ModulT offers a cost-effective combination of durability and optimised weight reduction

The Haldex ModulT program is an innovative air disc brake platform developed specifically for the purpose of meeting increased customer demands on performance, robustness, service up-time, weight and total cost. The basic design of the ModulT consists of a large single tappet mechanism, a monobloc calliper and two sliding pins.

The key factor of the ModulT product line as a whole is light weight and optimised design. The design of the ModulT caliper body, a metal casting, went through a computer-based topology optimisation tool that involves only having material where it is absolutely required when making a strength calculation. By placing forces on the model and observing its reaction, the program calculates how much material it needs to keep. Product designers use this information to fine-tune the model for production.

Other design features support the slimmed-down form. The single casting reduces weight by avoiding the need for an extra interface for bolting together (as well as the bolts). A stainless steel sliding pin offers long lifetime and even pad wear. A single, rather than twin, tappet mechanism involves fewer parts. This single tappet brake includes a relatively wide T-shaped thrust plate, similar to a two-tappet design, ensuring an even pressure application to the brake pad.

Including pads, the DBT22LT caliper for 22-inch wheels weighs just over 30kg (depending on the carrier) and creates 20kNm braking force, while the smaller DBT19LT is 29kg, including pads, and generates up to 18kNm braking force. The benefits don’t end with small size. A modular approach to design means that both brakes use exactly the same components except the pads, caliper and the carrier. The benefit for the customer is the same spare parts for both brakes. That reduces the complexity of ordering and parts stocking.