Haldex, the brake system specialist within the SAF-HOLLAND Group, has been developing brake solutions for modern commercial vehicles for decades and is one of the world’s leading suppliers in this segment. The focus is not only on braking performance and efficiency, but above all on a consistent safety concept – from the design of individual components and manufacturing through to maintenance in day-to-day fleet operations.
“Safety does not come from individual components, but from the perfect interaction of design, manufacturing quality, serviceability and intelligent system technology,” explains Alexander Kraus, Senior Commercial Product Manager at SAF-HOLLAND. “Particularly in modern trailer systems, robust and reliable brake systems that are easy to service are crucial to maximum availability and cost-effectiveness.”
Proven disc brake for international use
With ModulT, Haldex offers an air disc brake that has proven itself in the European market for more than ten years and is now used in hundreds of thousands of trailers worldwide. The brake has been designed consistently for reliability, low weight and high long-term durability.
The brake design allows effective cooling and water drainage, while the mechanism bellows is folded inwards to reliably protect sensitive moving components from stone chippings, road salt and surface water kicked up from the road. Haldex also uses stainless sliding pins for calliper movement. Together with protective metal caps, this concept significantly reduces the risk of corrosion and impaired calliper movement.
Haldex also applies a consistent safety approach to the design of the brake calliper itself. Modern simulation software is used to analyse loads precisely and place material specifically where it is required for stability and fatigue strength. Particular attention is paid to transitions between sections with different material thicknesses to ensure uniform stress distribution and maximum structural integrity.
High manufacturing quality through automated processes
In addition to design, production quality plays a central role in the operational safety of modern brake systems. Haldex therefore manufactures the ModulT using highly automated production processes with continuous quality monitoring. Measurement systems inspect components directly during production and identify even the smallest deviations at an early stage. This is supplemented by additional sample inspections during series production.
“For safety-critical components in particular, consistent manufacturing quality determines long-term reliability in the field,” emphasises Kraus. “Our production processes are therefore systematically designed for repeatability and process reliability.” At the same time, as part of the SAF-HOLLAND Group, Haldex benefits from the Group-wide exchange of technical expertise and internationally established quality standards in the development of safety-critical suspension and brake systems.
Maintenance safety as part of the overall concept
Serviceability was also specifically taken into account in the development of the ModulT. The system enables simplified brake pad replacement, reducing maintenance times and minimising potential sources of error. At the same time, a boltless pad retainer ensures that the brake pads remain securely fixed in place.
Additionally, the single tappet mechanism reduces the number of components and contributes to weight saving. To ensure that braking force is nevertheless distributed evenly across the pads and uniform wear is maintained, Haldex uses a relatively wide T-shaped thrust plate for even pressure application to the brake pad.
Another focus is on minimising hysteresis losses – energy losses caused by internal friction and restoring forces. Haldex uses double roller bearings to reduce friction within the moving assemblies and improve braking performance.
Decades of expertise in drum brakes
In addition to disc brakes, Haldex has decades of experience in automatic brake adjusters for drum brakes. The company has been developing these systems for more than 50 years and is one of the technology pioneers in this segment worldwide.
While the Haldex AA1 relies on a precisely defined reference position during installation, the modern S-ABA (self-setting automatic brake adjuster) establishes its own reference point after just a few brake applications. This reduces installation errors and further increases operational safety. Haldex was also the first supplier to offer an automatic brake adjuster with electronic brake lining wear detection.
Digital monitoring for greater safety in fleet operations
As modern trailers become increasingly digital, Haldex is continuously adding intelligent monitoring functions to its brake systems. Pad wear indicators and sensors (PWI/PWS) provide either a wear limit indication or continuous monitoring of brake pad condition. This gives fleet operators greater transparency over the maintenance status of their vehicles and allows them to plan service work more precisely.
The EB+ 4.0 electronic trailer brake system provides the basis for modern connected trailer concepts. Thanks to its modular design strategy, additional safety, braking and comfort functions can be integrated flexibly. Within the SAF-HOLLAND Group, this is increasingly giving rise to integrated solutions in which brake systems, suspension technologies and digital vehicle functions are intelligently interconnected. This is creating comprehensive system solutions for modern commercial vehicles in which safety, efficiency and reliability are optimally coordinated.
