Haldex Expands ModulT to Truck Market

Haldex is advancing further into the truck market by introducing its innovative ModulT braking system to an on-highway truck OEM. Originally designed for trailers in 2011, this is a key milestone for the ModulT system as it gains its first on-highway truck customer. Without mentioning the customer by name, the expansion highlights the growing capabilities of Haldex in delivering efficient and lightweight braking solutions to the commercial vehicle sector.

Key Highlights of the Expansion:

First on-highway truck customer for the ModulT system, originally developed for trailers.
The single-tappet design reduces weight, costs, and enhances efficiency.
Adaptation of the system to trucks includes additional adjustment functions tailored to on-road vehicles.
Haldex’s modular design allows shared components across truck brakes while ensuring customization.

The single-tappet design of the ModulT system, a unique feature offered only by Haldex, stands out in the market by providing significant weight reduction and cost-effectiveness. “Our main goal was to make the lightest trailer brake available,” says Charlotte Wall, vice president of product management at Haldex. To achieve this, Haldex not only reduced the weight of the casted parts but also minimized the number of components. This feature enables Haldex to apply sufficient brake force with fewer parts compared to competitors who rely on dual-tappet systems, resulting in easier maintenance and reduced weight.

Wall explains, “The main reason we are able to make this brake work is the force distribution. We have a very wide mechanism support, which applies load onto the thrust plate evenly, creating pressure on the pad. This allows us to stabilize the setup.” This design means fewer parts and, consequently, lower maintenance and operational costs for vehicle operators.

Expanding ModulT to trucks required modifications to adapt to truck-specific requirements. Wall adds, “The difference between trailer and truck brake versions is mainly the adjustment function. If you use the brake on a truck or a bus, the brake spectra – the number of applications on different torque levels as well as parking brakes – is different compared to a trailer.” To manage the more demanding braking scenarios in trucks, Haldex employs a modular design that maintains consistency across different components while customizing cast parts and pads to meet specific wheel sizes.

Looking ahead, Haldex intends to continue expanding its presence in the truck and bus markets, though each new application involves a dedicated period of customization and rigorous validation. Wall states, “There is always a period of time that is required to make those customizations and validations.” These processes include regulatory and customer-specific tests, covering temperature, disc crack, and lifetime tests, as well as extensive field testing that may take 12 months to two years.

Despite advances in virtual testing, particularly for stress analysis of materials, certain aspects still require real-world trials. Wall notes, “You can’t do virtual testing when it comes to the friction couple, as some failures can only be found in the field.” Field testing is essential to address challenges like uneven wear on the brake pads, which often arise from broader installation issues rather than the brake itself.

With over 25 years of experience at Haldex, spanning roles from logistics to R&D, Wall has a comprehensive understanding of the complexities of brake system development. She now oversees product and project management for both Haldex and SAF-Holland in Europe, following Haldex’s acquisition by SAF-Holland.

The expansion of the ModulT system into the truck market marks a pivotal step in Haldex’s journey towards providing lighter and more efficient braking solutions for the commercial vehicle industry.

Yes, sign me up!