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Romax. Designer Single Product Model for Transmission Design & Analysis Romax. Designer Single Product Model for Transmission Design & Analysis

About this Presentation n Aims of the presentation n Modelling the components: • shafts About this Presentation n Aims of the presentation n Modelling the components: • shafts • bearings • gears n Assembling the gearbox n Defining the loads and powers n Running the analysis n Review of the results and further Romax. Designer capabilities Copyright © Romax Technology Limited 2000 - 2005

Introduction Aims of this presentation are to show how: n To model an existing Introduction Aims of this presentation are to show how: n To model an existing transmission in just one day n To analyze the model for shaft, bearing and gear performance and life n To use the analysis results to optimize an existing design Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Key Stages for Creating a Romax. Designer Model n Definition of Modelling the Transmission Key Stages for Creating a Romax. Designer Model n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling stages: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling stages: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The first step is to create a shaft by simply Modelling the Transmission n The first step is to create a shaft by simply selecting it from the menu: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Specify the approximate shaft outer dimensions: Copyright © Romax Technology Modelling the Transmission n Specify the approximate shaft outer dimensions: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n To create shaft sections of different sizes, use the cutter Modelling the Transmission n To create shaft sections of different sizes, use the cutter icon to define steps: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Specify the dimensions of each section including any tapers and Modelling the Transmission n Specify the dimensions of each section including any tapers and bores if needed: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The user need only input the geometry n Romax. Designer Modelling the Transmission n The user need only input the geometry n Romax. Designer will generate static and dynamic models from this data instantaneously Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Romax. Designer automatically generates a solid model and 3 -D Modelling the Transmission n Romax. Designer automatically generates a solid model and 3 -D view for easy visualization: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n To add bearings, select the bearing icon and click at Modelling the Transmission n To add bearings, select the bearing icon and click at the approximate position: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Romax. Designer has complete bearing database catalogues for SKF and Modelling the Transmission n Romax. Designer has complete bearing database catalogues for SKF and FAG to choose from - as well as a Custom specification option: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n View the details of a range of bearings and accept Modelling the Transmission n View the details of a range of bearings and accept the most suitable: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Every bearing is a fully specified engineering object ready for Modelling the Transmission n Every bearing is a fully specified engineering object ready for analysis: Virtual Component has : - Dimensions - Engineering Properties Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Specify its exact position on the shaft, and conditions such Modelling the Transmission n Specify its exact position on the shaft, and conditions such as axial constraints and pre-load: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Repeat the procedure to add further bearings: Copyright © Romax Modelling the Transmission n Repeat the procedure to add further bearings: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The 3 -D view is updated automatically: Copyright © Romax Modelling the Transmission n The 3 -D view is updated automatically: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission To add gear pairs there are two options for defining gear Modelling the Transmission To add gear pairs there are two options for defining gear geometry: n Concept gear pair • Basic gear data required for the calculation of forces on the shafts and bearings n Detailed gear pair • Requires additional macro-geometry data for gear rating Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Create a new concept gear pair: Copyright © Romax Technology Modelling the Transmission n Create a new concept gear pair: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Detail the concept pair if full analysis results are required: Modelling the Transmission n Detail the concept pair if full analysis results are required: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n A completed detailed gear pair: Copyright © Romax Technology Limited Modelling the Transmission n A completed detailed gear pair: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Mount the gear on the shaft with the gear icon: Modelling the Transmission n Mount the gear on the shaft with the gear icon: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Create and connect more gears to complete the shaft: Copyright Modelling the Transmission n Create and connect more gears to complete the shaft: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The completed solid model of the shaft in 3 -D: Modelling the Transmission n The completed solid model of the shaft in 3 -D: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Romax. Designer automatically produces a static model: Copyright © Romax Modelling the Transmission n Romax. Designer automatically produces a static model: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n And a dynamic model to completely simulate the behaviour of Modelling the Transmission n And a dynamic model to completely simulate the behaviour of the shaft: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling Overview Gear mounting definition There are four options for defining gear mounting in Modelling Overview Gear mounting definition There are four options for defining gear mounting in the model: n Integral with shaft • The gear is manufactured into the shaft n Rigidly mounted to shaft • The gear is permanently attached to the shaft n Synchronizer or clutch connection • The gear is free to rotate on the shaft unless the synchroniser/clutch is engaged n Free Rotation • The gear is free to rotate on the shaft Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Selection of gear mounting method: Copyright © Romax Technology Limited Modelling the Transmission n Selection of gear mounting method: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Define the details of the gear blank for inertia calculations: Modelling the Transmission n Define the details of the gear blank for inertia calculations: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n Once the other shafts have been generated, their relative positions Modelling the Transmission n Once the other shafts have been generated, their relative positions need to be specified: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The completed gearbox: Copyright © Romax Technology Limited 2000 - Modelling the Transmission n The completed gearbox: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission n The completed solid model is ready for analysis: Copyright © Modelling the Transmission n The completed solid model is ready for analysis: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions n Add input and output power loads with the power Defining the Load Conditions n Add input and output power loads with the power load icon: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions n Define the time and clutch/synchro for each speed: Copyright Defining the Load Conditions n Define the time and clutch/synchro for each speed: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions n Define the loads for each speed: Copyright © Romax Defining the Load Conditions n Define the loads for each speed: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions n The completed duty cycle with six defined speeds, ready Defining the Load Conditions n The completed duty cycle with six defined speeds, ready to run: Copyright © Romax Technology Limited 2000 - 2005

Defining the Load Conditions n The duty cycle results on all components are calculated Defining the Load Conditions n The duty cycle results on all components are calculated in under a minute on a standard PC: Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Review of Results n Romax. Designer calculates complete duty cycle results, in under a Review of Results n Romax. Designer calculates complete duty cycle results, in under a minute, on a standard PC n The results for each load case include: • Forces, moments, displacements and stresses for all shafts • Deflections, tilts and displacements on all bearings • Mesh misalignment for all gear meshes • Life rating for all bearings and gears including misalignment effects Copyright © Romax Technology Limited 2000 - 2005

Review of Results n The results for a single load case will be examined Review of Results n The results for a single load case will be examined first: • Shaft loadings and deflections leading to bearing rating and gear mesh misalignment n Then the cumulative effect of the duty cycle will be shown n This gives a final assessment of gear and bearing performance for the specified duty cycle Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n The input shaft forces in 1 st Results for a Single Load Case n The input shaft forces in 1 st speed in the xdirection: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n The input shaft shear force diagram in Results for a Single Load Case n The input shaft shear force diagram in 1 st speed in the x-z plane: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Input shaft moments in 1 st speed Results for a Single Load Case n Input shaft moments in 1 st speed in the x-z plane: Moment from the bearing arises from the calculated tilt stiffness Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Input shaft displacements in 1 st speed Results for a Single Load Case n Input shaft displacements in 1 st speed in the xdirection: The bearing displacement is non-zero Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Input shaft bending stresses in 1 st Results for a Single Load Case n Input shaft bending stresses in 1 st speed: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Bearing results showing the life, as well Results for a Single Load Case n Bearing results showing the life, as well as the relative and absolute displacements: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Bearing results showing the bearing stiffnesses: Copyright Results for a Single Load Case n Bearing results showing the bearing stiffnesses: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n Shaft deflections are converted into gear mesh Results for a Single Load Case n Shaft deflections are converted into gear mesh misalignment: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n The life rating for the gear pair Results for a Single Load Case n The life rating for the gear pair is then calculated to ISO 6336 or AGMA 2001: Copyright © Romax Technology Limited 2000 - 2005

Results for a Single Load Case n The user can choose to include the Results for a Single Load Case n The user can choose to include the effect of misalignment in the gear rating: Copyright © Romax Technology Limited 2000 - 2005

Duty Cycle Results n For each component, the duty cycle result includes a contribution Duty Cycle Results n For each component, the duty cycle result includes a contribution from each load case:

Duty Cycle Results n Complete ISO life and the Adjusted life (which includes the Duty Cycle Results n Complete ISO life and the Adjusted life (which includes the effect of misalignment on bearings): Copyright © Romax Technology Limited 2000 - 2005

Duty Cycle Results n Also duty cycle results for the gear pair : Copyright Duty Cycle Results n Also duty cycle results for the gear pair : Copyright © Romax Technology Limited 2000 - 2005

Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the Modelling the Transmission Romax. Designer Modelling Areas: n Definition of components n Mounting the gears on to shafts n Definition of gearbox internal geometry n Powerflow definition and analysis n Review of results n Options for further analysis and optimization Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (i) Examples of additional work possible using the Romax. Designer software: n Further Analysis (i) Examples of additional work possible using the Romax. Designer software: n The influence of Housing Stiffness on the system deflections n The misalignment of synchronized gears mounted on needle roller bearings n Stress concentration factors and shaft fatigue analysis. Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (ii) Examples of additional work possible using the Romax. Designer software: n Further Analysis (ii) Examples of additional work possible using the Romax. Designer software: n A more detailed duty cycle, e. g. for different driving styles and conditions n Gear micro-geometry definition and transmission error calculation n Synchronizer sizing and simulation. Copyright © Romax Technology Limited 2000 - 2005

Further Analysis (iii) Examples of additional work possible using the Romax. Designer software: n Further Analysis (iii) Examples of additional work possible using the Romax. Designer software: n Driveline dynamic analysis and NVH n Perpendicular shafts, hypoid, spiroid and bevel gears n In-depth analysis of bearings. Copyright © Romax Technology Limited 2000 - 2005

Conclusions Romax. Designer allows: n Modelling of a complete gearbox … in less than Conclusions Romax. Designer allows: n Modelling of a complete gearbox … in less than 1 day n Duty cycle analysis of a gearbox … in under 1 minute n World-leading analysis in an easy-to-use interface n This speed-of-use allows rapid iterative design optimization for the first time Copyright © Romax Technology Limited 2000 - 2005

Your Next Step! Thank you for reviewing Romax. Designer. You may now wish to: Your Next Step! Thank you for reviewing Romax. Designer. You may now wish to: Start using Romax. Designer Take one of the Romax in-depth training courses on transmissions, or gear design using Romax. Designer (email us - see next slide) Contact Romax for more details on Romax software solutions (see next slide) Copyright © Romax Technology Limited 2000 - 2005

For more information contact: Romax Technology Limited Rutherford House Nottingham Science and Technology Park For more information contact: Romax Technology Limited Rutherford House Nottingham Science and Technology Park Nottingham England, NG 7 2 PZ Tel: +44 (0)115 951 8800 Fax: +44 (0)115 951 8801 e-mail: [email protected] com http: //www. romaxtech. com