Messages

3D View

User Interface

Tables

Schematic

Figure2.1-1 Views available in KISSsys

The tree structure, the schematic and the messages can be shown/hidden using the following buttons:

Figure2.1-2 Show/hide tree structure, messages and schematic

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.

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2.1.2 2.1.3

Arranging elements in the schematic Connection between 3D view, schematic and tree structure

The elements shown in the schematic can be arranged with the left mouse button.

If an element in the tree structure is selected (left mouse click), it is highlighted blue. Also, in the 3D view, a local co-ordinates system is shown in the centre of the element.

Figure2.1-3 Selecting an element in the tree structure highlights it in the 3D view

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.

Figure2.1-4 Information about the element in the schematic

2.1.4 2.1.5

Using the 3D view Refresh All

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.

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Figure2.1-5 Refresh All

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.

2.2 In- and output of data

In the user interfaces and the tables, the following text elements are used Feature Black Red Type Output / text Input Use Using black, results are shown that change with the analysis. Comments are also in black. In these fields, values can be entered directly or they can be chosen from an underlying list (double click). The values entered or chosen are then stored in the respective variables. Functions are executed through double-click (left mouse button)

Grey background

Functions

2.3 Starting KISSsoft analysis

Through the tree structure, the KISSsoft analysis can be started by a double click on the respective symbols as shown below:

KISSsoft bearing analysis KISSsoft bevel gear analysis KISSsoft chain drive analysis KISSsoft crossed helical gear analysis KISSsoft feather key analysis KISSsoft helical gear analysis KISSsoft interference fit analysis KISSsoft journal bearing analysis KISSsoft planetary gear analysis KISSsoft polygon analysis KISSsoft shaft analysis / graphical editor KISSsoft spline analysis KISSsoft splined shaft analysis KISSsoft toothed belt analysis KISSsoft v belt analysis KISSsoft woodruff key analysis KISSsoft worm gear analysis
Figure2.3-1 KISSsoft analysis

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3 Using the model 001-KISSsys-Tutorial

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:

Figure3.1-1 Results in the User Interface after execution of kinematics analysis

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 analyzed again by executing the function Kinematic in order to get the corresponding results.

3.2 Analysis of root and flank safety factors

On execution of the function Strength (double click) the kinematics are calculated again, followed by the strength analysis of the gears, bearings and shafts. The resulting safety factors for the root and flank are shown in the user interface (based on a lifetime of 20000h):

Figure3.2-1 Output of resulting safeties for root and flank

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 F5 has to be pressed, then exit KISSsoft.:

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Figure3.2-2 Changing the required lifetime

After that, the calculation of the safety factors can be repeated by double click on Strength

3.3 Changing gear data, bearing data and shaft geometry

The gears, shafts and bearings can be changed in KISSsoft in the usual manner. For this, double click on a KISSsoft symbol in the tree structure in order to get into the KISSsoft analysis of the desired element. Here, for example fine sizing of gears can be executed or the type of bearing may be changed in the bearing analysis. In order to make the changes permanent, Calculate F5 has to be pressed before exiting KISSsoft. 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.

5 Structure of the system

The new system will be built from elements like gears, shafts and couplings and the respective KISSsoft analysis modules. These elements and analysis modules will be imported from a library, called Templates.

5.1 Start KISSsys

First a new project / folder is defined, e.g. C:\MyTutorial. Then, start KISSsys with this folder as project. KISSsys is then opened with an empty model. Using File/Save from the menu, this file is given a name, e.g. KISSsys-Tutorial-001. In order to be able to build a new model, KISSsys should be used in the administrator mode, which is activated in the Options - menu:

Figure5.1-1 Change to Administrator mode

If the option Administrator is not available, the respective license is missing. Contact KISSsoft AG.

5.2 Loading the templates

As a first step when creating a new model, the templates are to be imported through the menu File, Open templates, templates.ks. In the Templates, all elements available in KISSsys are now listed:

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Figure5.2-1 Element library Templates

After having imported the templates, the model can now be assembled

5.3 Principles
5.3.1 Elements, templates

In KISSsys, a model is assembled from different elements. These elements are arranged in a tree structure. The following types of elements are available: Machine elements (red symbols) Analysis modules for the respective machine element (light blue) Connections (grey) Tables Graphics They are available from a library, called the templates. The templates may be modified by the user (recommended for experienced users only). The user can switch between the elements arranged in the tree structure and the template using the tabs as shown below or for easier use tabs can be arranged to be seen simultaneously:

Figure5.3-1 Elements and templates 11 / 34

The model is arranged in the Model - section.

5.3.2

Drag/Drop, Copy/paste, rename, delete

User can select how to copy elements from templates to the model. You may drag and drop elements or you can copy and paste elements from the templates to the tree structure using Ctrl+C / Ctrl+V or, with right mouse click, copy / paste. Delete elements by selecting them and press Del or right mouse click and Delete element. Renaming an element is performed by right mouse click and selection of Rename. Note: Renaming an element will result in the connections to this element being invalid. Renaming elements is hence not recommended.

5.4 Insert machine elements

All machine elements are arranged in a group. For this, the element kSysGroup is imported from the Templates into the Element section. The name is changed to GB for this example. The gearbox features three shafts. They are added by copying from the templates (element kSysShaft) and inserted in the group GB. They are called s1, s2 and s3. In the schematic, the shafts can be arranged using the left mouse. The model should look as follows:

Figure5.4-1 View of the model after the first steps

Now, the other machine elements are integrated. They are arranged in the tree structure below their respective parent element (the respective shaft). First, the element kSysCoupling is copied from the templates and pasted below s1 and below s3. Use the names cIn for the coupling on shaft 1 (power input) and cOut for the coupling on shaft 3 (power output). Similarly, on shaft 1 and 3, a single gear and on shaft 2 two gears are placed. They are copied from the templates, element kSysHelicalGear, and pasted below s1, s2 and s3. Use the names z1, z2, z3 and z4. The model should look as follows:

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Figure5.4-2 Couplings and gears added

Now, two roller bearings are included for each shaft. From the templates, the element kSysRollerBearing is copied and pasted twice below each shaft. Use the names b1, and b2 in this example. On the output shaft (s3), a centric load is added. For this, the element kSysCentricalLoad is copied from the templates and pasted below s3 and named as f1. The model should look as follows:

Figure5.4-3 KISSsys model with all elements used 13 / 34

5.5 Definition of the kinematics

In the next step, the kinematics and the power flow of the system is defined. For this, connections between the gears are introduced. For this the element kSysGearPairConstraint is copied form the templates and pasted into the group GB twice (names: gp1 and gp2). When inserting these connections a dialog appears where the two elements to be connected are selected:

Choose first element of connection Choose second element of connection Efficiency (leave at 1.00)

Figure5.5-1 Dialog for the definition of a gear-gear connection, left for the first connection called gp1, right for the second connection called gp2

In this example, the efficiency is to be left at 1.00. The definition of the power input is thorough the element kSysSpeedOrForce. For the input, paste the element on the same level as GB, using the name Input. Again, a dialog appears, where the connection to the coupling of the input shaft is defined. The input speed is defined as well by setting Speed constrained to yes and giving a value for the input speed:
The Kinematics of the gearbox is defined by two parameters, a speed and a torque. In this example, the speed on the input and the torque on the output are defined. To set the speed on the input, choose Speed constrained, yes. Set Torque constrained, no since the torque is defined for the output, not for the input. The power is defined by the speed and the torque and is shown here for information.

Figure5.5-2 Definition of the power input

For the output, a second element kSysSpeedOrForce is added, to be called Output. In the dialog, the coupling on the output shaft is to be selected as the connecting element. Here, the torque is to be given with e.g. -20Nm (Torque constrained, yes). Set a negative value for the torque to get a negative power.

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On the output, only the torque (with sign) is defined, Torque constrained, yes. The speed is not defined here, it is calculated based on the gearbox kinematics and the speed on the input, hence Speed constrained, no.

If a torque of +20Nm instead of -20Nm is used, the direction of the powerflow in the gearbox is reversed.

Figure5.5-3 Definition of the power output

The symbols for the power input and output should be rearranged in the schematic. The KISSsys model should now look as follows:

Figure5.5-4 KISSsys model with power flow

Double click on menu Calculate kinematics to start kinematics calculation. In the status line (bottom of the window), a message Kinematic calculated occurs. There should be no error message.

Figure5.5-5 Execution of kinematics analysis 15 / 34

Note that the connections shown in the schematic have not turned red to indicate that power flows through them. Use Refresh button on menu to show power flow through the system. The information on the power flow is given with right mouse click on the element Input and selecting Dialog:
Opposed to Figure5.5-2 not only the pre-defined speed at the input is shown but also the calculated torque.

Figure5.5-6 Power input. The torque is calculated from the torque given for the input, the efficiency and the gearbox kinematics

The analysis of the kinematics is now working.

5.6 Adding KISSsoft analysis modules

Next step is including the KISSsoft analysis modules. These are copied from the templates, kSoftCalculations\withSystem. KISSsoft analysis modules for shafts, bearings and gears are needed.

5.6.1

KISSsoft shaft analysis

The shaft analysis Shaft is copied from the templates and pasted below the three shafts. They are called S1, S2 and S3. On pasting them, a dialog appears in which the shaft to be analyzed is to be selected. Saving mode should set to Save file in KISSsys.
Select the element for which the analysis will be used There are different ways to safe the KISSsoft analysis modules. With Save file in KISSsys, all data is saved in KISSsys This is the most simple way. It is also possible to import or export KISSsoft files. Figure5.6-1 Dialog for definition of shaft to be analyzed

The KISSsys model should now look as follows:

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Figure5.6-2 Model with KISSsoft shaft analysis added for all three shafts

5.6.2

Add KISSsoft gear analysis

From the templates, copy HelicalGearPair and paste them below the two connections gp1 and gp2, using the names GP1 and GP2. Again, the analysis is connected to the connection using a dialog as follows. Set Saving mode to Save file in KISSsys:

Figure5.6-3 Dialog for definition of connection to be analyzed (gear stage)

The KISSsys model should now look as follows:

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Figure5.6-4 Model with KISSsoft gear analysis added

Through a double click on the KISSsoft gear analysis icon, the KISSsoft interface for definition of gears is shown. Here, gears can be defined in the usual way and the centre distance can be calculated. It is also possible to import gear data from an existing KISSsoft file for a gear pair. After having defined the gears, press Calculate F5 and exit.

Figure5.6-5 Definition of the two gear stages, here for stage 1

This has to be done for both stages. Accept the input by pressing Calculate F5 and close the KISSsoft window.

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5.6.3

Adding bearing analysis

The bearing analysis Bearing2 is imported from the templates (index 2 since two bearings are to be analyzed). They are pasted below the three shafts, once per shaft. Names: B_s1, B_s2 and B_s3. In the dialog that appears, the shaft where the bearings to be analyzed are seated is to be selected. Set Saving mode to Save file in KISSsys:

Figure5.6-6 Selection of shaft where the bearings to be analysed are seated

With this procedure, the KISSsoft bearing analysis is included. The KISSsys model should now look as follows:

Figure5.6-7 KISSsys Model with all KISSsoft analysis modules (light blue icons) included

5.7 Positioning the elements

5.7.1 Preliminary positioning

Next step: preliminary positioning of the parts on the shaft so that they can be identified more easily in the graphical shaft editor (when importing the elements from the templates, they all have position=0 mm). This step is not necessary to accomplish. For the bearings, gears and couplings, using right mouse click on the elements (z1 through z4, cIn, cOut and all b1 and b2) and selecting Properties, the variable position is available. Set the value for example to 10 mm for the left bearings (b1), 100 mm for the right bearings (b2), to 120 mm couplings on the output and input shaft, 120 mm for the force f1 and 30 mm and 70 mm for the gears. Example: left bearing on the input shaft:

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Figure5.7-1 Right mouse click on the element (here b1 below s1, the left bearing on the input shaft), select Properties

A list with all variables available for the bearing appears. Set the value for the variable position to 10:

Figure5.7-2 Definition of the position of the left bearing to y=10 mm

This should be repeated for all elements. After pressing Refresh, the elements are shown in the correct order in the schematic:

Figure5.7-3 Correct order of the elements in the schematic

5.7.2

Positioning of the shafts

The shafts are still to be positioned with respect to each other. The second shaft should be parallel to the first shaft, the distance being the centre distance of the first gear pair. Shaft 3 should be parallel to shaft 2, and again in the distance of the centre distance of the second gear pair.
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Positioning procedure is started by right mouse click on s2 and s3, select Dialog:

Figure5.7-4 Dialog for positioning of shafts

First, s2 is positioned with respect to s1. In the dialog, select Parallel to Shaft:

Figure5.7-5 First part of the dialog, positioning with respect to an existing shaft

In the second part of the dialog, the shaft is positioned using a polar co-ordinates system. The distance between the two shafts (the radial co-ordinate) is equal to the centre distance of the first gear pair. The centre distance is available from the variable GB.gp1.GP1.a. The angle and the axial displacement are set to zero (no input required):
In Element reference element is selected. The starting point of the shaft (always its left end) to be positioned can now be defined using polar or Cartesian coordinates. Easier is to use polar coordinates. The radial co-ordinate is equal to the centre distance of the gear pair 1 (= variable GB.gp1.GP1.a)

Figure5.7-6 Second part of dialog, positioning of shaft 2 with respect to shaft 1

To be repeated for shaft 3.

5.7.3

3D View

Now that all elements have been positioned (although only preliminary), the 3D view can be included (copy from templates, element kSys3Dview and insert on the same level as the group GB). Using right mouse click and Show, the 3D view is shown as follows:

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Figure5.7-7 3D view of the system

The shaft geometry and the bearings have not been defined yet.

5.8 Definition of the shaft geometry

With double click on the KISSsoft shaft analysis modules S1, S2 and S3 the KISSsoft shaft analysis is started. Here, in the graphical shaft editor, the shaft can be modeled 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=20mm and length 130mm is defined for all three shafts, shown here for the first shaft:

Figure5.8-1 View when opening the graphical shaft editor

After having inserted a cylindrical shaft:

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Figure5.8-2 View with cylindrical shaft added

The shaft can now be detailed in the usual way. 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. This should be repeated for all three shafts (in this example, all shafts are 130 mm long and 20 mm, 30 mm and 40 mm in diameter. The 3D view changes as shown below when pressing Refresh All:

Figure5.8-3 3D View with shaft geometry as defined

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5.9 Definition of bearings

Now that all three shafts have been properly defined, the bearings can be defined. This order in defining the elements (shafts first, bearings second) is important since the inner diameter of the bearings is governed by the outer diameter of the shaft and the position of the bearing on the shaft. Double click on the bearing analysis (here using shaft 1 as example) B_s1, the respective KISSsoft analysis interface is shown. The inner diameter of the bearing is defined through the shaft diameter and the position of the bearing. Now, a suitable bearing can be chosen as usual.

Figure5.9-1 Selection of bearing in KISSsoft for the given inner diameter of the bearing (=shaft diameter)

After having chosen the bearing type and the bearing, press Calculate F5 in order to activate the selection. To be repeated for all three pairs of bearings. The 3D view changes accordingly after pressing Refresh All:

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6 User Interfaces
6.1 Table with information on gear and bearing data
From the templates, the following three tables can be copied into the tree structure below the group GB: Bearing2Calculations, GearPairCalulations and ShaftCalculations:

Figure6.1-1 Tables to be copied from the templates

Once copied, using a right mouse click on the tables and pressing Show gives:

Figure6.1-2 Tables with gear data, bearing data and KISSsoft gear pair analysis data

These tables offer an overview over the parameters used. Parameters in red can be changed using the tables.

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6.2 User Interfaces

6.2.1 Introducing an user interface

A table for definition of the main input and output data is to be introduced: Choose the table UserInterface from the templates and copy it into the tree using the name UserInterface. With Show, the table is shown. Use function Dialog to define the number of rows and columns for table size.

Figure 6.2-1 Resizing a table

6.2.2

Adding text

Use right mouse click and Insert String to insert text as shown in the figure below. The text is to be defined in the field Value:

Figure 6.2-2 Adding text to the user interface

If information in the field is only a text user can also directly write the information in the right field.

6.2.3

Display of results

First, the speed at the output and the torque at the input (these values are calculated from the input values and the gear kinematics) are included in the user interface. With right mouse click, Insert real, the following dialog is shown. In Expression the name and the path of the variable should be given. The speed at the output is given in the variable speed. Note that the full path Output.speed is to be given. Press Ok to accept and the result is shown in the user interface.

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Figure6.2-3 Showing the speed at the output

Figure6.2-4 Result in the user interface

In the same manner, the torque at the input is shown in the user interface. Right mouse click on the desired field, Insert Real, Expression: Input.torque, and the torque should be shown as follows:

Figure6.2-5 Showing the torque at the input

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:

Figure6.2-6 Calculation of the total reduction from input speed and output speed

Expression is extended to have a condition (IFTHEN and ELSE) to check that Output speed is not zero to be able to evaluate the formula.

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It is also possible to change the type of information e.g. from real value to text. Total efficiency of the system 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 digitst) 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 6.2-7 Condition and formula to calculate efficiency of the system and to convert the value to a text

Now, the root and flank safety factors for the three gears shall be included. The procedure is illustrated using the root safety of gear 1 as an example. Again, with right mouse click and Insert Real, the following dialog is shown. Set the expression as follows:

Figure6.2-8 Showing the safety factor for the root of gear 1

With this dialog, the variable SF1 is shown in the user interface. The complete path (as defined in the tree structure) has to be given in the expression. In the same manner, the other root and flank safety factors are shown. Use the expressions in the table below to get the correct variables:
Gear Input Shaft, Gear 1 (z1) Input Shaft, Gear 1 (z1) Second Shaft, Gear 1 (z2) Second Shaft, Gear 1 (z2) Second Shaft, Gear 2 (z3) Second Shaft, Gear 2 (z3) Output Shaft, Gear 1 (z4) Output Shaft, Gear 1 (z4) Root/Flank Root Flank Root Flank Root Flank Root Flank Variable inclusive of path, text to be entered _O.GB.gp1.GP1.SF1 GB.gp1.GP1.SH1 GB.gp1.GP1.SF2 GB.gp1.GP1.SH2 GB.gp2.GP2.SF1 GB.gp2.GP2.SH1 GB.gp2.GP2.SF2 GB.gp2.GP2.SH2

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The user interface should now look as follows (or similar):

Figure6.2-9 User Interface with safety factors for root and flank for all four gears

6.2.4

Changing values using the UserInterface

In this example, the input speed and the output torque are given to calculate the kinematics. Changing these values through the user interface should be made possible in this example model. For this, a so-called Reference is added to the User Interface. Right mouse click into the desired field, insert real and activate Reference. It is important to define the name of the variable to be addressed in the field Reference to. After Ok, the value is shown in the user interface in red. Reference needs to be written in quotation marks e.g. Input.speed.

Figure6.2-10 Defining a reference to the variable Input.speed

Figure6.2-11 Field (red) for defining the input speed

In this field (red text) a value for the input speed can be typed directly. This value is then written into the variable Input.speed to be used for the next kinematics analysis. In the same manner, the output torque is included in the user interface (reference to Output.torque).

6.2.5

Changing calculation method from the UserInterface

To be able to perform calculations for the gears existing calculation method need to be selected for the gears. This change can easily be done via UserInterface, instead of doing it for every gear calculation separately. To do this create reference to the gear calculation methods in the UserInteraface. Select field to add new data. Select Insert database list as a type of information. This calculation method is coming form the KISSsoft database and therefore list values are needed to be connected to the values defined in the database. Create
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reference to gear calculation methods. Note that definer reference variables need to be in quotation marks (Variable name). Gear pair GP1 GP2 Reference to _O.GB.gp1.GP1.CalcMethod _O.GB.gp2.GP2.CalcMethod

Figure 6.2-12 Reference to the calculation method

6.2.6

Further settings

To be able to change the efficiency of the gear pairs use reference to real in the table to change the values. Gear connection Reference to gp1 _O.GB.gp1.eta gp2 _O.GB.gp2.eta It can also be interesting to change the layout of the shaft positions easily via a table. To do this user needs to create new variables in UserInterface table, show these new variables in the table as reference and then make link from these variables to the positions of the shafts. Create first new variables angle1 and angle2 under UserInterface table selecting table from the tree and using function NewVariable. Select type to be real, name is angle1 and value can be set to desired. Do the same to create also angle2.

Figure 6.2-13 Create new variable under "UserInterface"

Insert again real value to the table field and set reference to

Figure 6.2-14 Create access to the new value angle1 form the table 30 / 34

Set expression to the shaft positions (angles) to change from the table. Select shaft s2 from the tree and use function Dialog to do settings. Add new value for the angle as taken from UserInterface. (_O.UserInterface.angle1)

The angle is equal to the angle defined in the UserInterface table (= variable UserInterface.angle1)

Figure 6.2-15 Angular positioning

6.2.7

Execution of functions
calculates the kinematics of the gearbox execution of KISSsoft strength analysis KISSsoft interface for gears of first stage KISSsoft interface for gears of second stage

In the user interface, functions can be included. In this example, four functions are included: - Function Kinematic - Function Strength - Function GP1 - Function GP2

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. For the function Kinematic:
The name of the function Kinematic will be visible in the User Interface, but has no other effect otherwise. System.calcKinematic(); means that in System, the function calcKinematic is executed (empty brackets since no values are handed over to the function), ; to complete the command line kSys_Refresh corresponds to Refresh All, to ensure that the values calculated (the output speed and the input torque) are shown as results in the user interface. Enter the following text: System.calcKinematic(); kSys_Refresh();

Figure6.2-16 Definition of the function to calculate the kinematics

For the function KISSsoft

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In the first step, the kinematics of the gear is analysed again to ensure that the correct power is used.

System.kSoftCalculate(); calls the function kSoftCalculate under System. This command executes all KISSsoft strength analysis.

Enter the following text:

System.calcKinematic(); System.kSoftCalculate(); kSys_Refresh();

Figure6.2-17 Definition of the function for strength analysis using KISSsoft

For the functions GP1 and GP2:

The command kSoftInterface opens the corresponding KISSsoft analysis. The full path has to be included to identify the KISSsoft analysis to be shown.

Enter the following text: GB.gp1.GP1.kSoftinterface();

Figure6.2-18 Definition of the function for calling KISSsoft interface for the gears of stage 1 (repeat for stage 2)

Now, the user interface shows four light blue fields with executable (double click) functions:

Figure6.2-19 Functions added in the UserInterface 32 / 34

7 Completing the model

7.1 Setting 3DView
Use function System specific settings from menu to set 3DView colors and appearance.

Figure 7.1-1 Function to set 3DView presentation

7.2 Display of the coupling

The couplings may not yet be shown in the 3D view since their width is still zero. Right mouse click on the couplings (cIn and cOut), Properties and define variable b (=width) and d (=diameter). Let the width be 20 mm and the diameter 50 mm for example. After RefreshAll the 3D view looks as follows:

Figure7.2-1 3D Display of couplings (red)

7.3 Definition of fixed and free bearings

Until now (if you didnt define axial load supports in shaft editor) the bearings are free bearings. All left bearings b1 shall be defined as fixed bearings. Right mouse click on all left bearings, select Dialog, select radial/axial and <> (fixed bearing).

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Figure7.3-1 Definition of fixed bearing

The schematic is updated by pressing Refresh:

Figure7.3-2 Schematic with fixed bearings

7.4 Definition of the force acting on the output shaft

On the output shaft, a force has been introduced. The five components of the force (Fx, Fy, Fz, Mx, Mz) can either be defined in the Properties directly or through the user interface (reference to the variable, as shown above). The force has an effect on the lifetime of the bearings, but not the gears.

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