Coventry Plant

AUTOMOTIVE

Coventry Plant

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Company Profile

Trelleborg Automotive’s Coventry plant has a heritage that can be traced back over a hundred years, to the time when Dr John Boyd Dunlop began manufacturing bicycle tyres here in the city. By the mid 1950’s Dunlop were able to draw on their expertise in the design & manufacture of tyres & rubber products to introduce Pneuride Air Suspension.

Commencing initially with convoluted bellows & levelling valves, the product range extended to introduce rolling diaphragms, complete trailer axle kits & in the mid 80,s the award winning drive axle air suspension, factory fitted by Iveco Ford amongst others.

In 1985 BTR bought Dunlop, retaining the specialist products & technology, but disposing of the automotive tyre business to Sumitomo. BTR provided investment funds, management skills & saw the suspension business grow & prosper.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE In 1996 Dunlop Ltd Suspension & Components position was further strengthened by its incorporation into the BTR Automotive Anti Vibrations Systems Group which offered access to world-wide manufacturing facilities.

On 1st March 2000 BTR Automotive Anti Vibration Systems was purchased by Trelleborg who promptly incorporated the Coventry Plant into the Trelleborg Automotive Group. Trelleborg Automotive AVS, Systems & Components, Coventry is recognised as a world class supplier of suspension systems & components, & has the following OEM Customers:

Volvo Terex Equipment Transbus International Bell Equipment Renault ERF Isuzu Scania Land Rover LDV Ford Leyland Trucks General Motors MG Rover

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

To compliment this customer base, Trelleborg Automotive AVS, Systems & Components, Coventry has been accredited the following quality standards:

ISO 9001

Ford Q1

ISO 14001

OHSAS 18001

ISO/TS16949

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Capability

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Capability AUTOMOTIVE

• Trelleborg Automotive AVS, Systems & Components, Coventry can Design & Develop Electronic Control Air Suspension Systems, Air springs & Polyurethane bump stops to meet customer requirements from conception of design to volume production.

• The Coventry plant has dedicated project managers along with supporting design & development engineers to support all projects. Additional support can also be provided in the form of resident engineers & video conferencing.

• In-house test facility is equipped with the latest test equipment & machines required to conduct Design Verification testing of all our products.

• Various CAD & FEA tools are available to support in the design & development of new products.

Further information can be obtained by contacting Trelleborg Automotive AVS, Systems & Components, Coventry.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Coventry Product Profile

Hydragas

Microvon

Air Suspension (Air Springs)

Electronically Controlled Air Suspension (E.C.A.S)

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Hydragas AUTOMOTIVE

Trelleborg Hydragas suspension is a simple thoroughly developed system which has proved itself on a variety of vehicles with a range of gross weights.

The Hydragas suspension combines the function of a coil spring & shock absorber into compact units at each wheel station which are interconnected to provide an extremely low pitch rate.

Inert gas provides the springing medium & water based fluid,regulated by a damper valve pack,controls the bump & rebound. The units are interconnected, simply & conveniently by hydraulic pipe.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Features AUTOMOTIVE

Besides simplicity, Hydragas suspension offers significant advantages which can be applied to a variety of vehicle types.

Much lower pitch rate.

Relatively high bounce & roll rates - no need for anti-roll bars.

Less intrusion into passenger & luggage space.

Maintenance free. Sealed for life unit.

Highly tuneable - can be adapted to meet a wide variety of pitch, bounce, bump & rebound conditions.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Hydragas - Application AUTOMOTIVE

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Introduction To Microvon

Trelleborg recognised the market need for an improved performance version of our already low cost environmentally friendly ‘Daltek’ microcellular MDI (DiPhenyl Methane Diisocyanate) polyurethane product,- which led to the development of Daltek NV.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE DALTEK NV

Trelleborg Automotive together with our development partner Huntsman Polyurethanes have developed DALTEK NV (New Variant) - an improved performance microcellular MDI polyurethane material.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Method of Manufacture

Microcellular Polyurethane is produced by low pressure mixing of the two components at high speed. Polyol & Isocyanate. This liquid mix is then immediately injected into a heated steel tool. The microcellular polyurethane expands to fill the form cut into the mould and cures to a blown elastomer. Parts can then be automatically removed from the mould by robot, after a cure time of typically 4 minutes.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Performance Properties

Daltek NV has much improved processing range over Daltek. This allows greater scope in meeting load deflection characteristics at a range of densities and alternative profiles.

The uniform performance of Daltek NV over a wide processing range results in less material variation during production and greater consistency of product performance.

Daltek NV exhibits much improved green strength at demould which dramatically reduces splitting and cracking.

Daltek NV has been developed to a specification which ensures that a single material, has a wide application range.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Performance Properties – cont. AUTOMOTIVE

The general mechanical properties, tear strength, tensile strength, elongation at break and compression set, are more than adequate to provide the requisite energy management functions over the life of the vehicle.

Daltek NV additionally exhibits low water absorption without the need for specific additives and the requisite solvent resistance for use in the automotive environment (oils, fuel, glycol and brake fluid) due to its skinned, open, microcellular structure.

Daltek NV has improved resilience over Daltek. This property gives the new variant a dramatically improved fatigue performance in a wider variety of applications. In addition to the ability of the new material to survive high cyclic fatigue at constant load, the material demonstrates much lower height loss after completion of the test due to a reduced hysteresis effect.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Performance Properties - summary

Daltek NV has excellent resistance to both hydrolysis and bio degradation.

These properties are inherent in the polymer and are not dependent upon specialised additives.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Low Environmental Impact Raw Materials

All isocyanates are potential respiratory irritants.

Both NDI (Naphthalene Diisocyanate) and TDI (Tolulene Diisocyanate) are many times more volatile than MDI and therefore more likely to damage the environment.

MDI has the least environmental impact.

The base material of MDI used by Trelleborg, has the least environmental impact.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Recycling

Huntsman PU have identified and trialled, on a pilot commercial scale, a method for recycling MDI polymers. This process produces a high yield of flexible and rigid polyol precursors in equal quantities. The flexible polyol can be re-used in the original application whilst the remainder can be used for rigid applications.

TDI/NDI products can also be recycled but have a tendency to produce toxic by products.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Current Applications

Spring Aids. Bump Stops. Radiator Mounts. Dust Covers for Steering Joints. Dust Seals for Steering Joints. Anti-Vibration Mounts.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Potential Applications

Shock Absorber Mounting Eye & Bush.

Suspension Spring Seat Isolation Mount

Anti Roll Bar Bushes.

Suspension Control Arm Bushes.

Engine Anti-Vibration Mounts.

Shock Absorber Top Mounts.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Benefits of DALTEK NV

Improved performance when compared to DALTEK.

Improved process tolerance providing excellent process capability

Optimised balance of physical properties that are approaching NDI.

Minimal loss of properties during long term adverse conditions.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Microvon – Application AUTOMOTIVE

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Air Suspension Product Range

Air Springs

Bellows & Bellow Assemblies

Levelling Valves

Metalwork - Pistons / Clamp Plates etc

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US DiaphragmDiaphragm ConstructionConstruction AUTOMOTIVE

The diaphragm construction comprises of two layers of nylon cord positioned at a specified bias angle to form a lattice work. The lattice provides the diaphragm strength and is protected by an inner and outer rubber covering. To create the sealing force when attaching the diaphragm to its top plate and piston,high tensile wire is built into the sealing bead of the diaphragm.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US SelfSelf SealingSealing AirAir SpringSpring AUTOMOTIVE

Air spring comprises of top plate,piston,diaphragm and bump stop. Sealing is achieved by a self sealing technique by utilising the internal air pressure to force the diaphragm against the top plate and piston.The technique is very similar to a tubeless tyre. Assembly of the components into an air spring is much simpler than the crimp bead type and the diaphragm is easily replaced without the added expense of having to replace the complete assembly.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AirAir SpringSpring ComponentsComponents AUTOMOTIVE

Top Plate Mounted to chassis using bolts,studs or clips Manufactured in steel aluminium or plastic. Provides air inlet connection.

Piston Mounted to axle using bolts, studs or clips Manufactured in steel, aluminium or plastic.

Diaphragm attached to piston and top plate. Construction in rubber and fabric.

Bump Stop Can be internally attached to top plate or piston Manufactured in rubber or polyurethane.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Standard Diaphragm Range

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US ICIC 33063306 AUTOMOTIVE

Trelleborg Part Applications Air spring 254.0 Number Assemblies IC 3306 Leyland National Leyland Tiger PNP 31270 00 00 Leyland Titan Leyland Olympian Leyland Royal Tiger Wilson Double Deck 381.0

165.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US ICIC 33083308 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies IC 3308 Leyland National Leyland Tiger PNP 30729 00 00 Leyland Titan PNP 30732 00 00 Leyland Olympian PNP 30732 00 00 Leyland Royal Tiger PNP 30729 00 00 Dennis Dragon Volvo Olympian 381.0 MCW Various

165.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 0376003760 0202 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 03769 02 00 Renault PR 100 Ranault PR 180

296.0

131.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3000830008 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 194.0 Number Assemblies PNP 30008 01 00 Leyland National Leyland Tiger PNP 30730 00 00 Leyland Titan Leyland Olympian Leyland Royal Tiger Dennis Javelin PNP 31330 01 00 Volvo Olympian 418.0 Mercedes Various DAB PNP 31607 01 00 Scania K113 Chassis

120.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3010030100 0101 0101 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 30100 01 01 Mercedes Truck Various DAF Various

454.0

130.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3014730147 0101 0202 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 30147 01 02 Mercedes Truck Various DAF Various Volvo B10M Setra Van Hool Various Neoplan Jetliner 405.0

131.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3027330273 0101 0101 AUTOMOTIVE

Trelleborg Part Applications Air spring 300.0 Number Assemblies PNP 30273 01 01 Neoplan Various DAF Various

355.0

196.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3049830498 0101 0101 AUTOMOTIVE

Trelleborg Part Applications Air spring 254.0 Number Assemblies PNP 30498 01 01 DAF Various Iveco Various Volvo B10M Setra Neoplan Jetliner Van Hool MAN 399.0 Kassbohrer

150.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3051430514 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 194.0 Number Assemblies PNP 30514 01 00 Scania K113 Chassis A1 1123 00 13 PNP 31058 01 10 PNP 31313 01 00 PNP 31572 02 02 Dennis Fire A1 1194 00 07 LAG 523.0 EOS Coach PNP 30598 01 03

120.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3052130521 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 30521 01 00 Scania K113 Chassis PNP 31572 02 00 PNP 31572 02 01 Pegaso LAG EOS Coach PNP 31385 01 00

446.0

165.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3061630616 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 30616 01 00 Leyland Various

497.0

165.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3078030780 0000 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 300.0 Number Assemblies PNP 30780 00 00 Fiat Van Hool Various DAF Various Neoplan

420.0

198.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3079830798 0000 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 254.0 Number Assemblies PNP 30780 00 00 Flexolink Trailer (Dunlop) PNP 31074 00 00 PNP 31074 00 01 PNP 31074 00 04 Flexolink lightweight PNP 31154 00 00 Trailer (Dunlop)

621.0

165.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3105531055 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 200.0 Number Assemblies PNP 31055 01 00 Volvo Truck

511.0

130.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3138731387 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 224.0 Number Assemblies PNP 31387 01 00 Volvo Truck

534.0

130.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3167231672 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 215.0 Number Assemblies PNP 31672 01 00 Fiat Inbus Various

280.0

130.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3167331673 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 215.0 Number Assemblies PNP 31673 01 00 Fiat Inbus Various

360.0

130.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3167431674 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 246.0 Number Assemblies PNP 31674 01 00 Inbus Various

290.0

167.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3167531675 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 216.0 Number Assemblies PNP 31675 01 00 Fiat Various

385.0

167.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3167631676 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 216.0 Number Assemblies PNP 31676 01 00 Fiat Various

450.0

167.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3169031690 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 216.0 Number Assemblies PNP 31690 01 00 Fiat Various

365.0 375.0

150.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3169131691 0101 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 216.0 Number Assemblies PNP 31691 01 00 Fiat Various

400.0

150.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US PNPPNP 3125431254 0202 0000 AUTOMOTIVE

Trelleborg Part Applications Air spring 118.0 Number Assemblies PNP 31254 02 00 LDV 400 Convoy A1 1413 00 18 Mercedes Sprinter Fiat Ducato Volkswagen Carvelle

340.0

73.0

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US TechnicalTechnical DataData AUTOMOTIVE

SUPPORTIVE LOAD MAX PRESSURE (kg)

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US DiaphragmDiaphragm CrossCross ReferenceReference ListList AUTOMOTIVE

Trelleborg Part No.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Air Spring - Application AUTOMOTIVE

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

IntroductionIntroduction TrelleborgTrelleborg PneuridePneuride BellowsBellows areare usedused inin aa widewide varietyvariety ofof applicapplications:ations:

PrimaryPrimary applications:applications: VehicleVehicle SuspensionSuspension TrelleborgTrelleborg PneuridePneuride BellowsBellows areare usedused asas thethe suspensionsuspension mediamedia inin aa numbernumber ofof typestypes ofof vehiclesvehicles (buses,trucks,(buses,trucks, trailers,trailers, semisemi trailers,trailers, demountabledemountable systems,systems, concontainertainer handlinghandling systems,systems, coaches,coaches, ambulances,ambulances, etc).etc).

SecondarySecondary applications:applications: IndustrialIndustrial ApplicationsApplications TrelleborgTrelleborg PneuridePneuride BellowsBellows whilstwhilst originallyoriginally designeddesigned forfor vehicvehiclele applicationsapplications havehave aa rangerange ofof uniqueunique characteristicscharacteristics whichwhich makemake themthem extremelyextremely attractiveattractive forfor industrialindustrial applicationsapplications suchsuch asas pneumatic/hydraulicpneumatic/hydraulic actuation,actuation, isolationisolation mounts,mounts, heightheight andand levelevell controlcontrol devices.devices. AlthoughAlthough notnot specificallyspecifically designeddesigned asas aa noisenoise insulatorinsulator PneuridePneurideBellowsBellows dodo reducereduce noisenoise transmission.transmission. TheThe TrelleborgTrelleborg PneuridePneuride BellowsBellows areare producedproduced inin aa rangerange ofof sizessizes fromfrom 41/241/2 xx 11 upup toto 211/2211/2 xx 2.2.

ConvolutesConvolutes TrelleborgTrelleborg PneuridePneuride BellowsBellows areare manufacturedmanufactured usingusing aa mixturemixture ofof elastomerselastomers andand textiletextile reinforcementreinforcement whichwhich producesproduces aa highhigh quality,quality, highhigh performanceperformance prproduct.oduct. TheyThey areare frictionless,frictionless, economicaleconomical andand virtuallyvirtually maintenancemaintenance freefree andand comecome packagedpackaged inin oonene ofof threethree forms.forms. (1,(1, 2,2, oror 33 Convolutes)Convolutes)

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Pneuride - Air Bellows

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Typical Industrial Applications

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Industrial Applications

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Trelleborg Pneuride Bellows are an excellent solution to vibration isolation problems. The table opposite shows the natural frequency of the bellows at static height when pressurised at 4 bar (0.4 Mpa). The table below allows the calculation of the percentage isolation at given forcing frequencies and natural airspring frequencies.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Bellows Assembly DATA SHEETS

Technical Data.

General Dimensions.

Bellows Schematic.

Bellows Mounting Data.

Effective Area Curves.

Volume Curves.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

441/21/2”x1”x1

Do not exceed stated stroke. Do not inflate assembly when it is unrestricted. Do not inflate beyond pressures stated without prior consultation with Trelleborg. Respect maximum and minimum heights. The bellows must be securely fixed. Do not use without air pressure.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

441/21/2”x2”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

441/21/2”x3”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 6”x16”x1

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 6”x26”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 6”x36”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 8”x18”x1

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 8”x28”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

991/41/4”x2”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 10”x110”x1

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 10”x210”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 10”x310”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 12”x112”x1

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 12”x212”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 12”x312”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

14141/21/2”x1”x1

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

14141/21/2”x2”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE

14141/21/2”x3”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 16”x216”x2

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US BellowsBellows AUTOMOTIVE 16”x316”x3

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Bellows - Application AUTOMOTIVE

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Levelling Valves

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Why Trelleborg Levelling Valves? AUTOMOTIVE

Made in EU

Easy to Fit

Constant Ride Height

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Why Trelleborg Levelling Valves – cont.? AUTOMOTIVE

Versatility

Full Spares & technical support

Trelleborg.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Electronically Controlled Air Suspension (E.C.A.S)

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE What Can E.C.A.S Do For You ?

Reduce peak shock loads into body due to progressive rate springs.

Improved ride quality, due to less variation in ride frequency between laden and unladen.

Reduced Noise, Vibration & Harshness (N.V.H)

Constant ride height maintained.

Increased axle strokes.

Automatic lowering and raising of vehicle.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE What Can E.C.A.S Do For You ?

Various ride heights available.

Side tipping.

Manual selectable vehicle height changes.

Air springs are lighter than steel coil springs.

Air springs will outlast steel springs on endurance for maximum deflection

Air springs are easier to install than steel springs.

Auxiliary air inflation facility.

Active damping control

Diagnostic Capability

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE The E.C.A.S system consists of the following components

Air Springs

Electronic Control Unit (ECU)

Height Sensors

Reservoir

Compressor

Air Dryer

Valve Block

Pressure Switch / Transducer

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Air Springs

These provide the primary vehicle support.

The size of the component is a fine balance associated with vehicle load (air pressure) and packaging restraints to provide optimum ride quality. The air springs are normally designed to suit each application. The ride quality attainable is a function of air spring volume, air pressure, and piston profile.

Air Spring Assembly

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Electronic Control Unit (E.C.U.)

The E.C.U is an electronic control unit which drives all the electrical components in a predetermined logical manner.

ECU can be developed remotely to a given specification, or be developed hand in hand as a bespoke product. Alternatively a off the shelf generic ECU can be used.

The E.C.U receives various signals from the vehicle, these signals can be hardwired to the ECU or collected over vehicle communications protocol, such as CAN, Class 2, GM LAN or others as required. Through such vehicle communications, the input signals are unlimited, but typically include the following:- road speed, engine speed, foot brake,handbrake off switch, height sensors, pressure switch, doors, ECAS control switches and state of health messages etc. cont over.. HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Electronic Control Unit (E.C.U.) – cont.

..from previous page The ECU interrogates these signals and establishes vehicle height, road / driving conditions and system air pressure.

Based upon this information and following pre-determined algorithms, the ECU then turns on /off the valves or compressor relay, which inflate or deflate the air springs. The ECU also contains onboard diagnostics to establish system faults and maintain safety of operation. Bespoke laptop diagnostics are available, as are the options of OTP or flash based programming, plus calibrated options such as height, levelling times & speeds.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Height Sensors The height sensors are primary means of measuring the vehicle body height relative to the axle. The height sensors are attached close to each air spring. The sensor is an electric rotary potentiometer which feeds an electrical voltage as a function of angular position to the Electronic Control Unit. The sensor is mounted onto the chassis rail or lower body. From the sensor protrudes a lever and link the other end of which is connected to a moving suspension member, such as an axle. As the suspension moves, the link moves the lever, which rotates the potentiometer, producing a change in voltage. The lengths of the links and levers are designed to give maximum safe angular movement to suit maximum suspension travel. Due to lever / conrod set-ups & the fact each vehicle is calibrated individually, a height measuring resolution of around 1.1mm can be attained.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Reservoir

The Reservoir is a pressure vessel which stores pneumatic energy. The pressure in the reservoir produces potential energy which establishes the upward movement vehicle response time. The volume of the reservoir provides stored air capacity to allow sufficient upward vehicle travel before the system requires recharging. A vehicle application which does not required fast upward response time can feed from the compressor directly, thus not requiring a reservoir.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Compressor The compressor provides a means of charging the air suspension system either directly or through the reservoir. The compressor is a reciprocating wobble piston type driven by an electric motor. The compressor draws air in at atmospheric pressure, compresses the air to system pressure. The inlet is through a silencer / filter, or via an inlet pipe with remote entry for applications where the compressor is located below the vehicle wade line. The unit can include an integral thermal protection device to prevent motor burn- out. The volume of compressed air available to the system is limited to the time the compressor can run prior to the thermal protection device taking effect. The device is self re-setting once the temperature is reduced.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Air Dryer

The Air Dryer is placed in the circuit to ensure the components on the inboard side receive clean dry air. This is done to prevent the valves from freezing in cold climates and to prevent the reservoir and air springs from filling with water. The Air Dryer is a regenerative design filled with absorbent material. The regenerative capability of the dryer requires the component to be placed in the circuit in a position where the exhaust flow purges the dryer.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Valve Block The Valve block is a housing which contains all operating valves, and pressure relief valve where fitted i.e. only fitted in conjunction with a reservoir. The block may include an “up” valve, a “down” valve, and one for each or both air springs. The direct solenoid valves have different orifice sizes to provide the required flow rate. There is a special “dump” valve on fast lowering systems, which is a pilot operated diaphragm valve located on the wet side of the dryer. The valve allows the wet air collected in the dryer to be purged from the system. The valve block pneumatically connects all valves, the pressure relief valve, and any non-return valves in the correct manner to produce the desired functionality.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Valve Block - continued AUTOMOTIVE

The valve block interfaces with the air springs, dryer, and reservoir via push in fittings. The main exhaust is via a silencer or through a pipe to a remote exit for under chassis applications where the valve block is below the vehicle wade line.

The pilot exhaust for the “dump” valve is similarly protected. The electrical connection to the valves are achieved through one common plug.

A pressure switch can be incorporated into the valve block, so as to keep the reservoir constantly topped up. This will enable fast upward response times.

Alternatively a pressure transducer could be fitted, this will act in the same manner as the pressure switch, but will also monitor air spring pressure, so as to inhibit levelling if vehicle payloads exceed gross vehicle weights.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE ECAS – Application

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Next Generation Product Developments

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Development Goals For Valve Blocks

Develop low cost valve block unit.

Easier to manufacture.

Reduction in supply base.

Reduction in component count.

Easier to package.

Reduction in weight.

Reduction in energy used.

Increase value added.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE Development Goals For Valve Blocks – cont.

Greater “intelligence”

Reduction in copper.

Quality \ RFT rate improvement

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US Valve Block Improvements AUTOMOTIVE

Machined from aluminum block Block moulded in composite Large valves and solenoids which Small integrated solenoids require driver circuitry Integrated ECU Separate ECU Low cost assembly Labour intensive Minimal package envelope Large package envelope

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

AIRSPRING DEVELOPMENT

Development goals are to:-

Reduce hysteresis to 70N @ 0.1 Hz

Increase internal air spring pressure to 15 bar static (35 bar burst)

Increase temperature range from -40 to 110 degrees C

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

AIRSPRING DEVELOPMENT

Deliverables:

Thin wall sleeve (less than 2mm thick)

Options of Chlororprene.

Aramid and Chlororprene / Nylon sleeves depending on Application / cost.

Crimp band technology.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

AIRSPRING / STRUT DEVELOPMENT

Development goals are to:

Optimise side load compensation.

Be able to exchange ‘coil for air’ struts directly.

Utilise latest sealing technology.

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US AUTOMOTIVE

Further Information can be obtained by contacting the following:

Jas Gill Stephanie Houillon Sales Executive Sales & Marketing Assistant

Tel: +44 (0) 24 7629 3320 Tel: +44 (0) 24 7629 3440 Fax: +44 (0) 24 7629 3385 Fax: +44 (0) 24 7629 3385

Email: [email protected] Email: [email protected]

Or Write To: Trelleborg Automotive AVS, Systems & Components Holbrook Lane Coventry CV6 4QX United Kingdom

Tel: +44 (0) 24 7629 3300 Fax: +44 (0) 24 7629 3390

HYDRAGAS MICROVON AIR SPRINGS PNEURIDE LEVELLING VALVES ECAS NEXT GENERATION CONTACT US