Haldex BrakeSight tracks pad and rotor wear status

NASHVILLE—SAF-Holland has launched the Haldex BrakeSight for ModulT air disc brake systems to provide real-time visibility into the remaining life of brake pads and rotors.

The company also unveiled HOLLAND SmartSTO to improve safety when uncoupling air-release fifth wheels and stowing trailer connection lines, and a new UltraLite40 Slider for the ULX40 mechanical sliding suspension and axle system.

The robust sensor mounts into an existing space on the caliper and continuously monitors the caliper adjustment mechanism, which rotates as the pads and rotors wear. The system, which works for both tractor and trailer brake systems, uses an algorithm to calculate that movement as remaining pad and rotor life for each wheel end, explained Mike Ginocchio, VP of Product Line Management for SAF-Holland.

Ginoccio explained that SAF-Holland can “fine-tune” the parameters for each fleet based on road type and acceptable remaining pad life. For example, one fleet may want alerts at 20% pad life while another could be 15%.

“It reduces unnecessary service and helps avoid costly rotor damage,” he added. “BrakeSight ensures that brake pad rotors and pads are served at exactly the right time, not too early, not too late.”

The BrakeSight sensor can be added at any stage of the ModulT’s life cycle and connects to a frame-mounted ECU, where the signal is converted via the CAN to real-time data, according to SAF-Holland. It is J1939-compliant and compatible with all telematics providers.

The overall goal of BrakeSight is to improve total cost of ownership and avoid unplanned downtime related to the air disc brakes.

“We understand rotor damage is expensive and preventable,” Ginocchio explained. “That's why brake site alerts fleets before the pads and the rotors reach critical wear levels, and also prevents premature service on those pads.”

Key features include:

• Continuous measurement of brake pad wear.
• Ultrasonically welded sensor housing for long-term durability.
•  IP6K9K sealing for harsh road and wash-down environments.
• Sensor warranty of 3 years or 350,000 miles, matching ABS coverage.
• Operating temperature range from -40°C to +125°C.

SmartSTO

“[SmartSTO] was built around one simple priority, protecting people and equipment, Ginocchio said. “Uncoupling happens 1000s of times every day, each time carries a risk.”

Because a driver or other personnel typically has to reach under the fifth wheel to manually activate the air release, the potential for injury or vehicle damage is always present. But with SmartSTO, the release is moved to a box on the back of the cab. Once the parking brake is set and the glad hands and electrical lines are stowed correctly, the fifth wheel release light will illuminate, signaling that the driver can push and hold the button on the box to release the fifth wheel.

“There's no reaching underneath and no guesswork,” Ginoccio said. “SmartSTO ensures parking brakes are set before the uncoupling operation, and it also prevents the drivers from pulling away while the lines are still connected to the trailer. This reduces costly damage, avoids violations, and increases uptime.”

Installation is eased by requiring three airline connections.

SmartSTO will be available Q4 2026.

UltraLite40 Slider

The 40,000-lb. UltraLite40 was designed to provide 3.6 times more durability and is 30 lbs. lighter than SAF-Holland’s previous suspension option for on-highway dry and reefer trailers. The mechanical sliding suspension system uses spring-ride technology and offers lower maintenance due to standard galvanized coating to resist corrosion and hardened steel wear pads to extend surface life. The open style C-rail slide sub-frame implements a 10” rail and shorter hangar for more strength and durability.

Ginoccio said the system was validated through “a more demanding test cycle,” and that the UltraLite40 will extend trailer life and maximize payload efficiency without increasing cost.

The addition of a QwikRelease pin pull system provides 20% less pulling effort, while an optional air-operated release allows for easier slider repositioning.

The system will be available Q4 2026, and is compatible with P89 PSP7 pr P89 Plus air disc brakes, as well as ConMet PreSet Plus SC7 dressed drum wheel-end packages.