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KISSsoft AGUetzikon 4

8634 Hombrechtikon, Switzerland0041 55 254 20 50info@KISSsoft.ch

Verification, tractor transmission

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1. Tractor transmission should be modified to allow higher power rating

2. Strength critical parts have to be identified / re-designed3. Positive experience / know-how with existing transmission to be

used4. Different concepts have to be evaluated / compared

Cost effective, parametrised calculation of strength and lifetimeof the transmission components is required

Objective

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KnowledgeDatabase

Design verification of upgradedtransmission

Very flexible model in case

of designchanges

Two parameterized KISSsys Models (current/new design)

Quick yetdetailledconceptanalysis

Permitsdetection of

weak parts orfatal load

steps

Objective

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General assumptionsapplicable

for both designs

Load cases, load spectrafor existing design

Load cases, load spectrafor modified design

Existing design

KISSsys modelfor analysis

KISSsys modelfor analysis

Modified designResulting

safety factorsand lifetimesfor modified

design

Resultingsafety factorsand lifetimesfor existing

design

Comparison, using results fromexisting design as reference

Methodology

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•Analysis of the existing transmission using several load cases and a load spectra allows for quantification of experience

•Results of these analysis are used as benchmark results•The KISSsys model may be used in future as a knowledge database

Benchmarking process

ComparisonKISSsys Prototype ProductionNew design

Ex. design

Testing

Knowledge database, benchmarks

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Lifetime

Lifetime, static safety

BearingsISO281

--Lifetimesand safetyfactors

Calculationwith loadspectra

Safetyfactors

Safetyfactors

Safetyfactors

Calculationwith nominal load

Shaft-hubconnectionsDIN7190DIN …

ShaftsDIN743

GearsISO6336AGMA2001DIN3990

Scope of calculations

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•F, R: Forward, reverse

•M, LL, H: Medium, low and high speed range

•PTO: Power take off (not modelled)

•1, 2, 3, 4: Speeds

•2WD / 4WD•Total 24 speedsPower distribution: Front: 38%, Rear: 62%

Input

Output Rear Axle

Output Front Axle

Rear PTO

Current transmission design

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KISSsys allows for modelling of:

•Gear pairs•Chains of gears•Couplings•Idlers•Superimposed shafts•Statically overdetermined shaft supports

•Power split•Kinematics constraints

Input

Output Rear Axle Output Front Axle

Current transmission design

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Tree structure

MessagesSchematics

Load Spectra

Results

3D Representation

Current transmission design

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Production drawings for all elements were provided

Corresponding KISSsoft files needed to be generated

Current transmission design

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Speeds: R,3,M,4WD Speeds: F,1,H,2WD

KISSsys model

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1. Couplings can be closed/opened2. Gear forces have to be applied on the main shafts

The reaction forces off the change gear parts define the action forces on the main shafts

Reaction Forces

Action Forces

Itera

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Itera

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KISSsys model

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Nominal Load => correct results (Kwb changes)

Load spectra => result for safety factor in the root is to high for intermediate gears (Kwb does not change between calculation steps)

Problem occurs only when shifts1 and H are active (only time when Kwb of z52 changes to 0.7->or when z52 acts as intermediate gear)

Comparison still possible

Engineering assumptions

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Possible Inputs:

KISSsys

Other programs: import of a *.txt file with “;” as seperator (Excel)

Load spectrum

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Positions provided by Manufacturer3D Representation with coordinate system

Positioning Dialog in KISSsys

Spatial arrangement

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User defined representation of most important results

Results

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Gearstage data in predefined tables Lifetime for each load step exported to Excel

Includes detailed KISSsoft reports

Results

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Using a parametrised model of a complete transmission,modelled in KISSoft / KISSsys,

strength / lifetime verification using load spectra is performedresults were compared to experience / field resultsto use results as benchmark for further calculations

in the sense of a kowledge database

Conclusion