New 2-speed Gearbox Solution from KATE

The Russian company KATE, known for design of the gearbox solution for Aurus family, has recently presented a 2-speed gearbox for hybrid/electric trucks and buses.

Currently, many major automakers put in great efforts in developing vehicles of the future, which will operate on the basis of environment-oriented technologies. Traditional powertrain solutions are gradually being replaced with new hybrid and electric solutions, mainly operated by means of the traction e-motor, actuating the driving axle. However, when developing an e-motor for a particular vehicle, it is problematic to provide its max performance level over the full range of torque and RPM. Therefore, many manufacturers of gear shifting solutions started developing electric gearboxes for cars of the future.

KATE, having solid experience and advance equipment for creation of sophisticated products, started working on the solution for electric vehicles 6 years ago. And now the company has come up with the 2-speed gearbox in full compliance with specifications of the customer, whose name was not disclosed. The new product has 2 forward gears, 1 R-gear, as well as N-gear. This solution also features semi-auto and auto gear shifting capacity.

The N position ensures safety during the vehicle towing in case of the e-motor breakdown, which was a specific request of the client. This innovative solution also has numerous sensors responsible for keeping track of the actuated gear, which is shown on the driver's display. The process of the gear change is implemented automatically when the driver pushes a button (the option of fully independent gear shifting operation can also be integrated).

Technical specifications of the new gearbox

The torque transfer can be implemented in both rotational directions, thus the e-motor can also be applied in the braking and recuperation modes. The new solution can operate in severe temperature conditions, and it is equipped with a special sensor keeping track of the temperature.

The 1-st pre-production models of the abovementioned product were produced and tested five years ago. On the basis of test results, KATE engineers corrected all flaws and repeated the same cycle. At this stage, all engineering drawings for this project have been finished and the company undertakes preparations for mass production of the 2-speed gearbox. Looking forward, KATE engineers can combine this 2-speed unit with the final drive into a unit built in a single housing. Flexibility in dimensions and torque allows KATE engineers to adjust the unit in compliance with different customer requirements.

New buses equipped with hybrid or electric gearboxes have enhanced tractive and dynamic parameters, which significantly outperform buses with manual gearboxes. The new 2-speed gearbox and e-motor can find application in modern environment-friendly hybrid or electric vehicles.