Annual Report 2012 - Knorr-Bremse AG.

70 Report ProduCts // Commercial vehicle systems
The N2G has been designed to be more robust than its predecessor. Knorr-Bremse has also transferred
the entire assembly process to its Aldersbach plant, where it has developed a separate assembly
line and appropriate test rigs. And all the components needed for the assembly of the N2G adjuster
are now being sourced directly from the suppliers by Knorr-Bremse.
The new short spring
brake takes account
of the ever smaller
installation envelopes
at the wheelend.
Short NG3 spring brake added to portfolio
Knorr-Bremse has added the Short NG3 spring brake to its portfolio. As the name suggests, this is an
extra-short spring brake measuring just 204 mm. While it can be customized for any brake application
and output force requirement, the new spring brake was primarily designed for use on the front
axle. With its reduced length and the resultant drop in weight, it takes account of the ever smaller
installation envelopes at the wheelend – that is hub, bearings and brake disc. The improved location
of its center of gravity means that the Short NG3 will also offer high vibration resistance.
In the year under review, initial prototypes were produced at Knorr-Bremse and the first tests conducted
together with a customer. The target for volume production is the end of 2015.
Knorr-Bremse KAMA further develops drum brake
Disc brakes predominate in the Western European truck market, but there is still comparatively strong
demand for drum brakes in Eastern Europe, Russia, North and South America and Asia. This has both
historical and practical reasons. Drum brakes are relatively enclosed, which means the surfaces of the
brake pads and drums are well protected from corrosion and dirt when the vehicle is operating in
rough terrain.
Knorr-Bremse currently manufactures a tried-and-tested drum brake in Russia in a joint venture set up
in 2007 with Russian vehicle manufacturer KAMAZ, but in the medium and longer term the plan is to
develop an entirely new concept for the next generation.
In the year under review the joint venture – with the support of Knorr-Bremse’s subsidiary Bendix
Spicer – started work on optimizing the existing brake, with the aim of improving its functionality,
reducing its weight and introducing modern technologies for its production. A further requirement
was that the modified brake should be easier to install. Most of the development work on the new
brake is being carried out by Knorr-Bremse KAMA, the Russian joint venture, but the product is destined
to be sold in all markets worldwide.
Volume production of Pneumatic Booster System PBS
Knorr-Bremse’s Pneumatic Booster System (PBS) eliminates so-called turbo-lag in commercial vehicle diesel
engines during drive-off. It boosts engine performance and also enables down-speeding or down-sizing,
which saves fuel. In 2012 a major customer started to install the system as standard equipment.
Several seconds can pass before a large turbo-diesel engine reaches maximum torque. PBS briefly
boosts the engine’s power output by blowing compressed air from the braking system into the engine
air intake, effectively overcoming the turbo-lag that can occur during drive-off, overtaking or on uphill
gradients. The engine responds more rapidly, and as the vehicle accelerates, the driver can select a
higher gear earlier. This reduces average engine revs – which can result in fuel savings of up to 5%.
A vehicle equipped with PBS accelerates as though it had an engine with 20% to 30% more cubic
capacity, which means that a smaller engine equipped with PBS can replace a larger one. Particularly
in the case of local public transport and freight distribution operations this is a considerable advantage,
as less installation space is required for the engine.