The Brakes Must Be Able To Manage All Possible Situations!

The Brakes must be able to
manage all possible situations!
P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

1
Development
Mark II Mark III
043-
Mark IV
ModulX
ModulX
143- 243-

2
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

3
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

4
2
ModulX Components / Mechanism

5
Common application module

Mechanism/
application
• Twin Tappets module
• 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)

6
3
Mechanism / Housing
The same Mechanism in

DB19, DB22 and DB22LD
Mechanism Housing
Spare Parts
ModulX
DB22 DB22LT DB19

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

8
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°)

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 Corrosion test
• Dust protected with silicon rubber 14 days (Haldex) 3 days (competitor)
bellows
• Protective solid cover in calliper
• One kit fits 3 brake sizes

10
5
2 x 2 needle bearings = low hysteresis
• Reduced friction
• High efficiency
• Low Hysteresis
(Important for proper ABS-
ABS-function)
function)

11
VWI, Visual Wear Indicator
• Casted arrow on the caliper

New Pads
• Slotted steel pin seated in

the carrier
• The distance from the arrow

to the end of the slotted pin Worn out Pads
indicates remaining friction
material

12
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

13
Wear indication system, PWS
PWS Pad wear sensor

CWS Continous wear sensor
Connector
Sensor housing
Adjustment screw O-ring x 2 Fixation screw
Sensor rod Caliper collar seat Sensor collar

14
7
Limits of the drum brake
Decreasing efficiency at ~300°

Extended brake chamber stroke.
Increased temperature =
increased elasticity
of the wheel brake
components.

15
Dyno comparison test

16
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
200 100
0 0
0 50 100 150 200 250 300 350 400 450 500 550 600 Time (sec.)
( Constant application pressure)

17
Haldex Disc Brake

18
9
The idea isn’t new !
isn’t
DISC BRAKES
1902 Patent Lanchester
1950 Jaguar - Le Mans
1960 Passenger cars
1990 Truck
1996 Truck break through
1997 Trailers
2006 Physical laws still valid
The Disc Brake really has been around for a while - - -

19
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

20
10
Disc Brake Characteristic
Drag Testing
1800 800
Disc Brake Torque
1600 700
1400
600
1200
500
1000
Disc Brake Temperature
400
800
300
600
200
400
200 100
0 0
0 50 100 150 200 250 300 350 400 450 500 550 600 Time (sec.)
( Constant application pressure)

21
Characteristic: Drum Brake

compared to Disc Brake
Drag Testing
1800 800
Disc Brake Torque
1600 700
1400
600
1200
Drum Brake Torque 500
1000
Disc Brake Temperature
400
800
300
600
200
400
Drum Brake Temperature
200 100
0 0
0 50 100 150 200 250 300 350 400 450 500 550 600 Time (sec.)
(Constant application pressure)

22
11
Safety Æ Brake Distance
Tractor + semi-
semi-trailer,
trailer, 40 tonnes, speed 85 Km/h
62 m + Æ Cold
54 m
+ Æ Cold
46 m
+ Æ Cold
85 m + Æ Warm
46 m +
Æ Warm
23
Product Testing
• Dynamometer test
• Torque test (Chucker)
• Dirt Chamber
• Fatigue (Puls test)
• Vibration test (Hydropuls)
• Vehicles (Lab)
• Vehicle field test

24
12
Product Testing
• Dynamometer test
• Torque test (Chucker)
• Dirt Chamber
• Fatigue (Puls test)
• Vibration test (Hydropuls)
• Vehicles (Lab)
• Vehicle field test

25
Truck Racing
• Our participation in various Truck Haldex Standard

Racing Cups, shows that Haldex Disc
Brake manage tough conditions with Production Disc Brakes !
very good results.
• The low hysteresis is one of the reasons
for our good results.

26
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%
P/N 90151 / edt. 2006 – 01 / Landskrona

84345-01/06.98 Innovative Vehicle Technology
27
Rossfeld Test
• Two-axle drawbar trailer

• Single wheels
• Total weight: 18 tonnes
Retarder
• 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.

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

29
84345-02/06.98
Product Identification
Explanation
1. Haldex/OEM logo
2. OEM P/N (if required)
3
3. Haldex EC (origin)
4. Haldex P/N
5. Haldex S/N 5120111
5 = year, 2005
12 = week No. of the year 5
0111 = sequential No. 1
4 2

30
84345-02/06.98
15
Spring Brake Chamber
Parking Brake released Service Brake released

(Air on) (Air off)

31
84345-02/06.98
Parking Brake released Service Brake applied

(Air on) (Air on)

32
84345-02/06.98
16
Parking Brake applied Service Brake released

by the spring (Air off)
(Air off)

33
84345-02/06.98
Parking Brake released Service Brake released

mechanical (Air off)
(Air off)

34
84345-02/06.98
17
COMPOUNDING !
Parking Brake applied Service Brake applied
(Air off) (Air on)

35
84345-02/06.98

Anti
Compound
valve
Parking Brake released Service Brake applied

(Air on) (Air on)

36
84345-02/06.98
18
Service Brake Chamber

37
84345-02/06.98

38
84345-02/06.98
19

39
84345-02/06.98

40
84345-02/06.98
20
Haldex Disc Brake, exploded view

41
Mechanism, exploded view

42
21
Function description
Rest position Adjuster

housing
Companion Adjustment
sleeve spring
Friction
spring Lever
Adjustment
sleeve

43
Rest position

44
22
Application
C = clearance

45
Ce = excessive clearance
Application
Ce = excessive
clearance

46
23
Elasticity
Application
E = elasticity

47
Clearance
Release
C = clearance

48
24
Elasticity
Release
E = elasticity

49
Excessive Clearance
Release / back
in rest position
Ce = excessive
clearance

50
25
HALDEX Disc Brake
Rolling Road Test

51
Rolling Road Test

Fahrzeugtyp / Hersteller: MAN 19-502, de la Huz Fahrzeugtyp / Hersteller: FISA D-2356 Make / Typ : DAF(XF430 Gines Camacho Make / Typ : HERMANNS
Fahrzeug-Ident-Nr. : AL-9265-T Fahrzeug-Ident-Nr. : R-3090-BBD Vehicle Identificaton No.: XLRTEXS0E453739 Vehicle Identificaton No.: VS9CHALALS1V085492
Erstzulassung : 00 03 02 Erstzulassung : First registration : 25-6-97 First registration : 22-3-01
Amtl. Kennzeichen : AL9562T Amtl. Kennzeichen : AL9562T Licence number : GR-8014-AM Licence number : R-9465-BBF
Prüfdatum : 01 09 06 Prüfdatum : 01 09 06 Date of test : ####### Date of test : 13-11-02
Prüfgewicht Achse 1 : 7000 kg Prüfgewicht Achse 1 : 9000 kg Actual weight axle 1 [kg] : 6660 kg Actual weight axle 1 [kg] : 7080 kg
Prüfgewicht Achse 2 : 12000 kg Prüfgewicht Achse 2 : 9000 kg Actual weight axle 2 [kg] : 13090 kg Actual weight axle 2 [kg] : 7080 kg
Prüfgewicht Achse 3 : kg Prüfgewicht Achse 3 : 9000 kg Actual weight axle 3 [kg] : kg Actual weight axle 3 [kg] : 7080 kg
∑ Prüfgewicht : 19000 kg ∑ Prüfgewicht : 27000 kg ? Actual weight [kg] : 19750 kg ? Actual weight [kg] : 21240 kg
Max. ∑ Achsl.(PRmax) : 27000 kg Max. ? axle weight(PRmax) : 21240 kg
Rollenfaktor: Factor for roller : 0,000 0 0 0 0
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
Abbremsung z
Brake ratio
40,0% 0,4
35,0% 0,4
30,0% 0,3
25,0% 0,3
20,0% 0,2
MW / SZM Tractor :
15,0% 0,2
Anhängefahrzeug Trailer
10,0% 0,1
Streuband Anhängefz. tolerance band trailer
5,0% 0,1
Streuband MW tolerance band tractor
0,0% 0,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 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 4,5 5,0 5,5 6,0 6,5 7,0 7,5
Kupplungskopfdruck Pm pm pressure

52
26
Rolling Road Test , ideal balance
Make / Typ : VOLVO FH12 Make / Typ : Primball D1812
Vehicle Identificaton No.: YVA2A4B3A8WB206355 Vehicle Identificaton No.: VV5STNSTLXV998892
First registration : 98 06 25 First registration : 20-04-00
Licence number : V4292GD Licence number : R7240BBC
Date of test : 01 10 30 Date of test : 01 09 06
Actual weight axle 1 [kg] : 6500 kg Actual weight axle 1 [kg] : 8000 kg
Actual weight axle 2 [kg] : 11500 kg Actual weight axle 2 [kg] : 8000 kg
Actual weight axle 3 [kg] : kg Actual weight axle 3 [kg] : 8000 kg
? Actual weight [kg] : 18000 kg ? Actual weight [kg] : 24000 kg
Max. ? axle weight(PRmax) : 27000 kg
Factor for roller : 0,000 0 0 0 0
0,8
0,8
0,7
0,7
0,6
0,6
0,5
0,5
Brake ratio
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 4,5 5,0 5,5 6,0 6,5 7,0 7,5
pm pressure

53
Tractor EBS System
Red Line
Yellow Line
ISO 7638
ISO 1185

54
27
HALDEX Disc Brake
LSV
REV
ISO 7638
ISO 1185 Haldex

HALDEX
ECU
ECU ABS

55
PROBLEMS ?

56
28
Thermal overload
Pad friction material wear in relation to temperature.
Factor
35
30
Relative
friction 25
material 20
wear
15
10
5
0
50 100 150 200 250 300 350 400
Disc temperature oC

57
Thermal Overload
New tractor/trailer
with EBS
~25000Km.

58
29
Thermal Overload
Heat distortion

59
Thermal Overload

60
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.
61
Importance of harmonisation

62
31
Some other PROBLEMS ?

63
Accelerated wear of inner pad
One reason for differential pad wear
Fixation of the piping has

immobilized the caliper
sliding function

64
32
Pad wear, inner/outer
Fixation of the piping has

immobilized the caliper
sliding function

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).
66
33
Damaged thrust plates
The trust plate

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

67
Contact damages
Bellows burnt
Wheel bearing break down
Contact

68
34
Impossible to release the brake
adjustment enough to fit new pads?
Thermal overload:
overload: Protection springs out of position
overheated/
overheated/crystallized Interference !!
grease
Change bellows, clean /put

new high temp. grease on
Note! The protection spring must be put
the adjustment screws and
- - - rectify the root cause! back in its ordinary position!
69
Water ingress Æ corrosion
Sealing joints

70
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!

71
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!

72
36
Water - dirt – accelerated wear
Life is
not always so easy !
73
Water - dirt – accelerated wear
With protection
Without protection
Pad wear:
wear: 20 - 30 Km = 7mm !
74
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 !

75
I didn’t know all that !

76
38

The Brakes Must Be Able To Manage All Possible Situations!

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The Brakes Must Be Able To Manage All Possible Situations!

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The Brakes must be able to

manage all possible situations!

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Mark II Mark III

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Two piece caliper

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Common application module

• One self contained

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

The same Mechanism in

DB22 DB22LT DB19

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

The 4 slide pins makes it possible to:

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

• Rubber bellows – protection against

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

• Stainless steel slide pins for

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

VWI, Visual Wear Indicator

• Casted arrow on the caliper

• Slotted steel pin seated in

• The distance from the arrow

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

PWI Pad wear indicator

Type of wiring and connector according to customer demand

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Wear indication system, PWS

PWS Pad wear sensor

Adjustment screw O-ring x 2 Fixation screw

Sensor rod Caliper collar seat Sensor collar

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Decreasing efficiency at ~300°

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Dyno comparison test

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

( Constant application pressure)

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Haldex Disc Brake

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

1902 Patent Lanchester

1950 Jaguar - Le Mans

1960 Passenger cars

1996 Truck break through

2006 Physical laws still valid

The Disc Brake really has been around for a while - - -

Haldex Disc Brake

Application pressure per Cm²

•More efficient at higher temperature

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

( Constant application pressure)

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

Characteristic: Drum Brake

(Constant application pressure)

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology

• Torque test (Chucker)

• Fatigue (Puls test)

• Vibration test (Hydropuls)

• Vehicle field test

P/N 90151 / edt. 2006 – 01 / Landskrona Innovative Vehicle Technology