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ELECTROMAGNETIC BRAKING SYSTEM 1Krunal Prajapati,

2Rahul Vibhandik,

3Devendrasinh Baria,

4Yash Patel

Student, Automobile department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat

Corresponding Author Detail:

Krunal Prajapati

Student, Automobile department,

Laxmi institute of Technology,

Sarigam-Valsad, Gujarat.

Internal Guide Detail:

Mr. Kevalkumar Ishwarbhai Patel

Assistant Professor, Automobile department,

Laxmi institute of Technology,

Sarigam-Valsad. Gujarat.

ABSTRACT

An electromagnetic braking system is a new concept. This project is a new technology of

braking system. Electromagnetic braking system is new braking system it is used in LMV

and HMV like jeep, buses, car, truck, train and motor bikes. The electromagnetic braking

system are also called electro-mechanically brake. Future to highly produced accident to use

this braking system to avoid the accidents. These braking systems are described in working of

prototype model. An electromagnetic braking system used magnetic force while applied the

force on brake, but the power is transmitted on manually operate the brake. The rake disc is

connected to the shaft and electromagnetic kit are attach in a frame. The power source is used

in electricity. The electric power applied to the magnetic coil to the developed the magnetic

field in armature coil and attracts the electromagnet aluminum disc. To applied the brake and

stopped the road wheel and vehicle.

KEYWORDS: Peak Force, Fade, Drag, Flux, Electro Magnet.

INTRODUCTION

A brake is a device which inhibits motion. Its opposite component is a clutch. Most

commonly brakes use friction to convert kinetic energy into heat, though other methods of

energy conversion may be employed. For example regenerative braking converts much of the

energy to electrical energy, which may be stored for later use.

The brakes are different to use in stopped the reciprocating parts and motion automobile

vehicles. The new technology is produced in automobile engineering. An automobile industry

is developing new technology of braking system. These worlds are new possibility and new

thinking of braking system. The automobile industry are also developed new braking system

like to drum brake, disc brake, hydraulic brake, pneumatic brake, air brake and

electromagnetic brake. The different brakes are working on different principle operation.

Future is used in time of hydraulic and disc or drum brake. The different types of friction

brake and electromagnetic brake use. The main principle of electromagnetic brake to induced

kinetic energy into heat energy.

Braking system is used to automobile vehicle speed reduced in slowly. The brake are applied

the manually force on a brake pedal to the mechanical linkage operate and applied the brake

drum wheel and motion is slowly reduced and applied the brake. Brake applied to the vehicle

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

IJSRE Vol. 1 (3), March, 2017 www.ijsre.in Page 239

speed reduced in several time and vehicle to rest. The electromagnetic brakes are new

technology of automobile industry for future concept to use for automobile vehicle and other

industry level. Brakes are new technology to use for vehicle required specification.

Automobile vehicle to use for required use in purpose for like sports car, light motor vehicle,

heavy motor vehicle, bikes, sports bikes and off road vehicles. Heavy motor vehicle is use

brakes this time of air brakes. The electromagnetic brakes are new developed in braking

system in automobile engineering. This type brake mainly working principle is one rotating

metal disc in between the two magnets to apply the brake to induced electric current in circuit

to induced magnetic field in armature to attract the magnet to the rotating metal disc and

stopped the rotation in several time while applied brake.

PRINCIPLE OF BRAKING SYSTEM

The principle of braking in road vehicles involves the conversion of kinetic energy into

thermal energy (heat). When stepping on the brakes, the driver commands a stopping force

several times as powerful as the force that puts the car in motion and dissipates the associated

kinetic energy as heat. Brakes must be able to arrest the speed of a vehicle in short periods of

time regardless how fast the speed is. As a result, the brakes are required to have the ability to

generating high torque and absorbing energy at extremely high rates for short periods of time.

ELECTROMAGNETIC BRAKES

Electromagnetic brakes operate electrically, but transmit torque mechanically. This is why

they used to be referred to as electro-mechanical brakes. Over the years, EM brakes became

known as electromagnetic, referring to their actuation method. The variety of applications

and brake designs has increased dramatically, but the basic operation remains the same.

Single face electromagnetic brakes make up approximately 80% of all of the power applied

brake applications.

NOMENCLATURE

V=Initial velocity

U=Final velocity

A=Deceleration of rotating mass

F=Braking force

T=Braking torque

H=magnetic field length

N= No. of turns/ length of solenoid

C=clamping force

P=average power

K.E=kinetic energy

CONSTRUCTION AND DESIGN

INSTALLATION LOCATION


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Electromagnetic brakes work in a relatively cool condition and satisfy all the energy

requirements of braking at high speeds, completely without the use of friction. Due to its

specific installation location, electromagnetic brakes have better heat dissipation capability to

avoid problems that friction brakes face as mentioned before. Typically, electromagnetic

brakes have been mounted in the transmission line of vehicles. The propeller shaft is divided

and fitted with a sliding universal joint and is connected to the coupling flange on the brake.

The brake is fitted into the chassis of the vehicle by means of anti-vibration mounting.

DESIGN OF ELECTROMAGNETIC BRAKE SYSTEM

Figure-1 Model of Electromagnetic Brake System

1. FRAME – MS BAR RIGHT ANGEL= 35-5 mm

HEIGHT (H) = 16inch

LENGTH (L) = 12inch

2. BRIGHT METAL SHAFT (Drive shaft) – OUTER DIAMETER = 20 mm

LENGTH (L) = 17 inch

3. DISK- ALUMINUM CAST:

BUSH MS MATERIAL

INNER DIAMETER = 20 mm

TAPPING = 3.8 B – SECTION

4. ELECTROMAGNET = 230 W, 5 HENRY

5. SINGLE PHASE A.C MOTOR = 1200 rpm

6. PULLY = 1.5 inch B-SECTION

7. V-BELT = 14 (RUBBER)

8. BALL BEARING –TATA :

INNER DIAMETER = 20 mm

MODEL CONSTRUCTION PROCESS

1. MACHINING PROCESS

2. CUTTING PROCESS

USE HAND HACK SHOW

3. WELDING PROCESS



ARC WELDING

4. DRILLING PROCESS

RADIAL DRILL

5. MACHINING SHAFT

It work by lathe machine, cutting process, parting tools and turning process is completely on

dimension.

ID –BORING PROCESS

OD-TURNING PROCESS

WORKING OF ELECTROMAGNETIC DISC BRAKE

The electromagnet is energized by the AC supply where the magnetic field produced is used

to provide the braking mechanism. When the electromagnet is not energized, the rotation of

the disc is free and accelerates uniformly under the action of weight to which the shaft is

connected. When the electromagnet is energized, magnetic field is produced thereby applying

brake by retarding the rotation of the disc and the energy absorbed is appeared as heating of

the disc. So when the armature is attracted to the field the stopping torque is transferred into

the field housing and into the machine frame decelerating the load. The AC motor makes the

disc to rotate through the shaft by means of pulleys connected to the shaft.

Figure-2 Working of Electro Magnetic Disc Brake

A. ENGAGEMENT TIME

There are actually two engagement times to consider in an electromagnetic brake. The first

one is the time it takes for a coil to develop a magnetic field, strong enough to pull in an

armature. The second one is air gap, which is the space between the armature and the coil

shell. CAD systems can automatically calculate component inertia, but the key to sizing a

brake is calculating how much inertia is reflected back to the brake. To do this, engineers use

the formula: T = (WK2 × ΔN) / (308 × t) Where T = required torque in lb-ft, WK2 = total



inertia in lb-ft2, ΔN = change in the rotational speed in rpm, and t = time during which the

acceleration or deceleration must take place.

RESULT

By using the electromagnetic brake as supplementary retardation equipment, the friction

brakes can be used less frequently, and therefore practically never reach high temperatures.

The brake linings would last considerably longer before requiring maintenance, and the

potentially “brake fade” problem could be avoided. In research conducted by a truck

manufacturer, it was proved that the electromagnetic brake assumed 80 percent of the duty

which would otherwise have been demanded of the regular service brake.

Furthermore, the electromagnetic brake prevents the dangers that can arise from the

prolonged use of brakes beyond their capability to dissipate heat. This is most likely to occur

while a vehicle descending a long gradient at high speed. The installation of an

electromagnetic brake is not very difficult. It does not need a subsidiary cooling system. It

does not effect on the efficiency of engine. Electromagnetic brake also has better

controllability. Thermal stability of the electromagnetic brakes is achieved by means of the

convection and radiation of the heat energy at high temperature. The electromagnetic brakes

have excellent heat dissipation efficiency. Electromagnetic brakes have better thermal

dynamic performance than regular friction brakes.

ADVANTAGES

1) Problems of drum distortion at widely varying temperatures. Which is common for

friction-brake drums to exceed 500 °C surface temperatures when subject to heavy

braking demands, and at temperatures of this order, a reduction in the coefficient of

friction („brake fade‟) suddenly occurs.

2) This is reduced significantly in electromagnetic disk brake systems.

3) Potential hazard of tire deterioration and bursts due to friction is eliminated.

4) There is no need to change brake oils regularly.

5) There is no oil leakage.

6) The practical location of the retarder within the vehicle prevents the direct impingement

of air on the retarder caused by the motion of the vehicle.

DISADVANTAGES

1) Dependence on battery power to energize the brake system drains down the battery much

faster.

2) Due to residual magnetism present in electromagnets, the brake shoe takes time to come

back to its original position.

3) A special spring mechanism needs to be provided for the quick return of the brake shoe.

CONCLUSION

With all the advantages of electromagnetic brakes over friction brakes, they have been widely

used on heavy vehicles where the „brake fading‟ problem exists. The same concept is being



developed for application on lighter vehicles. The concept designed by us is just a prototype

and needs to be developed more because of the above mentioned disadvantages. These

electromagnetic brakes can be used as an auxiliary braking system along with the friction

braking system to avoid overheating and brake failure. ABS usage can be neglected by

simply using a micro controlled electromagnetic disk brake system .These find vast

applications in heavy vehicles where high heat dissipation is required.

In rail coaches it can used in combination of disc brake to bring the trains moving in high

speed. When these brakes are combined it increases the life of brake and act like fully loaded

brakes. These electromagnetic brakes can be used in wet conditions which eliminate the anti-

skidding equipment, and cost of these brake are cheaper than the other types. Hence the

braking force produced in this is less than the disc brakes if can be used as a secondary or

emergency braking system in the automobiles.

REFERENCES

1. Dr. Kirpal Singh. Automobile Engineering and Technology, Vole 1

2. Khurmi & Gupta “Machine Design” S Chand Publication.

3. V.B. Bhandari "Design of Machine Elements" Tata McGraw hill.

4. http://www.thefullwiki.org/Electromagnetic_brake

5. http://electric-brake.com/Heald, M.A., „„Magnetic braking: improved theory,‟‟ American

Journal of Physics, Vol. 56,No. 6, pp. 521–522, 198.

6. “ADJUSTABLE MAGNETIC BRAKE” by Hung-Chi Wu, 958-2, Ghung Shan Rd., Tao-

Yuan, Taiwan United States Patent Number: 5,096,024.

7. “MAGNETIC BRAKE SYSTEM FOR A VEHICLE” by Jae-Woong Lee. Seoul, Rep. of

Korea United States Patent Number: 5,746,294.



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