International Journal of Scientific Research in Engineering (IJSRE) Vol.

1 (3), March, 2017

ELECTROMAGNETIC BRAKING SYSTEM

1
Krunal Prajapati, 2Rahul Vibhandik, 3Devendrasinh Baria, 4Yash Patel
Student, Automobile department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat

Corresponding Author Detail: Internal Guide Detail:

Krunal Prajapati Mr. Kevalkumar Ishwarbhai Patel
Student, Automobile department, Assistant Professor, Automobile department,
Laxmi institute of Technology, Laxmi institute of Technology,
Sarigam-Valsad, Gujarat. Sarigam-Valsad. Gujarat.

ABSTRACT
An electromagnetic braking system is a new concept. This project is a new technology of
braking system. Electromagnetic braking system is new braking system it is used in LMV
and HMV like jeep, buses, car, truck, train and motor bikes. The electromagnetic braking
system are also called electro-mechanically brake. Future to highly produced accident to use
this braking system to avoid the accidents. These braking systems are described in working of
prototype model. An electromagnetic braking system used magnetic force while applied the
force on brake, but the power is transmitted on manually operate the brake. The rake disc is
connected to the shaft and electromagnetic kit are attach in a frame. The power source is used
in electricity. The electric power applied to the magnetic coil to the developed the magnetic
field in armature coil and attracts the electromagnet aluminum disc. To applied the brake and
stopped the road wheel and vehicle.
KEYWORDS: Peak Force, Fade, Drag, Flux, Electro Magnet.

INTRODUCTION
A brake is a device which inhibits motion. Its opposite component is a clutch. Most
commonly brakes use friction to convert kinetic energy 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.
The brakes are different to use in stopped the reciprocating parts and motion automobile
vehicles. The new technology is produced in automobile engineering. An automobile industry
is developing new technology of braking system. These worlds are new possibility and new
thinking of braking system. The automobile industry are also developed new braking system
like to drum brake, disc brake, hydraulic brake, pneumatic brake, air brake and
electromagnetic brake. The different brakes are working on different principle operation.
Future is used in time of hydraulic and disc or drum brake. The different types of friction
brake and electromagnetic brake use. The main principle of electromagnetic brake to induced
kinetic energy into heat energy.
Braking system is used to automobile vehicle speed reduced in slowly. The brake are applied
the manually force on a brake pedal to the mechanical linkage operate and applied the brake
drum wheel and motion is slowly reduced and applied the brake. Brake applied to the vehicle

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International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

speed reduced in several time and vehicle to rest. The electromagnetic brakes are new
technology of automobile industry for future concept to use for automobile vehicle and other
industry level. Brakes are new technology to use for vehicle required specification.
Automobile vehicle to use for required use in purpose for like sports car, light motor vehicle,
heavy motor vehicle, bikes, sports bikes and off road vehicles. Heavy motor vehicle is use
brakes this time of air brakes. The electromagnetic brakes are new developed in braking
system in automobile engineering. This type brake mainly working principle is one rotating
metal disc in between the two magnets to apply the brake to induced electric current in circuit
to induced magnetic field in armature to attract the magnet to the rotating metal disc and
stopped the rotation in several time while applied brake.

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.

ELECTROMAGNETIC BRAKES
Electromagnetic brakes operate electrically, but transmit 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. The variety of applications
and brake designs has increased dramatically, but the basic operation remains the same.
Single face electromagnetic brakes make up approximately 80% of all of the power applied
brake applications.

NOMENCLATURE
V=Initial velocity
U=Final velocity
A=Deceleration of rotating mass
F=Braking force
T=Braking torque
H=magnetic field length
N= No. of turns/ length of solenoid
C=clamping force
P=average power
K.E=kinetic energy

CONSTRUCTION AND DESIGN

INSTALLATION LOCATION

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International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

Electromagnetic brakes work in a relatively cool condition and satisfy all the energy
requirements of braking at high speeds, completely without the use of friction. Due to its
specific installation location, electromagnetic brakes have better heat dissipation capability to
avoid problems that friction brakes face as mentioned before. Typically, electromagnetic
brakes have been mounted in the transmission line of vehicles. The propeller shaft is divided
and fitted with a sliding universal joint and is connected to the coupling flange on the brake.
The brake is fitted into the chassis of the vehicle by means of anti-vibration mounting.

DESIGN OF ELECTROMAGNETIC BRAKE SYSTEM

Figure-1 Model of Electromagnetic Brake System

1. FRAME – MS BAR RIGHT ANGEL= 35-5 mm

HEIGHT (H) = 16inch
LENGTH (L) = 12inch
2. BRIGHT METAL SHAFT (Drive shaft) – OUTER DIAMETER = 20 mm
LENGTH (L) = 17 inch
3. DISK- ALUMINUM CAST:
BUSH MS MATERIAL
INNER DIAMETER = 20 mm
TAPPING = 3.8 B – SECTION
4. ELECTROMAGNET = 230 W, 5 HENRY
5. SINGLE PHASE A.C MOTOR = 1200 rpm
6. PULLY = 1.5 inch B-SECTION
7. V-BELT = 14 (RUBBER)
8. BALL BEARING –TATA :
INNER DIAMETER = 20 mm

MODEL CONSTRUCTION PROCESS

1. MACHINING PROCESS
2. CUTTING PROCESS
USE HAND HACK SHOW
3. WELDING PROCESS

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ARC WELDING
4. DRILLING PROCESS
RADIAL DRILL
5. MACHINING SHAFT
It work by lathe machine, cutting process, parting tools and turning process is completely on
dimension.
ID –BORING PROCESS
OD-TURNING PROCESS

WORKING OF ELECTROMAGNETIC DISC BRAKE

The electromagnet is energized by the AC supply where the magnetic field produced is used
to provide the braking mechanism. When the electromagnet is not 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 field is produced thereby applying
brake by retarding the rotation of the disc and the energy absorbed is appeared as heating of
the disc. 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. The AC motor makes the
disc to rotate through the shaft by means of pulleys connected to the shaft.

Figure-2 Working of Electro Magnetic Disc Brake

A. ENGAGEMENT TIME
There are actually two engagement times to consider in an electromagnetic brake. The first
one is the time it takes for a coil to develop a magnetic field, strong enough to pull in an
armature. The second one is air gap, which is the space between the armature and the coil
shell. CAD systems can automatically calculate component inertia, but the key to sizing a
brake is calculating how much inertia is reflected back to the brake. To do this, engineers use
the formula: T = (WK2 × ΔN) / (308 × t) Where T = required torque in lb-ft, WK2 = total

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inertia in lb-ft2, ΔN = change in the rotational speed in rpm, and t = time during which the
acceleration or deceleration must take place.

RESULT
By using the electromagnetic brake as 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 percent of the duty
which would otherwise have been demanded of the regular service brake.
Furthermore, the electromagnetic brake prevents the dangers that can arise from the
prolonged use of brakes beyond their capability to dissipate heat. This is most likely to occur
while a vehicle descending a long gradient at high speed. The installation of an
electromagnetic brake is not very difficult. It does not need a subsidiary cooling system. It
does not effect on the efficiency of engine. Electromagnetic brake also has better
controllability. Thermal stability of the electromagnetic brakes is achieved by means of the
convection and radiation of the heat energy at high temperature. The electromagnetic brakes
have excellent heat dissipation efficiency. Electromagnetic brakes have better thermal
dynamic performance than regular friction brakes.

ADVANTAGES
1) Problems of drum distortion at widely varying temperatures. Which is common for
friction-brake drums to exceed 500 °C surface temperatures when subject to heavy
braking demands, and at temperatures of this order, a reduction in the coefficient of
friction („brake fade‟) suddenly occurs.
2) This is reduced significantly in electromagnetic disk brake systems.
3) Potential hazard of tire deterioration and bursts due to friction is eliminated.
4) There is no need to change brake oils regularly.
5) There is no oil leakage.
6) The practical location of the retarder within the vehicle prevents the direct impingement
of air on the retarder caused by the motion of the vehicle.

DISADVANTAGES
1) Dependence on battery power to energize the brake system drains down the battery much
faster.
2) Due to residual magnetism present in electromagnets, the brake shoe takes time to come
back to its original position.
3) A special spring mechanism needs to be provided for the quick return of the brake shoe.

CONCLUSION
With all the advantages of electromagnetic brakes over friction brakes, they have been widely
used on heavy vehicles where the „brake fading‟ problem exists. The same concept is being

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developed for application on lighter vehicles. 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 loaded
brakes. These electromagnetic brakes can be used in wet conditions which eliminate the anti-
skidding equipment, and cost of these brake are cheaper than the other types. 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.

REFERENCES

1. Dr. Kirpal Singh. Automobile Engineering and Technology, Vole 1

2. Khurmi & Gupta “Machine Design” S Chand Publication.
3. V.B. Bhandari "Design of Machine Elements" Tata McGraw hill.
4. http://www.thefullwiki.org/Electromagnetic_brake
5. http://electric-brake.com/Heald, M.A., „„Magnetic braking: improved theory,‟‟ American
Journal of Physics, Vol. 56,No. 6, pp. 521–522, 198.
6. “ADJUSTABLE MAGNETIC BRAKE” by Hung-Chi Wu, 958-2, Ghung Shan Rd., Tao-
Yuan, Taiwan United States Patent Number: 5,096,024.
7. “MAGNETIC BRAKE SYSTEM FOR A VEHICLE” by Jae-Woong Lee. Seoul, Rep. of
Korea United States Patent Number: 5,746,294.

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