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

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,
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.

10.11.2014

2 / 35

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
2.1.4.2

Connection Planet/Sun, Sun/Ring ................................................................................... 13

2.1.5
Definition of the boundary conditions ....................................................................................... 14
2.1.6
Adding KISSsoft calculation elements ...................................................................................... 15
2.2
Input of Gear, shaft, and bearing data .......................................................................................... 17
2.2.1
Gear data ................................................................................................................................. 17
2.2.2
Definition of shafts and bearings .............................................................................................. 19
3D View .................................................................................................................................................. 20
3.1
Adding 3D view in the tree structure ............................................................................................. 20
3.2
Location of the shafts ................................................................................................................... 21
3.2.1
Positioning of the shafts group Middle ................................................................................... 21
3.2.2
Positioning of the shaft group Main ........................................................................................ 21
3.2.3
Positioning of the group Planet .............................................................................................. 22
3.3
Work with the 3D Viewer .............................................................................................................. 22
3.3.1
Inside diameters of the gear wheels ......................................................................................... 22
3.3.2
Color and transparency ............................................................................................................ 23
3.4
Insert data from CAD system ....................................................................................................... 24
Changing of gears .................................................................................................................................. 25
4.1
Background Information about clutch elements ........................................................................... 25
4.2
Application in the current example ............................................................................................... 25
4.3
Call the function ............................................................................................................................ 26
4.4
Table approach............................................................................................................................. 27
User Interface......................................................................................................................................... 28
5.1
Input of the power ......................................................................................................................... 28
5.2
Execute buttons for function in the User Interface ........................................................................ 30
Completing the model ............................................................................................................................ 31
6.1
Input of the speed ratio for front and rear drive ............................................................................ 31
6.2
Input of efficiency.......................................................................................................................... 33
6.3
Settings to calculation methodology ............................................................................................. 33
Annex ..................................................................................................................................................... 34
7.1
Code [line numbers are not part of the code] ............................................................................... 34
7.1.1
Clarification ............................................................................................................................... 34
7.2
Code to set the internal diameter di of the gears ....................................................................... 35

10.11.2014

3 / 35

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.

1.2 Systematic 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

1.3 Errata and remarks

1.

If questions or difficulties arise during the tutorial, KISSsoft Hotline can be used for assistance (email address, phone no.etc. are written on the front page).

10.11.2014

4 / 35

2.

3.

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.
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).

1.4 Modelling 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.

10.11.2014

5 / 35

Figure 1.

Diagram of the gearbox to be modelled

1.5 Starting 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 administrator mode. 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)

1.6 Selection of the project directory

KISSsys uses projects to manage the files. Project folder simply defines where KISSsys models and the

10.11.2014

6 / 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.
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.

Figure 2.

Opening the project folder

1.7 Use 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.

1.8 Loading the templates

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

10.11.2014

7 / 35

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
method

for this tutorial.

2.1 Tree structure

In a first step the shaft groups (element kSysGroup) Input, Middle and Main must be defined in a tree
structure under the element GB (also element kSysGroup). Now all the coaxial shafts must be placed
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.

2.1.1 Shafts 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 copied into Planet. The shaft pin (Planet pin) is fixed
with the planet carrier s5 by a coupling.

10.11.2014

8 / 35

Figure 6.

Adding the Shaft group Planet

2.1.2 Machine 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.

10.11.2014

9 / 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.

10.11.2014

10 / 35

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 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. 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

10.11.2014

11 / 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

2.1.4 Connections of the gears

2.1.4.1

Helical gearpair connections

In the next step the gears are connected. For the spur gears, the type "kSysGearPairConstraint"
necessary. The following connections need to be defined:

10.11.2014

is

12 / 35

Connection

Element1

Element2

gp1

z1

z2

gp2

z3

z4

gp3

z4

z5

gp4

z6

z7

Figure 13.

2.1.4.2

Table for the gearpair connections

Connection Planet/Sun, Sun/Ring

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:

Figure 15.

10.11.2014

Model Tree after adding the connections

13 / 35

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
Input
PTO
OutR
OutF

Element
CIn
cPTO
crOut
cfOut

Figure 16.

Speed contraint
Yes
No
No
Yes

Speed[1/min]
2000

Torque constraint
Yes
Yes
No
No

Power/Torque input
Torque with sign
Torque with sign

Torque [Nm]
100
10

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.

Figure 17.

Additional definition of the output speed for OutF.

Now the kinematic calculation can be performed by clicking on

follows:

10.11.2014

. After a Refresh, the sketch looks as

14 / 35

Figure 18.

Diagram after the definition of the boundary conditions and the kinematic calculation

2.1.6 Adding KISSsoft calculation elements

Next step is to introduce the KISSsoft analysis modules. These are copied from the templates. 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
module kSoft3HelicalGears
is copied on the same level like the connections. This regards the
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.

10.11.2014

15 / 35

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.

Figure 21.

10.11.2014

Model tree after adding the calculation elements

16 / 35

2.2 Input of Gear, shaft, and bearing data

2.2.1 Gear data
The following teeth data is used in this example. To switch to the KISSsoft interface double-click on the
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

10.11.2014

17 / 35

Figure 24.

10.11.2014

Input data for the three gear train GP2_3 in KISSsoft

18 / 35

Figure 25.

Input data for the planetary stage in KISSsoft

2.2.2 Definition 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:
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.

10.11.2014

Input data for the shaft group MIDDLE

19 / 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 = 165mm
carriercoup,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

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.

10.11.2014

20 / 35

Figure 30.

View of the model in 3D before positioning the shafts

3.2 Location of the shafts

3.2.1 Positioning 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

3.2.2 Positioning 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 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.

Figure 32.

10.11.2014

Positioning of the shaft group main

21 / 35

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.

Figure 33.

Positioning of the group Planet

Press Refresh button on menu to see all components places correctly in the space.

3.3 Work with the 3D Viewer

3.3.1 Inside 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.

10.11.2014

22 / 35

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).

Figure 35.

Representation settings of the 3D view

Figure 36.

3D View after changing the settings

10.11.2014

23 / 35

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-CADdata.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 refresh

needed to see the graphical changes. Positioning of the wheels can be done
manually entering in the Properties and changing position values.

Figure 38.

10.11.2014

Positioning of the housing element

24 / 35

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.

4.2 Application in the current example

The function for changing gears should be contained in a table "Settings". First from the templates the table
"UserInterface" must be copied into the highest level of the tree structure. The table has to be named
"Settings". Using the right mouse button, the size of the table can be defined under "dialog". The table can
be visualized by selecting "show". Using the right mouse-click under "Settings" in the tree structure, 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.

10.11.2014

Edit the function SetGear

25 / 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
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:

4.3 Call 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.

10.11.2014

Implementing a function into a cell

26 / 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.

4.4 Table approach

There is also another type of approach available in KISSsys. This is reprogrammed Speed-table to select
different speeds in the model without own programming. For more details, please see ins-305SpeedTable.pdf.

10.11.2014

27 / 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.

5.1 Input 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 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
Note: the path must be located in quotation marks. The values are
variables
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

Figure 45.

10.11.2014

User Interface after inserting the values

28 / 35

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

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.

10.11.2014

Inserting a variable directly as reference

29 / 35

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

5.2 Execute buttons for function in the User Interface

The following function should be executed from the User Interface:
1)
2)
3)
4)

Selection of the gear (already accomplished in section 4)

Calculation of kinematics as speed, torque and power flow
Performing all of the KISSsoft calculations
Show the whole calculation report for the entire gearbox

The functions which can be inserted are defined as follows:

In a first step, the dialogue for the selection of the gear is

called (as defined above).
Next the kinematics computation is called. After conclusion
of the kinematics computation, a refresh takes place.

Figure 49.

Implementing the function Kinematics into the UserInterface table

The KISSsoft calculations are called with the function

kSoftCalculate, these are defined under System. After
termination of the computations, a refresh takes place.

Figure 50.

10.11.2014

Implementing the function Strenght into the UserInterface table

30 / 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

6.1 Input of the speed ratio for front and rear drive
The number of revolutions at the front axle is still opposite and equal to that of the rear axle. It should be
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":

10.11.2014

31 / 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:

10.11.2014

32 / 35

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:

Figure 56.

Definition of ratio between front and rear axis

6.2 Input 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.

6.3 Settings to calculation methodology

The kinematic analysis contains conditions for the torques and speeds, which are to be solved only by iterative
computation. Therefore, select "iteration for speed and torques with damping" under system
"kSysKinematicMode".

10.11.2014

33 / 35

Figure 57.

Setting for the kinematic calculation

7 Annex
7.1 Code [line numbers are not part of the code]
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

VAR res;
res=CADH_VarDialog( ["SetSpeed",250,250,0.4,1],
[[C:VDLG_StrCom],"Speed:",["On-Road","Off-Road"],[OnOffRoad],1],
[[C:VDLG_Real],"Front to Rear:",Settings.FrontRearRatio,Settings.FrontRearRatio]
);
IF res[0] THEN
OnOffRoad=res[1];
Settings.FrontRearRatio=res[2];
IF res[1]=0 THEN
GB.Input.c1.stateRy=1;
GB.Input.c2.stateRy=0;
GB.Input.c1.kSys_3DTransparency=0;
GB.Input.c2.kSys_3DTransparency=0.7;
ELSE
GB.Input.c1.stateRy=1;
GB.Input.c2.stateRy=0;
GB.Input.c1.kSys_3DTransparency=0;
GB.Input.c2.kSys_3DTransparency=0.7;
ENDIF
System.calcKinematic();
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.

10.11.2014

34 / 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
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 onroad 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.

7.2 Code 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

10.11.2014

35 / 35