07.05.2007 Kögel presents its own axle system

TRAX – The Kögel Premium Axle Burtenbach, May 2007. Kögel, together with the global market leader for axle and braking systems, ArvinMeritor, will be presenting the new "Kögel TRAX" trailer axle system at the "Transport Logistics" trade fair in Munich in June 2007. The axle has been jointly developed according to Kögel specifications and corresponds to the high requirements placed on all Kögel components and systems. The range of tests conducted up to now at the US laboratories of ArvinMeritor are very promising. The TRAX clearly exceeded the demanding development specifications of Kögel regarding all relevant characteristics such as low level of wear, maintenance-free operations, high braking performance and low weight.

New engineering solutions for brakes, axle trailing arms and connections ensure excellent vehicle performance and long service life just as much as the high-quality materials and, not least, careful processing using the latest process engineering methods. Kögel manufactures the axle system at a specially installed production and Kögel offers the TRAX axle system without any surcharge for all semi-trailers in the MAXX product range. If requested, customers continue to have the option of equipping their vehicles as has been the case with premium axles from BPW, SAF and Daimler Chrysler.

The new Trailer axle: Kögel TRAX. hires_TRAX_backgound.jpg Axle beam with Bionic Design Thanks to the worldwide network of ArvinMeritor´s development expertise and the trailer know-how of Kögel, the two partners have succeeded in creating a new trailer axle system which combines all the advantages of modern technology in one system. Immediately at the first glance, the unusual form of the trailing arm stands out which guides the axle in a longitudinal direction and connects it to the vehicle. During the development stage, engineers modelled the design on nature itself and determined the form and material thickness according to the respective operational demands by means of complex finite element calculations. At the same time they searched hard to find the most suitable materials and production process for the manufacture of this new trailing arm. This type of construction is known in the industry as bionic design. This free-form design engineering using steel casting technology ensures not only a low dead weight but also a very long life cycle of the axle. In the process, precision-welding robots securely connect the cast components of the trailing arm to

the axle tube resulting in a maintenance-free fitting. In combination with subsequent zinc phosphate plating and KTL surface treatment, the axle is guaranteed a very long service life. In addition, the intelligent design ensures an extremely low axle weight. Complete with axle support and breaks, the Kögel TRAX weighs a mere 438 kg.

Mounting of the brake calliper hires_brakecalliper.jpg New maintenance-free and wear-resistant brakes Axle and brakes were given the same priority during the development. Thus, construction took place concurrently whereby the components of both systems were optimally matched to one another. Engineers focused not only improved braking performance. Thanks to decades of experience and access to the resources available at development departments in its worldwide networks, design engineers at ArvinMeritor have suceeded in substantially improving the service life. The developers paid particular attention to the wear resistance of the brake pads and discs as well as very good braking performance. The proven and well-known disc brake with a 430-millimetre diameter, as used in Volvo and Renault truck tractors, served as the basis. It was further optimized for use with trailers. An all-round air gap for the cupped disc provides for good ventilation and excellent heat dissipation. It also prevents heat stress occurring on the wheel bearing above the cupped disc. Particular importance has been attached to the specially-designed „anti-coning“ break disc. It has been designed in such a way so that, under the influence of heat, only a radial expansion process takes place. This prevents the formation of cracks on the disc. Through this characteristic, the disc remains plane and the brake pads always have full contact when braking. This leads in turn to low wear of both the brake discs and pads. Customers can easily check when the pads are due to be replaced by means of a mechanical brake pad wear indicator on the brake calliper. A clearly visible pin penetrates further into the brake calliper with increasing wear, and quickly and reliably indicates a possibly pad change when carrying out the legally required visual checks which have to be done on a regular basis. A timely brake pad replacement can prevent any damage being caused to the brake discs. But even if repairs to the disc are due, this is where the brake shows its strengths: the disc can be removed and replaced without having to dismantle the wheel bearing. The wheel bearing has been designed as a maintenance-free and sealed compact wheel bearing unit which, in turn, has a very positive effect on the service life.

Welding Robot hires_welding_robot.jpg Trailer brake with a non-linear characteristic curve A technical highlight of the Kögel TRAX axle system is the brake calliper - this has two absolutely parallel brake pistons which are guided in teflon bushing. These produce the braking force in a non-linear characteristic curve. This means that during adaption breaking with brake pressure up to two bar, brakes reaction is extremely fast and breaking pressure can be very sensitively applied up to 5.5 bar. This applies to more than 80 per cent of all braking procedures. During emergency braking with high brake pressure over six bar, the brake pistons subject the pads, however, to a disproportionate level of high pressure. This is comparable to the function of a mechanical brake assistant and in emergency braking situations leads to considerably higher brake performance and ultimately to a very strong grip on the brake itself. In this way, the new development has managed to combine low brake pad wear – thanks to good metering capability – and a safe braking process – due to a strong braking procedure – in one individual brake. The development team have, however, also focused a lot attention on the other brake components. High-grade materials and improved sealing used in the newly-developed ArvinMeritor brake cylinder effectively prevent moisture infiltration which then normally leads to corrosion of the spring in the spring brake. The high-grade materials and improved sealing used in the newly developed ArvinMeritor brake cylinder effectively prevent this problem. Good guidance feature thanks to optimized axle connection The fact that the developers of the TRAX did not omit a single detail is shown by the axle connection on the axle support. The new support bearing mounted can be considered unique. It consists of a rubber ring complete with steel inlay and is so designed that it behaves rigidly in the driving direction whilst having a cushioning effect in the direction of the stroke. Due to the free-form design of the axle trailing arm, the shock absorber can be connected above the arm itself – this provides excellent protection against stone chippings. The brake cylinders are laterally attached to the trailing arm likewise in a protected position. A strong partnership for development and production ArvinMeritor, global market leader for axle and braking systems and exclusive development partner of Kögel in the trailer sector is responsible for the development and manufacture of all components, in particular the complete braking system. Thus, it can be guaranteed that individual systems are optimally matched with everything from one source. Interface

problems, such as integrating the brakes into the overall system, do not arise here. Quality is the highest priority also with production. All components originate from ArvinMeritor´s world-wide production facilities. The manufacture of the axle system takes place at Kögel´s main plant in Burtenbach. Axle assembly is carried out using a fully automatic robotic arc welding cell which is process-controlled and extremely precise. As is standard at Kögel, the surfaces are provided with excellent anti-corrosion protection by means of zinc phosphate plating plus KTL coating using the very latest technology. The assembly of the axle system takes place in a specially erected assembly facility complete with full process control for each assembly step and serial number-related documentation of all process data.

Kögel is one of the largest trailer and body manufacturers in Europe. The head office of the company is in Burtenbach near Augsburg. In addition, Kögel has a production plant in Chocen in the Czech Republic as well as the central after-sales operations in Ulm. In 2006, the company produced around 12,000 vehicles of which more than two thirds were supplied to customers outside of Germany throughout Europe. The1,000-strong workforce at home and abroad generated a turnover of over 275 million euros. According to market requirements, Kögel has divided its products into three different areas. The main brand, Kögel MAXX, provides the complete range of all transportation solutions required in the area of trailers and swap bodies. The MAXX vehicles offer quality corresponding to the highest industry standards. The Kögel foxx brand stands for robustness, functionality and good quality at unbeatable prices. As the first manufacturer in the industry, Kögel offers here the possibility of ordering trailers online. Kögel foxx semi-trailers are exclusively available via the internet at www.koegel foxx.com. The Kögel Phoenixx is, without doubt, the absolute premium brand in the company and stands for the future of trailer body construction. Phoenixx provides the freedom required for trend-setting innovations such as the use of carbon fibre composite materials. Contact: Andreas Lubitz Press Officer tel +49 · 82 85 · 88 · 312 fax +49 · 82 85 · 88 · 7312 mobile +49 · 1 63 · 9 78 90 75 email andreas.lubitz@koegel.com web www.koegel.com