ACKNOWLEDGMENTS

We express immensely our deep sense of graduation to PROFESOR SHUNIL KAMAL DWIVEDI
Department of Mechanical Engineering, "JAWAHAR LAL NEHRU COLLEGE OF TECHNOLOGY REWA"
REWA DISTRICT for his valuable guidance and encouragement at every stage of the work made it a
successful fulfilment

We are thankful to Professor SHUNIL KAMAL DWIVEDI Head of the Department, Mechanical
Engineering, "JAWAHAR LAL NEHRU COLLEGE OF TECHNOLOGY REWA" for their valuable suggestions.

We express our sincere thanks to the members of non-teaching staff of Mechanical Engineering for their
kind co-operation and support to carry on work.
Last but not the least, we like to convey our thanks to all who have contributed
either directly or indirectly for the completion of our work.

1. OMKAR SAKET
2. GAURAV MISHRA
3. AMAN SHAHU
4. SHIVAM KUMAR SAKET
5. PANKAJ PATEL
6. SHUBHAM KUMAR
7. VINOD KUMAR PANDEY
 ABSTRACT
Majority of braking systems work on the principle of dissipation of kinetic energy to heat energy.
This method has its own drawbacks and must be replaced with a more reliable braking system
that is quick in response, doesn’t heat up and is maintenance free. In this project the design of an
electro-magnetic braking system and optimization for various operational parameters has been
done and the advantage of using the electromagnetic braking system in automobile is studied.
These parameters have been previously iterated in cited projects and papers and also in the
simulation models and are to be cross-checked with the experimental setup

An Electromagnetic Braking system uses Magnetic force to engage the brake, but the power
required for braking is transmitted manually. The wheel is connected to a shaft and the
electromagnet braking unit is attached to one side of the wheel. Here the braking unit consists of
a hollow circular steel plate and a stator which has 3 spokes made of iron wounded with copper
wire (or) magnetic wire. Here the round steel plate which is attached to the wheel rotates when
wheel rotates with the help of motor. when current is supplied to the stator the spokes gets
magnetized and creates an magnetic field which tries to attract or oppose the motion of rotating
circular plate with the help of magnetic field created. In this brakes there is no contact between
the electro-magnetic coils and rotating circular plate (i.e 2mm gap between coil and circular plate)
so this is also called as contactless braking system which is a main advantage in using this
brakes. In this 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.
 LIST OF CONTENTS

CHAPTER-I : INTRODUCTION

1.1Types of Brakes
1.1.1 On the Basis of Power Source
1.1.2 On the Basis of Frictional Braking Contact
1.1.3 On the Basis of Application
1.2 Principle of Braking System
1.3 Types of Braking System
1.4 Objectives
1.5 Significance and Scope

Chapter - ll : LITERATURE SURVEY

CHAPTER-Il : ELECTRO-MAGNETIC BRAKING SYSTEM

3.1 Background and History

3.2 Components of Electro-Magnetic Braking System
3.3 Construction of Electro-Magnetic Braking System
3.4 Working of Electro-Magnetic Braking System
3 5 Advantages
3.6 Dis-advantages
3.7 Applications

CHAPTER -IV : CONCLUSION

CHAPTER -V : REFERENCES
 CHAPTER-I

INTRODUCTION
 CHAPTER-I
INTRODUCTION

Brake Definition and Background

A brake is a mechanical device that inhibits motion by absorbing energy from a moving system. It is
used for slowing or stopping a moving vehicle, wheel, axle, or to prevent its motion, most often
accomplished by means of friction. Brakes may be broadly described as using friction, pumping, or
electromagnetic. One brake may use several principles: for example, a pump may pass fluid
through an orifice to create friction.

Most brakes commonly use friction between two surfaces pressed together to convert the kinetic
energy of the moving object 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. Other methods convert kinetic energy into potential energy in
such stored forms as pressurized air or pressurized oil. Eddy current brakes use magnetic fields to
convert kinetic energy into electric current in the brake disc, fin, or rail, which is converted into heat.
Still other braking methods even transform kinetic energy into different forms, for example by
transferring the energy to a rotating flywheel.

Brakes are generally applied to rotating axles or wheels, but may also take other forms such as the
surface of a moving fluid (flaps deployed into water or air). Some vehicles use a combination of
braking mechanisms, such as drag racing cars with both wheel brakes and a parachute, or
airplanes with both wheel brakes and drag flaps raised into the air during landing.

Since kinetic energy increases quadratically with velocity (KE=1/2 mv2), an object moving at 10
m/s has 100 times as much energy as one of the same mass moving at 1 m/s, and consequently
the theoretical braking distance, when braking at the traction limit, is 100 times as long. In practice,
fast vehicles usually have significant air drag, and energy lost to air drag rises quickly with speed.
Almost all wheeled vehicles have a brake of some sort. Even baggage carts and shopping carts
may have them for use on a moving ramp. Most fixed-wing aircraft are fitted with wheel brakes on
the undercarriage. Some aircraft also feature air brakes designed to reduce their speed in flight.
Notable examples include gliders and some World War II-era aircraft, primarily some fighter
aircraft and many dive bombers of the era. These allow the aircraft to maintain a safe speed in a
steep descent. The Saab B 17 dive bomber and Vought F4U Corsair fighter used the deployed
undercarriage as an air brake.

Friction brakes on automobiles store braking heat in the drum brake or disc brake while braking
then conduct it to the air gradually. When traveling downhill some vehicles can use their engines to
brake. When the brake pedal of a modern vehicle with hydraulic brakes is pushed against the
master cylinder, ultimately a piston pushes the brake pad against the brake disc which slows the
wheel down. On the brake drum it is similar as the cylinder pushes the brake shoes against the
drum which also slows the wheel dow.

1.1Types of Brakes
1.1.1 On the Basis of Power Source
1.1.2 On the Basis of Frictional Braking Contact
1.1.3 On the Basis of Application
1.1.4 On the Basis of Brake Force Distribution

1.1.1 On the Basis of Power Source

The power source which carries the pedal force applied by the driver onbrake pedal to the final
brake drum or brake disc in order to de accelerateor stop the vehicle the braking systems .
Magnetic Brakes.

In this types of braking system, the magnetic field generated bypermanent magnets is used to
cause the braking of the vehicle.

It works on the principle that when we pass a magnet through a cooper tube, eddy current is
generated and the magnetic field generatedby this eddy current provide magnetic braking.

This is the friction less braking system thus there is less or nowear and tear.

This is the advanced technology in which no pressure is neededto cause braking.

The response to the braking in this is quite quick as comparedto other braking systems.

Diagram of solenoid
1.1.2 On Frictional Contact Basis

On the basis of the final friction contact made between the rotating brakecomponents i.e. brake drum
or disc rotor and the brake shoe the brakingsystems.

Disc Brake or External Contracting Brakes.

It is the types of braking system in which instead of a drum assembly adisc rotor attached to the hub
of the wheel in such a fashion that it rotates withthe wheel, this disc rotor is clamped in between the
caliper which is rigidlyfixed with the knuckle or upright of the vehicle.

This caliper used is the housing of the brake shoes along with theactuation mechanism (mechanical
linkages or caliper cylinder).

When the brakes are applied the actuation mechanism contracts theattached brake shoes which in
turn makes the frictional contact with therotating disc rotor and causes the braking of the vehicle

Diagram of disc plate

1.1.3 On Application Basis
1. Service Brake or Foot Brakes

It is the type of brakes in which the brakes are applied when the driver presses the brake pedal
mounted inside the cockpit or at the foot space of the vehicle with his foot, this pedal force
applied by the driver is furthermultiplied and sent to the braking drum or disc either by
mechanical linkagesor by hydraulic pressure which in turn causes braking.

In cars foot operated brakes are used and in bikes thecombination of foot and hand operated
brakes are used

2.Hand Brake or Parking Brake

This type of brakes are also known as emergency brake as they areindependent of the main
service brake, hand brakes consists of a handoperated brake lever which is connected to the
brake drum or disc rotorthrough the metallic cable.

When hand brake lever is pulled, tension is created in themetallic rod which in turn actuates the
brake drum or disc rotormechanism and final braking occurs.

Hand brakes are usually used for stable parking of the vehicleeither on flat road or slope that is
why it is also called parking brakes.
1.2 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

1.3 Types of Braking System

(a) Electromagnetic Brake System

A rising style of brake system, electromagnetic brakes use an electric motor that is included in the automobile which help the
vehicle come to a stop. These types of brakes are in most hybrid vehicles and use an electric motor to
charge the batteries and regenerative brakes. On occasion, some buses will use it as a secondary retarder brake.

(b) Frictional Brake System

A frictional brake system is found in many automobiles. They are service brakes, and typically found in two forms; pads and
shoes. As the name implies, these brakes use friction to stop the automobile from moving. They typically include a rotating
device with a stationary pad and a rotating weather surface. On most band brakes the shoe will constrict and rub against the
outside of the rotating drum, alternatively on a drum brake, a rotating drum with shoes will expand and rub against the inside of
the drum.

(c) Hydraulic Brake system

A hydraulic brake system is composed of a master cylinder that is fed by a reservoir of hydraulic braking fluid. This is connected
by an assortment of metal pipes and rubber fittings which are attached to the cylinders of the wheels. The wheels contain two
opposite pistons which are located on the band or drum brakes which pressure to push the pistons apart forcing the brake pads
into the cylinders, thus causing the wheel to stop mov
1.4 Objective

(a) Primary Objective

The main objective of our project is to design and fabricate an

Electromagnetic Braking System model.

(b)Secondary Objective

Besides the main objective, following are our secondary objectives:

To understand project planning and execution.
To understand the fabrication techniques in a mechanical workshop.
To understand the usage of various mechanical machine tools and also measuring tools.
To make day to day human life more easier by proper use of technology.

1.5 Significance and Scope

Electromagnetic brakes satisfy all the energy requirements of braking without the use of friction.
They have better heat dissipation capability to avoid problems that friction brakes faces times.

They can also be used as supplementary retardation equipment in addition to the regular friction
brakes on heavy vehicles.

These brakes’s component cost is less so these brakes are cheap.

They can be used as an alternative method for the future crisis of the crude oils.
 Chapter-2
LITERATURE SURVEY
 Chapter-2
Literature Survey

The following are the few journals in which the study was on electromagneticbraking system with
different modifications

Innovative Electro Magnetic Braking System by Sevvel P and S Mukesh published in International
Journal of Innovative Research in Science, Engineering and Technology (IJIRSET), Volume-3 in April
2014, Second National Conference on Trends in Automotive Parts Systems and Applications (TAPSA
-2014) at Sri Krishna College of Engineering & Technology, Kuniamuthur, Coimbatore,Tamilnadu, India .
Mr. Sevvel P and S Mukesh Et al find that the 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. 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 antiskidding equipment.
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

Design & Fabrication of Eddy Current Braking System by Oscar Rodrigues, Omkar Taskar, Shrutika
Sawardekar, Henderson Clemente, Girish Dalvi published in International Research Journal of
Engineering and Technology (IRJET). The purpose of the study was to perform a comparative study of
theoretical and practical braking time and establish a practical air gap limit beyond which the
electromagnetic brakes lose their effectiveness. From theoretical calculations and experimented braking
time values, a maximum reduction in braking time 23.97% is found and max air gap limit of 3 mm is
obtained beyond with electromagnetic brakes are found to be ineffective. Further, a magnet of higher
magnetic flux density can be used to minimize the braking time. Also, magnets can be positioned at
different locations around the disc in radial arrangement to get better breaking torque distribution
Modeling and control of electromagnetic brakes for enhanced braking capabilities or automated
highway systems’ by M. Qian, and P. Kachroo, University of Nevada, LasVegas, IEEE Conference on
Intelligent Transportation Systems, pp. 391396, January, 1997. A modified mathematical model is
developed for electromagnetic brakes, is proposed to describe their static characteristics i.e.
angular speed versus brake torque. This paper describes electromagnetic brakes as a
supplementary system for regular friction brakes. This system provides better response time for
emergency situations, and in general keeps the friction brake working longer and safer.

To control the brakes, a robust sliding mode controller is designed to maintain the wheel slip at a
given value. Simulations show that the controller designed is capable of controlling the vehicle with
parameter deviations and disturbances

Design and fabrication of electromagnetic braking system published international Review of

Mechanical Engineering (I.RE.M.E.) by M.Z.Baharom, M. Z. Nuawi, S. M. Haris.

The behaviour of electromagnetic braking using eddy current was studied.Startedwith preliminary
study investigating 3 difference materials of aluminum, copper and zinc to choose the best material
as brake disc. It also looks on effects of increasing current induced into electromagnet. From the
experiment that has been conducted, it can be concluded that aluminum is the best material
compared to copper and zinc to be use as the disc brake for eddy current braking using
electromagnetic.
Besides that, we may conclude that A16061 is better than A17075 to be uses as the brake disc
material for our electromagnetic braking system using eddy current project. Thicker disc will
generate high torque which will approach the motor torque in order to stop the disc rotation which
in this study disc of 5 mm is better than 4mm of thickness. Smaller air gap will produce high braking
torque and give better performance to the electromagnetic braking which air gap of 1mm shows
the best result compared to 3mm and 5mm is better than 4mm of thickness. Smaller air gap
will produce high braking torque and give better performance. To the electromotive braking which
air-gap of 1mm shows the best result compared to 3mm and 5mm gap. A16061 which has higher
electrical conductivity than A17075 shows great
performance of braking torque produced in the study. Therefore, finding of mentioned parameters from
this study are parallel; with the theory and will be the guidance to extend this project for any potential
application
 Chapter-3
ELECTRO-MAGNETIC BRAKING SYSTEM
 Chapter -3
Electro-magnetic braking system
3.1 Background and Rational

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 trams, the
variety of applications and brake designs has increased dramatically, but the basic operation
remains the same. Electromagnetic brakes are the brakes working on the electric power & magnetic
power. They work on the principle of electromagnetism. These brakes are an excellent replacement on the
convectional brakes due to their many advantages. The reason for implementing this brake in
automobiles is to reduce wear in brakes as it frictionless. Electromagnetic brakes are of today’s
automobiles. The working principle of this system is based on faradays first law of electromagnetic
induction i.e when a magnetic flux linking with a conductor changes an emf is induced in the coil. An
additional current is supplied to the coils so that it creates an opposing torque. This results in the rotating
wheel or rotor comes to rest/ neutral.

History

It is found that electromagnetic brakes can develop a negative power which represents nearly twice the
maximum power output of a typical engine, and at least three times the braking power of an exhaust
brake. (Reverdin 1994). This performance of electromagnetic brakes make them much more competitive
candidate for alternative retardation equipments compared with other retarders. By using by using the
electromagnetic brakes are 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% of the duty which would otherwise have been demanded of the regular
service brake (Reverdin 1974). Furthermore the electromagnetic brakes prevent the danger that can arise
from the prolonged use of brake beyond their capability to dissipate heat. This is most likely to occur while a
vehicle descending a long gradient at high speed. Ina study with a vehicle with 5 axles and weighting 40
tones powered by a powered by an engine of 310 b.h.p travelling down a gradient of 6% at a steady
speed between 35 and 40 m.h.p, it can be calculated that the braking power necessary to maintain this
speed ot the order of 450 hp. The brakes, therefore, would have to absorb 300 hp, meaning that each brake
in the 5 axels must absorb 30 hp, that a friction brake can normally absorb with self destruction. The
magnetic brake is wall suited to such conditions since it will independently absorb more than 300 hp
(Reverdin 1974). It therefore can exceed the requirements of continuous uninterrupted braking, leaving the
friction brakes cool and ready for emergency braking in total safety. The installation of an electromagnetic
brake is not very difficult if there is enough space between the gearbox and the rear axle. If did not need a
subsidiary cooling system. It relay on the efficiency of engine components for its use, so do exhaust and
hydrokinetic brakes. The exhaust brake is an on/off device and hydrokinetic brakes have very complex
control system. The electromagnetic brake control system is an electric switching system which gives it
superior controllability.

3.2 Components of Electro-Magnetic Braking System

The electro-magnetic braking system consists of mainly the following parts.

They are:-
1. Base frame
2. Shaft
3. chain
4. AC- motor
5. Braking unit
6. Tire(or) wheel
7. Bearings
8. Disc plate
9. Electromagnate
10. Flywheel
11. Battery
12. Coper wire
1. Base Frame

The components require support during the operation. The base frame facilitates necessary support for
this purpose

Diagram base frame

2. Shaft

A shaft is a rotating machine element, usually circular in cross section, which is used to transmit power
from one part to another, or from a machine which produces power to a machine which absorbs power.
The various members such as Chain and gears are mounted on it.

One end of the shaft is connected to motor with the help of pulley and belts and the other end is connected
to wheel so that it helps in transmitting motion from motor to
wheel

Types
They are mainly classified into two types.

(a) Transmission shafts are used to transmit power between the source and the machine absorbing
power; e.g. counter shafts and line shafts.
(b)Machine shafts are the integral part of the machine itself; e.g. crankshaft.
Materials

1. The material used for ordinary shafts is mild steel. When high strength is required, an alloy steel such as
nickel, nickel-chromium or chromium-vanadium steel is used.

2. Shafts are generally formed by hot rolling and finished to size by cold drawing or turning and grinding.

Standard sizes

Machine shafts

1. Up to 25 mm steps of 0.5 mmTransmission shafts

2. 25 mm to 60 mm with 5 mm steps
3. 60 mm to 110 mm with 10 mm steps
4. 110 mm to 140 mm with 15 mm steps
5. 140 mm to 500 mm with 20 mm steps

The standard lengths of the shafts are 5 m, 6 m and 7 m

Stresses

The following stresses are induced in the shafts.

1. Shear stresses due to the transmission of torque (due to torsional load).
2. Bending stresses (tensile or compressive) due to the forces acting upon the machine elements like gears
and pulleys as well as the self weight of the shaft.
3. Stresses due to combined torsional and bending loads

Shaft diagram
3 Chain

A Chain is a wheel on an axle or shaft that is designed to support movement and change of direction
of a tight chain to flywheel, or transfer of power between the shaft and flywheel.

Diagram of chain and flywheel

4. AC-Motor:
A DC motor is any of a class of rotary electrical machines that converts direct current electrical
energy into mechanical energy. The most common types rely on the forces produced by magnetic
fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or
electronic; to periodically change the direction of current flow in part of the motor

DC motors were the first type widely used, since they could be powered from existing direct-current
lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using
either a variable supply voltage or by changing the strength of current in its field windings. Small DC
motors are used in tools, toys, and appliances. The universal motor can operate on direct current but
is a lightweight brushed motor used for portable power tools and appliances. Larger DC motors are
used in propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The
advent of power electronics has made replacement of DC motors with AC motors possible in many
applications.
Power ratings are 160-24 volts, maximum current is 2.0A and the speed is 0-1425 rpm
 Diagram of AC motor

5. Braking Unit

The braking unit consists of a permanent magnet and a stator which has 3 spokes made of iron having
copper wires windings.

The stator may consist of 2 to 18 spokes depending upon the application. The copper wires may be of
different gauges. On increasing the no.of turns of copper windings the braking effect can be increased due
to passage of more current through the coils.

Diagram of motor of windings

6. Tire (or) Wheel

A wheel is a circular block of a hard and durable material at whose center has been bored a circular
hole through which is placed an axle bearing about which the wheel rotates when a moment is
applied by gravity or torque to the wheel about its axis, thereby making together one of the six simple
machines.

Diagram of a whee

7. Bearings

A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts. The design of the bearing may, for example, provide for free
linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a
motion by controlling the vectors of normal forces that bear on the moving parts. Most bearings
facilitate the desired motion by minimizing friction. Bearings are classified broadly according to the
type of operation, the motions allowed, or to the directions of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical systems, and
transfer axial and radial loads from the source of the load to the structure supporting it. The simplest
form of bearing, the plain bearing, consists of a shaft rotating in a hole. Lubrication is often used to
reduce friction. In the ball bearing and roller bearing, to prevent sliding friction, rolling elements such
as rollers or balls with a circular cross-section are located between the races or journals of the
bearing assembly. A wide variety of bearing designs exists to allow the demands of the application to
be correctly met for maximum efficiency, reliability, durability and performance.
he purpose of Bearing is to reduce rotational friction and support radial andaxial loads

Types of bearings

There are at least 6 common types of bearing, each of which operates on

different principles:-
1. Plain bearings
2. Rolling element bearings
3. Jewel bearings
4. Fluid bearings
5. Magnetic bearings
6. Flexure bearings

1. Plain bearing,
consisting of a shaft rotating in a hole. There are several specific styles: bushing, journal bearing,
sleeve bearing, rifle bearing, and composite bearing.

2. Rolling-element bearing
in which rolling elements placed between the turning and stationary races prevent sliding friction.
There are two main types
(a). Ball bearing - in which the rolling elements are spherical balls
(b). Roller bearing -In which the rolling elements are cylindrical, taper and spherical rollers

3. Jewel bearing - a plain bearing in which one of the bearing surfaces is made of an ultra hard glassy
jewel material such as sapphire to reduce friction and wear

4. Fluid bearing - a noncontact bearing in which the load is supported by a gas or liquid,
5. Magnetic bearing - in which the load is supported by a magnetic field
6. Flexure bearing - in which the motion is supported by a load element which bends
 Diagram of bearings
3.3 Construction of Electro-Magnetic Braking System:

The motor is placed on the bottom of the frame and the motion transmission from motor to shaft
is done with the help of pulleys and belt i.e one end of the shaft is connected to a pulley and the
shaft pulley is connected is to the motor pulley with the help of belt so that when motor pulley
rotates due to the power supply the shaft pulley rotates and the shaft pulley rotates and the shaft
rotates which is mounted on the frame with the help of bearings. Here the other end of the shaft
is connected to one side of the wheel so that when shaft rotates wheel also rotates. The braking
unit consists of permanent magnet, stator which has 3 spokes of iron winded with copper wires.
The permanent magnet is attached to the other side of the wheel and the stator
outer frame is welded to the base frame.

3.4 Working of Electro-Magnetic Braking System:

There are two methods of operations of the braking system.

(a) Braking system with EMF generation effect

(b) Braking system without EMF generation effect

(a) Braking system with EMF generation effect -

In this type an alternator of bikes is used as an braking unit. The braking unit consists of
permanent magnet and stator which has three spokes of iron materialwinded with copper wires
or magnetic wires. The permanent magnet and stator are connected to the equipment as
mentioned in the construction above
connected to the equipment as mentioned in the construction above. When magnet which is
attached to the wheel rotates an EMF is generated in the coils according to Faraday’s Law of
Electromagnetic Induction, This generated EMF can be used to charge batteries with the help of
rectifier and regulator because the output EMF is in AC form. So this process of generating EMF
when wheel is freely rotating is known as EMF generating effect. In order to apply brakes a reverse
current is supplied from the adaptor which should be more than the produced EMF so that the
electro magnetic poles gets interchanged and creates an opposing torque to the rotating wheel and
tries to stop the wheel.

But in this method of operation the EMF generated is more than the reverse current which we are
supplying from adaptor. So the brakes are not making the wheel stop. To avoid this either we have
to increase the adaptor specifications (current and voltage) or to stop the EMF generating effect. If
we change the adaptor specifications I.e. increasing current and voltage the coils in the
electromagnet gets damaged due to coils gauge and less no. of turns. So we have done this
experiment in second method of operation which is to eliminate EMF generating effect is as follows.

(ii) Braking system without EMF generation effect -

The construction details are same as the first method. But only difference is the magnetic replaced
by circular steel plate in the braking unit. So when electromagnet is energized by supplying current
from adaptor it creates a magnetic field which attracts the rotating circular steel plate creating an
opposing torque to stop the rotation of the wheel. In this there is a gap of 2mm between the steel
plate and electromagnet so this is frictionless braking system which is major advantage. As the
rotating circular plate does not produce any EMF, so the brakes are applied without any EMF
generation.
So we used 2nd method of operation to apply brakes in order to overcome the difficulties obtained
in the first method.
3.5. Advantages of Electro-Magnetic Braking System

1. We can use these brakes to charge batteries with the help of rectifiers and regulators

2. Problems of drum distortion at widely varying temperatures.

3. Which is common for friction-brake drums to exceed 500 °C
4. surface temperatures when subject to heavy braking

5.demands, and at temperatures of this order, a reduction in the coefficient of friction (“brake fade‟) suddenly
occurs

6. This is reduced significantly in electromagnetic disk brake systems.

7. Potential hazard of tire deterioration and bursts due to friction is eliminated.
8 There is no need to change brake oils regularly.
9. There is no oil leakage

10. The electromagnetic brakes have excellent heat dissipation efficiency owing to the high temperature of the
surface of the disc which is being cooled.

11. Due to its special mounting location and heat dissipation mechanism, electromagnetic brakes have better
thermal dynamic performance than regular friction brakes

12. Burnishing is the wearing or mating of opposing surfaces .This is reduced significantly here.

13. In the future, there may be shortage of crude oil; hence by-products such as brake oils will be in much
demand. EMBs will overcome this problem.

14. Electromagnetic brake systems will reduce maintenance cost.

15. The problem of brake fluid vaporization and freezing iseliminated.
16. Electric actuation, no fluid.
17. Easy individual wheel braking control
3.6.Disadvantages of Electro-Magnetic Braking System

1. Failure to act as a holding device

2. Usage of electric power for braking

3. Less effective under very low velocities..

4. It cannot use grease or oil.

5. Dependence on battery power to energize the brake system drains down the battery much
faster.

6. Due to residual magnetism present in electromagnets, thebrake shoe takes time to come back
to its original position.

7. The installation of an electromagnetic brake is very difficult if there is not enough space
between the gearbox and the rear axle.
3.7. Applications

1. Already in use under some railway system

2. Can be used for any road vehicles

3. Equally applicable to heavy and light vehicles

4. Can be used as additional retarder for aircrafts

5. May also find application in virtually any rotating system which have metallic parts

6. This brake system can be use in two wheeler.

7. Electromagnetic braking system can be used as a modern technology of braking in

automobile

8. Electromagnetic braking system will be used in all types of light motor vehicle like car and
heavy motor vehicle

3.8 Assumption

1.The wheel is considered as solid disc for calculating the moment of inertia of wheel above
central axis

2. Assuming the Torque produced by the brake is equal to Torque given by the motor for
calculation purpose. Since the torque from the brake is difficult to calculate experimentally
CHAPTER-VII
CONCLUSION
 CHAPTER-VII
CONCLUSION AND FUTURE SCOPE

CONCLUSION

Electromagnetic brakes are important supplementary retardation equipment in addition to the regular
friction brakes. They have been used in heavy vehicles such as coaches, buses, trucks under conditions
such as reducing speed in motorways and trunk roads and braking for prolonged periods during down
slope operations. New types of electromagnetic brakes have been under development for lighter
vehicles as well. Regular friction brakes have an outstanding and vital load absorbing capability if kept
cool. Electromagnetic brakes help friction brakes to retain this capability under all conditions by
absorbing energy at a separate location based on a totally different working principle.

This report presents the performance of an electromagnetic braking system which includes various
components with its cost effectiveness and efficient methodologies to utilize the supplied energy. With
the application of the effective and strong electromagnet we can have greater efficient braking system.
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.
CHAPTER-IX
REFERENCES
 CHAPTER-IX
REFERENCES

1. Akshyakumar S.Puttewar1, Nagnath U. Kakde2, Huzaifa A. Fidvi3, Bhyshan Nandeshwar4,

“Enhancement of Braking System in Automobile using Electro-magnetic braking”.

2. Sevvel P1, Nirmal Kanann V2, Mars Mukesh S3, “Innovative Electromagnetic Braking System”.

3. Journal- Eddy Current in Magnetic Brakes- Henry A. Sudano and Jae SungBae .

4. Design of a magnetic braking system, Min Jou, Jaw-Kuen Shiau, ChiChian Sun

5. Analysis of an eddy-current brake considering finite radius and induced magnetic flux- Journal of
Applied Physics, Kapjin Lee, Kyihwan PaMax Baermann, (1970) “Permanent Magnet Eddy Current Brake or
Clutch”, USPO3, 488,535

6. P. Hanyecz, (1982), “Calculation of Braking force in Eddy current brakes”, Department of Theoretical
Electricity. Technical University Budapest Pushkin Kachroo, (1997), “Modelling and control of
Electromagnetic brakes”, Faculty Publications, University of Nevada, LasVegas

7. Tohuru Kuwahara, (1999), “Permanent type eddy current braking system”, USPO5944149

8. Marc T. Thompson, “Permanent Magnet Electrodynamic Brakes Design Principles and Scaling laws”,
Worcester Polytechnic

9. K.D. Hahn, E.M. Johnson, A. Brokken, & S. Baldwin (1998) "Eddy currentdamping of a magnet moving
through a pipe", American Journal ofPhysics 66:1066–66.

10. ELECTRICAL AND ELECTRONIC ENGINEERING BY U V BHAKSHI

11. DESIGN OF MACHINE ELEMENTS BY V.B.BHANDARI