The Brakes must be able to manage all possible situations!

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P/N 90151 / edt. 2006 – 01 / Landskrona 1

Development Mark II

Mark III

043Mark IV

ModulX ModulX

143P/N 90151 / edt. 2006 – 01 / Landskrona

243Innovative Vehicle Technology

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1

The Haldex concept

•

Modular design

•

Two piece calliper

•

Quadruple slide pins

•

Unhanded

•

Low hysteresis actuator

•

Twin tappets / spindles

•

Heat protected tappet bellows

•

Clearance sensing adjuster

•

Repairable

•

Spare parts kits available

P/N 90151 / edt. 2006 – 01 / Landskrona

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Two piece caliper •

Completely unhanded

•

Light weight and small package size

•

Accommodates different rotor thickness by changing one piece

•

No sealing elements subject to high loads

P/N 90151 / edt. 2006 – 01 / Landskrona

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2

ModulX Components / Mechanism

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P/N 90151 / edt. 2006 – 01 / Landskrona 5

Common application module •

Twin Tappets

•

One self contained application unit for multiple brake sizes

•

High efficiency with cylindrical roller bearings

•

Serviced as an assembly

•

Silicone rubber bellows

•

Heat protecting springs (Optional)

P/N 90151 / edt. 2006 – 01 / Landskrona

Mechanism/ application module

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3

Mechanism / Housing The same Mechanism in DB19, DB22 and DB22LD Mechanism Housing Spare Parts ModulX

DB22

DB22LT

P/N 90151 / edt. 2006 – 01 / Landskrona

DB19 Innovative Vehicle Technology

7

Unhanded The 4 slide pins makes it possible to: •

Fit the same brake both left and right hand side

•

Carrier and calliper parts built to receive the forces in both directions of rotation

•

Less parts in stock, less number of parts to manage

P/N 90151 / edt. 2006 – 01 / Landskrona

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4

A sensible part of the Disc Brake Tappet protection •

Protection Springs - protection against heat radiation and physical damages (peak à 300°)

• Rubber bellows – protection against ‘‘‘‘water and dirt ingress.

(Operation Temperature –60° to +250°, peak à 300°)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 9

An important function : The sliding function •

Stainless steel slide pins for improved stability and corrosion resistance

•

Self lubricating, Teflon® slide bearings for low friction

•

Dust protected with silicon rubber bellows

•

Protective solid cover in calliper

•

One kit fits 3 brake sizes

P/N 90151 / edt. 2006 – 01 / Landskrona

Corrosion test

14 days (Haldex)

3 days (competitor)

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5

2 x 2 needle bearings = low hysteresis

• • •

Reduced friction High efficiency Low Hysteresis (Important for proper ABSABS-function) function)

P/N 90151 / edt. 2006 – 01 / Landskrona

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VWI, Visual Wear Indicator

•

Casted arrow on the caliper

•

Slotted steel pin seated in the carrier

•

The distance from the arrow to the end of the slotted pin indicates remaining friction material

P/N 90151 / edt. 2006 – 01 / Landskrona

New Pads

Worn out Pads

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6

Wear indication system, PWI

PWI Pad wear indicator Gives a warning when the friction material is worn out

Type of wiring and connector according to customer demand

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P/N 90151 / edt. 2006 – 01 / Landskrona 13

Wear indication system, PWS PWS Pad wear sensor CWS Continous wear sensor

Connector

Sensor housing

Adjustment screw Sensor rod

P/N 90151 / edt. 2006 – 01 / Landskrona

O-ring x 2 Caliper collar seat

Fixation screw Sensor collar

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7

Limits of the drum brake

Decreasing efficiency at ~300° Extended brake chamber stroke. Increased temperature = increased elasticity of the wheel brake components.

P/N 90151 / edt. 2006 – 01 / Landskrona

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Dyno comparison test

P/N 90151 / edt. 2006 – 01 / Landskrona

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8

Drum Brake Characteristic

Drag Testing

Torque (Nm)

Temp. (°C)

1800

800

1600

700

1400

600

1200

500

1000

Drum Brake Torque

400

800

300

600

200

400

Drum Brake Temperature

100

200 0

0

50

100

150

200

250

300

350

400

450

500

550

600

0

Time (sec.)

( Constant application pressure)

P/N 90151 / edt. 2006 – 01 / Landskrona

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Haldex Disc Brake

P/N 90151 / edt. 2006 – 01 / Landskrona

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9

The idea isn ’t new ! isn’t DISC BRAKES

1902

Patent Lanchester

1950

Jaguar

1960

Passenger cars

1990

Truck

1996

Truck break through

1997

Trailers

2006

Physical laws still valid

-

Le Mans

The Disc Brake really has been around for a while - - P/N 90151 / edt. 2006 – 01 / Landskrona

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Haldex Disc Brake Application pressure per Cm² Cm² on the friction material is 4 times higher in the disc brake than in the drum brake •More efficient at higher temperature •Less stroke extension at high temperature •Less elasticity at high temperature

P/N 90151 / edt. 2006 – 01 / Landskrona

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10

Disc Brake Characteristic Drag Testing

Torque (Nm) 1800

Temp. (°C) 800

Disc Brake Torque

1600

700

1400

600

1200

500

1000

Disc Brake Temperature

400

800 300

600

200

400

100

200 0

0

50

100

150

200

250

300

350

400

450

500

550

600

0

Time (sec.)

( Constant application pressure)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 21

Characteristic: Drum Brake compared to Disc Brake Drag Testing

Torque (Nm) 1800

Temp. (°C) 800

Disc Brake Torque

1600

700

1400

600

1200 1000

Drum Brake Torque

500

Disc Brake Temperature

400

800 300

600

200

400

Drum Brake Temperature

100

200 0

0

50

100

150

200

250

300

350

400

450

500

550

600

0

Time (sec.)

(Constant application pressure) P/N 90151 / edt. 2006 – 01 / Landskrona

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11

Safety Æ Brake Distance Tractor + semisemi-trailer, trailer, 40 tonnes, speed 85 Km/h

62 m

+

54 m 46 m 85 m

+

Æ Cold

+

Æ Cold

+

46 m P/N 90151 / edt. 2006 – 01 / Landskrona

Æ Cold

Æ Warm

+

Æ Warm

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Product Testing •

Dynamometer test

•

Torque test (Chucker)

•

Dirt Chamber

•

Fatigue (Puls test)

•

Vibration test (Hydropuls)

•

Vehicles (Lab)

•

Vehicle field test

P/N 90151 / edt. 2006 – 01 / Landskrona

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12

Product Testing

•

Dynamometer test

•

Torque test (Chucker)

•

Dirt Chamber

•

Fatigue (Puls test)

•

Vibration test (Hydropuls)

•

Vehicles (Lab)

•

Vehicle field test

P/N 90151 / edt. 2006 – 01 / Landskrona

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Truck Racing •

•

Our participation in various Truck Racing Cups, shows that Haldex Disc Brake manage tough conditions with very good results. The low hysteresis is one of the reasons for our good results.

P/N 90151 / edt. 2006 – 01 / Landskrona

Haldex Standard Production Disc Brakes !

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13

Haldex Disc Brakes reduces the risk for fading brakes •

Haldex Disc Brakes are tested in the German Alps. Rossfeld mountain is a well-known alpine distance for testing.

Rossfeld mountain, southern Germany Peak: 1600 metres above sea level Test track: 11 km Altitude difference: 1000 m Average gradient: 9.1% Maximum gradient: 14% Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 84345-01/06.98 27

Rossfeld Test Two-axle drawbar trailer • Single wheels • Total weight: 18 tonnes • Descent time: 23 minutes • Brakes applied ~150 times • Speed increased to 35Km/h thereafter, by braking, reduced to25Km/h, increased to 35Km/h again etc. •

P/N 90151 / edt. 2006 – 01 / Landskrona

Retarder

Innovative Vehicle Technology

28 84345-02/06.98

14

Special Tool Kit Haldex Disc Brake Service Manual (Not included in Tool Kit P/N 81918)

Tool Kit P/N 81918

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 29 84345-02/06.98

Product Identification Explanation 1. Haldex/OEM logo

3

2. OEM P/N (if required) 3. Haldex EC (origin) 4. Haldex P/N 5. Haldex S/N 5120111 5 12

= year, 2005 = week No. of the year

0111 = sequential No.

P/N 90151 / edt. 2006 – 01 / Landskrona

5 4 2

1

Innovative Vehicle Technology

30 84345-02/06.98

15

Spring Brake Chamber

Parking Brake released (Air on)

Service Brake released (Air off)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 31 84345-02/06.98

Spring Brake Chamber

Parking Brake released (Air on)

P/N 90151 / edt. 2006 – 01 / Landskrona

Service Brake applied (Air on)

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32 84345-02/06.98

16

Spring Brake Chamber

Parking Brake applied by the spring (Air off)

Service Brake released (Air off)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 33 84345-02/06.98

Spring Brake Chamber

Parking Brake released mechanical (Air off)

P/N 90151 / edt. 2006 – 01 / Landskrona

Service Brake released (Air off)

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34 84345-02/06.98

17

Spring Brake Chamber COMPOUNDING ! Parking Brake applied (Air off)

Service Brake applied (Air on)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 35 84345-02/06.98

Spring Brake Chamber Anti Compound valve Parking Brake released (Air on)

P/N 90151 / edt. 2006 – 01 / Landskrona

Service Brake applied (Air on)

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18

Service Brake Chamber

P/N 90151 / edt. 2006 – 01 / Landskrona

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37 84345-02/06.98

Service Brake Chamber

P/N 90151 / edt. 2006 – 01 / Landskrona

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38 84345-02/06.98

19

Service Brake Chamber

P/N 90151 / edt. 2006 – 01 / Landskrona

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39 84345-02/06.98

Service Brake Chamber

P/N 90151 / edt. 2006 – 01 / Landskrona

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20

Haldex Disc Brake, exploded view

P/N 90151 / edt. 2006 – 01 / Landskrona

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Mechanism, exploded view

P/N 90151 / edt. 2006 – 01 / Landskrona

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21

Function description Rest position

Adjuster housing

Companion sleeve

Adjustment spring

Friction spring

Lever

Adjustment sleeve

P/N 90151 / edt. 2006 – 01 / Landskrona

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Function description Rest position

P/N 90151 / edt. 2006 – 01 / Landskrona

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22

Function description Application C = clearance

P/N 90151 / edt. 2006 – 01 / Landskrona

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Function description Ce = excessive clearance Application Ce = excessive clearance

P/N 90151 / edt. 2006 – 01 / Landskrona

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23

Function description Elasticity Application E = elasticity

P/N 90151 / edt. 2006 – 01 / Landskrona

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Function description Clearance Release C = clearance

P/N 90151 / edt. 2006 – 01 / Landskrona

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24

Function description Elasticity Release E = elasticity

P/N 90151 / edt. 2006 – 01 / Landskrona

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Function description Excessive Clearance Release / back in rest position Ce = excessive clearance

P/N 90151 / edt. 2006 – 01 / Landskrona

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25

HALDEX Disc Brake Rolling Road Test

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 51

Rolling Road Test Fahrzeugtyp / Hersteller: MAN 19-502, de la Huz Fahrzeug-Ident-Nr. : AL-9265-T Erstzulassung : 00 03 02 Amtl. Kennzeichen : Prüfdatum : Prüfgewicht Achse 1 : Prüfgewicht Achse 2 : Prüfgewicht Achse 3 : ∑ Prüfgewicht :

AL9562T 01 09 06 7000 kg 12000 kg kg 19000 kg

Fahrzeugtyp / Hersteller: FISA D-2356 Fahrzeug-Ident-Nr. : R-3090-BBD Erstzulassung : Amtl. Kennzeichen : AL9562T Prüfdatum : 01 09 06 Prüfgewicht Achse 1 : 9000 9000 Prüfgewicht Achse 2 : 9000 Prüfgewicht Achse 3 : 27000 ∑ Prüfgewicht : Max. ∑ Achsl.(PRmax) :

Make / Typ : DAF(XF430 Gines Camacho Vehicle Identificaton No.: XLRTEXS0E453739 First registration : 25-6-97 Licence number : Date of test : Actual weight axle 1 [kg] : Actual weight axle 2 [kg] : Actual weight axle 3 [kg] : ? Actual weight [kg] :

kg kg kg kg

Make / Typ : HERMANNS Vehicle Identificaton No.: VS9CHALALS1V085492 First registration : 22-3-01 Licence number : R-9465-BBF Date of test : 13-11-02 Actual weight axle 1 [kg] : 7080 kg 7080 kg Actual weight axle 2 [kg] : 7080 kg Actual weight axle 3 [kg] : ? Actual weight [kg] : 21240 kg

27000 kg

Max. ? axle weight(PRmax) :

Rollenfaktor:

Factor for roller :

80,0%

0,8

75,0%

0,8

70,0%

0,7

65,0%

0,7

60,0%

0,6

55,0%

0,6

50,0%

0,5

45,0%

0,5 Brake ratio

Abbremsung z

GR-8014-AM ####### 6660 kg 13090 kg kg 19750 kg

40,0% 35,0%

0

21240 kg

0

0

0

0,4 0,4

30,0%

0,3

25,0%

0,3

20,0%

0,000

0,2

MW / SZM

15,0%

Tractor :

0,2

Trailer

Anhängefahrzeug 10,0%

0,1

Streuband Anhängefz.

5,0%

tolerance band trailer

0,1

Streuband MW

0,0%

tolerance band tractor

0,0 0,0

0,5

1,0

1,5

2,0

2,5

P/N 90151 / edt. 2006 – 01 / Landskrona

3,0 3,5 4,0 4,5 Kupplungskopfdruck Pm

5,0

5,5

6,0

6,5

7,0

7,5

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5 4,0 pm pressure

4,5

5,0

5,5

6,0

6,5

7,0

7,5

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26

Rolling Road Test , ideal balance Make / Typ : VOLVO FH12 Vehicle Identificaton No.: YVA2A4B3A8WB206355 First registration : 98 06 25 Licence number : Date of test : Actual weight axle 1 [kg] : Actual weight axle 2 [kg] : Actual weight axle 3 [kg] : ? Actual weight [kg] :

Make / Typ : Primball D1812 Vehicle Identificaton No.: VV5STNSTLXV998892 First registration : 20-04-00

V4292GD 01 10 30 6500 kg 11500 kg kg 18000 kg

Licence number : R7240BBC Date of test : 01 09 06 Actual weight axle 1 [kg] : 8000 kg 8000 kg Actual weight axle 2 [kg] : 8000 kg Actual weight axle 3 [kg] : 24000 kg ? Actual weight [kg] : Max. ? axle weight(PRmax) :

Factor for roller :

0,000

0

27000 kg

0

0

0

0,8 0,8 0,7 0,7 0,6 0,6 0,5

Brake ratio

0,5 0,4 0,4 0,3 0,3 0,2

Tractor :

0,2

Trailer 0,1

tolerance band trailer

0,1

tolerance band tractor

0,0 0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5 4,0 pm pressure

4,5

5,0

5,5

P/N 90151 / edt. 2006 – 01 / Landskrona

6,0

6,5

7,0

7,5

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Tractor EBS System

Red Line

Yellow Line

ISO 7638

ISO 1185 P/N 90151 / edt. 2006 – 01 / Landskrona

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27

HALDEX Disc Brake

LSV

REV

ISO 7638

ISO 1185

Haldex HALDEX ECU ECU ABS

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 55

PROBLEMS ?

P/N 90151 / edt. 2006 – 01 / Landskrona

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28

Thermal overload Factor

Pad friction material wear in relation to temperature.

35 30

Relative friction 25 material 20 wear 15 10 5 0 50

100

150

Disc temperature

200

250

300

350

400

oC Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 57

Thermal Overload New tractor/trailer with EBS ~25000Km.

P/N 90151 / edt. 2006 – 01 / Landskrona

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29

Thermal Overload Heat distortion

P/N 90151 / edt. 2006 – 01 / Landskrona

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Thermal Overload

P/N 90151 / edt. 2006 – 01 / Landskrona

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30

Thermal Overload Summary, Thermal Overload: •Just to change damaged components doesn’t solve the problem the new components will get damaged as well! •Each axle/vehicle in a combination must perform braking in relation to the weight it is carrying for the moment - dynamics included. Proper action: •Change damaged components. •Identify the root cause to the problem. •Take action as required for proper repairs/adjustments. •Verify actions taken. P/N 90151 / edt. 2006 – 01 / Landskrona

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Importance of harmonisation

P/N 90151 / edt. 2006 – 01 / Landskrona

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31

Some other PROBLEMS ?

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 63

Accelerated wear of inner pad One reason for differential pad wear Fixation of the piping has immobilized the caliper sliding function

P/N 90151 / edt. 2006 – 01 / Landskrona

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32

Pad wear, inner/outer Fixation of the piping has immobilized the caliper sliding function

P/N 90151 / edt. 2006 – 01 / Landskrona

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65

Equal wear on inner /outer pad inner/outer Ensure that the fixation of the piping doesn’ doesn’t restrict the free floating of the caliper !

Wear compensation: The caliper must be allowed to have free floating, floating, without influence of directing forces, throughout the complete caliper travel (needed for compensation of pad wear). wear). P/N 90151 / edt. 2006 – 01 / Landskrona

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33

Damaged thrust plates

The trust plate has been in contact with the disc = worn out pads, including the back plate! (Inspections?)

Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 67

Contact damages Bellows burnt Wheel bearing break down

Contact P/N 90151 / edt. 2006 – 01 / Landskrona

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34

Impossible to release the brake adjustment enough to fit new pads? Thermal overload: overload: overheated/ overheated/crystallized grease

Change bellows, clean /put new high temp. grease on the adjustment screws and - - - rectify the root cause!

Protection springs out of position Interference !!

Note! The protection spring must be put back in its ordinary position! Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 69

Water ingress Æ corrosion

Sealing joints

P/N 90151 / edt. 2006 – 01 / Landskrona

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35

Water ingress Æ functional disorder All plugs in the brake chamber housing fitted ! This means no ventilation = vacuum will immobilize the brake chamber = the disc brake will not work! This will/may be identified as a non functional disc brake !

Vacuum!

P/N 90151 / edt. 2006 – 01 / Landskrona

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Water ingress Æ functional disorder

The upper plug is removed The bottom plug is fitted The brake chamber housing will be filled with water = at temperature below 0o C the water will freeze which will/may immobilize the brake chamber, damage the diaphragm etc. Immobilized brake chamber will/may be identified as a non functional disc brake! P/N 90151 / edt. 2006 – 01 / Landskrona

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36

Water - dirt – accelerated wear

Life is not always so easy ! Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona 73

Water - dirt – accelerated wear

With protection Without protection Pad wear: wear: 20 - 30 Km = 7mm ! P/N 90151 / edt. 2006 – 01 / Landskrona

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37

HALDEX DISC BRAKE

Conclusion Are disc brakes the ultimate solution? As with all mechanical devices they have their limitations, but provided that the application is correctly designed and the distribution is properly made, they are probably nearer to the ultimate than any other braking device available today.

2006

Physical laws are still valid !

P/N 90151 / edt. 2006 – 01 / Landskrona

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I didn’t know all that !

P/N 90151 / edt. 2006 – 01 / Landskrona

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38