Visveswaraya Technological University, Belagavi

A project synopsis on
DESIGN, ANALYSIS AND FABRICATION OF EDDY CURRENT BRAKING SYSTEM
Submitted in partial fulfillment of the requirements for the award of degree of Bachelor of Engineering in Mechanical Engineering
by

Narasimha Bhargava H R (4VV14ME073) Natesh N (4VV14ME074)

Sharath Narasimha J (4VV14ME099) Praveen C (4VV14ME083)
Under the noble guidance of
Prof. Shivashankar R, M.Tech
Assistant Professor

Department of Mechanical Engineering

Vidya Vardhaka College of Engineering
Gokulam 3rd stage, Mysuru-570002
Karnataka, India
Academic Year - 2017-2018
 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

Introduction
 Conventional braking system: Conversion of kinetic energy to heat energy by friction
 Has its drawbacks and needs replacement
 Proposed setup must be heat resistant and requires low maintenance

Principle of Operation
 Eddy current: Current induced in a rotor when exposed to changing magnetic field.
 Induced current in the conductor opposes the motion of the rotor by Lenz law.

Classification of ECB based on type of magnet used

There are 2 ways by which we can induce eddy current in the rotor.
i) Strong permanent magnet
ii) Electromagnet.
Department of Mechanical Engineering, VVCE, Mysuru. 2
 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

PROJECT CONSIDERATION

 Electromagnets are DC type that can be powered by battery and they have faster electrical
actuation with lower losses.
 But we are using a strong permanent magnet to reduce the overall cost of the project and to
overcome the dis-advantage of an electromagnet.
 In order to simulate a rotating wheel which rotates by the help of an IC engine with variable
loading condition, we are using a DC motor with variable rpm regulator. To simulate real life
conditions we are using a foot brake pedal that contains lever mechanism with a permanent
magnet attached at its end.

Department of Mechanical Engineering, VVCE, Mysuru. 3

 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

STATEMENT OF THE PROBLEM

 In the present scenario, most of the braking systems involve the conversion of kinetic energy to

heat energy by friction. This is accomplished by friction between two rubbing surfaces

 These brakes pose several problems i.e. significant wear, fading, complex and slow actuation, lack

of fail-safe features, increased fuel consumption due to power assistance, and requirement for

anti-lock controls
 So the problem statement will be to find a solution in order to overcome these problems

Department of Mechanical Engineering, VVCE, Mysuru. 4

 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

OBJECTIVE OF THE PROJECT

 To design, fabricate and analyze a contactless braking system which works on the application of
eddy currents that are induced in the rotor due to the influence of varying magnetic field

SCOPE OF THE PROJECT

 The drawbacks of the conventional braking system can be overcome by eddy current braking
system.
 Contactless brakes can be applied to machineries including electric vehicles, passenger trains,
bullet trains, roller coasters, hydraulic and turbo machinery, machine tools, elevators, etc.
 The wide range applicability of these brakes strongly imply the effectiveness and ease of operation.
 With increasing R&D on ECBs in International level, the ECB may evolve as a major alternative to
conventional friction braking system
Department of Mechanical Engineering, VVCE, Mysuru. 5
 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

ADVANTAGES OF EDDY CURRENT BRAKING SYSTEM

 There is no need to change brake oils regularly.

 Due to its special mounting location and heat dissipation mechanism, eddy current brakes have
better thermal dynamic performance than regular friction brakes.
 In the future, there may be shortage of crude oil; hence by-products such as brake oils will be in
much demand. ECBs will overcome this problem.
 Eddy current brake systems will reduce maintenance cost.
 The problem of brake fluid vaporization and freezing is eliminated.
 Easier integration with anti-lock, traction, and dynamic stability controls.
 No need of any power source as in electromagnets.
 Light weight compared to other type of braking systems.

LIMITATIONS OF EDDY CURRENT BRAKING SYSTEM

 
 Failure to act as a holding device.
 Less effective under very low velocities.
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  DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

APPLICATIONS OF EDDY CURRENT BRAKING SYSTEM

 For additional safety on long decants in mountain area.
 For high speed passenger and goods vehicle.
 In mountain areas where continuous braking force is needed, for a long time, the eddy current
braking is very much useful for working without overheating.
 It can also be used to slow down the trolleys of faster roller coasters.
 There are a number of major commercial applications of eddy current brake technology in the
mining, railroad, and elevator industries.
 We will also find eddy current brakes in all kinds of machines, such as circular saws and other
power equipment. And they are rowing machines and gym machines.

Department of Mechanical Engineering, VVCE, Mysuru. 7

 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM
PROPOSED SKETCH

COMPONENTS

1 – DC MOTOR
2 – ALUMINIUM DISC
3 – SHAFT SUPPORT STAND
4 – SHAFT
5 – PERMANENT MAGNET
6 – BRAKE PEDAL
7 – RPM REGULATOR
8 – RIGID BASE

Department of Mechanical Engineering, VVCE, Mysuru. 8

 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM

CONSTRUCTION AND WORKING

 Initially, the aluminum disk is coupled with shaft which contains a DC motor. The speed of
the disk can be varied with the help of rpm regulator. By the application of brake pedal the
permanent magnet is brought near the rotating disk with very small air gap. Then eddy
currents are induced in the rotor due to varying magnetic flux and these eddy currents
oppose the rotation of the rotor and hence within a few seconds the rotor comes to rest.
 The air gap can be adjusted by using suitable clamping mechanism and since we are using a
rpm regulator, we will be able to vary different parameters of the ECB and come to suitable
results based on the analysis.

SOURCE OF THE IDENTIFIED PROBLEM

 International Research Journal of Engineering and Technology (IRJET)
Volume: 03 Issue: 04 | Apr-2016
Title : Eddy Current Braking System

Department of Mechanical Engineering, VVCE, Mysuru. 9

 DESIGN, FABRICATION AND ANALYSIS OF EDDY CURRENT BRAKING SYSTEM
COST CONSIDERATION

At present, the price of friction brakes for each wheel costs from Rs.8000 to Rs.12000. But the proposed model costs around
Rs.10000. We are using a permanent magnet to reduce the overall cost of the project. Electromagnet can also be used if the
budget is higher. Even though the initial investment is high, it will become economical in the long run due to very low
maintenance.

COST ESTIMATION

PARTICULARS DESCRIPTION ESTIMATED COST

DC MOTOR 24V-36V, 3500RPM 2750
ALUMINIUM DISC MATERIAL- AL6061 1500
SHAFT SUPPORT STAND CAST IRON 900
SHAFT STAINLESS STEEL 650
PERMANENT MAGNET NEODYMIUM 1500 ( 1 PIECE)
 
BRAKE PAD STAINLESS STEEL/ RUBBER 600
RPM REGULATOR INSTRUMENT 1500
RIGID BASE CAST IRON 600
TOTAL COST 10000
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• THANK YOU…