INDEX

Sr. Content Page

No. number
1 Introduction 3-5
Methodology 5-7
2

Requirement of Hardware and Software for the 8-12

Proposed Project (list of components and their
specifications)
3

Limitations and Scope of the Project 12-14

(Advantages and Disadvantages)

Applications 14-15
5

References 15
6

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 I.INTRODUCTION
In today’s era safety is the first priority in automobile manufacturing industry. Braking system in automobiles ensure
the optimization and good control over the vehicle and reduces the chances of accidents. Braking System should
ensure the safety and comfort of the passenger, driver and other road user. The brake must be strong enough to stop
the vehicle during emergency within shortest distance. The convention braking system are bulky and power to
weight ratio is low. Most of the braking systems utilize friction forces to transform the kinetic energy of a moving
body into heat that is dissipated by the braking pads. The overuse of friction-type braking systems causes the
temperature of the braking pads to rise, reducing the effectiveness of the system. An electromagnetic brake is a new
and revolutionary concept. These are totally friction less. Electromagnetic brakes are the brakes working on the
electric & magnetic power. Electromagnetic Braking System is used which is efficient way of braking with high power
to torque ratio and also provide less amount of friction. An Electromagnetic Braking system uses Magnetic force to
engage the brake, but the power required for braking is transmitted manually. The disc is connected to a shaft and
the electromagnet is mounted on the frame .When electricity is applied to the coil a magnetic field is developed
across the armature. The eddycurrent is created by the relative motion between a magnet and a metal (or alloy)
conductor. The current induces the reverse magnetic field and results in the deceleration of motion. The proposed
mechanism implements this phenomenon in developing a braking system. The potential applications of the braking
system can be a decelerating system to increase the safety of any vehicle. As a result it develops a torque and
eventually the vehicle comes to rest. In this project the advantage of using the electromagnetic braking system in
automobile is studied. These brakes can be incorporated in heavy vehicles as an auxiliary brake. The electromagnetic
brakes can be used in commercial vehicles by controlling the current supplied to produce the magnetic flux. Making
some improvements in the brakes it can be used in automobiles in future. It also reduces the maintenance of braking
system. An advantage of this system is that it can be used on any vehicle with minor modifications to the
transmission and electrical systems. The major parts of an electromagnetic braking system are braking disc,
Electromagnets and battery power. Electromagnetic braking system is classical example of increased effectiveness of
braking system while minimizing losses. In our prototype we focus on Electromagnetic system is to increase the
safety of the device meanwhile keeping the losses to minimum. An effective design is one which performs the
required task efficiently and is safe under extreme operating conditions, while being economical in the material used
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as well as the manufacturing process needed yet having an aesthetic appeal. Analysis aids in understanding the
behaviour of a component under a particular loading cycle for both failures and redundancies. For a design
optimization of prototype it is necessary to look into the design aspects and literature available in order to better
understand the need of the components .Our team goes through various different review papers so we can know
about other people’s work on different brakes. We studied numerous papers in which different researchers have
given their contribution on the development this certain topic. Sevvel , Nirmal Kannan , Mars Mukesh in their paper
Innovative Electro Magnetic Braking System [1] specified that an Electromagnetic Braking system uses Magnetic
force to engage the brake, but the power required for braking is transmitted manually. The electromagnetic brakes
can be used in commercial vehicles by controlling the current supplied to produce the magnetic flux. Lindberg; Teppo
(Nuppulinna, FI) Assignee: Kone Oy (Helsinki, FI) United States Patent[9] invented a vehicle braking system including
a brake disk structure defining an annular surface means and having an axis, an annular magnet support assembly
disposed adjacent to the annular surface means in the direction of the axis, a plurality of circumferentially spaced
apart pairs of circumferentially spaced apart permanent magnets mounted on the magnet support and
circumferentially spaced apart thereon, each pair Arranged with like the polarities of the pairs of permanent mag
nets facing the annular surface means alternating circumferentially, an annular pole piece support assembly, and a
plurality of ferromagnetic pole pieces mounted on the pole piece support assembly and circumferentially spaced
apart in positions between the annular surface means and the permanent magnets, each pole piece disposed
adjacent to a pair of the permanent magnets and having a circumferential length substantially greater than the
circumferential length of either of the adjacent pair of permanent magnets. United States Patent, US 6,286,637B1,
Kwangju Institute of Science & Technology (KR) was published In which the two cores are arranged the edge of the
brake disc while being spaced apart from each other at an angle of (90) each of the cores is wound with a coil thus
forming and electric magnet A control units calculates Dc or Ac control in response to a speed signal output from the
sensor thus outputting control current value to the coils, while the AC current is variable in the frequency in
accordance with the pedalling force as well known to those skilled in an art known contact brakes for cars are
designed to be operated by hydraulic or pneumatic pressure thus pressing against the brake disc of a wheel using
frictional brake pads are frictionally In that the brake pads and making a car go slow or stop. Akshaya S. Putt war and
Nagnath U. Enhancement of Braking System in Automobile Using Electromagnetic Braking published in IOSR Journal
of Mechanical and Civil Engineering (IOSR-JMCE), in 2009[3] discovered that electromagnetic brakes can build up a
power which is almost double the most extreme power yield of a normal motor, and no less than three times the
braking energy of a fume brake to stop the vehicle. These results of electromagnetic brakes make them essentially
more focused possibility for elective hindrance hardware’s contrasted and different retarders. This project expects to
limit the brake inability to stay away from the street mis – happenings. While in electromagnetic braking system as
four-disc plates, coils and firing circuits are attached individually on each wheel, even any coil fails the brake does not
completely fails remaining three coil works properly. The electromagnetic brakes can be used as an auxiliary braking
system along with the friction braking system to avoid overheating and brake failure. When these brakes are
combined with mechanical brakes, 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. Similarly (ICEVT)
October 30-31, in 2018, Surakarta, Indonesia[2] researchers aimed to investigate the relationship between braking
torque with the amount of coil and the air gap in single disc axial brake ECB (Eddy current braking). FEM is used in
ECB performance modelling. In this paper by changing the air gap and number of conductors the torque is also
changed. By using FEM, we can find this. The braking torque Is strongly affected by the parameter of eddy current
brake. By result of this research we can conclude that smaller air gap increases the braking torque and also number
of conductors is improving the performance of eddy current brake also by change in design the braking torque is also
change. Better braking performance is obtain when using 0.5mm air gap and 360 conductors. Yash Gandhi & Dipam
Modh in their review Paper on Eddy Current and Electromagnetic Brake[13] found that the larger thickness of disc, a
greater number of turns of electromagnet and higher electrical conductivity of conductor influences the generation
of greater braking torque. Greater the speed greater the efficiency. Design and Development of Electromagnetic
Braking System Sivasubramanian R, Siva sundar S, Umakhesan A, Ravel M, Saravanan M [9] Electromagnetic brake

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slows down a moving object by means of electromagnetic induction, in which it will create a resistance. A pressure is
created by the Friction brakes on two separate objects to gradually reduce the speed of the vehicle in a controlled
way. The current of the magnet turns in the form of heat of the plate which will reduce the kinetic energy. In this
magnetic type of braking system whenever force is applied by the driver on the brake pedal the Intensity of braking
is sensed by a pressure transducer and delivers the output actuating signals to the microprocessor. This controller
sends a signal to the capacitor and from the respective unit a pulsating D.C. current is sent to the power pack. [8-9]
As per the driver’s requirement a proportionate torque is developed to decelerate the vehicle. The paper published
by Yogesh Kumar Yadav1, Aadarsh Kumar Shah2, Jitendra Kumar Yadav3, Jitendra Pratap Patel4 Electromagnetic
Braking System [11] focuses around utilization of electromagnetic power to stop vehicle. An Electromagnetic Braking
structure uses Magnetic power and what’s more turn current to attract the brake, however the power required for
braking is transmitted through current source. The circle (rotor) is associated with a pole and the electromagnet is
mounted on the calliper and lasting magnet is intertwined or mounted on plate at an edge. Exactly when control is
associated with the twist an appealing field is created over the armature because of the present gushing over the
circle and influences armature to get pulled in towards the twist. Because of fascination between magnets in
callipers and circle, it builds up a torque which restricts the movement of rotor and in the long run the vehicle stops
and furthermore, whirlpool current is produced on the plate when exceptionally quality magnet Is set close to the
moving circle. Swirl current created in the plate build up their own attractive field which contradicts the connected
attractive field. In this manner, rotor or circle stops by torque created because of resistance of attractive field i.e. (of
provided and vortex current`s attractive field). Along these lines, this brake utilizes both attractive power and also
whirlpool current to connect with brake. These brakes can be joined in substantial vehicles and auto as an assistant
brake. The electromagnetic brakes can be utilized as a bit of business vehicles by controlling the current provided for
make the engaging development. Design & Theoretical Study of Electromagnetic Braking System [12] tells us about
the behaviour of two different materials to be used as brake disc which are aluminium & copper was studied. The
experiment also aimed to see the effects of Increasing the current induced into electromagnet which produce drag
force that will slow down the motion. A few graph been presented to show the best material to be used as the brake
disc for electromagnetic braking system using eddy current project. The variation in braking time & braking torque
with respect to variation in air gap & current was studied & graphs were plotted to show the results.

II.METHODOLOGY
The system consists of a rectangular shaped frame, made up of mild steel. The pillow bearings are mounted on the
frame by welding. The shaft is being hold in between the bearings. The wheel and the mild steel disc is mounted on

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 the shaft at a specific distance. Two AC type electromagnets are situated near the mild steel disc and mounted on
the frame. The torque is provided to the shaft through chain drive, which is driven by a motor, mounted on the
frame.

Electromagnetic brakes operate electrically, but transmit torque mechanically. This is often why they are utilized to refer
as electro-mechanical brakes. Over the years, Electromagnetic brakes became referred to as electromagnetic, pertaining
to their actuation method. The variability of applications and brake designs has increased dramatically, but the essential
operation of braking remains same. Single face electromagnetic brakes structure approximately 80 percent of all of the
facility applied brake applications. The electromagnet is energized by the AC supply where the magnetic flux produced is
employed to supply the braking mechanism. When the electromagnet isn’t energized, the rotation of the disc Is free and

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accelerates uniformly under the action of weight to which the shaft is connected. When the electromagnet is energized,
magnetic flux is produced thereby applying brake by retarding the rotation of the disc and therefore the energy absorbed
is appeared as heating of the disc. So, when the armature Is interested in the sector the stopping torque is transferred
into the sector 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.

The brake Rotor, Shaft, mountings and frame are the crucial component as every force experienced by the model is
passed on through it. Also analysing every effect of this complex ever changing moment and forces becomes
complicated. A worst case scenario’s is therefore recommended where forces are scaled and restrains are applied in view
of real time. The team performed various finite element computational analysis to match approximately with the actual
conditions that will be experienced by the component so as to avoid failure in real-time. There are many different types
of analysis that must be completed to ensure that the part in question is able to withstand the applied loads. In addition,
there are other factors that must be included in each analysis to ensure that the analysis itself is correct. In order to
analyse the part correctly, the restraints must be an accurate representation of the real world scenario and the loads
must be calculated for different loading scenarios. Finally, the mesh must be as homogenous as possible. This would
include minimizing the difference in aspect ratio between elements, as well as maximize element mapping quality. We
must ensure that all of the meshes we use for the different components in our assembly are set up to be compatible
with one another. The main objective behind analysis was to check the maximum stress induced, predict the life of
component and establish a suitable factor of safety in design. All of the analysis was done in student package of Solid
works Simulation module. Modal analysis was also done on the component to determine how the system behaves in its
displacement dynamic response. It was done to check how different frequencies naturally excite the system to a degree
where resonance fluctuates through the component resulting in dropping of life expectancy of the system.
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III.REQUIREMENT OF H/W AND S/W FOR THE PROPOSED PROJECT

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IV.LIMITATIONS AND SCOPE OF THE PROJECT (Advantages and disadvantages)

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V. APPLICATIONS

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VI. REFERENCES

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