Gear Software

KISSsoft & KISSsys Components sizing, optimisation, rating System design and analysis www.KISSsoft.ch www.EES-KISSsoft.ch

KISSsoft worldwide
History Started as in house software with Kissling AG gear company KISSsoft AG founded in 1998 KISSsoft LLC, US, founded in 2005 EES KISSsoft GmbH, founded 2008 KISSsoft software has been commercially available for the last 25 years Installations Current software version: KISSsoft 03-2011 About 1700 commercial installations worldwide About 120 educational installations worldwide Main office KISSsoft AG, Switzerland www.KISSsoft.ch US branch KISSsoft LLC, USA www.KISSsoft.com General distributor Asia EES KISSsoft GmbH, Switzerland www.EES-KISSsoft.ch Sales and support partners Estudio Pina, Argentina CETIM, France Stadler Antriebstechnik, Germany Saltini, Italy Mega Makina, Turkey Kadkraft Systems, India STech&H, Korea Seakou Technology, China Consultancy and engineering Provided through EES Gear GmbH Specialised in wind gearboxes and industrial gearboxes EES Gear GmbH is sister company to EES KISSsoft GmbH

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Applications
Fine pitch, plastic and sintered gearing White ware Brown ware Automotive actuators Medical and research Powertools Energy generation Turbo gears Wind energy, main gearboxes Generator shafts Pitch and yaw drives Aerospace Rovers, satellites Helicopter transmission Turbine PTO Flap actuators, UAV Industrial General purpose and heavy duty gearboxes Mining and raw materials Cranes and winches Vertical roller mill gearbox Steel mill gearboxes Servomotors, geared motors, gearheads Robotics Material handling Vehicle applications Automotive, LCV transmissions Trucks and busses Tractors, harvesters Motorbikes and three wheelers Snow bikes Motorsport Battle tanks, military vehicles Locomotives, trams, cableways Forklifts And many more
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Training
Form Public trainings in German or English language Company specific trainings Topics KISSsoft software usage KISSsys software usage KISSsys programming Gear theory, gear design technology Language and location At customer site, in our offices in Switzerland In German or English (French, Italian, Finnish, Mandarin, Korean on request) Costs Public trainings: 500EUR per day per person Company specific trainings: request quote Trainers Mechanical engineers with strong engineering background Long time software users or programmers

Maintenance and support (AMC)

Services Software updates Patches Installation support Software support (software usage) Technical support (software application) Costs percentage of software costs on annual basis Types Perpetual (by service contract) Annual renewal

Software modules
Combination of modules Basic modules for gearing, shafts, connections Expert modules as add-o Total of about 50 modules Adding modules Modules may be added to an existing licence Complete list of modules Request through reseller or directly from EES KISSsoft GmbH
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Modules
General KISSsoft modules can be run independently KISSsys module requires KISSsoft CAD modules require KISSsoft KISSsoft Cylindrical gears, rack & pinion, bevel and hypoid gears, worm gears, face gears, crossed axis helixal gears, non-circular gears Shafts and roller bearings, hydrodynamic bearings, shaft systems Shaft-hub connections High strength bolted connections Spring analysis, chains and belts Tolerance stack up, local stress analysis, Hertzian contact stress, spindles KISSsys Ready made gearbox models for helical gearboxes, bevel-helical gearboxes, wormhelical gearboxes Machine element library to build own models Programming language module Now also including synchronizers and animation of movement CAD 2D CAD export in neutral format or graphical format 3D export to CAD systems (gear geometry)

Databases
General Database consists of 80 parts for various data Database is user editable and can be transferred from one release to next Includes copy past functions Materials General material database Specific materials for gears, shafts, springs Bearings FAG/INA, SKF, Koyo, NSK, Timken For standard bearing data and bearing inner geometry (only through user input)
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KISSsys, systems module

The KISSsys software combines kinematic analysis, lifetime calculation, 3D graphics, user defined tables and dialogs with a programming language. It is the tool of choice for strength and lifetime analysis of various kinds of drive trains and gearboxes. KISSsys lets the user do quick yet detailed parametric studies of a complete power train in very little time to compare different variants of a concept or to analyse a given design for different loads. In KISSsys, all parts (gears, shafts, bearings, connections) of the gearbox are linked and the strength/lifetime analysis is performed simultaneously for all elements. A three dimensional graphical presentation of the current state of the system immediately shows the geometrical influence of every change in parameters. This approach greatly accelerates the design process and results in a much more balanced design even during the concept phase. The machine elements calculated range from gears, shafts, bearings, shaft-hub connections to bolts. This will result in a more balanced starting design and fewer modifications will be necessary further down in the design process to reach an optimised design. Furthermore, documentation of the calculation is simplified and all calculation data for a whole drive train or gearbox is stored in a single file. KISSsys uses KISSsoft for the strength and lifetime calculations of the various machine elements. KISSsys features: Kinematics Calculation: power flow / speed with spur, bevel, worms and face gear stages, modelling of rotational mechanisms (planetary, Ravigneaux, Wolfrom,), differentials, (with bevel or spur gears), chain and belt transmissions, couplings can be activated and deactivated, slippage taken into account,

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Integrated strength and lifetime calculation: to do this, KISSsys accesses KISSsoft calculation modules bearing stiffness, transmission error, profile modification, efficiencies Machine element library: Spur/helical gear pair Planetary gears, compound planetary gears Bevel and hypoid gears Worm gears, crossed axis helical gears Face gears Shaft-bearing systems Shaft-hub connections Synchronizer 3D-models: automatic 3D-display (based upon the data defined in KISSsoft), 3D-model export to CAD platforms, gearbox housing import, (-step / -iges), checking for collisions. Special features: calculations with load spectra for all machine elements in the model integrated programming language for implementation of special functions Animation of gear movement Display in cut-away section Display of deformed systems KISSsys is used e.g. to Analyse wind turbine gearboxes again and again for different loading conditions Ensure that the design of a plastic gear set for an automotive actuator fits into a given design space Calculate power flow in CVT transmission Maintain a database of geared motor gears Estimate the manufacturing cost of a gearbox even during the design phase Optimise bearing lifetime by variation of the gears positions on a shaft Create specific reports e.g. for certification And many more
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GPK module
Description GPK module is a set of ready made KISSsys models. The models are provided to the customers as a library to be used in KISSsys. The models made available cover the most typical industrial gearboxes. The models feature advance level functions to accelerate the design process of standard industrial gearboxes. The need for the user to build his own models is eliminated and detailed reporting functions further reduce the time to document the design. Automatic sizing functions for the gears, bearings and shafts result in a well balanced gearbox. Price calculations based on user defined cost per mass data allow for constant control over gearbox costs. Types of gearboxes Helical gearboxes Bevel, helical-bevel gearboxes Worm, worm helical gearboxes Planetary gearboxes Configurations One, two, three, four or five stage helical gearboxes, with or without roller bearings One bevel without, with one, two or three helical stages, all with roller bearings One worm without, with one, two or three helical stages, all with roller bearings Functions Sizing of gear stages (distribution of ratio among the stages, sizing for given centre distance) Sizing of shafts and bearings (based on stress levels and required bearing life) Cost estimation (considering bearings, shafts and gears) Report generation (summary, pricing and detailed report) Detailed gear, bearing and shaft design through KISSsoft Free arrangement of shafts in space External forces on input and output shaft Settings for lubrication, temperature, orientation of gearbox in space, materials, calculation methods and graphics
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Helical gear basis modules

Configurations Spur or helical gear, herringbone gear, considering face width offset Grease or oil lubricated or dry running gears Metallic or plastic gears Involute or non-involute gears Any number of teeth, any type of tooth height, internal or external gears Gear geometry calculation Reference profile along ISO53.2, DIN867, JIS, BS5482 or own input Tolerances along DIN3967, ISO1328, own input or for theoretical gearing Centre distance along ISO286, ISO7168, DIN58405 or own input Gear quality along ISO1328, AGMA2015-1A01, DIN3961, DIN3961, DIN3963, DIN23961, DIN23962, DIN23963, AGMA200A88 Gear rating DIN3990 method B, DIN3990 method B with YF along method C, DIN3990 Part 41 (vehicles) method B ISO6336:2006, ISO6336:2006 with corrigendum 2007 Static rating against yield AGMA2001-B88, AGMA2001-C95, AGMA2001D04, AGMA2101-D04, AGMA2101-D04 metric AGMA6004-F88 Plastic gears along Niemann, VDI2545, VDI2545 modified As FVA software for DIN3990 BV/Rina FREMM3.1, Rina 2010 For nominal load or load spectrum Report listing For efault report or user specific template Tooth geometry and material Factors of general influence Tooth root strength, tooth flank strength Tooth scuffing strength Tooth thickness dimensions, tooth tolerances Modifications, manufacturing Additional data
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Helical gear general modules

Gear geometry calculation Calculation based on gear or tool reference profile Calculation based on true tool geometry Calculation based on mating gear geometry Import and export of gear or tool geometry from CAD system Calculation of theoretical, acceptance and operating backlash for metallic and plastic gears and housings Load spectrum calculation Direct input of load spectrum or import from text or Excel file Up to 300 load steps in spectrum Calculation of lifetime based on required safety factor, safety factors based on required lifetime and permissible torque based on required safety factor and lifetime Calculation of partial damages For DIN3990, ISO6336 and AGMA2001 AGMA925 calculations Calculation of scuffing safety Calculation of contact stress, lubricant film thickness Micropitting calculation Micropitting rating along ISO TR 15144 Specific lubricant film thickness calculation along AGMA925 Lubricant film thickness calculation along ISO TR 15144 based on true contact stress Additional reports Gear data for drawings Manufacturing tolerances along ISO1328-1, ISO1328-2, DIN3961, DIN23961, AGMA20151, AGMA200, BS436-2 Proposal for hardness depth along Niemann, AGMA2101, ISO6336 User specific reports based on templates Master gear calculation Calculation of master gear geometry Meshing of master gear with gear
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Helical gear sizing modules

Configurations Sizing functions to find optimised gears (in terms of mass, power density, stiffness, space requirements) Functions to reverse engineer gears Functions to optimise gear properties Rough sizing Proposal of several gear solutions for required power rating, required ratio, given material Considers gear quality, permissible ratio error For single load level or load spectrum With standard reference profile Fine sizing Define permissible ranges for module, pressure angle, helix angle, centre distance and profile shift Define target ratio and permissible deviation Define maximum number of solutions Set maximum permissible tip diameter and minimum permissible root diameter For pre-defined number of teeth or varying number of teeth Different filter and sorting functions Display solutions in table or in graphical form Report with assessment of solutions for different criteria Centre distance sizing Sizing from gear pair data Sizing for target profile shift sum Sizing of profile shift For balanced specific sliding To avoid pointed tooth or undercut For turbo gears For maximised strength on flank or root or maximised scuffing strength Sizing of tooth height / reference profile Sizing of reference profile for target transverse contact ratio Sizing of maximum possible root radius Sizing of profile and lead corrections Sizing of tip and root relief for different shapes Sizing of end relief and crowning Automatic search for optimium corrections

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Helical gear modifications, contact analysis

Configurations Considers all modifications in profile and lead direction Calculation based on up to 41 gear sections Pitch errors may be considered in part or fully Calculation for nominal or operating centre distance Calculation for nominal or partial load level Meshing friction considered in calculation Considers true gear geometry from manufacturing simulation Output Calculation of load distribution in profile direction Calculation of load distribution in lead direction True stress levels compared to stress levels calculated along standards (ISO/DIN/AGMA) True root stress calculation Calculation of YS and YF along full tooth root Considering true root geometry from manufacturing Root geometry optimisation for minimised root stresses Calculation along ISO6336-7 Calculation of specific lubricant film thickness alon g ISO6336-7 Considering true contact stress, temperatue in contact, surface roughness and lubricante properties Lead and profile modifications End relief (left and right end) Crowning Helix angle modification Linear and progressive tip/root modification Profile crowning (barrelling) Pressure angle modification Tip chamfer or rounding Grinding disk plunge depth Graphical output in involute diagram Flank twist Triangular end relief (left and right end)
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Helical gears, Tooth contact analysis

Configurations Considers all modifications in profile and lead direction Calculation based on up to 41 gear sections Pitch errors may be considered in part or fully Calculation for nominal or operating centre distance Calculation for nominal or partial load level Meshing friction considered in calculation Considers true gear geometry from manufacturing simulation For internal and external gears User defined accuracy level in calculation Mesh stiffness calculation Calculation of Transmission Error for spur and helical gears, showing peak to peak transmission error, average and standard deviation Calculation of normal force, torque variation, contact stiffness, bearing forces, kinematics, specific sliding and local heat generated over meshing cycle Results displayed vs. roll angle, pinion diameter, length on line of action, pinion angle of rotation Calculation has been verified in benchmarks against reference software and FEM calculations Output Graphics, exportable as graphic format or dxf Report including calculation settings and results summary Report including all graphics True contact ratio calculation Calculation of true transverse contact ratio under load Calculation of true total contact ratio under load

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Planetary, herringbone, idler gear modules

General, planets Based on helical gear calculation modules Calculation of planet pin location for nonevenly spaced planets Influence of rim thickness of ring gear and planet gears considered Assembly check Sizing function for load distribution factor along AGMA6123 Rough and fine sizing function Strength rating, planets Along ISO6336, DIN3990, AGMA2001, AGMA6004, BV/Rina FREMM3.1 for metallic gears Along VDI2545 and Niemann for plastic gears Calculation of ring gear strength along VDI2737 Calculation of alternating bending factor for planet root General, idler gears, herringbone gears Based on helical gear calculation modules For one or two idler gears Load input on first, output on last gear

Worm gear modules

General For ZC, ZI, ZA, ZN, ZK, ZH geometry Includes rough sizing fucntion Strength rating Along E DIN3996:2005, DIN3996:1998, ISO/DIS14521.2:2006, AGMA6034, AGMA6135 Safety against root and flank failure, wear, deflection and temperature System data Considers drive direction, bearing power loss, seal loss, permissible wear Considers cooling through housing and lubricant and running time
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Bevel gear modules

General Strength rating for nominal load or load spectrum Database for reference profile and tolerances Different geometry configurations with uniform tooth depth, constant slot width, modified slot width, different root and tip apex positions For spur, helical or spiral bevel gears Sizing function Strength rating Strength rating along ISO10300, Method B and C, DIN3991, AGMA2003 Strength rating along CN3028/KN3030 for Cyclo-Palloid gears and along KN3025/KN3030 for Palloid gears Hypoid gear calculation along KN3029/KN3030 for Cyclo-Palloid gears and along KN3026 for Palloid gears Strength rating along VDI2545 or Niemann (for plastic gears) Static strength rating and rating of differential planetary gears Manufacturing For face hobbed or face milled gears Considering Klingelnberg machine list Gear 3D geometry only for selected cases

Rack and pinion modules

General For spur or helical arrangement Input of load cycles Input of centre distance based on rack height Strength rating Along ISO6336, DIN3990, AGMA2001, AGMA6004, BV/Rina FREMM3.1 for metallic gears Along VDI2545 and Niemann for plastic gears Output Reports for manufacturing tolerances, drawing data, hardness depth proposal
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Crossed axis helical gear modules

General Strength rating along ISO6336 (modified along Niemann), along Hoechst for worm gears and along Hirn for worm gears Calculation of theoretical backlash, acceptance and operating backlash Calculation of flank, root and scuffing safety factor with single load or load spectrum Output of control measures like dimension over pins and balls Configurations For plastic and metallic materials Calculation with lead or helix angle Calculation of meshing efficiency For worm type or helical gear type mesh (any helix angle) Tooth form calculation with modifications like tip and root relief, chamfer, tip rounding, elliptic root rounding for improved noise and strength properties

Face gear modules

General Strength rating along ISO6336 (modified along Niemann, Roth and Basstein), ASS/Crown Gear/DIN3990, based on ISO10300, based on DIN3991 For 90deg or other shaft angle, with axis offset, for spur and helical gears Configurations Crown gear with cylindrical pinion as spur or helical gear Calculation of crown gear geometry at different diameters by simulating manufacturing with a pinion type cutter Check against undercut and pointed tooth by varying tooth height Export of 2D or 3D geometry considering tolerances Crowning of face gear through modifications on pinion type cutter Output of contact lines on face gear
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Non circular gears

From release 08-2009, non circulare gears can be calculated in KISSsoft. A new module has been added to the module list. The module code is Z040. Note that this module is available to customers as a package if combined with a joint project in order to ensure that the software does meet the customer requirements. Design of geometry: required momentary ratio may be defined required meshing curve may be defined From there, the following is calculated calculation of meshing curve from momentary ratio calculation of shaping cutter from gear/tooth data calcualtion of backlash such that no jamming occurs calculation of non-circular gear contour export to CAD with different levels of accuracy (up to 800 points per flank) add tip rounding modify root geometry to increase strength check of meshing / collisions in 2D calculation of position of rolls for dimension over rolls measuring

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Shaft modules
General Graphical shaft editor for fast modelling Add features to shaft to define stress concentrations Add force elements like gears, pulleys or couplings for simple load definition Material and lubricant database Search function for critical cross sections Configurations Single shaft or shaft systems Combined with multiple roller bearings Different materials from database or own input Linear or non-linear calculation with Euler or Timoshenko beam model considering temperature effects Strength rating Strength rating along DIN743, FKM guideline or Hnchen & Decker For static and fatigue strength, for single load case or load spectrum Using material database or own definition for S-N curve Automatic recognition and calculation of stress concentrations Buckling, natural frequencies Calculation of combined bending and torsion natural frequencies and natural modes Considers bearing stiffness Deformation and stiffness calculation Non-linear bearing stiffness is considered based on inner bearing geometry Up to eight concentric shafts may be modelled with connections Any number of loads may be added Tooth trace calculation Calculation of shaft deformation of pinion shaft, calculation of necessary lead correction Housing stiffness, bearing stiffness and shaft stiffness may be considered

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Bearing modules
Configuration Calculation of single bearing or bearing-shaft system With single load or load spectrum Sizing function for bearing selection Statically over-determined shaft systems, paired bearings Bearing life rating Basic rating using load capacity numbers Modified rating considering lubricant properties Reference rating considering load distribution Modified reference rating Along ISO281, ISO TS16281, ISO76 Bearing stiffness Based on bearing inner geometry Shaft-bearing interaction for shaft and bearing systems Considers clearance/pre-tension Considers bearing, shaft, hub tolerances Load distribution calculation Load distribution among rolling elements Contact stresses for balls Contact stresses for rollers, considering roller geometry modification (logarithmic) Thermal rating Along DIN732 Bearing database Bearing data from different bearing suppliers For different bearing types Database for basic bearing properties Database for bearing inner geometry, user editable Separate database for lubricants, lubricant purity definitions along ISO4406 Hydrodynamic bearings Axial bearings according to DIN31653 Radial bearings along DIN31654, Niemann and Spiegel (for grease lubricated bearings)

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Shaft-hub connections modules

Cylindrical interference fit Strength rating along DIN7190 Sizing function for tolerances Stress calculation for stepped hub and hollow shaft Considers torsional, radial and bending load, including centrifugal loads Calculation of mounting temperatures Conical interference fit For different mounting procedures Calculation along Kollmann Considers cone angle and cone angle tolerances Key Geometry along DIN6885, ANSIB17.1 Strength rating along DIN6892 Woodruff key Involute spline Geometry along DIN5480, ISO4156, ANSIB92, own definition Tolerances along DIN5480, ISO4156, ANSIB92, own definition Reference profiles along DIN5480, ISO4156, ANSIB92, own definition Strength rating along Niemann or DIN5466 Graphical output Straight sided spline Geometry along DIN5464, DIN5471, DIN5472, ISO14, own definition Strength rating along Niemann Graphical output Serrated spline Geometry along DIN5481 Strength rating along Niemann Polygons 3-sided and 4-sided polygon along DIN32711, DIN32711 Strength rating along Niemann

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High strength bolting modules

Bolt rating along VDI2230, configurations Connection under axial load only Connection under axial and shear load Flange type bolted connection Arbitrary bolting pattern Bolt, nut and washer types Own bolt geometry definitions Own nut and washer definition Washers: ISO7089, ISO7090, ISO7093, ISO940 Nut: ISO274, ISO4032, ISO4035, ISO8673, ISO8675 Bolt: ISO4762, ISO4014, ISO4017, ISO1207, ISO8765, ISO8676, Strength classes, 8.8, 10.9, 12.9, A1A5, own definition Tightening Considers different tightening procedures Considers pre-tension loss Considers friction in thread and under head/nut Temperatures For low and high temperatures Considers assembly temperature, temperature of bolt and temperature of clamped parts

Shear pins
Calculation along Niemann, configurations Bolt under shearing Cross pin under torque Longitudinal pin under torque Pin under bending Calculations Static or fatigue loads For full or notched type pins Material database Sizing function for pin diameter

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Springs modules
Compression springs Geometry along DIN2098 or own definition Tolerances along DIN2095 or DIN2096 Calculation along EN 13906-1 Tensile springs Different end geometries Tolerances along DIN2097 or DIN2096 Calculation along EN13906-2 Garter springs Tolerances along DIN2194 Calculation along EN13906-3 Spring disks Geometry along DI2093 or own definition Calculation along DIN2092 Torsional spring Different head forms Single or multiple springs Calclation along 2091

General purpose modules

Hertzian contact Contact between balls, cylinders, ellipsoid and plane Calculation of contact ellipse dimension Calcualtion of contact stress and sub-surface stress Local stress analysis Strength verification along FKM guideline For steel and aluminium For 1, 2 and 3 dimensional stress state Tolerance analysis Min/Max values, statistical calculation Standardised or user defined tolerances Belt drives, chain drives Chain sprocket geometry Belt and chain length Belt and chain strength
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CAD interfaces
KISSsoft offers the following CAD interfaces:

Thus, at the pressing of a button, the gears defined in KISSsoft can be exported to any of the above mentioned CAD platforms. Gear Geometries supported are indicated above. A gear can be generated for an existing construction or, simply, as a new part. Gears are generated by polylines, circular arc approximation or splines. The exact tooth profile is generated by manufacturing simulation considering tools like shaping cutter or protuberance hob. In addition, it is possible to place several gears on shafts already modelled in the CAD environment. Neutral interfaces in 2D and 3D formats complete the CAD-specific export functions.

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Licensing
Types of licenses Single user license protected by USB dongle (hardware locked) Single or multi user network license (with license on server) Any number of seats Installation Hardware locked license: software is installed and run on PC Floating license: software can be installed on server or on clients Operating system Windows (XP or Vista) 32 or 64 bit systems

Documentation, publications and downloads

Downloadable documents from www.EES-KISSsoft.ch/download White papers and application reports KISSsoft and KISSsys tutorials List of software modules Screenshots of software Documentation Manual, 850 pages Tutorials, about 100 pages

Memberships
EES Gear GmbH / EES KISSsoft GmbH is member of the following associations

Contact details
All business related to the sale of KISSsoft & KISSsys software in Asia is conducted through EES KISSsoft GmbH. Contact EES KISSsoft GmbH through: Dipl. Ing. H. Dinner, Director / Dipl. Ing. T. Uvermann, Director EES Gear GmbH 0041 41 755 09 54 (Phone) Neudorfstr. 10 0041 41 755 09 48 (Fax) P. O. Box 121 www.EES-KISSsoft.ch / www.EES-Gear.ch 6313 Menzingen [email protected] Switzerland [email protected]
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