DESIGN AND FABRICATION OF INTELLIGENT

ELECTROMAGNETIC BRAKING SYSTEM

ABSTRACT

A brake is device that uses friction, which is applied to the rotating axles or wheels
to slow or stop a moving object. Friction brakes on vehicles store braking heat in
the drum while braking then conduct it to the air gradually. When traveling
downhill some vehicles can use their engines to brake. When the brake pedal is
pushed the caliper containing piston pushes the pad towards the brake disc which
slows the wheel down. On the drum brake it is also similar as the cylinder pushes
the brake shoes towards the drum which also slows the wheel down.

In this system we use a concept of electromagnetic system to engage the brake.

Trams and trains use electromagnetic track brakes where the braking element is
pressed by magnetic force to the rail. They are distinguished from mechanical track
brakes, where the braking element is mechanically pressed on the rail.

These electromagnetic are basically frictionless, because they do not require any
contact between the disc and the braking element. 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 because of the current
flowing across the coil and causes armature to get attracted towards the coil. As a
result, it develops a torque and eventually the vehicle comes to rest.
This project studies the core of electromagnet and how it can be incorporated to
commercial vehicles by controlling the current supplied to produce the required
magnetic flux to stop or slow the vehicle.

Fig: Single pivot side-pull caliper brake Fig: Rendering of a drum brake
 LITERATURE REVIEW

#1
Investigation on Eddy Current Braking Systems
Journal: Applied Mechanics and Materials (Volumes 592-594)
Authors: G.L. Anantha Krishna and K.M. Sathish Kumar
Review:
The changing magnetic field will induce eddy currents in the
conductor. These currents will dissipate energy in the conductor
and generate drag force. It is found that Aluminum is the best
material as conductor compared to Copper and Zinc. It is also
found that the larger thickness of disc, more number of turns of
electromagnet and higher electrical conductivity of conductor
influences the generation of greater braking torque.
Conventional braking system relies on adhesion force between
rail and wheel. It is found that a brake built up from permanent
magnet pieces that combine both magnetic rail brake and eddy
current brake permits the most profitable braking action
through the whole range of acceptable speeds. Permanent
magnet eddy current brake uses Neodymium magnets. The
analysis of permanent magnet eddy current shows that the
parallel magnetized eddy current has the superior braking
torque capability. In electrically controlled eddy current braking
system resulted in highest braking torque.
#2
An Anti-Lock Braking Control System for a Hybrid
Electromagnetic Brake-By-W ire System

Journal: Proceedings of the 2004 American Control

Conference
Authors: S. Anwar
Review:
Anti-lock braking system (ABS) is a safety feature in automobile
system which gives better control to the vehicle. It utilizes the
wheel slip to control the wheel pressure using a set of valves and
a pump in order to control the wheel braking system. Brake by
wire is a hybrid vehicle which has hybrid actuators mounted on
the front wheels. The data are taken such as vehicle mass, wheel
inertia, etc., if the ABS command detects maximum available
torque command from ABS controller, it estimates the maximum
available torque for the eddy current brakes at a given wheel
speed. If the ABS torque command is larger than the eddy current
brake available torque, then the eddy current brake is commanded
full excitation and if we use this system in under critical weather
it gives better control to the wheels using this system.
#3
Fabrication of Electromagnetic Clutches and Braking
System

Journal: ELK Asia pacific journals

Authors: K.Saurabh, I.Ali
Review:
Electromagnetic braking system basically uses application of
magnetic flux to stop the vehicle. And in this clutch, are used to
make and break the contact electromagnetically with the help of
electromagnet which can be stopped and apply brakes at different
clutches. A flywheel is used in this due to the rotation of the
flywheel magnetic field is created thus is used to apply the brake.
As magnetic flux increases, efficiency also increases which
causes to brake properly and cope with the speed of the vehicle
and if the speed decreases the magnetic field also decreases. We
can use rectified power supply instead of constant power supply.
#4

Obstacle Avoidance With Ultrasonic Sensors

Journals: IEEE JOURNAL OF ROBOTICS AND

AUTOMATION
Authors: JOHANN BORENSTEIN AND YORAM KOREN
Review:

The ultrasonic sensors are basically used to avoid the obstacles

and to avoid collisions and physical damage. Ultrasonic sensors
are used to detect the distance which is front of it by sending
waves to it and that waves are reflected back to the sensor by this
we can measure the distance. If this sensor is attached to the
braking system we can avoid the collisions by detecting the
distance and apply the brakes. We can make the braking system
more responsive when the distance is less and the collisions
occurrence is more during this time more force is applied to brake
the vehicle and if the distance is far it is vice versa.
#5
Electromagnetic Braking System Using Eddy Current for Brake
Disc of AL6061 AND AL7075
Journal: International Review of Mechanical Engineering
Authors: M.Z.Baharom, M.Z.Nuawi, G.Priyandoko, S.M.Haris
Review:
The behavior of electromagnetic braking using eddy current was
studied. Started with preliminary study investigating 3 different
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. Aluminum performs better
copper and zinc, and then the study continues using two different
series of aluminum which are Al6061 and Al7075. A few
parameters have been varied such as air-gap, brake disc thickness,
number of electromagnet turns and voltage supplied to DC motor.
For the purpose of recording speed (rpm) and time (s), an optical
tachometer connected to PULSE analyzer has been used. Graphs
presented to show the behavior and reaction of parameters
involved, including the calculation of braking torque. From this
study, it can be concluded that Al6061 has greater performance
than Al7075 as the brake disc material. It also founded that the
thicker the disc, small air-gap, large number of electromagnet
turns and increasing the current induced will increase the
performance of this electromagnetic braking. All parameters that
have been studied show significant effects to be considered in
developing electromagnetic braking to replace the conventional
braking system.
#6
THE DESIGN OF EDDY-CURRENT MAGNET BRAKES
Journal: Transactions of the Canadian Society for Mechanical
Engineering
Authors: Der-Ming Ma, Jaw-Kuen Shiau
Review:
The eddy-current is created by the relative motion between a
magnet and a metal 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 an elevator or any guided rail transportation system.
To provide scientific investigation for industrial application of
magnetic braking, this study presents four systematic
engineering design scenarios to design a braking system. The
constant magnetic field is the simplest and easiest design to
implement. The optimal magnetic field distribution is obtained
by minimizing the deceleration effort. The piecewise-constant
magnetic field distribution offers a compromise between
performance and magnetic field requirements. In the study, an
experimental braking system using constant magnetic field is
built to demonstrate the design procedure.