1. WORKSHOP 2 Driveline Components

3. This Workshop This Workshop
Beginning with a simple FWD driveline model:
Build a Differential
Differential Assembly
Build a Flexible Shaft
Optional:
Build bearing attachments
Modify gear elements to the differential
Assemble templates into a benchtest and test functionality after building each component

4. General Workshop tips Menu Navigation Shorthand
“From the main menu bar, click File, navigate to Gear Pair, click New..”
Abbreviated as: File >> Gear Pair >> New…
Right-Click Context Menu
“Right-click over the hardpoint icon for hps_origin, navigate to hps_origin >> Modify…”
Abbreviated as: Modify hps_origin
Context menu usage
“After selecting the Pick option from the entry field’s context menu, right click over the ges_input_shaft, then select it from the Select List”
Abbreviated: Pick ges_input_shaft Or (as part of dialog box fill instructions):
I Part: ges_input_shaft
Tree Menu Usage
From the tree menu, point to desired element, Right click the entity you want to modify, Select Modify.

5. Getting Started Getting started Start Adams/Driveline in Template Mode
File >> Open >> Templates….
Open _driveshaft_diff_start.tpl from adriveline_training.cdb
This template consists of:
Mount parts/communicators for “engine” and “suspension mount” (wheels)
“Dummy” differential, model has no differential action
Rigid driveshafts
Revolute joint connecting the diff to the engine

6. Save and Test Save and test
Use File > Save As to save template as _driveshaft_diff.tpl in the adriveline_training database.
Switch to Standard Interface (F9)
Open FWD_RollerRig.asy
File > Open > Assembly
Assembly: Right-Click in field> Search > adriveline_training > FWD_rollerRig.asy
Select Yes when prompted to use the template in memory
You may be see some warning messages like “WARNING: Part diff_case_front was not found in template…” but these can be ignored.

7. Save and Test Save and test Decrease Error and HMAX (1.0e-3)
Use GSTIFF, I3, Modified corrector (faster simulation)

8. Save and Test Save and test Run a RPM Sweep
Select Review > Animation Controls then play the animation. This should show each component of the driveline rotating, and the tire transferring the motion to the roller rig.

9. Retest with Split Mu Retest with split mu
Modify a tire to have decrease traction
Right-Click the right tire/wheel graphic
Select Wheel: rtire.whr_tire > Modify
Set Symmetric to No
Pick low_fricton.rti from adriveline_training for the Property File
Apply
Re-Run RPM Sweep
Select Review > Animation Controls

10. View the Results View the results Press F8 to switch to Post-Processor
Plot the Curves as Shown
Use the Control key to select multiple items
Check the Surf Box
Note that regardless of the Split or Even Tire Mu, both tires achieved approximately the same RPM

11. Create Diff Create differential
Now we will create a open (spool) differential assembly that allows relative motion between the rear wheels
Replace the dummy diff part with a kinematic (open) differential assembly
Switch back to template builder (F9)
Create a differential assembly to replace the ges_dummy_diff
Driveline Components > Complex Components > Entire Differential Unit
Differential Center Ref:
Right-Click > Pick
Right-Click over the center of the dummy diff (pink cylinder)
Pick the reference frame cfs_diff_pos from the pick list
Tip: The V key toggles icon visibility.

12. Create differential
Create a differential assembly to replace the ges_dummy_diff (cnt’d)
Mass: 20
Ixx/Iyy/Izz:6e4
Leave other fields default
Apply

13. Re-connect attachments
Modify josrev_diff_to_engine
Pick ges_diff_case_front for the I part replacing ges_dummy_diff
Alternately you can modify joint from tree menu. Point to Attachment>Joints and then right cleck the joint you want to modify,select Modify.
Apply

14. Re-connect attachments
Modify jortra_tripot_diff
Pick ger_side_gear_front for the I part replacing ges_dummy_diff
Apply
Delete ges_dummy_diff

15. Save and Test Save and test Save template
Switch to Standard Interface (F9)
Close and re-open FWD_RollerRig.asy
File > Close > Assembly
Do not save assembly
File > Open > Assembly
Open FWD_rollerRig.asy from adriveline_training
Select Yes when prompted to use the template in memory
Run RPM Sweep again

16. Retest with Split Mu Retest with split mu
Modify a tire to have decreased traction:
Right-Click the right tire/wheel graphic
Select Wheel: rtire.whr_tire > Modify
Set Symmetric to No
Pick low_fricton.rti from adriveline_training for the Property File
Apply
Run RPM Sweep again

17. View the Results View the results Press F8 to switch to PostProcessor
Plot the Curves as Shown
Use the Control key to select multiple items
Check the Surf Box
Note that the tires have significantly different rotational velocities in the cases of even and split mu

18. Make the driveshafts into a flexible link
Make the driveshaft into a flexible link
Make the driveshafts into a flexible link
Replace the driveshaft with a flexible representation
Switch back to Template Builder (F9)
Go to Driveline components > Flexible Shaft > New
Name: flex_shaft
I Coordinate Reference: Pick > cfl_shaft_inner
J Coordinate Reference: Pick > cfl_shaft_outer
I and J CRFs are located at either end of the driveshaft at the centers of the CV joints
Continued on next slide

19. Make the driveshafts into a flexible link
Cnt’d
Outer Diameter: 30
Thickness: 5
N Beams: 4
Select Apply

20. Reconnect the flexible shaft
Re-connect the CV joints to the new flexible shaft and delete the rigid body driveshaft part
Right-click > Modify the jolcon_shaft_inner. Choose nrl_1_flex_shaft instead of gel_ driveshaft for the I Part

21. Reconnect the flexible shaft
Re-connect the CV joints to the new flexible shaft and delete the rigid body driveshaft part
Right-click > Modify the jolcon_drive_shaft_outer. Choose nrl_5_flex_shaft instead of gel_driveshaft.

22. Delete rigid driveshafts
Reconnect the flexible shaft
Delete rigid driveshafts
Delete gel_driveshaft

23. Create a request
Build a new request to measure the deflection in the flexible shafts.
Build > Request > New
Request Name: shaft_deflection
Define using Function Expression
F2:AZ(._driveshaft_diff.nrr_1_flex_shaft.cm,._driveshaft_diff.nrr_5_flex_shaft.cm)
F3:AZ(._driveshaft_diff.nrl_1_flex_shaft.cm,._driveshaft_diff.nrl_5_flex_shaft.cm)
Result Set Name: shaft_deflection
X: shaft_deflection_right Unit: angle
Y: shaft_deflection_left Unit: angle

24. Save and test Save template Switch to Standard Interface (F9)
Close and re-open FWD_RollerRig.asy
File > Close > Assembly
Do not save assembly
File > Open > Assembly
Open FWD_rollerRig.asy from adriveline_training
Select Yes when prompted to use the template in memory
Simulate RPM Sweep

25. View the Results View the results Press F8 to switch to PostProcessor
Plot the shaft_deflection request created earlier
Use the Control key to select multiple items
Check the Surf Box
Note: that shafts flex several degrees during RPM rampup!

26. Optional Tasks Optional tasks
Replace grsred_pinion_drive_to_ring with one of the following gear type connections between ges_diff_output and ges_ring_gear_front
Spur Gear Element (Under Gear Tool menu)
Hypoid Gear Force
Spline Gear Force (Under Gear Tool menu)
Replace on or both of the following revolute connections with a with a Bearing force
josrev_diff_to_engine
josrev_diff_input_to_body
Notes:
Press F1 for context help from any dialog box
When needed, example property files can be found in adriveline_shared
Try to guess reasonable input values, but more importantly, remember to do functionality checks as often as possible!