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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

DESIGN AND FABRICATION OF EDDY CURRENT BRAKING


SYSTEM FOR BICYCLE
Sirumalla Gnana Prakash1, Bathula Manoj2, G. Arunkumar3

1,2Final Year Students, Department of Mechanical Engineering,


3Professor, Department of Mechanical Engineering,
1,2,3Sathyabama Institute of Science and Technology, Chennai, Tamilnadu, India – 600119,

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Abstract - In Automotive Industry many traditional Environmental damage might be caused by brake dust.
brakings which are used now a days by the concept of Reference: (Kukutschova et al., 2009) [2]. A number of toxic
mechanical blocking. It results in skidding and wear and tear chemicals in the debris have been shown to induce cancer
on the vehicle. And if the vehicle's speed is very high, the brake via interactions with DNA in live beings (Uexkull et al., 2005)
can't deliver that high braking force and it will cause [3]. When compared to traditional braking systems, eddy
problems. These disadvantages of ordinary brakes can be current braking offers various benefits. It's eco-friendly, and
overcome by a simple and effective braking mechanism called it helps keep brake pads from wearing out prematurely and
'Eddy Current Brake'. It is a method without abrasion for vibrating excessively. According to its proponents, eddy
braking vehicles, including trains. It makes use of the opposite current brakes are good for the planet because they cut
tendency of eddy current. Eddy current is the swirling current down on brake shoe wear, a major source of air pollution.
produced within a conductor, which is subject to a change of This experiment was designed to investigate the workings of
magnetic field. Due to the tendency of eddy currents to be an eddy current braking system using electromagnets and
oppositional, eddy currents lose energy. Eddy current brake aluminium for the brake discs in light of the need for novel
consists of a conductive non-ferromagnetic metal disc (rotor) braking systems that are both environmentally friendly and
attached to the rear axle of the bicycle wheel, with an capable of alleviating the aforementioned typical difficulties.
electromagnet located with its poles on the disk without I was. Eddy currents are a crucial phenomenon in
contact, so the magnetic field by electromagnets passes electromagnetic induction that may be used in a wide variety
through the disk. The electro-magnet makes it possible to vary of fields. When a conductive substance travels through a
the braking force. stationary magnetic field, it generates a drag force called
eddy current braking (Jou et al., 2006, p. Energy is lost and
Key Words: Eddy Current Braking System, Eddy Current, friction is created when flux changes cause eddy currents in
Magnetic Field, Brakes, Frictionless Brake Disc, Wheel. conductors (Jou et al., 2006) [8]. As a result, the
electromagnetic braking system has no contact parts to
lessen lining wear. Worn-out debris is reduced, which is a
Nomenclature:
positive for the environment.
P is the power lost per unit mass (W/kg), 2. WORKING PRINCIPLES OF EDDY CURRENT:
Bp is the peak magnetic field (T), Faraday's law of induction states that a changing magnetic
d is the thickness of the sheet or diameter of the wire (m), field inside a conductor would cause current loops, or "eddy
currents," as seen in Figure 1. When a magnetic field is
f is the frequency (Hz), applied to a conductor, eddy currents will form closed loops
inside the conductor and flow in a direction perpendicular to
k is a constant equal to 1 for a thin sheet and 2 for a thin the field. Changes in the magnetic flux associated with a
wire, metallic conductor result in a closed-loop induced current in
the conductor (Figure 1). Eddy currents are the common
ρ is the resistivity of the material (Ω m), and
name for several types of currents. When a conductor is
D is the density of the material (kg/m3). interrupted by the time-varying magnetic flux, eddy currents
are produced. In a conductor, eddy currents move in a plane
1.INTRODUCTION transverse to the magnetic field, following closed loops.
Lenz's law states that eddy currents react to the source of
Transitioning to a new braking system is necessary for light the magnetic field by producing a magnetic field that is
of the green technology trend, which emphasizes the perpendicular to the change in the magnetic field that caused
significance of protecting the environment. Compared to the it. These eddy currents, which circulate within the
present braking system, which employs brake pads, the new conductor, cause a magnetic field of the opposite polarity to
technology creates far less air pollution when braking. that of the externally applied field. Current in a closed loop is

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 616
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

proportional to the magnetic field intensity, the loop area, the intensity of the magnetic field (and therefore the braking
and the magnetic flux rate of change, and inversely effect) can be adjusted with electromagnets, they are often
proportional to the resistivity of the material. Two magnetic employed in place of permanent magnets for eddy current
fields interacting generates a force that opposes magnetic braking. Eddy current brakes suffer mostly from a lack of
flux changes. When a moving magnetic field induces eddy retaining torque, which is a critical safety feature. Since this
currents in a nearby conductive surface, that surface acts as is the case, they are often utilized in addition to regular
a drag force against the moving magnet. Eddy current mechanical brakes.
braking is a technique that makes advantage of this
phenomenon. By way of illustration, a moving magnetic field The following equation [25] may be used to determine the
induces eddy currents in a nearby conductive surface, which power lost per unit mass for a thin sheet or wire due to eddy
creates drag and therefore resistance to the magnet's currents under particular conditions (uniform material,
forward motion. Eddy current braking makes advantage of uniform magnetic field, no skin effect, etc.).
this phenomenon. When the power is turned off, the motor
of the power tool is immediately stopped by the eddy
current brakes. When electricity flows through a conductor's
resistance, heat is generated.
this equation is valid only under the so-called quasi-static
conditions.

4. BRAKING EFFICIENCY:

The effectiveness of a brake may be measured by its capacity


to slow a vehicle to a halt, to keep it moving at a constant
rate while going downhill, or to keep it moving downhill.
[12]

STEP 1

The only place to get an accurate estimate of your car's


overall braking effort is at a repair shop. To stop your
automobile with the floor brake engaged, the overall braking
force is equivalent to what you would normally exert. Tires
Figure 1 : Eddy Current Braking are tested on a special machine that spins them around and
then stops them cold. It's designed to make you feel like
3. METHODOLOGYOF EDDY CURRENT BRAKING you're driving a real automobile, complete with stops and
BICYCLE: starts. Get your automobile checked out on the tyre machine
so the technician can calculate how much force is needed to
Rather of using friction and kinetic energy to slow down an stop the vehicle.
object's movement, as is the case with traditional mechanical
brakes, eddy current brakes use electromagnetic. By STEP 2
producing an opposing force that spins inside the conductor
as it moves through a magnetic field, eddy currents are Find out how much your car weighs. In the owner's
generated. Lenz's Law states that eddy currents are the handbook, you may find the vehicle's curb weight.
inverse reaction to a magnetic field, since they generate a
magnetic field that is in opposition to the source magnetic STEP 3
field. Clean deceleration is possible because to this
To get the braking efficiency %, multiply this quantity by 100
electromagnetic force response. Eddy current braking is
and then divide the result by the vehicle's weight.
cutting edge technology that has several benefits over
traditional mechanical stopping. Eddy current brakes are 5. SUGGESTED MATERIALS REQUIRED FOR THIS
great for many equipment since they need no moving parts
PROJECT:
and require almost little maintenance. Eddy current braking
is often used by manufacturers because of its physical and 1 Electromagnets12v 5 Square Rod
financial benefits. A non-ferromagnetic, electrically 2 MS disc 6 Bolts and Nuts
conducting disc spins vertically in a toroidal magnetic field 3 Battery12v 7A 7 PressSwitch12v7A
to provide an eddy current brake. Eddy currents are induced 4 Wires 8 Bicycle
in the conductor when the disc spins. A braking torque is
then generated by spreading the force over the disc. Since Table 1 : Materials for Eddy current Braking System

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 617
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

5.1 COMPONENTS OF EDDY CURRENT BRAKING (As a wide variety of devices, including motors, generators,
per Table 1) : relays, speakers, hard drives, MRI machines, scientific
equipment, and magnetic separation devices.
5.1.1 ELECTROMAGNETS: Electromagnets are used for lifting and moving heavy
ferrous materials in the industrial sector, such as scrap metal
and steel.

5.1.2 BATTERY

It is suggested that electromagnets' Eddy Current Braking


may benefit from a lead acid battery. Here, the energy from
the battery will be temporarily converted into a magnetic
field around the disc.

5.1.3 MS DISC: Mild steel plates, which are formed of flat


steel, have many uses in the building, manufacturing, and
industrial industries due to their strength and versatility
(not aesthetically). Standard practice calls for inches to be
used for describing the thickness of mild steel.
Figure 2 : Electromagnets
5.1.4 Ms Rod: Structural steel, often known as a ferrous
Electromagnets are often made by winding a wire into a coil, metal, is composed of iron and carbon. It's an inexpensive
as seen in Figure 2. When the current flows through the wire, material that can be put to use in many common engineering
a magnetic field is produced, with its centre of attraction applications. Mild steel's high magnetic properties belie its
located at the coil's central hole. When the power is cut, the low carbon content. Therefore, it is referred to as a
magnetic field dissipates at the disc. Wire is often wrapped "ferromagnetic" material.
around a core of a ferromagnetic or ferrimagnetic material,
such as iron, to generate a magnetic field. A stronger magnet 6.FEATURES OF EDDY CURRENT BRAKING:
may be produced by concentrating the magnetic flux in a
core. 1. There is no friction, hence there is no wear and tear.
The main benefit of electromagnets over permanent magnets 2. Not a peep, not a stink. Force of the brakes is variable.
is that the intensity of the magnetic field may be quickly
adjusted by varying the current through the windings. 3. Strong stopping power at high velocities.
Electromagnets, in contrast to permanent magnets, do 4. Functions as a service brake as well.
require a source of energy in order to maintain their
magnetic field steady. 5. Magnetic force is replaced by electromagnetic force. Non-
mechanical (no moving components, no friction) (no moving
A battery might power this DC electromagnet. Instead of parts, no friction).
employing permanent magnets, electromagnets are
employed. This is because electrical actuation is not only 6. Allows for electrical signal activation at will
faster than mechanical actuation, but also results in less
energy being wasted. Furthermore, magnetic fields cannot 7. Easily maintained
be stored like permanent magnets, thus they must be 8. Inconspicuous in weight
generated as needed. Increasing the current through the coil
or the number of turns may both increase the magnetic 9. Avoids any grating
field's strength. Permanent magnets, which are necessary for
large magnetic fields, are bulky and difficult to set up. 10. Reduced comfort
Electromagnets are lightweight, portable, and don't interact
11. decreased section wear.
with other metals. An electromagnet is a kind of magnet that
is driven by electricity to generate a magnetic field. Cutting 12. Total electronic control.
off the current to the disc causes the magnetic field there to
disappear. An electromagnet's magnetic field is typically 13. Superb capability to recoup energy lost when braking.
produced by a large number of closely spaced twists of wire.
14. Possible recovery of energy lost while braking.
Wire is often wrapped around a core of a ferromagnetic or
ferrimagnetic material, such as iron, to generate a magnetic 15. No regular brake oil changes are required.
field. A stronger magnet may be produced by concentrating
the magnetic flux in a core. Electromagnets may be found in 16. Avoids oil leakage.

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 618
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

17. Fewer expenses for maintenance. Note: Provide the smallest possible space between the
electromagnets and the Ms disc.
18. Higher durability as compared to standard brakes.
6. Install the battery in the frame of the bike. Attach a button
to the grip of the handlebars.

7. Connect the battery to the electromagnets and the switch.

8. The flux is produced at the discs attached to the wheel


while the bicycle is in motion.

9. If we flip the switch, we get the opposite flux.

The discs and electromagnets generate an eddy current,


which causes the system to decelerate and eventually halt.

Figure 3 : Suggested design at rear wheel.

Figure 4 : Suggested Design of Eddy Current Braking for


Bicycle .

7. FABRICATION OF EDDY CURRENT BRAKING


BICYCLE:
Chart 1 : Materials for Eddy current Braking System
Fabrication Process as shown in Chart 1 as per Fig 3 and
8.RESULTS:
4:
To stop a moving vehicle or to prevent it from moving while
1. Flatten down discs of Ms Steel plate.
stopped, braking is used. Brakes work by generating friction
2. Welding the disc to the shaft of a bicycle requires between a stationary component and a disc or drum that
removing the hub. spins in tandem with the wheels. Friction generates the
stopping force by transforming the kinetic energy of the
3. Use nuts and bolts to secure the wheel hub. moving vehicle into heat, which is then dissipated into the
4. Construct a frame for the electromagnets using the rods at surrounding air. Frictional forces are affected by the kind of
the end and weld it together. contacting surfaces, the forces acting on those surfaces, and
the speed at which the surfaces are moving past one another.
5. Install the electromagnets in the welded frame. The amount of effort required to slow down is directly

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 619
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

related to the frictional force between the lining and the 10.References:
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[10] GigihPriyandoko, M.Z Baharom, (2015), “Eddy current
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braking experiment using brake disc from aluminium series
Taking on a project together is a great way to bring academia
of A16061 and A17075”
and business together, in our opinion. Bicycles equipped
with electromagnetic eddy current braking systems that are [11] G. Priyandoko, M.Z. Baharom, (2011), “Eddy Current
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[13] Gurav Mahadeo, Neeraj Gupta, Shivam Chaturvedi,
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brake”- Manuel I Gonzalez- Departamento de F´ısica,
Universidad de Burgos, 09006 Burgos,Spain

© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 620
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072

[15] “Design of an Innovative Car Braking System using Eddy


Currents”- David Jose Torres Cruz- Bachelor in Aerospace
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[16] Gagarin, G., Kroger, U. And Saunweber, E., „„Eddycurrent


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[22] Design & Fabrication of Eddy Current Braking System


Oscar Rodrigues1, Omkar Taskar1, Shrutika Sawardekar1
Henderson Clemente1, Girish Dalvi2

[23] Eddy Current Braking In Automobiles Sarath G Nath1,


Rohith Babu2, George Varghese Biju3, Ashin S4 ,Dr.Cibu K
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[24] CALCULATION OF BRAKING FORCE IN EDDY CURRENT


BRAKES, Department of Theoretical Electricity. Technical
University Budapest

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