Proactive spring development streamlines Haldex Disc Brake product

2012-10-22 In a strategically important project, Lesjöfors has developed a brake pad spring in a lighter, stainless material which also extended the product´s lifespan. Extensive knowledge of materials, high-tech expertise and a proactive approach is behind the success.

Haldex is a global producer of advanced braking and suspension systems for the commercial vehicle industry. Some years ago Lesjöfors in Värnamo, Sweden offered a spring to Haldex used for the brake pads in heavy goods vehicles.

Opportunities for further development
Lesjöfors´ development engineers noted in the process that Haldex´ former spring system was fully functional but not optimal from a number of aspects. Thanks to the Lesjöfors team's good record of high-strength stainless steel materials, opportunities to improve the performance of the spring were identified with an unchanged cost level. Haldex showed great interest in the further development of the brake pad spring.

Lighter component in cost efficient production
With solid knowledge of various spring materials combined with resources for calculations, testing and prototype development, Lesjöfors´ design engineers were able to develop and refine the design and execution of the spring. Among other has sophisticated FEM calculations been used. The end result was a spring in stainless steel where no costly hardening or surface treatment was required. The product is also lighter as the material dimension has been reduced from 1.8 mm to 1 mm.
- The end product was preceded by a development process of about 1.5 years, where we in close cooperation with Haldex continuously tested the spring and finally found our way. We have been able to deliver an ideal solution that exceeded the customer's high demands without changing the cost structure, which we are extremely proud and happy of, says Marcus Hartvigsson, Technical Manager at Lesjöfors in Värnamo.

In addition, longer lifespan
Not only did the brake pad spring become lighter, it has also been given a longer life. The spring now lives 50 per cent longer than the previous component in carbon steel. This summer, the product went into production and is now in use in the Haldex product.
- We are delighted about our partnership with Lesjöfors. Thanks to their ideas, knowledge and experience we have been able to improve our disc brake product, which ultimately benefits our end customers both from an environmental and a cost perspective, says Anders Lindqvist, Project Manager at Haldex.



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