TONAR axle formulaWide range of axles with a large margin of safety

Spare parts for the TONAR 9042 axle

TONAR axle formulaWide range of axles with a large margin of safety

Yuri Petrov. Photo by the author and MZ "TONAR"

If the machine-building plant produced the first commercial trailers for passenger cars back in 1992, the need for its own chassis at the Gubinsk enterprise only came after 1997, when the assembly of full-size semi-trailers for truck tractors was mastered.

The development of new production was prompted by two factors: the expansion of our own production of trailers and semi-trailers, as well as the solid cost of axle units.

The plant began producing its own axles in 2002. At that time, this step did not seem consistent and logical to everyone, because the vast majority of companies in the world use chassis of the world leaders in this field - SAF, BPW, etc. Why look for difficulties in life? But the Russian economy was growing steadily, and a general shortage of axles arose on the market, which chronically hampered the production of semi-trailers.

From the very beginning, the plant produced one type of axles, which were installed on all the plant's products. The increase in sales of Tonar axles and their growing population on Russian roads aroused interest among carriers, who relied only on driver reviews. So, ingenuously, sales of axles began - without advertising, without exhibitions, simply, as they say, by word of mouth!

At the end of 2008, crisis phenomena began to develop, and in 2009, the plant management decided to transform these small sales into a new direction and increase the range of axles and suspensions manufactured by the plant. At that time, due to the rise in world currencies, axles from foreign manufacturers accounted for a significant portion of the price. And for buyers, the deadline is also important.

For example, now the delivery time for Tonar axles, depending on the complexity, is 2–3 weeks - exactly the same as it takes to complete an order for a trailer or semi-trailer. Modern axles are manufactured in accordance with European standards and, as a result, they are interchangeable with other axles, which is appreciated by many carriers and service centers. Today it supplies axles to many factories for the production of trailers and semi-trailers, so you can order the trailer you need on Tonar axles.

Over 14 years at Tonar we have gained vast experience in the design, manufacture, and operation of axles and suspensions. The chosen vector for 90% localization of all production eventually led to the expected success - the axles began to win the trust of consumers. If 60 thousand axles have been produced since 2002 (!), now the share of imported axles is less than 5% of production. While 95% are produced on Tonar axles, and carriers recently no longer want to overpay for an imported brand.

A typical axle is made from a solid pipe with a diameter of 146 mm and a wall thickness of 14 mm. The beam steel is selected with a high yield strength. It absorbs shock and dynamic loads well, while maintaining high welding properties, which contributes to reliable fastening of the calipers and axle beam brackets throughout its entire service life. The brake mechanisms are assembled onto the beam. They are selected in such a way that the carrier does not have problems with the selection of spare parts, in addition, the plant has about 65 spare parts partners in the regions.

In 2015, the plant set a course for import substitution for many components, and today the price of products is not very dependent on currency fluctuations. Suspension parts consist almost entirely of Russian components. The exception is the Phoenix air spring, which is supplied by the Continental group.

Our own production has made it possible to offer a wide range of axles, which are used not only on long-haul refrigerators and semi-trailers, but also on mining dump trucks, scrap trucks, log trucks, trailers for agriculture and livestock breeding. After all, the range of rolling stock produced already reaches hundreds! Today the plant produces axles with loads of 9, 10, 11, 13, 20 and 25 tons.

The most typical axles in the range are axles with drum brakes: a 9-ton axle with a single-pitch tire on pneumatic and spring suspension, an 11-ton axle with a double-pitch tire. The remaining axles are installed depending on the design of the trailer - 13-, 20-, 25-ton.

The program includes 2-axis axle units mod. 9132 for long-haul semi-trailers with single tires (load 20 t) and double tires (22 t). Separately for gable busbars, the plant has mastered the production of five mod axles. 9042 (load 11 t, R22), 1130 (11 t, R17.6), 1342 (13 t), mod. 20883 (20 t) and mod. 2545 (25 tons), since the axles are always released under trailers, and not vice versa), this is essentially how trailers for agriculture, metallurgy and construction appeared in the program, where “balancers” are often used.

The range of balancing axle units, in particular, is represented by two basic models - a 20-ton PT-4 for tractor trailers and a 20-ton spring suspension for double tires.

Particularly worth highlighting are the 3-axle suspensions, designed for dual-pitch tires: this is a mod. 1342 t, rated at 39 t, and 20833 suspension, rated at 60 t.

The widest model range is based on model 9042 axles with single (10 t) and double (11 t) tires. They are used in the version with 1-, 2- and 3-axle axle units, on a lever, spring, or air spring suspension. Based on this series, a steering axle was developed, which, at the customer’s choice, can be aggregated with spring or air suspension.

In addition to axles for long-haul semi-trailers and trailers, upon request, Tonar produces axle units for special-purpose trailers with a ride height (distance from the center of the axle to the lower edge of the side member) from 150 to 570 mm.

Mastering the production of multi-link road trains in 2009 made it possible to offer consumers a completely original product at the level of global manufacturers - axle units with an axle lifting function. Thus, on 4-axle models, raising the first and second axles allows you to reduce fuel consumption during empty runs and reduce tire wear. Now the plant's design bureau is working on new lifting and steering axles for Tonar dump trucks and tractors.

The plant notes that its own axles show equally stable results in difficult domestic operating conditions at both high and low temperatures. This is largely the merit of the designers, who have built in a large margin of safety, which allows them to withstand significant overloads.

Hub cover with Tonar branding at the factory and at the BAUMA-2016 exhibition

Now the average mileage of Tonar axle units is more than 1,000,000 km, although there are examples with mileage under 2,000,000 km!

They guarantee the performance of their own axles for 36 months, without limiting the mileage of the vehicle. The service interval is 60,000 km.

Spare parts for TONAR lifting axle

Axle lifting mechanisms: device, operating features, operating principle

On the roads there are often trucks with 2-3 axles on a trailer, one of which is in a suspended “lazy” state and does not touch the road surface. Many people wonder about the purpose of these wheels. The fact is that proper load distribution throughout the entire chassis of the van affects the safety of movement. A successful solution to this issue was the lifting axle, which does not touch the road while driving and lowers under increased load. Read on to find out what its functions and features are.

What is a lift axle?

The rear axle located on the semi-trailer is called the “sloth”, which provides unloading of the drive axle and increases the carrying capacity of the vehicle.

The sloth is a full-fledged axle with air springs and a braking system. The lazy axle helps reduce fuel consumption and extends the service life of rubber coatings. In practice, the semi-trailer moves on one axle, the “lazy” one remains suspended.

The lifting model is equipped with an axle lifting mechanism, which ensures the axle moves in the vertical direction. Thanks to this, the wheels rise above the road. When installing this mechanism, the pressure on the road decreases and the tonnage increases.

When lifting sloth wheels, it is important to pay attention to compliance with axle load standards. Vertical mounting is allowed when the car is not fully loaded.

Principle of operation

The wheels can be lowered and raised automatically or through activation by the driver. The tractor is automatically lowered when the vehicle is overloaded. If it is unloaded, there is no need for additional wheels and they rise.

Automatic lifting is performed using a special valve. It is controlled by an electronic unit. Special equipment “flashes” the block so that it can send a signal to the valve under certain circumstances.

In addition, a crane can be used for automatic control, which is similar in design to a mechanical one. It has an adjustable pneumatic valve that controls the axle depending on the pressure in the system.

The lifting function for any control method is carried out taking into account the following operating principle:

• The tap activates the function.
• There is a disconnect between the air springs of the main axles and the lifting air springs.
• The air is vented into the atmosphere and enters in this state from the receiver into the air bags.

To control the driver, a special button is installed in the cab, and there is a control panel on the van. In this case, you can enable the desired position:

1. Transport – the bridge is not used. It is pressed against the body and does not touch the road. The load is distributed between the main axles.
2. Working - wheels touch the road. The axle takes on part of the load from the drive axle through air springs. In this case, the truck brakes better and is more stable. It is worth considering that in this position fuel consumption increases.
3. Transitional - the wheels touch the road, but do not take on the load. This position is suitable for driving on ice or on roads with sharp turns to protect the tires.

Forced control is performed using a 2-circuit valve. It can be mechanically controlled (using a special button) or electrically controlled. On an electric type faucet there is a connector where the electric switch is turned on. It can be taken to any convenient place.

Pros and cons of an optional lift axle

The use of “sloth” guarantees the following advantages:

• increase in braking force;
• reducing the load on other axles of the truck;
• protection of tires from early wear;
• improving vehicle maneuverability;
• reduction in fuel consumption;
• increase in the number of reserves.

When using a sloth, you cannot do without disadvantages:

• It takes up free space under the bottom of the truck, and the volume of the fuel tank decreases accordingly.
• Operating costs increase.

The use of lifting wheels depends on the load level. The sloth allows you to transport more cargo without requiring an increase in the weight of the vehicle itself.

The additional axle can be used as a spare wheel.

The sloth can be lifted forcibly so that the load on the non-driving axle increases and the car receives additional traction. This way, the vehicle can start moving without slipping, after which the additional axle will automatically move into the desired position.

A lift axle is an effective element that significantly expands the capabilities of freight transport. It helps increase the load capacity of semi-trailers. Unlike a car with an additional axle, the axle does not overload the truck, so fuel consumption is reduced.

Brake pad and lining TONAR

Catalogs of semi-trailers with SAF and BPW axles
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Tonar brake drums

The Tonar semi-trailer is a non-motorized wheeled vehicle towed by a tractor, on the platform of which a body is installed. Most of the semi-trailers from the Tonar engineering plant have two pivot points - that is, they can be used with tractors of both American and European origin. All semi-trailers are required to be equipped with ABS, and their braking systems also have Tonar brake drums. In the future - equipping semi-trailers with built-in electronic units that have functions that prevent semi-trailers and trailers from tipping or folding.

On frameless semi-trailers, after their service life has expired or after overload at the attachment point of the coupling device, the floor is deformed (densed inward), and the tonar brake drums also fail. In this regard, further operation of semi-trailers is not possible. In the process of repairing semi-trailers, not only cosmetic repairs are made to the floor panels and the brake system, but the floor panels are strengthened using the metal-frame method and a bunch of floor panels with side walls, and Tonar brake drums are also replaced. After such repair work on semi-trailers, not only their maximum load capacity is restored, but their normal operation in Russian road conditions is also guaranteed. If necessary, it is also possible to reinforce the side walls, after which the semi-trailers can be used to transport even bulk cargo.

If your semi-trailers skid when entering a turn and extraneous noises are heard while driving, then the braking system is not functioning correctly, which changes the longitudinal stability of the semi-trailers. In case of such malfunctions, semi-trailers need to update spare parts, which means it is worth visiting our company, having previously carried out diagnostics using modern equipment, because our original Tonar spare parts will allow you to carry out repair work at the highest level. Our company invites motor vehicles, fleets, and owners of several units of trucks to cooperate. We value every client, so we have a system of personal discounts for each of you. The form of payment can be any, deferred payment is also possible. We are firmly convinced that our prices will pleasantly surprise you, and the minimum delivery time for spare parts and Tonar parts for maintenance and repair work will save you time and money, which will affect the well-being of your company and personnel as a whole.