Air Brake and Regulation Update Paul Johnston March 14, 2005 1
FMVSS121 Regulation Update Aiming For 50% Reduction in CV Related Fatalities NHTSA 9-Step process continues with the objective of reducing commercial vehicle fatalities by 50% by 2010. Study focuses on vehicle stopping distance, fleet maintenance practices, driver alertness,, vehicle roll-over over prevention and crash worthiness NHTSA still evaluating A / NPRM currently in their legal / economic review process Public brake forum event in Washington DC still targeted before comment closing date Current thinking is Summer / Fall 2005 Regulation changes focused on tractors and has softened from their initial anticipated 30% reduction to more like 20% - 25%. 75 MPH stopping distances anticipated to be excluded Anticipate regulatory changes to to be be effective no no earlier earlier than than 2008 2008 tractor tractor initially followed by by trailer, trailer, bus, bus, truck truck 2
Brake System Changes Regardless of amount of distance reduction, more steer axle braking is required Specifically highway tractors Rear tractor brake forces are near maximum as well as trucks, buses Vehicle configuration complexity will complicate any brake system change implementation Number of axles, axle GAWR, wheelbase 3
Current Air Brake Products Front, Rear and Trailer Axle Location Specialty Cam 2% ADB 1% 16.5" Cam 37% Specialty Cam 2% 15" Cam 60% Front Axles Rear/Trailer Axles 16.5" Cam 98% 4
ArvinMeritor Product Capabilities ArvinMeritor has two product alternatives Q Plus High Performance Drum Brake 16.5 front Q Plus brakes New Stamped Steel spider to minimize weight impact 16.5 x7 rear Q Plus brakes or 16.5 x8 / 8.62 rear Q Plus brakes for increased fade resistance / lining life Additional 12% - 23% more lining life High-Performance MA friction materials Meritor Automatic Slack Adjusters DiscPlus EX225 Air Disc Brake EX225L, EX225H in production Includes: hub/rotor, friction, chamber Steer axle modules available 5
Q Plus Drum Brake Diameter: 15.0 in. Width: 4.0 in. Chamber: T20 Diameter: 16.5 in. Width: 5.0 in. Chamber: T20 or T24 6
EX225 Air Disc Brake Global brake platform Utilizes common high volume components Engineered for regional applications Wheels and Wheel End Suspension Pad Actuator 7
Global Modular Caliper Design Bridge Piston Housing Modular Flexibility for Different Packaging Envelopes Common Global Piston Assembly Carrier (Saddle) 8
ArvinMeritor Air Disc Brake Exclusive Features Feature Actuator Secondary Seal Guided Trilobal Twin Pistons Robust Adjuster Drive and Internals Benefit Improved sealing (double seal) Improved reliability Minimal taper and radial wear Improved pad life Strong adjuster drive prevents damage internals withstand 100Nm drive No fuse components necessary Piston Stop and Internal Synchronization Corrosion Resistant Materials and Double Sealing Factory set internal tappet synchronization Travel stop prevents loss of tappets Factory set wear sensor drive Improved reliability Second barrier to water ingress in event of primary seal damage Optional stainless steel guide sleeve 9
Air Disc Brake N.A. Industry Issues Air disc brakes require changes to existing steer or drive axles Knuckle to bottom of caliper Axle mounting flanges Suspension options Air disc brakes do not fit all existing wheels OEM options to date have a restriction to 24.5 wheels 10
Wheel & Valve Stem Issue Current ADB packages do not meet minimum clearance on all wheels A similar issue prevailed in Europe as Air Disc Brakes were introduced to the market. Transitioned to a 335mm BC Transitioned to protected valve stem designs 11
Industry Summary Regulations (at best) will be implemented by 2008 New brake system solutions will not be driven by regulations Along with disc brakes, the 16.5 x 5, 7, 8.63 drum brakes are proven, established solutions to achieve higher performance Disc brakes require other vehicle changes or limitations to implement Wheels, Tires, Hubs Steering knuckles, Drive axle flanges Suspension packaging Will the industry accept a common direction on wheel fits? Regardless, the the industry will will implement increased total vehicle braking with with cost cost justified air air disc disc and and high performance drum brake alternatives 12
EX225 Product Features Details Appendix 13
DiscPlus Air Disc Brake Products EX225L2 EX225H2 / H3 Front Approved GAWR Up to 14.6K Up to 21.5K Rear Approved GAWR Up to 23K Up to 29K Caliper Weight (lbs.) w/o chamber 82 Wearable Lining (in 3 ) 2mm discard 44 Rotor Outer Diameter (in) 17.10 Stainless Steel Slide Pins Features Optional Lightweight compact caliper Designed to package in current high volume vehicle applications. 98 52 to 55 17.10 Standard Designed to meet the needs of the severe service duty cycle. Increased structural capability for higher output and GAWR Standard stainless steel sliding components for corrosion protection Targeted Vocations & Applications Line Haul Tractor & Trailer, General Truck & Bus Applications Vocational Truck And Bus Applications, Specialty Vehicles 14
EX225 Feature: Effective Secondary Sealing of Pistons Features: Exposed surfaces are smooth for optimal sealing (ARM Exclusive) Secondary piston seal to protect against internal contamination Easily replaceable primary piston boot Secondary Seal fitted inside Primary Rubber boot Smooth corrosion resistant surface Benefits: Brake protected even after primary boot damage (ARM Exclusive) Reduced risk of unscheduled service calls Lower cost of ownership 15
EX225 Feature: Chamber Secondary Seal Features: Secondary seal fitted for supplemental sealing of the direct mounted air chamber (ARM Exclusive) Benefits: Longer life - reliability Longer maintenance / inspection cycles Low cost of ownership Corrosion Resistant Sealing Surface for actuator seal Additional face seal 16
EX225 Feature: Guided Twin Pistons Features: Precision bushed pilot bores with substantial support (ARM Exclusive) Less than 1mm taper / radial pad wear α Benefits: Longer pad life - reliability Low cost of ownership Customer satisfaction Y X θ 17
EX225 Feature: Trilobal Anti-Rotating Pistons Features: Piston shape (ARM Exclusive) eliminates need for flimsy chain to synchronize tappets Internally fixed tappet synchronization maintained during service Benefits: Longer pad life - reliability Lower cost of ownership Customer satisfaction 18
EX225 Feature: Robust Adjuster Drive Features: 10 mm hardened adjuster drive and internals withstand >100 Nm torque (ARM Exclusive) Benefits: Robust serviceability shop tools Long life increased reliability Low cost of ownership 19
EX225 Feature: Outer Piston Travel Stop Features: Outer piston stop to limit maximum piston travel (ARM Exclusive) Benefits: Mechanic cannot cause assembly to fall apart by careless adjustment Low cost of ownership 20
Brake System Testing Details Appendix 21
Tractor Stopping Distance Testing 56,500 lbs. Configuration with an Un-Braked Trailer 60 MPH STOPPING DISTANCE SUMMARY 75 MPH STOPPING DISTANCE SUMMARY 600 500 400 FMVSS-121-355 ft Standard Brake Configuration 600 500 400 541 387 353 324 300 200 100 0 267 223 217 204 Average Stopping Distance (ft) High Performance Drum Brakes Front Air Disc Brakes All Wheel Air Disc Brakes 300 200 100 0 Average Stopping Distance (ft) Disc Disc brake brake stopping benefit benefit is is most most dramatic when when evaluating performance at at higher higher speeds due due to to drum drum brake brake in-stop in-stop fade fade 22
Truck Stopping Distance Testing Laden - 48,550 lbs., Un-laden - 27,260 lbs. 60 MPH STOPPING DISTANCE SUMMARY 75 MPH STOPPING DISTANCE SUMMARY 600 500 400 300 200 100 0 FMVSS-121 310 ft 204 209 180 211 Average Stopping Distance (ft) Empty w/ Drum Brakes Loaded w/ Drum Brakes Empty w/ All wheel Disc Brakes Loaded w/ All wheel Disc Brakes 600 500 400 300 200 100 0 398 Average Stopping Distance (ft) 337 Most Most current truck truck front front & rear rear drum drum brake brake specifications are are already optimized minimizes benefit benefit of of disc disc brakes brakes 23
Vehicle Testing Track Testing various configurations Tractor / Trailer Performance Compatibility School Bus NHTSA test program - VTRC Truck Fire truck / emergency Refuse Bus City transit Highway coach Motorhome Comprehensive Vehicle Testing Support and and Accomplishments 24
EX225 Product Features Details Appendix 25
Drum Brake Options to Change Brake Torque Chamber Size Lining Friction Shoe Width Shoe / Drum Diameter 26
Drum Brake Lining Volume and Weight 6x4 Tractor Front Rear Front Rear Drum Brake Specification 15"x4" 16.5"x7" 16.5"x5" 16.5"x7" Lining Volume - in 3 46 106 78 106 Total 6x4 Tractor - in 3 516 580 12% Weight - lbs 151 216 188 216 Brake Chamber Auto Slack Adjuster Drum Total 6x4 Tractor lbs. 1166 1240 6% 12%- 12%-23% 23% Increase in in Lining Lining Volume // Vehicle 74 74 lb. lb. Weight Premium Can Can be be Minimized // Still Still Lighter than than ADB ADB 27
EX225 Installation Details Appendix 28
Front Axle Steer Angle Issues Most prevalent on 14K+ axle designs Knuckle design can limit ADB clocking positions may result in limited turn angle 29
Rear Axle & Suspension Limitations Fixed air chamber position limits clocking options - can interfere with drive axle / suspension components 30