SAF-Holland said its new BrakeSight brake wear monitoring system can give fleets real-time visibility into brake pad and rotor wear on trucks and trailers equipped with Haldex ModulT air disc brakes.

The system monitors pad and rotor wear continuously and reports the remaining life at each wheel end, helping fleets schedule brake service at the optimal time. That can help extend rotor life, avoid unnecessary maintenance, and reduce unexpected repairs.

"BrakeSight delivers actionable data across the entire tractor and trailer network, which supports safer operations and smarter maintenance decisions," said Mike Ginocchio, vice president of product line management at SAF-Holland, in a press conference at the Technology & Maintenance Council annual meeting in Nashville.

"We understand rotor damage is expensive and preventable. That's why BrakeSight alerts before the rotors reach critical wear levels, and also prevents premature service. The result is extended rotor life, fewer unexpected repairs, and a lower total cost of ownership."

How BrakeSight Works

BrakeSight is an optional feature for the Haldex ModulT air disc brake. It integrates a sensor directly into the brake caliper within the adjustment system of the air disc brake.

As the adjustment mechanism rotates to compensate for pad and rotor wear, the sensor tracks that movement and converts it into a percentage of remaining pad and rotor life at each wheel-end.

That information is transmitted to a frame-mounted electronic control unit, which converts the signal and outputs it into real-time data via CAN. That data can be sent via the fleet’s telematics platform, providing real-time brake condition data across tractors and trailers.

BrakeSight is designed to work with any telematics provider through J1939 CAN communication, allowing fleets to integrate the data into their existing asset management platforms.

“BrakeSight delivers continuous real-time visibility into brake pad and rotor wear on both trucks and trailers," Ginocchio said.

SAF-Holland said the system can be installed during vehicle production or retrofitted later. Because all ModulT air disc brake calipers are equipped with the sensor mounting feature as standard, BrakeSight can be added at any stage without replacing the caliper.

BrakeSight carries a three-year, 350,000-mile warranty. It features an ultrasonically welded sensor housing for long-term durability and IP6K9K sealing for harsh road and wash-down environments.