7-speed automatic transmission

For B- and C-class transverse engine front-wheel drive vehicles.

Exceptional reliability, compactness, and simplicity of design are key components of popularity in the mass segment of cars

Exceptional reliability, compactness, and simplicity of design are key components of popularity in the mass segment of cars

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Large housing parts produced by the high-precision aluminum casting and precision machining method

Parts of complex spatial shape produced by the machining method

Planetary gear set parts produced by hobbing

Thin-walled cylindrical parts produced by flow forming

Rotatry disk parts produced by turning

Straight stepped rotary parts with deep holes inside and external splines produced by turning, milling, and deep drilling

Rotatry disk parts produced by stamping

A key control element consisting of hydraulic plates produced by casting and precision aluminum machining and valves produced by turning, galvanizing, and grinding

Gear pump of simple and reliable design with high performance

Low-pressure fine filter elements produced by ejection plastic molding and assembly with filtering materials

The transmission locking mechanism consists of a section related to the automatic transmission selector, a drive consisting of a lever, a linkage, a wedge bush, and a gust lock: a latch mounted on the axle in the crankcase and a toothed ring of the locking mechanism mounted on the output shaft of the automatic transmission

About the project

The innovative multi-speed automatic transmission is specifically designed for the mass segment of the automotive market - B and C front-wheel drive cars with transverse engine of up to 93 kW and torque up to 200 N*m.

Automatic transmission is built on the basis of a unique patented kinematic scheme and provides a wide kinematic range in ultra-compact dimensions. Instead of the traditional torque converter for starting the car, one of the friction control elements is used, and the direct-pressure solenoid valves are used in the electro-hydraulic system responsible for gear changes. All this provides design simplicity, reliability, and at low cost.

Automatic transmission is highly efficient in all gears, which has a positive effect on reducing fuel consumption and contributes to reducing air pollutant emissions, which are important parameters for modern cars.

At the same time, drivers will appreciate the impressive driving characteristics, including comfort while driving in city traffic, and the dynamic capabilities of the 7-speed automatic transmission with its quick shifting and wide range of gear ratios.

The first Russian FT703 7-speed automatic transmission for passenger cars

In 2005, domestic cars with front-wheel drive and automatic transmissions were not represented in the automotive market of the Russian Federation. Nevertheless, the results of market research in this area indicated that the demand for automatic transmission is constantly growing. This prompted the team of like-minded employees at KATE LLC, who were inspired by the idea of creating a new Russian automatic transmission and modern production, to start work on an innovative 7-speed automatic transmission. Our company were faced with challenging tasks, such as as developing and producing automatic transmissions with a sufficiently large number of gears at the price of a 4-speed automatic transmission.

In just a year, the detailed design documentation was developed, and the main suppliers were selected for the parts and assemblies of the first prototypes. Already by 2006, prototypes of the automatic transmission, which received the index KATE FT703, were installed on bench equipment for verifying the mechanical and electrohydraulic systems, as well as in LADA Kalina cars, for which the main work was carried out to adjust the control system. The electronic control unit of the automatic transmission was also designed and manufactured by KATE specialists on the basis of modern electronic components certified for use in the automotive industry. Accelerated tests, which were carried out in accordance with AvtoVAZ requirements, confirmed the operability and basic technical specifications of the new product. Nevertheless, it was required to make the second series of prototypes and conduct a full cycle of bench tests, including related to durability, climate and others. Given the lack of such a large bench base, and to attract world-class suppliers of automatic transmission components to the project, British company RICARDO was chosen as an engineering partner. The second-series prototypes, manufactured and tested during 2007-2008, demonstrated a high technical level and successfully passed the technical expertise of Porsche Engineering, ordered by the alliance Renault-Nissan-AvtoVAZ. In cooperation with the Austrian company AVL, which performs installation and calibration work for leading car manufacturers such as Porsche, Volkswagen, and BMW, we decided to continue the joint work of KATE-AvtoVAZ on developing and integrating the 7-speed automatic transmission system into LADA cars. As a result of the collaborative engineering work, and in close cooperation with the serial manufacturers of the main components of the automatic transmission system, a pre-production batch of automatic transmissions was produced and a set of resource-based tests in the car was carried out. The automatic transmission demonstrated full compliance with the actual technical specifications stated in the terms of reference, and was ready for work to commence on preparing for production.

Alongside the joint work and negotiations with AvtoVAZ PJSC, work on diversifying the portfolio of orders for the 7-speed automatic transmission is also actively carried out, and well-known Chinese automakers have shown interest in the automatic transmissions. These manufacturers initiated a series of tests at the CATARC (China Automotive Technology and Research Center), during which the transmission was tested on a bench that fully simulates the movement of a real car in Chinese driving cycle (which is being prepared for introduction into the PRC as a national standard). The results confirmed the stated functionality, as well as the stable operation of the wet starting clutch when starting from rest multiple times and long "creeping" modes that simulate traffic patterns in traffic jams. In general, the automatic transmission showed high efficiency for all transmissions in a wide range of speeds and is recommended for further field tests. At the moment, preparations to start this work are underway.

Well-known Chinese automakers show interest in the automatic transmission

Another application of the 7-speed automatic transmission can be found in the modern Russian roadster CRIMEA. This project is implemented by partners from the "Piston Engine Construction and Special Machinery" research and education center and the "Formula Student" design and engineering bureau of the Bauman Moscow State Technical University. We have already worked out the options for assembling the automatic transmission into the platform, and the issue of manufacturing the first demonstration samples is being discussed. The 7-speed automatic transmission, with its wide range of transmission gear ratios, high speed of shifting, and possibility of manual gearshifts, is a perfect fit for the modern dynamic roadster when driving on high-speed roads, without having to sacrifice comfort when driving in the city in automatic mode.

Technical Specifications

Number of forward gears 7
Number of reverse gears 1
Transmission ratio spread 6.46
Maximum input shaft torque 200 N*m
Maximum input shaft speed 6200 rpm
Maximum input shaft power 93 kW
Overall dimensions of automatic transmission (Length x Width x Height) 390 mm х 515 mm х 363 mm
Estimated efficiency (min. 1st gear/max. 5th gear) 0.866 / 0.98
Gear ratio of the final drive 3.608 / 3.313
Durability 250,000 km
Automatic transmission fluid specification Dexron VI
Prototype weight 62 kg
1 4.62
2 2.64
3 1.79
4 1.25
5 1
6 0.85
7 0.72
R -4.17

Application

Roadster CRIMEA

The Russian roadster CRIMEA is being developed by the team of the "Piston Engine Construction and Special Machinery" research and education center and the "Formula Student" design and engineering bureau of the Bauman Moscow State Technical University, and should become the most accessible mass roadster on the Russian automobile market. The idea of developing a Russian-made roadster came about in 2013. The concept involves producing cars of different versions: Collection, Premium, and Mass. All cars have a mid-engine arrangement, rear-wheel drive and are equipped with a gasoline 1.6-liter LADA engine, a five-speed manual transmission or a KATE 7-speed automatic transmission. A full-size model was presented at the motor show MIMS-2014, and one year later, the first working prototype was demonstrated at the “World of Motorsport 2015” festival. In 2016, the roadster CRIMEA passed a technical test run of 5,000 km, during which no serious malfunction was detected. The car was presented at the MIMS-2016 and aroused keen interest of the public. The project is actively developing, the Minister of Industry and Trade of the Russian Federation ordered to work out its commercial launch.

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