ZF develops kit for tractors with front suspension for sugarcane harvesting.

ZF has developed a conversion kit in Brazil to widen the track width of heavy tractors used in sugarcane operations. The solution is intended for machines equipped with front suspension and ZF TSA20 and TSA23 axles, in the 180 hp to 250 hp range. The goal is to allow the tractor to work with a three-meter track width in sugarcane, preserving the structural architecture of the assembly and maintaining the possibility of returning to the original configuration.

The project was conducted by ZF's engineering team in Brazil, where the company maintains its Global Competence Center for Agricultural Axles. The kit extends the flange-to-flange distance from approximately 1.900 mm to 3.000 mm, a necessary measurement to adapt the tractor to the spacing used in sugarcane and ethanol operations. With this modification, the machine can move between planting rows, reducing crop damage and decreasing compaction in sensitive areas of the field.

According to Juliano Alquati, Senior Business Management Manager of the Industrial Division at ZF South America, the solution caters to tractors used in sugarcane cultivation, where a 3-meter track width is necessary to reduce losses and adapt traffic to the planting system.

Traffic in the fields

Widening the track width is related to traffic management in production areas. In fields with defined row spacing, the tractor's width influences the position of the tires in relation to the crop residue. When the machine is not properly adjusted to the planting arrangement, there is a greater risk of trampling, damage to plants, and compaction outside the desired areas.

By increasing the wheel width to 3 meters, the tractor adapts better to the traffic conditions required in sugarcane fields. This configuration allows the wheels to work in lanes more compatible with the planting system, reducing direct interference with the crop. The kit was developed for heavy tractors used in tasks requiring traction, stability, and structural strength, such as harvesting support, preparation, subsoiling, internal transport, and movement between work fronts.

Dianteira Suspension

The main technical challenge of the project was to make the conversion feasible for tractors with front suspension. In machines without this system, widening the track can be done through simpler solutions, often with components applied to the ends of the axle. In tractors with front suspension, however, the interface between the suspension system and the axle structure imposes additional limitations.

According to ZF, the engineering team developed a new construction concept to avoid interference between the suspension and the components responsible for widening the track. The project involved new anchoring, increasing the length of the structural components, and redesigning the fastening system. The goal was to allow the kit to be installed without altering the original position of the front suspension and without compromising the overall architecture.

“The major technical challenge of the project was to make the application feasible on an axle with front suspension, something that was previously impossible due to interference between the suspension interface and the axle's structural components,” explains Alquati. According to the company, this concept was crucial in securing a patent application for the technology.

The project has already passed the structural concept validation stage and is currently undergoing physical field validation. This phase is relevant because sugarcane operations place significant stress on the front axle, especially in areas with uneven terrain, repetitive traffic, and maneuvers at headlands.

Gauge reversal

In addition to widening the track width, the kit was designed to allow for reversing the configuration. This means the tractor can operate at a 3-meter width during sugarcane operations and return to the original track width for other activities. This possibility expands the machine's use beyond the specific conditions of sugarcane traffic.

In practice, reversibility prevents the producer, mill, or service provider from having to maintain a tractor dedicated exclusively to the widened track gauge. The same machine can be used in the sugarcane harvest and then employed in soil preparation, subsoiling, internal movements, or transport between work fronts.

Reversing the configuration also impacts logistics. Tractors with wider track widths may require more care when moving, loading onto platforms, and transporting between distant areas. By allowing a return to the standard configuration, the solution reduces the need for special transport and facilitates the use of the machine.

shaft structure

One of the project's priorities was to avoid widening the track gauge by applying extensions to the ends of the axle. According to ZF, this type of adaptation can increase stress on bearings, hubs, journals, and other external components, impacting durability and maintenance needs.

In the kit developed by the company, the extension occurs in the central structure of the assembly, through spacer housings. This solution seeks to preserve the geometry of the steering system and the input of mechanical forces on the axle. The goal is to maintain the durability observed in the original configuration, even with the increase in operating width.

Since the modification involves structural components of the axle, the conversion must be performed by a trained user. According to ZF, when the procedure is done correctly, the factory warranty is maintained. Returning the track width to the standard configuration (3 meters) requires that the fixing points, alignment, and geometry be maintained within the specified parameters.

Maintaining the front suspension is another important aspect of the kit. In heavy tractors, this system helps reduce impacts transmitted to the cab and improves handling in operations on uneven ground. It also helps maintain more constant contact between tires and the ground, a condition that can improve traction and stability in areas with uneven terrain, ruts, and repetitive traffic.

The kit will be offered to the market as a conversion option, not as a factory item. Its application will depend on the operational needs of each producer or plant.