SIMPACK WIND. What is SIMPACK? Applications: Highlights: Accurate Fast Robust Versatile. Application

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1 Accurate Fast Robust Versatile SIMPACK WIND Application What is SIMPACK? SIMPACK is a general-purpose multi-body simulation (MBS) software tool which is used to aid the development of any mechanical or mechatronic device, ranging from single components through to complete systems, e.g. wind turbines, vehicles, and high performance Formula 1 engines. All SIMPACK products are 100% compatible. SIMPACK Wind is an add-on module tailored to the specific requirements of the wind turbine sector. Applications: Simulation of any wind turbine design Resonance analysis Stochastic and transient response Geometric and material modification Optimization Durability Hardware-Software-in-the-loop Highlights: Simulation of any design Extreme non-linear system behavior, e.g. emergency braking Acoustic analyses in the frequency and time domain Interfaces to aerodynamic codes, e.g. from NREL and ECN Scalable detail and complexity Batch jobs Automatic analysis reports Flexible rotorblade generator Available wind turbine models with highly detailed drivetrains

Features: Detailed gear pairs, originally developed for Formula 1 Dynamic separation of gear pairs Flexible body generation within SIMPACK Importation of flexible bodies from FEM codes Non-linear

tools In-house software Operating systems: In co-operation with: Windows and Linux. See: /platforms.

2 Features: Detailed gear pairs, originally developed for Formula 1 Dynamic separation of gear pairs Flexible body generation within SIMPACK Importation of flexible bodies from FEM codes Non-linear bending Easy implementation of user specific code Interfaces to: Aerodynamic software CAD software Control software FEM software Fluid dynamics simulation tools Fatigue analysis software Optimization tools In-house software Operating systems: In co-operation with: Windows and Linux. See: /platforms.html SIMPACK Customer Solution Centers Germany Worldwide Headquarters SIMPACK AG Friedrichshafener Strasse Gilching, Germany Phone: +49 (0) Fax: +49 (0) sales@simpack.de USA SIMPACK US Inc. Robert Solomon Telegraph Road, Suite 101 Southfield Michigan 48033, USA Phone: Fax: Mobile: info@simpack-us.com France SIMPACK France S.A.S. Immeuble "Le President", 4eme étage 40, Avenue Georges Pompidou Lyon, France Phone : +33 (0) info@simpack.fr Japan SIMPACK Japan K.K. 5F Okubo Bldg Yotsuya Shinjuku-ku Tokyo , Japan Phone: +81 (0) Fax: +81 (0) info@simpack.jp Great Britain SIMPACK UK Ltd. The Whittle Estate Cambridge Road Whetstone Leicester LE8 6LH, UK Phone: +44 (0) Fax: +44 (0) Mobile: +44 (0) info@simpack.co.uk

w. Accurate Fast Robust Versatile SIMPACK DRIVETRAIN Application What is SIMPACK?

optimization of any type of drivetrain system.

applied to any field of engineering where power transmission is required. All SIMPACK products are 100% compatible.

Optimization Stress and durability analysis Hardware/software-in-the-loop Highlights: Simulation of any design Extreme

3 w. Accurate Fast Robust Versatile SIMPACK DRIVETRAIN Application What is SIMPACK? SIMPACK is a general purpose, threedimensional multi-body simulation software, uniquely suited to the analysis and optimization of any type of drivetrain system. Primarily used for simulating drivetrains within the automotive, wind turbine and railway sectors, SIMPACK can be applied to any field of engineering where power transmission is required. All SIMPACK products are 100% compatible. Applications: System simulation of any embedded drivetrain design Resonance analysis Stochastic and transient response Optimization Stress and durability analysis Hardware/software-in-the-loop Highlights: Simulation of any design Extreme non-linear system behavior, e.g. emergency braking Acoustic analyses in the frequency and time domain Interfaces to third party software Numerous possible levels of fidelity Batch jobs Automatic analysis reports KOMAI TEKKO Inc.: Wind turbine KWT300

Features: Drivetrain specific elements: - Universal/Cardan and constant velocity elements - Bearings, elastomeric and hydro mounts - Gearboxes (gear shift, differential, planetary, etc.

bending Easy implementation of user specific code Interfaces to: FEM software Control software CAD software CFD software Fatigue analysis software Aerodynamic codes Optimization tools Operating

html SIMPACK Customer Solution Centers Germany Worldwide Headquarters SIMPACK AG Friedrichshafener Strasse 1 82205 Gilching, Germany Phone: +49 (0)8105 77266-0 Fax: +49 (0)8105 77266-11

Robert Solomon 25925 Telegraph Road, Suite 101 Southfield Michigan 48033, USA Phone: +1 248 996-8750 Fax: +1 248 996-8930 Mobile: +1 251 923 9566 info@simpack-us.com France SIMPACK France S.A.S. Immeuble "Le President", 4eme étage 40, Avenue Georges Pompidou 69003 Lyon, France Phone : +33 (0)437 5619-71 info@simpack.

4 Features: Drivetrain specific elements: - Universal/Cardan and constant velocity elements - Bearings, elastomeric and hydro mounts - Gearboxes (gear shift, differential, planetary, etc.) - Detailed gear pairs (individual tooth contact) - Flywheels, clutches and synchromeshes Flexible body generation within SIMPACK Importation of flexible bodies from common FEM codes Non-linear bending Easy implementation of user specific code Interfaces to: FEM software Control software CAD software CFD software Fatigue analysis software Aerodynamic codes Optimization tools Operating systems: Windows and Linux. See: /platforms.html SIMPACK Customer Solution Centers Germany Worldwide Headquarters SIMPACK AG Friedrichshafener Strasse Gilching, Germany Phone: +49 (0) Fax: +49 (0) sales@simpack.de USA SIMPACK US Inc. Robert Solomon Telegraph Road, Suite 101 Southfield Michigan 48033, USA Phone: Fax: Mobile: info@simpack-us.com France SIMPACK France S.A.S. Immeuble "Le President", 4eme étage 40, Avenue Georges Pompidou Lyon, France Phone : +33 (0) info@simpack.fr Japan SIMPACK Japan K.K. 5F Okubo Bldg Yotsuya Shinjuku-ku Tokyo , Japan Phone: +81 (0) Fax: +81 (0) info@simpack.jp Great Britain SIMPACK UK Ltd. The Whittle Estate Cambridge Road Whetstone Leicester LE8 6LH, UK Phone: +44 (0) Fax: +44 (0) Mobile: +44 (0) info@simpack.co.uk

Steven Mulski, SIMPACK AG Software Gear Pair Enhancements with SIMPACK Version 8904 Several new functionalities are available with the SIMPACK Gear Pair module in SIMPACK version 8904.

large variety of industrial sectors, e.g. automotive, wind, rail, shipping, aerospace, concrete mills, material handling, etc.

5 Steven Mulski, SIMPACK AG Software Gear Pair Enhancements with SIMPACK Version 8904 Several new functionalities are available with the SIMPACK Gear Pair module in SIMPACK version Not only has the visualization and handling of bevel gears and force arrows been vastly improved but major new functionalities (e.g. tooth profile and flank modifications, easy modelling of non-parallel axes, etc.) have been added. HISTORY Initially developed for Formula 1 high performance engines back in 2003 (by Lutz Mauer, an executive board member of SIMPACK AG), the SIMPACK Gear Pair functionality has since been used in a large variety of industrial sectors, e.g. automotive, wind, rail, shipping, aerospace, concrete mills, material handling, etc. GENERAL In SIMPACK, a large variety of elements are available for the simulation of torque converters. Depending upon the task at hand, elements of various level of detail may be used for achieving the optimum balance between solver speed and accuracy. For example, simple one-dimensional elements may be used for torsional analyses whereas gearbox elements (e.g. planetary gear stage) may be used for more detailed analyses when reaction moments on the housing are required. For simulations where individual tooth contact forces are required, the SIMPACK Gear Pair force element, FE 225, may be used. This element enables the additional analyses of the meshing forces and moments, shaft bending, bearing Fig. 2: Gear box with Gear Pair forces and other resultant forces Fig. 1: Bevel gear with crowning forces, and a host of other pertinent analyses (Fig. 2). The gear pair FE 225 is an analytical element, and therefore, extremely fast simulation times can be achieved. Graphical primitives are defined for the gear wheels which are subsequently used for the force calculations. This results in accurate animation of the gear tooth contacts and play. The element includes the following functionality [1, 2]: Involute spur, helical and bevel gears Internal and external gears Profile Shift Backlash and friction Single and multiple tooth contact (internal excitations due to tooth meshing) Dynamically changing gear pair center distance and backlash (particularly important for floating suns (Fig. 3) and elastically mounted shafts) The major gear pair enhancements with version 8904 are: Rack and pinion gearing Bevel gear primitive Tooth modification Flank modification Shuttling forces Easy slicing for non-parallel gear wheels and gear wheels with flank modification Easy handling of output values and animation of contact forces GEAR PAIR PRIMITIVES MAJOR ENHANCEMENTS With bevel gears, a new parameter, the Rim thickness, has been added for a more realistic graphical representation (Fig. 4). For all gear pair types, tooth and flank modification has been added. The modifications are primarily used for smoothing the non-linear internal excitations due to the continually changing number of teeth in contact. The following modification types have been added: Tip (Fig. 5) Root Circular Left and Right Side Lead Crowning (Fig. 6) Lead Angular Bias (Twist) Input Function Array All modification types can be input for the right and left flanks or for both together. Fig. 3: Motion of floating sun within a planetary stage ( IMM, TU Dresden) SIMPACK News September

Previous to version 8904, extra gear wheel primitives and force elements had to be used for this purpose. This functionality is now achieved by setting single parameter (i.e. Number of slices ) within the gear pair force element.

In the case of helical gears, this will result in an additional tilt moment. The graphical representation of rack gears has been available for a long time now. With Fig.

With version 8904, the user can now easily switch on and off, and choose between, various output value types. This enables easier handling and a more efficient use of data storage space.

This will result in a list being generated for each gear pair consisting of important input parameters and calculated data.

GEAR PAIR OUTPUT VALUES By way of parameterization, a user can choose for which gear pairs the Basic Output Values will be generated. These values include such data as the relative Fig.

6 Software Steven Mulski, SIMPACK AG Fig. 4: Bevel gear primitives GEAR PAIR FORCE ELEMENT MAJOR ENHANCEMENTS For simulating gear pairs with non-parallel axes, slicing of the gear wheels is necessary [3]. Previous to version 8904, extra gear wheel primitives and force elements had to be used for this purpose. This functionality is now achieved by setting single parameter (i.e. Number of slices ) within the gear pair force element. The handling of the offset angles for helical gears is now fully automatic. Slicing is also necessary if flank modification is used. Shuttling forces, i.e. the axial displacement of the contact forces, has now been implemented. In the case of helical gears, this will result in an additional tilt moment. The graphical representation of rack gears has been available for a long time now. With Fig. 5: Tip profile modification version 8904, the calculation of the rack and pinion forces has also been implemented (Fig. 7). With version 8904, the user can now easily switch on and off, and choose between, various output value types. This enables easier handling and a more efficient use of data storage space. The different types of output are described below. GEAR PAIR DATA CHECK In order to check the input parameters and initial conditions of the gear pairs within a model, a user can perform a Test Call. This will result in a list being generated for each gear pair consisting of important input parameters and calculated data. Information such as the theoretical center distance, radial offset, axial offset, transverse contact ratio, overlap ratio, and total contact ratio will now be readily available. GEAR PAIR OUTPUT VALUES By way of parameterization, a user can choose for which gear pairs the Basic Output Values will be generated. These values include such data as the relative Fig. 6: Crowning, left and right flank angles and angular velocities, total normal contact stiffness and the dynamic transmission error. Similarly, a user can also choose which Advanced Output Values are to be saved (Fig. 8). These values are primarily used for analyzing the coupling forces of the gear pairs, either for the sum of all teeth in contact or the individual tooth-pair contacts. In addition the Advanced Output Values enable easy animation of the force arrows in the PostProcessor (Fig. 9). After an integration run is complete a user can subsequently choose which output values to generate. Re-running the time integration is not necessary. Only reperforming measurements is required. CONCLUSION SIMPACK version 8904 represents a major milestone in the development of the gear Fig. 7: Rack and pinion gear Fig. 8: User choice for advanced output values pair module. New functionalities such as tooth and flank modification and automatic slicing and force arrow visualization, enable not only easier and faster model generation but also improved accuracy and quicker analyses. Although a significant development step has been achieved, the demanding and varied applications of the gear pair element will continue to result in further, more advanced requirements. The development of the gear pair element does not have one static functionality goal, after which the development can be seen as being completed, but rather a continually Fig. 9: Animation arrows of normal loads Indiv. load (fl_n) i,k advancing goal to which subsequent further SIMPACK development will ensure that the gear pair element can accompany industrial users long into the future. REFERENCES [1] L. Mauer, GearWheels in SIMPACK, SIMPACK News, July 2004 [2] L. Mauer, Modeling and Simulation of Drive Line Gears, SIMPACK News, July 2005 [3] E. Pfleger, Simulation of the Dynamic Behaviour of Nose Suspension Drives for Rail Vehicles Using SIMPACK-GearWheel, SIMPACK User Meeting 2006 All articles and presentations available at 26 SIMPACK News September 2010

Steve Mulski, Lutz Mauer, SIMPACK AG SIMPACk Software Fig 1: Spline coupling with angular misalignment Spline Coupling WHAT ARE SPLINE COUPLINGS?

The device consists of a spur gear fitted within a ring gear which permits axial displacement between the components. High torsional stiffness is achieved with contact occurring at every tooth pair.

This enables angular misalignment between the two coupling gear wheels. Small radial offsets can be allowed by applying backlash although, under load, the device is selfcentering.

7 Steve Mulski, Lutz Mauer, SIMPACK AG SIMPACk Software Fig 1: Spline coupling with angular misalignment Spline Coupling WHAT ARE SPLINE COUPLINGS? Spline couplings are commonly used connection devices within drivetrains for transmitting torque. The device consists of a spur gear fitted within a ring gear which permits axial displacement between the components. High torsional stiffness is achieved with contact occurring at every tooth pair. Generally, the sleeve s ring gears have unmodified flanks, whereas the pinion s spur gears are rounded by means of crowning [Fig. 2]. This enables angular misalignment between the two coupling gear wheels. Small radial offsets can be allowed by applying backlash although, under load, the device is selfcentering. Double spline coupling shafts are often incorporated as connections to the free floating suns of planetary stages, having a similar functionality to cardanic shafts. The allowable radial misalignment is proportional to the distance between the couplings. The spline coupling also permits the sun to tilt relative to the connecting shaft and therefore remain primarily parallel to the planetary gear wheels. Based on the SIMPACK Gear Pair force element, the spline coupling uses the same gear wheel primitives. Particular advantages of spline couplings over other devices are: Equally distributed load along the circumference Small installation size Transfer of rotational concentricity Angular misalignments Can allow for radial misalignment Suitability for high rotation speeds Relatively insensitive to overloading Gear Pair Enhancements, SIMPACK News, September 2010, page 25 26:). If used, the shift factor must be the same (although opposite in sign for both gear wheels). Profile and flank modification is not permitted on the sleeve. Crowning and circular profile modification, with the center point being automatically calculated, is applied to the pinion. Once defined, both primitives are directly accessed by the Spline Coupling Force Element FE 242, [Fig. 3]. Handling is similar to that of the Gear Pair Element FE 225. This ensures that the 3D visualization corresponds exactly with the calculation. Due to the necessity of crowning and correct calculation of angular alignment moments, slicing must be used. All other input parameters are similar to the Gear Pair Element with the added ability to apply not just coulomb friction but also viscous friction. Output values are also grouped into basic and visualization data, enabling users to easily reduce file output size. CONCLUSION The SIMPACK Spline coupling element is another new major functionality in the further development of SIMPACK for drivetrain applications. Linear and non-linear dynamics due to the implementation of detailed spline couplings can now be easily investigated. Because spline couplings are such an important component of many drivetrain applications, SIMPACK users need to have the ability to quickly and easily model these components and generate required measurements. This is now possible with the new spline coupling element in SIMPACK 9. Fig 2: Tooth crowning SPLINE ELEMENT IN SIMPACK Based on the SIMPACK Gear Pair force element, the spline coupling uses the same gear wheel primitives (see article SIMPACK Fig 3: Input parameters FE 242 SIMPACK News December

Accurate Fast Robust Versatile SIMPACK with Simulink SIMPACK for use with Simulink Interfaces SIMPACK for use with Simulink Interfaces are add-on modules for combining

SIMAT linear model export Export of linear MBS System matrices as S-Function Quick Design of control systems Linear State-Space matrices export to Simulink, e.g. for optimising control loops in Simulink.

within nonlinear models TCP/IP tool-coupling Co-Simulation of SIMPACK and Simulink, e.g. for coupling hydraulics to MBS.

Code Export non-linear model export Export of non-linear SIMPACK model to Simulink as S-Function, e.g. for HiL-/SiL-applications.

8 Accurate Fast Robust Versatile SIMPACK with Simulink SIMPACK for use with Simulink Interfaces SIMPACK for use with Simulink Interfaces are add-on modules for combining computer aided control system design (CACSD) with SIMPACK. SIMAT linear model export Export of linear MBS System matrices as S-Function Quick Design of control systems Linear State-Space matrices export to Simulink, e.g. for optimising control loops in Simulink. SIMAT co-simulation SIMPACK for use with Simulink co-simulation interface (exchange of data at discrete time steps) Use of all SIMPACK and Simulink modeling elements within nonlinear models TCP/IP tool-coupling Co-Simulation of SIMPACK and Simulink, e.g. for coupling hydraulics to MBS. MatSIM Export of non-linear Simulink model to SIMPACK as control element, e.g. for a wind turbine pitch controller. Code Export non-linear model export Export of non-linear SIMPACK model to Simulink as S-Function, e.g. for HiL-/SiL-applications. Import of Simulink models as SIMPACK control elements Simulink model completely embedded in SIMPACK (as dynamically linked library) Variable-step size SIMPACK solver Analysis in time- & frequency domain Exporting SIMPACK model as Simulink S-function Complete non-linear MBS model export Parameterization, SIMPACK solver export (optional) Analysis in time- & frequency domain Hil-/SiL-applications

systems (e.g. wind turbines, vehicles, and high performance Formula 1 engines). All SIMPACK products are 100% compatible.

9 What is SIMPACK? SIMPACK is a general-purpose multi-body simulation (MBS) software tool which is used to aid the development of any mechanical or mechatronic device, ranging from single components through to complete systems (e.g. wind turbines, vehicles, and high performance Formula 1 engines). All SIMPACK products are 100% compatible. Applications: Combining control with MBS dynamics Any kind of mechatronic application Full integration of MBS into control environment Full integration of CACSD into high-end MBS environment Hardware/Software-in-the-Loop Linear and non-linear analyses in time- and frequency domain Highlights: Detailed mechatronic systems Multiple Interfaces available (choice dependent upon simulation requirements) Easy to use for SIMPACK and/or Simulink users SIMPACK Solver use with exported Simulink models (MatSIM) Code Export for use on real-time environments Full parameterization of exported SIMPACK models (Code Export) Operating systems: Windows and Linux. See: /platforms.html MATLAB and Simulink are registered trademarks of The MathWorks, Inc. SIMPACK Customer Solution Centers Germany Worldwide Headquarters SIMPACK AG Friedrichshafener Strasse Gilching, Germany Phone: +49 (0) Fax: +49 (0) sales@simpack.de USA SIMPACK US Inc. Robert Solomon Telegraph Road, Suite 101 Southfield Michigan 48033, USA Phone: Fax: Mobile: info@simpack-us.com France SIMPACK France S.A.S. Immeuble "Le President", 4eme étage 40, Avenue Georges Pompidou Lyon, France Phone : +33 (0) info@simpack.fr Japan SIMPACK Japan K.K. 5F Okubo Bldg Yotsuya Shinjuku-ku Tokyo , Japan Phone: +81 (0) Fax: +81 (0) info@simpack.jp Great Britain SIMPACK UK Ltd. The Whittle Estate Cambridge Road Whetstone Leicester LE8 6LH, UK Phone: +44 (0) Fax: +44 (0) Mobile: +44 (0) info@simpack.co.uk

SIMPACK WIND. What is SIMPACK? Applications: Highlights: Accurate Fast Robust Versatile. Application

SIMPACK WIND. What is SIMPACK? Applications: Highlights: Accurate Fast Robust Versatile. Application Accurate Fast Robust Versatile SIMPACK WIND Application What is SIMPACK? SIMPACK is a general-purpose multi-body simulation (MBS) software tool which is used to aid the development of any mechanical or