A SEMINAr report on

Electromagnetic Braking System

Submitted by
Rajkrushna dhal
Regd. No.2101201199
Roll no. 2521M23

Under the Guidance of

Asst. prof. Kunja bihari Katiar

Department of Mechanical Engineering

Seemanta Engineering College, Mayurbhanj
[A constituent college of BPUT, Rourkela, Odisha]

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 CERTIFICATE

This is to certify that the seminar report , entitled “Electromagnetic Braking System”
submitted by Rajkrushna Dhal (Regd. No. 2101201199) is an authentic report that has
been carried out by them under my supervision and guidance for the requirement for
completing 7th semester in Mechanical Engineering at Biju Pattnayak University of
Technology, Rourkela.

Signature of the Signature of the

H.O.D., Mechanical Engineering seminar in charge
. Mr. Kunja bihari Katiar Mr. Kunja bihari Katiar

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 Acknowledgement
I would like to express my deep and sincere gratitude to my guide, Mr.Kunja bihari Katiar,
Assoc. Professor Mechanical Engineering department for his unflagging support and
continuous encouragement throughout the seminar work. Without his guidance and
persistent help this report would not have been possible. I must acknowledge all the faculty
and staff members of Mechanical Engineering department for their continuous support and
help.

Rajkrushna Dhal
Semester- 7th
Regd. No.- 2101201199
Mechanical Engineering

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 Abstract

This project aims to develop an electromagnetic braking system model capable of applying
brakes without any friction loss and without losing the energy supplied. It uses a two
electromagnets which runs by the supply of power from the circuit. Also, there is a wheel
which is attached to the motor so when the power the supplied, by the help of motor the
wheel rotates. Then a fan is attached near electromagnets to cool the electromagnets from
excessive heating. A metal bar is in the vicinity of the electromagnets and wheel so when
the electromagnets produces eddy currents which stops the rotating wheel or rotor. This
model helps in a way to be used as retardation equipment in vehicle.

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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 eddy-current 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 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 proto type 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.
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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,
in2018,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

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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 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.

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 Construction
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 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.

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.

The brake lines are attached with electromagnet and iron plate individually and both plates
insert the disc plate and this plate is rigidly attached with wheels. A battery of a minimum
of 12 volts is used for the external power supply. The electromagnet consists of a wire wound
over a soft iron core.

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 Working
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 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.

(Fabricated model of electromagnetic braking system)

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 every 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 analysis 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
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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.

● Brake Rotor Material:

Cast Iron IS 2062,
Torque applied 30Nm
Maximum Tensile Strength: 410 MPa
● Shaft: Material:
Mild Steel
Maximum Tensile Strength: 440 MPa
● Frame and mountings: Material:
Mild Steel
Maximum Tensile Strength: 440 MPa

(Stress Distribution on CAD Model)

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 (Stress distribution on Disc)

This lesson covers the concept of stress distribution in a rotating disc. It explains how each
material element in the disc is subjected to body forces when rotating, and how these forces
act in the radial direction. The lesson further discusses the radial displacement of a point in
the disc, the expressions for strains, and the conditions for plane stress in the disc. It also
elaborates on the equilibrium equations and how they are satisfied in the disc. The lesson
concludes with an explanation of how to calculate the torque capacity of a shaft and hub
assembly in a rotating disc.

Rotating discs:
When a disc rotates, each material element experiences body forces that act radially. A solid
disc with an inner hole can have high stress around the hole, which can lead to cracks if the
disc's angular speed increases.

Intervertebral discs:
The distribution of compressive stress in intervertebral discs can be affected by age and
degeneration. One study found that the stage of degeneration had a greater effect on stress
distribution than age. Another study found that the stress of the disc adjacent to interbody
fusion increases more at lower fusion sites or more fusion levels.

Orthotropic discs:
The stress distribution in rotating discs made of orthotropic material can be calculated using
algebraic and trigonometric series to define the displacement field.

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 Calculations

Nomenclature:-
T = Torque on disc.
r= Radius of rotor disc.
w= Angular velocity of disc

Fc = Centrifugal force.
N1= Input pulley speed= speed at driving pulley in RPM.
N2= Output pulley speed= speed at driven pulley in RPM.
D1= Input pulley diameter in cm.
D2= Output pulley diameter in cm
Calculation:-
1.Force at wheel lock or maximum braking force can be calculated by following:
FL = Mdal × g × ur
FL = possible braking force on axle
Mdal = dynamic axle load
g = acceleration due to gravity
ur = coefficient of friction between road and tire.

2. Braking torque require to stop wheel

T = BF × R/r
BF = Braking force
T = brake torque
R = radius of tire
r = speed ratio between the wheel and brake.

3. Braking force obtained by eddy current

Fe = pie × D2 × d × B0 2 × c × v/4ρ
c = ½ [1 – (1/4) * 1/(1 + r/A)2 (A – r/D)2]
Fe = braking force (N)
D = diameter of soft iron pole (m)
d = disk thickness
B0 = air gap induction at 0 speed (T)
A = disk radius (m)
c = proportionality factor, ratio of total disk Contour (outward curve) resistance to
resistance of Disk contour (outward curve) part under pole.
ν = tangential speed of the rotating disk
ρ = specific resistance of disc material.

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 Application and Future Scope
A revolutionary invention is made in the field of brakes. The Electromagnetic brakes are
excellent replacement for conventional automobile brakes. The use of Electromagnetic
brakes can be done for lighter vehicles also. With some modification, a regenerative braking
system can be equipped with the Electromagnetic brakes. The Electromagnetic brakes are
the future of automobile brakes.

• Electromagnetic brakes were before used in the application of locomotives where the set
up was a drum brake which is totally different from the present designs and works on the
same principle and it is well used in the present high speed electric trains.

• The electromagnetic braking system is not only used in automobiles it is even used in the
industrial fields where to retard or slow down the moving parts which is not efficiently
performed by the other conventional methods.

• Now a days these types of braking systems are used in the field of motorsports where it is
more responsive and effective and it is been used in cars like McLaren P1, La Ferrari

• Where the electromagnetic brakes are even used as clutches in other fields where they have
a high holding power to the other components which will be easier to transfer the work.

• The electromagnetic braking system is even used in the industrial robotic applications
where the requirement of pausing the actions.

• This type of braking system is even used in the recreational purposes where an example of
the climbing devices where the rope gets locked at a particular height with the help of the
electromagnetic braking inside.

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