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