Product brochure - Brake systems 2016

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Brake systems

We deliver everything from brake calculations and advising, to design, production and testing of brake systems.

Engineered by Rydahls

www.rydahls.com

Content: We are experts at customised brake systems...

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Advanced design and production of brake systems

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Knott - Disc and drum brakes 6-7 Safim - Cylinders and brake valves 8-9 TVZ - Axles 10 Knott Vortex - Electromagnetic brakes 11 MCS - Electric throttle controls 12-13 Customised brake systems 14-15

We are experts at customised brake systems for heavy machinery and vehicles.

At Rydahls we have extensive competence and know-how on brake systems for wheel loaders, dumpers, tractors, forest machinery, military vehicles and machinery in the manufacturing industry.

Through the process Engineered by Rydahls we look after everything from brake calculations and advising, to design, production and testing of the systems. We deliver complete installations that can go straight into your assembly lines.

Try us! We can promise you a partnership with full commitment to your brake systems.

We want to do more, it’s as simple as that!

Engineered by Rydahls

Brake experts since 1916 When you enter into cooperation with us you obtain a partner that knows its job. We don’t call ourselves brake experts for nothing. We have been in the industry since 1916 and we have always stayed ahead in technical developments, kept both eyes on the demands of the market and established ties with prominent and recognised competent suppliers. What you get from us always maintains top class, whether it’s individual parts or customised systems.

Engineered by Rydahls Most of the brake systems we produce are customised.

Within our concept “Engineered by Rydahls” we deliver custom-made brake systems that can go straight into your assembly lines. If you bring us in at an early stage of a project we can support you all the way with technical advice and assume responsibility for the entire process – everything from design, brake calculations and dimensioning, to production, tests and delivery of brake systems. Engineered by Rydahls is our signature for the unique brake systems we develop for machinery and vehicles, commissioned by customers from many parts of the world.

Top class systems and products Throughout the years we have carefully selected several suppliers that we know well, and whose products we stand for. When we design brake systems it’s our competence in combination with reliable and tested products that interacts and results in unique solutions. One thing that our partners share in common is that they are actively engaged in research and development, and that their products are among the best that can be found on the market.

Long-term sustainability We aim to run our business so that we can achieve maximum sustainability. Primarily this means what we can actually control – the consumption of energy, recycling, and modes of transport etc. But we also take the policies of our suppliers into consideration and as far as possible choose partners who share our view of long-term sustainability.

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Advanced design and production of brake systems.

Our job is to give you a brake solution that is not only one hundred per cent reliable, but which also gives you advantages in your production and in your delivery on the market.

It’s often about special solutions. We like to tackle challenges like this because that’s where we get to use all of our competence and innovative capacity, to create a cost-effective and reliable solution for you.

Our offer As in so many other contexts, the start is decisive for the end result. Together with you we go through the necessary requirements and we prepare technical specifications for the system. Stage two is the actual design, with drawings, brake calculations and dimensioning. In stage three we produce the system. The entire process takes place within a jointly agreed timetable for delivery.

Advising, design and brake calculations You will find us to be a technical advisor for all types of brake issues. We suggest materials and guide you through obstacles and problems. It’s important to know at an early stage what requirements are set for braking times, braking power and braking torque, so that we can do the correct brake calculations.

Designs and drawings It’s just as important to work on the basis of an explict definintion of the environment in which your brake system is going to operate. What does the area look like, what are the dimensions, which adjacent parts and materials do we have to take into consideration in terms of heat and moisture? From the set specifications our design department then produces a CAD drawing that forms the basis for the design.

Production of brake systems In our assembly workshop we can handle most requirements for the production of brake systems. Everything from mechanical processing, such as turning, drilling and milling, to the assembly of extra accessories and final assembly of complete brake systems. We also undertake to pack, label and adapt complete assemblies and brake system kits so that they can directly go into your assembly lines or spare part stocks. All systems are inspected prior to delivery.

Tests and testing In those cases where as a customer you have an express preference, we can conduct tests of brake systems in our own workshop. We can build up customised functional brake systems in test benches to clearly demonstrate the system for you, for training and to certify circuit pressure and functionality.

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Brake systems for machinery and vehicles We design and produce brake systems for most off-road vehicles, e.g. tractors, trucks, forestry machines and construction machinery. We have a comprehensive product range that covers all parts of the brake system. Everything from drum brakes, disc brakes, valves and cylinders, to hoses, nipples and couplings.

Hydraulic brakes and brake systems One of our specialities is hydraulic brake systems for semitrailers and custombuilt vehicles. And we are happy to tackle air suspension equipment with load sensing valves.

Pneumatic brakes and brake systems We deliver many different types of pneumatic brakes and brake systems, also for agricultural machinery. The brakes are delivered either in parts or as complete pneumatic brake systems, depending on your requirements.

We also have the opportunity to deliver brake systems built up of both hydraulics and pneumatics.

Electromagnetic brakes and clutches These types of products are used for example in electric trucks, industrial doors and lifts.

Axles for farming and forest trailers We have a strong offer of axles. Naturally, we can also take care of the activation no matter if it is pneumatic or hydraulic.

Electric throttle controls for off-road machines Diesel engines are steered via electronic hand or foot operated throttle controls on modern off-road machines.

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Knott has been our partner for many years. We have developed several different types of brakes together, and today we deliver brakes in many varieties to leading vehicle manufacturers. “We make your brake” is a reasonable motto in this case. Knott’s competence can be trusted. It is a partner that understands you and your projects. The result is a solution that fits all your needs.

Knott has a total of more than 2,000 different varieties of brakes to choose from. If that is not enough, a new design can naturally be developed just for you.

Cam brakes Available sizes: Ø 115mm – Ø 500mm Braking torques: up to 35 kNm

Hydraulic servo brake Available sizes: Ø 170mm – Ø 440mm Braking torques: up to 25 kNm

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Hydraulic Simplex brake Available sizes: Ø 115mm – Ø 500mm Braking torques: up to 35 kNm

Wedge-actuated brake Available sizes: Ø 410mm – Ø 500mm Braking torques: up to 40 kNm

Spring pack sliding calliper brake Available sizes: diameter 75 – 110 mm Braking torques: up to 9.500 Nm

Hydraulic fixed-calliper disc brake Available sizes: 2, 4 or 6 pistons with a diameter of 40-92 mm Braking torques: up to 120 kNm

Hydraulic sliding calliper disc brake Available sizes: 1 or 2 pistons with a diameter of 40-72 mm Braking torques: up to 10 kNm

Mechanical sliding calliper disc brake Available sizes: MGS 22, MGS 33, MGS 40, MGS 45 and MZB 40 Braking torques: up to 6000 Nm

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Safim Spa is our supplier of hydraulic pedals, valves and other hydraulic parts that can be found in a brake system. Safim has a flexible production, which makes it possible to customise solutions for different types of vehicles, such as farming, construction, forest and mining machines.

Master cylinder with booster Operating pressure up to 150 bar Volume 18-65 cm3

Master cylinder Operating pressure up to 150 bar

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Step-bore master cylinder Arbetstryck upp till 150 bar Volym 8-35 cm3

Proportional foot brake valves 1-4 circuits Up to 180 bar A number of different possibilities to configure the valve, for example accumulator charging valve, circulation pumping, steering support, hydraulically operated blowers, regulating and releasing the parking brake.

Trailer brake valves Available for variable pumps alternatively for fixed displacement pumps. As well as in a number of gear ratio between a non-traction vehicle and trailers.

Other valves Pressure relief, priority valves, accumulator charging valves, accumulators and pressure switches.

Brake cylinders Spring-applied brake cylinders, multi-function cylinders for parking, emergency and service brakes. Also available as single positive brake cylinders in several different sizes, for example 28, 30 and 35 mm.

S6 Power brake valves ‘Modular’ Type Distinguishing qualities for these brake valves are • Compact measurements • Nice brake feel - can be customised • Modular • Brake pressure up to 170 bar • Accumulator charging pressure 20-200 bar • 1-4 brake circuits

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TVZ is our partner for axles. It is a mediumsized company with products for the farming and construction machine sector. The company produces axles as well as braked and unbraked stub axles. The production consists to a large extent of modern CNC machines, which guarantees a high and constant quality and great flexibility.

Square axles for 25/40 km/h or 60/80km/h in braked and unbraked variants.

Steering axles for 25/40 km/h or 60/80 km/h in several different variants and designs.

Tire wear is normally a heavy expense for vehicles. By exchanging one or several axles to steering ones, the tire wear can decrease significantly. The life of the vehicle’s other components, such as the spring system, will also be extended when using steering axles.

Hydraulic or mechanical brakes that meet most European requirements, for instance TĂœV, ECE-R13 and UTAC.

Stub axles in several different designs suitable for smaller trailers as well as larger forestry and farming trailers.

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Electromagnetic brakes are often constructed to work as negative brakes. This means that the brake is activated when the power is switched off. These brakes are often used in different types of electric production, such as electric trucks, electric vehicles, conveyors and other types of industrial applications.

We can offer most types of electromagnetic brakes from our partner Vortex. Making customised solutions is not especially uncommon, and it is rarely a problem.

Spring-operated electromagnetic brakes • Available sizes: 37-500 mm in diameter • Torque range up to 1500 Nm • Low-wear • Easy to adjust • Several accessories

Permanent magnetic brakes Dry running Zero-backlash High temperature insulation Flexible mounting Torque range 0.4 Nm - 160 Nm

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MCS has focused on programmable Hall Effect Sensors for electric pedals and throttle controls for the last 15 years. These controls are compatible with all models of industrial diesel and CNG engines.

Electronic floor mounted throttle pedal 962 000 series Pedal angle: 30°- 35°- 45° Pedal travel angle: 22° Return springs: 2 Operating temperature: -40°C / + 85°C Protection: IP66/IP69 CE Certified Complies with FMVSS 124 Available with CAN - J1939

Electronic floor mounted throttle pedal 964 000 series Pedal travel angle: +-15° Return springs: 2 Operating temperature: -40°C / + 85°C Protection: IP66/IP69 CE Certified Available with CAN - J1939

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Electronic suspended throttle pedal 963 000 series Pedal angle: 15° from horizontal Pedal travel angle: 24° Return springs: 2 st Operating temperature: -40°C / + 85°C Protection: IP66/IP69 Available as CAN - J1939

Electronic floor mounted throttle pedal 965 000 series Pedal angle in idle position: 30°- 35°- 45° Pedal travel angle: 22° Return springs: 2 Operating temperature: -40°C / + 85°C Protection: IP69K

Suspending pedal 967 000 series Pedal angle: Return springs: Operating temperature: Protection: Pedal travel angle:

17° eller 20° 2 -40°C / +85°C IP69K 17° or 20°.

Automotive floor mounted throttle pedal 969 000 series Integrated inductive technology Programmable dual analogue output Pedal travel angle: 16° Pedal angle in rest position: 55° Return springs: 2 Operating temperature: -35°C / +80°C Protection: IP5K0

In addition to these throttle controls, there are a number of different varieties of hand and foot operated controls available Some distinguishing qualities for all products are • cost-efficient solutions • easy to configure for your application • quick technical support in the construction phase • short time for prototypes • all products are approved according to all necessary standards • very high product quality

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Customised for optimal function Our job is to give you a brake solution that is not only one hundred per cent reliable, but also gives you advantages in your production and in your delivery on the market. It is often a matter of special solutions - customised from your needs. Below is a number of examples of customised solutions.

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rydahls.com/en/Brake-System

The brake experts2 After one hundred years in the industry we have built up unique experience and competence. We are experts at both individual products and customised brake systems and friction solutions, and offer a very comprehensive range of spare parts, products and m ­ aterials.

Our customers are primarily active in the engineering, machinery and vehicle industry and in the manufacturing industry. With the needs of customers in full focus, we supply innovative solutions, top class quality, and fully committed service.

Try us! We want to do more, it’s as simple as that!

Brisgatan 19, Box 12, SE-651 02 Karlstad, Sweden Tel. +46(0)10-550 94 00, Fax. +46(0)54 - 85 10 58 servicegruppen@rydahls.se

www.rydahls.com

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