KISSsys 03/2014 Tutorial 3 Gear transmission with planetary differential 07/11/2014 KISSsoft AG Rosengartenstrasse 4 8608 Bubikon Switzerland Tel:+41 55 254 20 50 Fax: +41 55 254 20 51 info@KISSsoft.AG www.KISSsoft.AG 10.11.20142 / 35 Foreword The tutorial has two parts to be studied in this order. Part I Introduction, explains the most important points for this modeling task and introduces how to start KISSsys. Part II Modelling, showstechniqueshowtobuildaKISSsysmodelofacomplexgearboxwithseveralpowerpath 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. 10.11.20143 / 35 Contents 1Introduction .............................................................................................................................................. 4 1.1Summary of the most important points ........................................................................................... 4 1.2Systematic procedure ..................................................................................................................... 4 1.3Errata and remarks ......................................................................................................................... 4 1.4Modelling task ................................................................................................................................. 5 1.5Starting KISSsys ............................................................................................................................. 6 1.6Selection of the project directory .................................................................................................... 6 1.7Use KISSsys in the administrator mode ......................................................................................... 7 1.8Loading the templates .................................................................................................................... 7 2Building a model....................................................................................................................................... 8 2.1Tree structure ................................................................................................................................. 8 2.1.1Shafts and shaft groups ............................................................................................................. 8 2.1.2Machine elements ...................................................................................................................... 9 2.1.3Connection of coaxial shafts .................................................................................................... 11 2.1.4Connections of the gears ......................................................................................................... 12 2.1.4.1Helical gearpair connections ............................................................................................ 12 2.1.4.2Connection Planet/Sun, Sun/Ring ................................................................................... 13 2.1.5Definition of the boundary conditions ....................................................................................... 14 2.1.6Adding KISSsoft calculation elements ...................................................................................... 15 2.2Input of Gear, shaft, and bearing data .......................................................................................... 17 2.2.1Gear data ................................................................................................................................. 17 2.2.2Definition of shafts and bearings .............................................................................................. 19 33D View .................................................................................................................................................. 20 3.1Adding 3D view in the tree structure ............................................................................................. 20 3.2Location of the shafts ................................................................................................................... 21 3.2.1Positioning of the shafts group Middle ................................................................................... 21 3.2.2Positioning of the shaft group Main ........................................................................................ 21 3.2.3Positioning of the group Planet .............................................................................................. 22 3.3Work with the 3D Viewer .............................................................................................................. 22 3.3.1Inside diameters of the gear wheels ......................................................................................... 22 3.3.2Color and transparency ............................................................................................................ 23 3.4Insert data from CAD system ....................................................................................................... 24 4Changing of gears .................................................................................................................................. 25 4.1Background Information about clutch elements ........................................................................... 25 4.2Application in the current example ............................................................................................... 25 4.3Call the function ............................................................................................................................ 26 4.4Table approach ............................................................................................................................. 27 5User Interface......................................................................................................................................... 28 5.1Input of the power ......................................................................................................................... 28 5.2Execute buttons for function in the User Interface ........................................................................ 30 6Completing the model ............................................................................................................................ 31 6.1Input of the speed ratio for front and rear drive ............................................................................ 31 6.2Input of efficiency .......................................................................................................................... 33 6.3Settings to calculation methodology ............................................................................................. 33 7Annex ..................................................................................................................................................... 34 7.1Code [line numbers are not part of the code] ............................................................................... 34 7.1.1Clarification ............................................................................................................................... 34 7.2Code to set the internal diameter di of the gears ....................................................................... 35 10.11.20144 / 35 1Introduction 1.1Summary 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.ThecalculationofaconnectionwiththreehelicalgearsiscalculatedwithKISSsoftcalculation 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. 1.2Systematic procedure The following steps are involved when building a KISSsys model: 1.Planning: Naming, range and goals of the model 2.Insert mechanical component in the tree structure (grey Icons) 3.Connect mechanical component to each other (grey Icons) 4.Define sources of power flow 5.Add KISSsoft calculation elements to the mechanical components (blue Icons) 6.Add 3D graphic, and position elements in the graphic 7.Add tables / User Interfaces 8.Program own functions 9.Tests, debugging 1.3Errata and remarks 1.If questions or difficulties arise during the tutorial, KISSsoft Hotline can be used for assistance (e-mail address, phone no.etc. are written on the front page). 10.11.20145 / 35 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 isused. 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). 1.4Modelling task A transfer gearbox for a 4x4 off-highway vehicle is to be modeled. The transmission possesses an on- and off -road gear as well as a lockable epicyclic differential acting as a longitudinal differential. A part of the power is continually taken off over a PTO. The bevel gear differentials in the axles are not modeled. The unlocked gears z1 and z3 on the input shaft clutches can be switched on or off. 10.11.20146 / 35 Figure 1.Diagram of the gearbox to be modelled 1.5Starting KISSsys First, a project folder has to be created. Then, KISSsys has to be started and the intended folder is chosen as project folder. Using Options, activate the administratormode. Then, the templates should be opened using File/Open templates. Make sure the latest Patch version is installed on your computer. (Download from www.KISSsoft.ch) 1.6Selection of the project directory KISSsys uses projects to manage the files. Project folder simply defines where KISSsys models and the 10.11.20147 / 35 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. File Open project folder, the project folder will be defined. If there is no Project folder defined everything will be saved in the default folder. E.g. Users KISSsoft. Inthefollowingfigureitisshowntheprojectfolderforthistutorial.InthiscasethefolderisC:\Programme\KISSsoft 03-2014\KISSsys\Tutorial. After the selection, this is confirmed and KISSsys opens. Figure 2.Opening the project folder 1.7Use KISSsys in the administrator mode KISSsys starts now with an empty model. As a first step, the "administrator" mode must be activated under the main menu "Extras". Figure 3.Activating the administrator mode If the option "Administrator" can not be selected, then the KISSsys license is missing. In this case contact KISSsoft AG. 1.8Loading the templates As a first step when creating a new KISSsys model, the templates have to be imported through the menu File Opentemplatestemplates.ks.Inthetemplates,allelementsarenowlistedwhichcanbeusedin KISSsys: 10.11.20148 / 35 Figure 4.Element library after loading the templates After having imported the templates, it can be started with building the model. 2Building a model Itisuptotheuserwhichmethodisusedtobuildthemodel.ItisrecommendedtousetheElementsbox methodfor this tutorial.2.1Tree structure In a first step the shaft groups (element kSysGroup) Input, Middle and Main must be defined in a tree structureundertheelementGB(alsoelementkSysGroup).Nowallthecoaxialshaftsmustbeplaced under each shaft group. It is highly recommended to name gears, shafts, bearings and couplings in such a way as shown in the illustration down. User can define first shaft (e.g. s1 with bearings b1 and b2) and then copy it to avoid adding all bearings one by one. 2.1.1Shafts and shaft groups Figure 5.Adding the groups Input, Middle and Main 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 copiedinto Planet. The shaft pin (Planet pin) is fixed with the planet carrier s5 by a coupling.10.11.20149 / 35 Figure 6.Adding the Shaft group Planet 2.1.2Machine elements The same names can be used several times for different mechanical components, as long as the mechanical components are in a different path of the tree. Please note all bearings are called "b". The bearing on the left hand side is "b1", the one on the right hand side is "b2". The following is important when modeling an epicycle gear train: 1)The planet stage is a configuration of coaxial shafts: sun shaft s4, ring s3 and planet carrier s5. 2)The planet is supported by two bearings of the planet pin (shaft pin). The pin is fixed with supports support1and 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. 10.11.201410 / 35 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. 10.11.201411 / 35 2.1.3Connection 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 treeafter adding the connection roller bearings The clutches c1, c2 and c3are 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.Soselectthe couplingc1andsetunderpropertiesthevariablestateRytofixed.Thesame setting can also be done by clicking with the right mouse button on the element and selecting Dialog. As it 10.11.201412 / 35 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. Figure 11.Condition for the clutch c3 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 2.1.4Connections of the gears 2.1.4.1Helical gearpair connections Inthenextstepthegearsareconnected.Forthespurgears,thetype"kSysGearPairConstraint"is necessary. The following connections need to be defined: 10.11.201413 / 35 ConnectionElement1Element2 gp1z1z2 gp2z3z4 gp3z4z5 gp4z6z7 Figure 13.Table for the gearpair connections 2.1.4.2Connection Planet/Sun, Sun/Ring TheplanetsneedthetypekSysPlanetaryGearPairConstraint"twotimes.Onewherethesunwheel 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: Figure 15.Model Tree after adding the connections 10.11.201414 / 35 2.1.5Definition 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: NameElementSpeed contraintSpeed[1/min]Torque constraintPower/Torque inputTorque [Nm] InputCInYes2000YesTorque with sign100 PTOcPTONoYesTorque with sign10 OutRcrOutNoNo OutFcfOutYesNo 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".Thisguaranteesthatthespeedattheoutputisequaltothespeedoftheshafts5,butin opposite direction of rotation. Figure 17.Additional definition of the output speed for OutF. Nowthekinematiccalculationcanbeperformedbyclickingon .AfteraRefresh,thesketchlooksas follows: 10.11.201415 / 35 Figure 18.Diagram after the definition of the boundary conditions and the kinematic calculation 2.1.6Adding KISSsoft calculation elements NextstepistointroducetheKISSsoftanalysismodules.Thesearecopiedfromthetemplates.KISSsoft analysis modules for coaxial shafts, bearings (included in the shaft calculation in the new release) and gears are needed. The gear pair calculations GP1 (gears z1 and z2) and GP4 (gears z6 and z7) are directly placed under the appropriate gear pair connection. For the connections gp2 and gp3 the KISSsoft analysis modulekSoft3HelicalGearsiscopiedonthesamelevelliketheconnections.Thisregardsthe connection of gear z4 with two gears and the therefore reduced lifetime. 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. 10.11.201416 / 35

Figure 20.Settings for the planetary stage calculation elementThe 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. Figure 21.Model tree after adding the calculation elements 10.11.201417 / 35 2.2Input of Gear, shaft, and bearing data 2.2.1Gear data Thefollowingteethdataisusedinthisexample.ToswitchtotheKISSsoftinterfacedouble-clickonthe computations (blue Icons) in the tree structure. After entering the design data, the input in each case has to be confirmed with "calculation F5". Afterwards, close the KISSsoft window with "exit" (cross in the right upper corner). Figure 22.Input values for the gearpair calculation GP1 in KISSsoft Figure 23.Input values for the gearpair calculation GP4 in KISSsoft 10.11.201418 / 35 Figure 24.Input data for the three gear train GP2_3 in KISSsoft 10.11.201419 / 35 Figure 25.Input data for the planetary stage in KISSsoft 2.2.2Definition of shafts and bearings 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: z2y = 50 mm z4y = 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 10.11.201420 / 35 position shaft planet:y = 2.5mm position zp: y = 5 mm Be careful! The displacement in x- and z- direction is set to fixed for support1 in the element editor. Figure 28.Input data for the shaft group PLANET position of the coup.(resp. appropriate shaft):cfOut: y = 10mm crOut: y = 165mmcarriercoup,coupling: both y = 0 c3: y = 238 mm position shafts: s4 y = 0 mm s3 y = 170 mm s5 y = 195 mm position bearings: s4:b1 y = 30 mm b2 y = 150 mm s3:b1 y = 30 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 Figure 29.Input data for the shaft group MAIN 33D View 3.1Adding 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. 10.11.201421 / 35 Figure 30.View of the model in 3D before positioning the shafts 3.2Location of the shafts 3.2.1Positioning of the shafts group Middle 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. Figure 31.Positioning of the shaft group Middle 3.2.2Positioning of the shaft group Main 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 to90. The position in y- direction must be chosen so that z4 and z5are 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. Figure 32.Positioning of the shaft group main 10.11.201422 / 35 3.2.3Positioning 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 to90. 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.

Figure 33.Positioning of the group Planet Press Refresh button on menu to see all components places correctly in the space. 3.3Work with the 3D Viewer 3.3.1Inside diameters of the gear wheels The inside diameters of the gear wheels should be set equal to the outside diameter of the respective shaft. For all gear wheels, except the internal gear, the variable di should have the following text inserted in the field expression: 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. 10.11.201423 / 35 3.3.2Color and transparency Byclickingontheusercanchangethecolorandtransparencyofthe3D-viewforgears,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). Figure 35.Representation settings of the 3D view Figure 36.3D View after changing the settings 10.11.201424 / 35 3.4Insert data from CAD systemDepending upon version of KISSsys *.sat, *.iges or *.step data from any CAD system can be imported. In addition,"kSysCasing"hastobecopiedfromthetemplatesintothetreestructure.Inthisexample,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. Figure 37.Settings to import the CAD data to de 3D view There is always a refreshneeded to see the graphical changes. Positioning of the wheels can be done manually entering in the Properties and changing position values. Figure 38.Positioning of the housing element 10.11.201425 / 35 Figure 39.3D view after importing and positioning the CAD data 4 Changing of gears 4.1Background 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.4.2Application in the current example The function for changing gears should be contained in a table "Settings". First from the templates the table "UserInterface"mustbecopiedintothehighestlevelofthetreestructure.Thetablehastobenamed "Settings". Using the right mouse button, the size of the table can be defined under "dialog". The table can bevisualizedbyselecting"show".Usingtherightmouse-clickunder"Settings"inthetreestructure,on selection of "new variable" a further variable with the name "SetGear" of the type "function" can be inserted. With the right mouse-click on "Settings" and the selection of Properties", the following window opens. Now the function editor can be called by the right mouse-click on "SetGear" and the selection of "Edit". Further, a variable "OnOffRoad" of the type "real" has to be added. This will describe the momentarily selected gear. If it is 0, the on-road gear is active, if 1 then the off-road gear is engaged. Figure 40.Edit the function SetGear 10.11.201426 / 35 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 ofthearraycorrespondstotheselectionmade.If"on-Road"isselectedthen0isreturned,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 newpowerflow.Toseetheclutchesin3D-view,theouterdiameterD,theinnerdiameterdandthe 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: 4.3Call the function With a right mouse-click on the desired cell in the user interface, the selection of "Insert function" has to be done and it has to be defined: Figure 42.Implementing a function into a cell 10.11.201427 / 35

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:

Figure 44.Change of the power flow by changing the speed 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. 4.4Table approach There is also another type of approach available in KISSsys. This is reprogrammed Speed-table to select differentspeedsinthemodelwithoutownprogramming.Formoredetails,pleaseseeins-305-SpeedTable.pdf. 10.11.201428 / 35 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. 5.1Input of the power In principle the following operations are used in the "UserInterface". There are more available, however, those noted here are the most frequently used. Input of textAs a commentClarifying text can be typed directly into a cell. This text appears in black writing with white background. Input of numbers Display of values of variable Right mouse-click on the desired cell, select "Real insert". An input mask appears. Into expression the path of the variable has to be written, their value should be displayed. The value appears in black writing with white background. See Figure 46. Reference on numbers For display and input of values of variables Right mouse-click on the desired cell, select "Real insert". An input mask appears left down "reference" must be pressed. After this, "reference up" the path of the variable has to be written their value should be displayed Note: the path must be located in quotation marks. The values are indicated in red writing with white background. See Figure 48. Insert execute buttons for functions Execute functions through double click Right mouse-click on the desired cell, select "function insert". An input mask appears. Under "name" the name can be inserted, where the function in the user interface has to be indicated with. In the field "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 Figure 45.User Interface after inserting the values 10.11.201429 / 35 The path of the variable has to be written into expression, then theirvalue is displayed. In the example shown, this variable is the power inputcalculatedfromthespeedandtorque.(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 Figure 46.Inserting the variable directly into the cell The User Interface looks then as follows: Figure 47.UserInterface with the variable values Now for the definition of the input torque and speed, a reference can be inserted for each: Figure 48.Inserting a variable directly as reference 10.11.201430 / 35 AfterReferenceisselected,thereferencetofieldisswitchontoinsertatext.Thepathofthedesired 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 5.2Execute buttons for function in the User Interface The following function should be executed from the User Interface: 1)Selection of the gear (already accomplished in section 4) 2)Calculation of kinematics as speed, torque and power flow 3)Performing all of the KISSsoft calculations4)Show the whole calculation report for the entire gearbox The functions which can be inserted are defined as follows: Inafirststep,thedialoguefortheselectionofthegearis called (as defined above).Nextthekinematicscomputationiscalled.Afterconclusion of the kinematics computation, a refresh takes place. Figure 49.Implementing the function Kinematics into the UserInterface table TheKISSsoftcalculationsarecalledwiththefunction kSoftCalculate,thesearedefinedunderSystem.After termination of the computations, a refresh takes place. Figure 50.Implementing the function Strenght into the UserInterface table 10.11.201431 / 35 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 The User Interface looks now as follows: Figure 52.UserInterface after inserting the functions If user doesnt want to create functions for Kinematics, Strength and Report it is possible to use buttons for the same from the menu. 6 Completing the model 6.1Input of the speed ratio for front and rear drive Thenumberofrevolutionsatthe frontaxleisstilloppositeandequaltothatoftherearaxle.It shouldbe possible however for any number of revolution relationships. The value of the speed ratio should be defined via a variable "FrontRearRatio" under "Settings". To create such a variable in the tree structure the right mouse-click must be pressed the on "Settings" and "new variable" selected. Then a variable "FrontRearRatio" can be added of the type "Real": 10.11.201432 / 35 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: Figure 54.Expression for the output speed OutF 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: 10.11.201433 / 35 Figure 55.Update of the function SetGear Thedialoguenowlooksasfollows.Forinstance,whenthevalue1.5isenteredfor"FronttoRear,the numbers of revolutions result is as shown: Figure 56.Definition of ratio between front and rear axis 6.2Input of efficiency 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. 6.3Settings to calculation methodology The kinematic analysis contains conditions for the torques and speeds, which are to be solved only by iterative computation.Therefore,select"iterationforspeedandtorqueswithdamping"undersystem "kSysKinematicMode". 10.11.201434 / 35 Figure 57.Setting for the kinematic calculation 7Annex 7.1Code [line numbers are not part of the code] 1VAR 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); 6IF res[0] THEN 7OnOffRoad=res[1]; 8Settings.FrontRearRatio=res[2]; 9IF res[1]=0 THEN 10GB.Input.c1.stateRy=1; 11GB.Input.c2.stateRy=0; 12GB.Input.c1.kSys_3DTransparency=0; 13GB.Input.c2.kSys_3DTransparency=0.7; 14ELSE 15GB.Input.c1.stateRy=1; 16GB.Input.c2.stateRy=0; 17GB.Input.c1.kSys_3DTransparency=0; 18GB.Input.c2.kSys_3DTransparency=0.7; 19ENDIF 20System.calcKinematic(); 21ENDIF 7.1.1Clarification 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. 10.11.201435 / 35 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 secondlinepermitstheinputofavalue.Thepre-emptionoftheinputmaskbecomesdefinedthrough[ 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. In line 20 the kinematics calculation will be executed. 7.2Code to set the internal diameter di of the gears # 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