ZF drives safety with trailer brake technology
Vehicle systems provider ZF has emphasised the importance of the role high-quality trailer air disc brake and brake actuation technology plays in the drive to improve road safety and optimise operational effectiveness.
“To bring optimal brake force to the road, an effective wheel-end solution with quality braking and brake actuator technology is of critical importance,” said the company.
“Having supplied over 8 million single-piston air disc brakes and more than 70 million brake actuators to the commercial vehicle market worldwide, ZF’s wheel-end solutions have long been trusted by OEMs, fleets and drivers…
“Its wheel-end solutions offer customers a wide range of benefits for daily operations including enhanced safety, regulatory compliance, more vehicle uptime, less maintenance, reduced repair costs and increased payload capabilities.”
There are two main types of brake actuators, says the company: an onboard service brake chamber reliably actuates the service brake while a spring brake chamber additionally enables parking and fail-safe braking.
“In addition to the proven reliability of Unistop service brake chambers, ZF’s Tristop D spring brake chambers enable all three braking functions: service, parking and fail-safe braking.
“Tristop D spring brake chambers feature a double diaphragm and provide a tailor-made and cost-efficient solution for trailer applications that must meet specific space and performance requirements. A range of options is available, from a basic application, with open-hole design and external release bolt, to premium variants with an internal breathing valve (IBV) and coil clash-free power spring.
“In the premium variant, a new integrated release bolt (IRB) design offers superior inner component protection for extended brake chamber life and vehicle uptime. The latest available IRB design for trailers eliminates the need for an external release bolt and dust plug, helping to significantly improve serviceability and increases protection against exterior contamination.
“ZF’s IBV technology also helps extend product life, as it enables the brake chamber to ‘breathe’ using clean air from the service side of the chamber. The combination of IBV and IRB technology fully seals the parking chamber and provides optimal protection.”
ZF provides service and spring brake chambers designed for various brake applications. This includes air disc, cam and wedge types featuring different brake chamber sizes and output forces to meet customer needs and whether service, parking and fail-safe braking functions are required.
Within the air disc brake (ADB) sector, ZF says its single-piston air disc brake technology has been proven to be more reliable and achieve higher braking efficiency levels with consistent brake performance throughout their lifespan compared to other ADB designs.
“The piston is a vital element of the brake’s clamping unit, responsible for transferring the output force by pressing the brake pads against the disc,” said the company.
“ZF’s smart and compact single-piston technology achieves the same high output force as double-piston designs, even in the most demanding applications.”
Specifically designed for all types of trailers, the fifth-generation single piston air disc brake Maxx 2.0 offers a 2kg weight saving compared to the previous generation and, with up to 40 per cent fewer parts, enables increased transport payloads while reducing total cost of ownership, ZF says.
“Additionally, its low drag-torque design, with smooth guiding system, contributes to pad resetting in brake-off condition, further boosting fuel efficiency. Engineered with an active taper wear mitigation system it reduces uneven pad wear and extends pad life. In addition, a newly designed carrier and brake pad system offers improved serviceability for quick and easy pad replacement.”
Maxx 2.0 features a unique adjuster mechanism to quickly adapt running clearance during both brake application and brake release, the technology provider adds.
“This increases clearance stability to help maintain optimal running clearance. It also provides rapid restoration of brake performance in extreme and long downhill operations and minimises the risk of over-adjusting, a common issue for hot runners. ZF offers solutions for all rim sizes from 17.5″ to 22.5″ and enables consistent performance of up to 30,000 Nm brake torque.”
Building on its proven braking and brake control solutions, ZF says it is committed to developing the technologies of the future.
“This includes advanced braking and vehicle control systems that support the commercial vehicle industry’s increasing adoption of autonomous driving, connectivity and electrification (ACE) technologies,” said the company.
“ZF is also powering wheel-end advances to support both conventional and electrified vehicles. This includes the development of continuous wear sensors and smart axles which enable continuous real-time monitoring and wheel end diagnostics.”
