Electromagnetic Braking system

ABSTRACT

A non-contact method, using magnetic drag force principle, was proposed to

design the braking systems to improve the shortcomings of the conventional braking
systems. The extensive literature detailing all aspects of the magnetic braking is briefly
reviewed, however little of this refers specifically to upright magnetic braking system,
which is useful for industries. One of the major issues to design upright magnetic
system is to find out the magnetic flux. The changing magnetic flux induces eddy
currents in the conductor. These currents dissipate energy in the conductor and
generate drag force to slow down the motion. Therefore, a finite element model is
developed to analyze the phenomena of magnetic flux density when air gap and
materials of track are varied. The verification shows the predicted magnetic flux is
within acceptable range with the measured value. The results will facilitate the design
of magnetic braking systems.
 Introduction
Equipment in addition to the regular friction brakes on heavy vehicles. We
outline the general principles of regular brakes and several alternative retardation
techniques in this section. The working principle and characteristics of
electromagnetic brakes are then highlighted. In this project we are trying to make a
braking system. Which can be applicable in two wheeler at Electromagnetic
brakes have been used as supplementary retardation high speed and low
maintenance cost. Here we are using an electromagnetic coil and a plunger. There
is an electromagnetic effect which moves the plunger in the braking direction.
When electricity is applied to the field, it creates an internal magnetic flux. That
flux is then transferred into a hysteresis disk passing through the field. The hysteresis
disk is attached to the brake shaft. A magnetic drag on the hysteresis disk allows for a
constant drag, or eventual stoppage of the output shaft.

Electromagnetic brakes (also called electro-mechanical brakes or EM brakes)

slow or stop motion using electromagnetic force to apply mechanical resistance
(friction). The original name was "electro-mechanical brakes" but over the years the
name changed to "electromagnetic brakes", referring to their actuation method. Since
becoming popular in the mid-20th century especially in trains and trolleys, the
variety of applications and brake designs has increased dramatically, but the basic
operation remains the same. Both electromagnetic brakes and eddy current brakes
use electromagnetic force but electromagnetic brakes ultimately depend on friction
and eddy current brakes use magnetic force directly.

LITERATURE REVIEW
1. Stephen Z. Oldakowski, Bedford, Ohio A magnetic brake provides braking or
locking capability and is remotely controlled by electric power. The magnetic
brake comprises a rotatable shaft and a brake disc mounted on the shaft. A non-
rotating core housing assembly located around the shaft includes a permanent
magnet and a bipolar solenoid. A magnetic armature adjacent to the core housing
assembly is capable of movement toward the core housing assembly and toward
and into engagement with a brake disc to prevent rotation of the shaft. A spring
urges the armature away from the core housing assembly and into engagement
with the brake disc. The brake does not use any electric power to maintain the
brake in the set mode with the rotating shaft fully locked or in the released mode
with the rotating shaft fully released. The permanent magnet is of sufficient
strength to hold the armature against urging of the spring until an opposite
polarity is supplied by the solenoid.
2. Karl Erny, Holzhausem An elevator drive has a brake device with compression
springs to actuate brake levers, and brake linings on a brake drum creating a
braking force. A sensor is provided to detect the movement of a brake magnet
armature tappet. A bracket is attached to the brake magnet tappet on one end and
a distance piece carrying the sensor housing is arranged on the other end. A
restoring lug is attached to the existing mechanical indicator. A monitor
evaluates the sensor signal and turns off the elevator drive in the event of
dangerous operational states via a safety circuit. The system allows the state of
the brake device to be monitored. The more the brake linings wear off due to
abrasion, the smaller the distance between the armature and the brake magnet
housing. If the armature is in contact with the brake magnet housing, the braking
ability of the brake linings is completely void.
3. Hung-Chi Wu, 958-2, Ghung Shan Rd., Tao-Yuan, Taiwan This invention
relates to an adjustable magnetic brake and in particular to one including an
 aluminum fan, a magnetic conducting ring enclosing the aluminum fan, a
permanent magnet disposed within the aluminum fan, a fixing seat for keeping
the permanent magnet in position, a sliding seat mounted in the fixing seat and
provided with a bearing, a housing, bolts provided on one side of the fixing seat
and extending out of the housing, a mounting plate connected with the bolts and
a wire connected with the mounting plate such that when the wire is pulled
outwards, the permanent magnet will be moved outwards.
4. Jae-Woong Lee, Seoul, Rep. of Korea Disclosed is a magnetic brake system for
a vehicle. comprising: a plurality of brake disk solenoids for generating the
magnetic force; a plurality of brake pad solenoids for generating the magnetic
force; a braking sensor for detecting whether a brake pedal is applied; a wheel
speed sensor for detecting wheel speed; a magnetic polarity sensor for detecting
magnetic polarity of the brake disk solenoids; and a control unit for controlling
the brake pad solenoids using signals from the braking sensor. The wheel speed
sensor and the magnetic polarity sensor.
5. Albert E. Miller, Dayton, Ohio This invention relates to a fishing reel and more
particularly to an improved type of reel having a compensated magnetic brake
means for preventing backlash or overrunning of the spool. An object of this
invention is to provide a reel which is inexpensive to manufacture and which is
durable and trouble-free in operation. Still another object of this invention is to
provide an improved form of magnetic brake having spring means for modifying
the brake action. A further object of this invention is to provide a fishing reel
which is smooth in operation and which is readily adjustable to desired degrees
of drag or braking effect. Further objects and advantages of the present invention
reside in the construction and combination of parts and in the mode of operation
as will be apparent from the following description, reference being had to the
accompanying drawings wherein a preferred form of the present invention is
clearly shown.
 Theory and main concept
The idea of using an electromagnet as a brake has been mainly used in large
vehicles and machines. There are several main types, most of which rely on using
magnetism to move a mechanical part or parts. The mechanical part can then be
used to produce friction with a moving part, thereby reducing speed. However, this
process is rather inefficient. Electromagnets can also be used to make frictionless
brakes which is what we are interested in. Further,

we are interested in reducing the rotation of a bicycle wheel and hence,

angular velocity. Thus, the desired brake involves dissipating rotational energy. In
theory, if a magnetic field is induced in a rotating disc, it will produce eddy
currents within the disc. These currents will then oppose the rotation of the disc by
dissipating kinetic energy in the form of heat (causing the temperature of the disc
to increase).

To me, this concept did not seem intuitive, so I decided to test it. The magnetic
field is usually generated by an electromagnet. Hence, I was interested in knowing
if an electromagnet could really affect the rotation of the wheel. Also, I wanted to
determine whether increasing the voltage running through the electromagnet would
cause a larger retarding force. The latter test may seem obvious, but I felt it was
necessary to validate the concept experimentally before making any conclusions.
BLOCK DIAGRAM
 PARTS

AC Motor:
An AC motor is an electric motor driven by an alternating current (AC). The AC
motor commonly consists of two basic parts, an outside stationary stator having coils
supplied with alternating current to produce a rotating magnetic field, and an inside
rotor attached to the output shaft producing a second rotating magnetic field. The rotor
magnetic field may be produced by permanent magnets, reluctance saliency, or DC or
AC electrical windings.
Less commonly, linear AC motors operate on similar principles as rotating
motors but have their stationary and moving parts arranged in a straight line
configuration, producing linear motion instead of rotation.

Electromagnet
An electromagnet is a type of magnet in which the magnetic field is produced by
an electric current. The magnetic field disappears when the current is turned off.
Electromagnets usually consist of a large number of closely spaced turns of wire that
create the magnetic field. The wire turns are often wound around a magnetic core made
from a ferromagnetic or ferromagnetic material such as iron; the magnetic core
concentrates the magnetic flux and makes a more powerful magnet. A simple
electromagnet consisting of a coil of insulated wire wrapped around an iron core. The
strength of magnetic field generated is proportional to the amount of current.
The main advantage of an electromagnet over a permanent magnet is that the
magnetic field can be quickly changed by controlling the amount of electric current in
the winding. However, unlike a permanent magnet that needs no power, an
electromagnet requires a continuous supply of electrical energy to maintain a magnetic
field.
Electromagnets are widely used as components of other electrical devices, such as
motors, generators, relays, loudspeakers, hard disks, MRI machines, scientific
instruments, and magnetic separation equipment. Electromagnets are also employed in
industry for picking up and moving heavy iron objects such as scrap iron and steel.

Aluminum Disk
1. The aluminum disk is the make from the aluminum.
2. This disk is mounted on the shaft.
3. And the shaft is connected to the ac motor so that the aluminum disk is rotates as
the same speed of the motor.
4. There are the two electro magnets are provided on the two other sides of the disk.
5. So that when the aluminum disk cuts the magnetic field created by the
electromagnet it is produce eddy current in it.
Metal FRAM
1. The metal frame is the base of the whole equipment.
2. The metal frame is suitable for the withstand the load of the assembly on it so it
is design properly.
3. There is the use the metal frame for the support the whole assembly on it.
4. The metal frame is made from the cast irons. The blocks of the cast iron are cut
by the cutting machine.
5. Arc Welding is use for the join the cast iron blocks as per the requirement so the
frame.
Shaft
1. The shaft is the life line of the any equipment.
2. In this project there is the use the 8mm cast iron shaft for the mounting the disk and
electric motor.
3. The shaft is attached to the motor and aluminum disk with help of the flange
coupling.
4. The shaft is supported on the frame by the bearing and bearing blocks.
Bearing (608)
A ball bearing is a type of rolling-element bearing that uses balls to maintain the
separation between the bearing races.The purpose of a ball bearing is to reduce
rotational friction and support radial and axial loads. It achieves this by using at least
two races to contain the balls and transmit the loads through the balls. In most
applications, one race is stationary and the other is attached to the rotating assembly
(e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as
well. Because the balls are rolling they have a much lower coefficient of friction than if
two flat surfaces were sliding against each other.
Ball bearings tend to have lower load capacity for their size than other kinds of
rolling-element bearings due to the smaller contact area between the balls and races.
However, they can tolerate some misalignment of the inner and outer races.
The most common standardized ball bearing size is the 608 series. In the 608
series, the ball bearing typically consists of optional closures, inner race, outer race,
balls, and ball retainer. It is characterized by an 8mm inner diameter (the bore of the
ball bearings), a 22mm outer diameter, and a width of 7mm.

Bearing Block
The fundamental application of both types is the same which is to mount
bearings safely enabling their outer ring to be stationary while allowing
rotation of the inner ring. The housing is bolted to a foundation through the
holes in the base. Bearing housings are either split type or unsplit type. Split
type housings are usually two piece housings where the cap and base can be
detached, while certain series are one single piece housings. Various seals are
provided to prevent dust and other contaminants from entering the housing.
Thus the housing provides a clean environment for the expensive bearings to
freely rotate, hence increasing their performance and duty cycle.
Bearing housings are usually made of grey cast iron. However various grades of
metals can be used to manufacture the same.

Flange Coupling
A coupling is a device used to connect two shafts together at their ends
for the purpose of transmitting power. Couplings do not normally allow
disconnection of shafts during operation, however there are torque limiting
couplings which can slip or disconnect when some torque limit is exceeded.
The primary purpose of couplings is to join two pieces of rotating
equipment while permitting some degree of misalignment or end movement or
both. By careful selection, installation and maintenance of couplings,
substantial savings can be made in reduced maintenance costs and downtime.
This coupling has two separate cast iron flanges. Each flange is mounted
on the shaft end and keyed to it. The two flanges are coupled together with the
help of bolts and nuts. The projected portion of one of the flanges and
corresponding recess on the other flange help to bring the shaft into line and to
maintain alignment. A flange which is provided with a shroud which shelters
the bolts heads and nuts is called protected type flange coupling.

Power off Brake

Power off brakes stop or hold a load when electrical power is either accidentally
lost or intentionally disconnected. In the past, some companies have referred to these as
"fail safe" brakes. These brakes are typically used on or near an electric motor. Typical
applications include robotics, holding brakes for Z axis ball screws and servo motor
brakes. Brakes are available in multiple voltages and can have either standard backlash
or zero backlash hubs. Multiple disks can also be used to increase brake torque, without
increasing brake diameter. There are 2 main types of holding brakes. The first is spring
applied brakes. The second is permanent magnet brakes.
Fig -2: Power off Brake
 Principle of electromagnet Brake 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.
Brakes may be applied for a prolonged periods of time in some applications such
as a heavy vehicle descending a long gradient at high speed. Brakes have to have
the mechanism to keep the heat absorption capability for prolonged periods of
time.
 Design and practical work
Theoretically, Model is divided into three main units (1) Base unit (2)
Driving unit and (3) Braking unit. Base unit consist of a angle to base of our
model, driving unit consist of a electrical motor, power control and bearing.
Braking unit consists of a electromagnet
Electromagnetic brakes (also called electro-mechanical brakes or EM
brakes) slow or stop motion using electromagnetic force to apply mechanical
resistance (friction). The original name was "electro-mechanical brakes" but over
the years the name changed to "electromagnetic brakes", referring to their actuation
method. Since becoming popular in the mid-20th century especially in trains and
trolleys, the variety of applications and brake designs has increased dramatically,
but the basic operation remains the same. Both electromagnetic brakes and eddy
current brakes use electromagnetic force but electromagnetic brakes ultimately
depend on friction and eddy current brakes use magnetic force directly.

Fig -1: Isometric View (Solidworks)

 Material Selection

Material selection process is depending on application of where the brake is

used. Generally plate is mostly used in aluminum because it is very efficient to
produce eddy current in plate. We should buy a most effective copper plate but it is
costly and not applicable for all buyers.

Table -1: Specification of parts

AC Round
Title Electromagnet battery
motor Plate
Specification 36gauge 5-12 V 180 mm 12 volt
magnet wire
 Construction
The construction of the electromagnetic braking system is very simple. The
parts needed for the construction are electro magnets, rheostat, sensors and
magnetic insulator. A cylindrical ring shaped electro magnet with winding is
placed parallel to rotating wheel disc/ rotor. The electro magnet is fixed, like as
stator and coils are wounded along the electromagnet. These coils are connected
with electrical circuit containing one rheostat which is connected with brake pedal.
And the rheostat is used to control the electric current flowing in the coils which
are wounded on the electro magnet and a magnetic insulator is used to focus and
control the magnetic flux. And also it is used to prevent the magnetization of other
parts like axle and it act as a support frame for the electromagnet. The sensors used
to indicate the disconnection in the whole circuit. If there is any error it gives an
alert, so we can avoid accident. Working principle: At the initial stage the brake
pedal and rheostat are in rest. When we apply the brake through the brake pedal,
the rheostat allows the current to flow through the circuit and this current energies
the electromagnet. The amount of current flow is controlled by the rheostat.
Depending on the current flow different amount of magnetic flux can be obtained.
By this varying magnetic flux, different mode of brakes can be obtained. For
example, if we want to suddenly stop the vehicle then press the brake pedal fully,
then the rheostat allos maximum current which is enough to stop the vehicle.
Similarly we can reduce the speed of the vehicle by applying the brake gradually.
FABRICATION OPERATIONS
Arc Welding
Arc welding is a fusion process for joining metals. By applying heat, metal at the
joint is melted and caused to weld directly with an intermediate molten filler metal.
The final weldment potentially has the same strength properties as the metal of the
parts since the joining is an intermixture of metals. This is in sharp contrast to non-
fusion processes of joining in which the mechanical and physical properties of the

base materials cannot be duplicated at the joint.

Fig -17: Arc welding

High heat required to melt the metal is produced in arc welding by using an
electric arc. The arc formed between work and electrode is manually or mechanically
guided along the joint. The electrode is used for carrying the current between tip and
work.
Brazing

Fig -18: Brazing Operation

 Brazing is done when two or more metal items needed to join together, by
means of melting and flowing a filler metal into the joint. The filler flows into the
gap between parts by means of capillary action. The filler heated to form the flux that
flows over the base metal and condensed to join the work pieces together. A major
advantage of brazing is the ability to join the same or different metals with
considerable strength.
Turning
In turning operation, cutting tool follows more or less straight line path as
the work piece rotates. During turning, metal piece is rotated and a cutting tool is
traversed along 1, 2, or 3 axes of motion to produce accurate diameters and depths.

Fig -19: Turning Operation

Turning can be either on the outside of the cylinder or on the inside to

produce tubular components to various geometries. The turning process is done on
a lathe and are of four different types like straight turning, taper turning, profiling
or external grooving. Different shapes like straight, conical, curved, or grooved
work piece can be produced by these processes. In general, turning uses simple
single-point cutting tools.
Drilling
Drilling is a process to cut a hole of circular cross- section in solid materials
by using drill bits. The bit is a multipoint cutting tool of rotary type. The bit is
pressed and rotated against the work piece at a rate from hundreds to thousands of
revolutions per minute. This forces the cutting edge to cut off chips from the hole
during drilling.

Fig -20: Drilling Operation

 CONCLUSIONS
As we discussed about the limitations of drum brakes, hydraulic brakes and
pneumatic brakes electromagnetic brake is a better and reliable solution.
Electromagnetic brake control system is an electric switching system which gives it
superior controllability. The installation of an electromagnetic brake is not very
difficult.

From the foregoing, it is apparent that the electromagnetic brake is an

attractive complement to the safe braking of heavy vehicles. Good results with
current design, a larger budget would improve performance.
 ADVANTAGES

o 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.
o This is reduced significantly in electromagnetic disk brake systems.
o Potential hazard of tire deterioration and bursts due to friction is eliminated.
o There is no need to change brake oils regularly.
o There is no oil leakage
o 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.
o The retarders help to extend the life span of the regular brakes and keep
the regular brakes cool for emergency situation.
o The electromagnetic brakes have excellent heat dissipation efficiency owing to
the high temperature of the surface of the disc which is being cooled.
o Due to its special mounting location and heat dissipation mechanism,
electromagnetic brakes have better thermal dynamic performance than regular
friction brakes.
o Burnishing is the wearing or mating of opposing surfaces .This is reduced
significantly here. In the future, there may be
o shortage of crude oil; hence by-products such as brake oils will be in much
demand. EMBs will overcome this problem.
o Electromagnetic brake systems will reduce maintenance cost.
o The problem of brake fluid vaporization and freezing is eliminated.
o Electric actuation, no fluid.
o Easier integration with anti-lock, traction, and dynamic stability
controls.
 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. The installation of an electromagnetic brake is very difficult if there is
Not enough space between the gearbox and the rear axle.
 REFERENCES

[1] “LATCHING BRAKE USING PERMANENT MAGNET” by Stephen Z.

Oldakowski, Bedford, Ohio United States Patent Patent Number: 5,121,018
[2] “ADJUSTABLE MAGNETIC BRAKE” by Hung-Chi Wu, 958-2, Ghung Shan
Rd., Tao-Yuan, Taiwan United States Patent Patent Number: 5,096,024
[3] “MAGNETIC BRAKE SYSTEM FOR A VEHICLE” by Jae-Woong Lee. Seoul,
Rep. of Korea United States Patent Patent Number: 5,746,294
[4] “BRAKE DEVICE FORAN ELEVATOR WITH MONITORING
CAPABILITIES” by Karl Erny, Holzhausem United States Patent Patent
No.: US 7,909,145 B2
[5] “MAGNETIC BRAKE” by Albert E. Miller, Dayton, Ohio United States Patent
Office Patent No 2,482,428
[6] Kesavamurthy, N., „„Eddy-current in solid iron due to alternating magnetic
flux,‟‟ The Institution of Engineers Monograph, No. 339U, pp. 207–213,
June, 1959,
[7] Ohyma, T., „„Adhesion at higher speeds, its basic characteristic, its
improvement and some related problem,‟‟ Japanese Railway Engineering,
Vol. 108, 1988.
[8] Mcconnell, H.M., „„Eddy-current phenomena in ferromagnetic material,‟‟ AIEE
Transactions,Vol. 73, part I, pp. 226–234, July, 1954.
[9] Ren He,Xuejun Liu “Brake Performance Analysis of ABS for Eddy Current
and Electrohydraulic Hybrid Brake System” School of Automotive &
Traffic Engineering, Jiangsu University, Zhenjiang 212013, China Received
24 September 2013; Revised 29 October 2013; Accepted 30 October 2013
[10] G. G. Desta, “Eddy Current Brake System,” 2004, US 6,698,554 B2.
Fig. 3 Working Model Of Electromagnet Brake