ELECTROMAGNETIC BRAKING SYSTEM

SYNOPSIS
INTRODUCTION

Electromagnetic brakes have been used as supplementary retardation

equipment in addition to the regular friction brakes on heavy vehicles.

Electromagnetic brakes operate electrically, but ransmit torque mechanically.

This is why they used to be referred to as electro-mechanical brakes. Over the

years, EM brakes became known as electromagnetic, referring to their Actuation

method. Since the brakes started becoming popular over sixty years ago, the

variety of applications and brake designs has increased dramatically, but the

basic operation remains the same.

A non-contact brake design actuated when an electric current charges a coil

that acts as an electromagnet. Electromagnetic brakes are widely used in

automated machinery and provide a high cycling rate. On trams and trains,

an electromagnetic brake is a track brake where the braking element is

pressed by magnetic force to the rail, i.e. the braking is by friction, not the

magnetic effect directly. This is different from an Eddy current brake where

there is no mechanical contact between the braking element on the moving

 vehicle and the rail.

An eddy current brake, like a conventional friction brake, is responsible

for slowing an object, such as a train or a roller coaster. Unlike friction brakes,

which apply pressure on two separate objects, eddy current brakes slow an

object by creating eddy currents through electromagnetic induction which

create resistance, and in turn either heat or electricity.

Electromagnetic brakes are similar to electrical motors; non-

ferromagnetic metal discs (rotors) are connected to a rotating coil, and

a magnetic field between the rotor and the coil creates a resistance used

to generate electricity or heat. When electromagnets are used, control of the

braking action is made possible by varying the strength of the magnetic field. A

braking force is possible when electric current is passed through the

electromagnets. The movement of the metal through the magnetic field of the

electromagnets creates eddy currents in the discs. These eddy currents

generate an opposing magnetic field, which then resists the rotation of the

discs, providing braking force. The net result is to convert the motion of the

rotors into heat in the rotors.

PRINCIPLE OF OPERATION

There are three parts to an electromagnetic brake: field, armature,

and hub (which is the input on a brake). Usually the magnetic field is bolted to

the machine frame (or uses a torque arm that can handle the torque of the

brake). So when the armature is attracted to the field the stopping torque is
transferred into the field housing and into the machine frame decelerating the

load. This can happen very fast (.1-3sec).

When the magnet is moved along the rail, it generates in non-

stationary magnetic field in the head of the rail, which then generates electrical

tension (Faraday's induction law), and that causes eddy currents. These disturb

the magnetic field in such a way that the magnetic force F, mentioned above, is

diverted to the opposite of the direction of the movement, thus creating a

parallelogram of forces consisting of the remaining vertical force FV and the

horizontal force FH, which works against the movement of the magnet.

The braking energy of the vehicle is converted in eddy current losses which lead

to a warming of the rail.The regular magnetic brake which is in wide use in

railways, exerts its braking force by friction with the rail, which also creates heat.

The eddy current brake does not have any mechanical contact with the rail, and

thus no wear and tear of it, and creates no noise or odor. The eddy

current brake is, as should be clear from the above explanation, unusable at low

speeds, but can be used at high speeds both for emergency braking as well as

regular and regulated braking.

Disengagement is very simple. Once the field starts to degrade flux falls rapidly

and the armature separates. A spring(s) hold the armature away from its

corresponding contact surface at a predetermined air gap.

 ADVANTAGES AND DISADVANTAGES

Electromagnetic brakes rely purely on magnetic action working through an air

gap to develop torque. They have an extremely wide torque range. Since

torque is produced without physical contact of parts Electromagnetic devices are

not subject to wear. This feature makes them distinctly superior to mechanical-

friction brakes in life expectancy, servicing requirements and consistency of

performance. Since their working members have no physical contact they do not

depend on mechanical friction. Therefore, hysteresis units are absolutely and

constantly smooth at any slip ratio. Torque is reasonably independent of slip

speed and is also directly proportional to coil current, making response time

extremely quick. Electromagnetic brakes are also the most repeatable braking

devices known. They will repeat their performance precisely, an indefinite

number of times, whenever operating factors are repeated. This makes it ideal

for many precision tension control and testing applications. These devices have

a number of advantages over magnetic particle brakes, in particular eliminating

the problem of confining the magnetic particles inside the gap. These

advantages include long life, environmental stability, precise repeatability and

consistency of performance and extremely low power consumption. They can

tolerate extreme temperatures and have high heat-dissipation capability. They

also have the widest speed range of all electronically torque-control devices.

Hysteresis units will outlast any other type of electromechanical unit. The

transmitted torque remains constant and smooth as the hysteresis element is

forced to rotate within the air gap and will respond to increases and decreases in

coil current with corresponding increases and decreases in torque.

Environment / Contamination

As brakes wear they create wear particles. In some applications such as clean

rooms or food handling this dust could be a contamination problem so in these

applications the brake should be enclosed to prevent the particles from

contaminating other surfaces around it. But a more likely scenario is that the

brake has a better chance of getting contaminated from its environment.

Obviously oil or grease should be kept away from the contact surface because

they would significantly reduce the coefficient of friction which could drastically

decrease the torque potentially causing failure. Oil midst or lubricated particles

can also cause surface contamination. Sometimes paper dust or other

contamination can fall in between the contact surfaces. This can also result in a

lost of torque. If a known source of contamination is going to be present many

clutch manufactures offer contamination shields that prevent material from falling

in between the contact surfaces.

In brakes that have not been used in a while rust can develop on the surfaces.

But in general this is normally not a major concern since the rust is worn off within

a few cycles and there is no lasting impact on the torque.

 REFERENCE

1. http://en.wikipedia.org/wiki/Electromagnetic_brake

2. Automotive chassis: brakes, suspension, and steering By Tim GilleS

3. http://www.magtorx.com/faq.htm#6._Why_we_using_Current_Regulated_

Power_Supply_for_electromagnetic_brakes_and_clutches_

4. http://scholar.lib.vt.edu/theses/available/etd-

5440202339731121/unrestricted/CHAP2_DOC.pdf

5. http://industrial.panasonic.com/ww/i_e/25000/fa_pro_sgeard_shing1_e/fa_

pro_sgeard_shing1_e/ctlg_geared_e_14.pdf