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PROJECT REPORT ON
ELECTROMAGNETIC BRAKE
Submitted in partial fulfillment of the award
BACHELOR OF TECHNOLOGY
In
(Mechanical Engineering)
Session 2012-13
Submitted By:
Affilated To
CERTIFICATE
(DEAN)
(ME Department)
Date :
Place:
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ACKNOWLEDGEMENT
One of the parts of preparing this project is to thanks those who have helped me through their valuable
participation , comments and suggestion . We wish to thanks , ARYAVART INSTITUTE OF
TECHNOLOGY & MANAGEMENT , LUCKNOW whose co-operation and attitude toward
encouraging a student is appreciable . We sincerely express our gratitude to the project guide Mr. Sandeep
Singh (Lecturer, ME Department) for his guidance in completing the project titled electromagnetic
brake . Without his guidance this project would not have been completed , her kindness and help have
been the source of encouragement for us thoughout the project.
We would like to thanks our project coordinator Mr. prince srivastava for all his
support and help in collecting information about ELECTROMAGNETIC BRAKE , implementing the
same in the project and using it successfully. Last but not the least , we express our deep gratitude to our
academic dean Mr. Simant Srivastava for contribution of his ideas for our project . We would also like to
pay our regard to the whole M.E department for their support and guidance .
Finally a lot of thanks to our friends and family member , who helped and
motivation us to develop such a wonderful solution.
(AJAY YADAV)
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TABLE OF CONTENTS
INTRODUCTION
GENERAL PRINCIPLE OF BRAKE SYSTEM
Conventional Friction Brake
How ordinary (friction) brakes work
Brake Fading Effect
Retarders
Construction
General Principle and Advantage of Electromagnetic Brakes (retarders)
Working Principle
Electric Control System
TYPES OF ELECTROMAGNETIC BRAKE
Characteristic of Electromagnetic Brakes
Thermal Dynamics
MERITS
DERMIRTS
APPLICATION
Summary
1. Introduction
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Materials
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Description:
The disc brake or disk brake is a device for slowing or stopping the rotation of a
wheel. A brake disc usually made of cast iron or ceramic composites is connected
to the wheel and the axle. To stop the wheel, friction material in the form of brake
pads is forced mechanically, hydraulically, pneumatically or electromagnetically
against both sides of the disc. Friction causes the disc and attached wheel to slow
or stop. But in our project hydraulic energy is used as the source of power, due to
high applied force and torque
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 a 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. Brakes may be
applied for a prolonged periods of time in some applications such as a heavy vehicle
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descending a long gradient at high speed. Brakes have to have the mechanism to
keep the heat absorption capability for prolonged periods of time.
Moving things have kinetic energy and, if you want to stop them, you have to get
rid of that energy somehow. If you're on a bicycle going fairly slowly, you can
simply put your feet down so they drag on the ground. The soles of your feet act as
brakes. Friction (rubbing) between the rough ground and the grip on your soles
slows you down, converting your kinetic energy into heat energy (do it long enough
and your shoes will get hot). Brakes on vehicles work pretty much the same way,
with "shoes" that press rubber pads (brake blocks) against discs mounted to the
wheels. (Find out more about this in our main article on brakes.) Even if you make
brakes from super-strong, hard-wearing materials like Kevlar, they're still going to
wear out sooner or later. But there are other problems with friction brakes. The
faster you go, the harder they have to work to get rid of your kinetic energy, and
the quicker they'll wear out. Use your brakes too often and you may suffer a
problem called brake fade, where heat builds up too much in the brakes or the
hydraulic system that operates them and the brakes can no longer work as
effectively. What if your brakes can't stop you in time?
5. Retarders
Retarders are means of of overcoming the above problems by augmenting a
vehicles foundation brakes with a device capable of opposing vehicle motion at
relatively low levels of power dissipation for long periods. There are several retarder
technologies currently available. Two major kinds are the hydrokinetic brake and the
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exhaust brake. Hydrokinetic brake uses fluid as the working medium to oppose
rotary motion and absorb energy . Hydrodynamic brakes are often built into
hydrodynamic transmissions . Exhaust brakes use a valve which is fitted into the
exhaust pipe between the exhaust manifold and silencer. When this valve is closed
air is compressed against it through the open exhaust valve by the piston rising on
the exhaust stroke. In that way the engine becomes a low pressure single stage
compressor driven by the vehicles momentum, resulting in a retarding effect being
transmitted through the transmission to the driving road wheels. The power-
producing engine is converted into a power absorbing air compressor . This
approach could put a lot of stress on the cylinder and exhaust system. So it may
require extra engineering efforts to implement this system. As a brake applied to
the engine, exhaust brakes can only absorb as much power as the engine can
deliver. But the power absorbed in braking is usually greater than the power
absorbed in driving. Compared with these retarders, electromagnetic brakes have
greater power capability, simplicity of installation and controllability.
6-construction-
The construction of the electromagnetic braking system is very simple. The parts
needed for the construction are electro magnets, rheostat, sensors and magnetic
insulator. A cylindrical ring shaped electro magnet with winding is placed parallel to
rotating wheel disc/ rotor. The electro magnet is fixed, like as stator and coils are
wounded along the electromagnet. These coils are connected with electrical
circuit containing one rheostat which is connected with brake pedal. And the
rheostat is used to control the electric current flowing in the coils which are
wounded on the electro magnet and a magnetic insulator is used to focus and
control the magnetic flux. And also it is used to prevent the magnetisation of other
parts like axle and it act as a support frame for the electromagnet. The sensors
used to indicate the disconnection in the whole circuit. If there is any error it gives
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an alert, so we can avoid accident. Working principle : At the initial stage the brake
pedal and rheostat are in rest. When we apply the brake through the brake pedal,
the rheostat allows the current to flow through the circuit and this current energise
the electromagnet. The amount of current flow is controlled by the rheostat.
Depending on the current flow different amount of magnetic flux can be obtained.
By this varying magnetic flux, different mode of brakes can be obtained. For
example, if we want to suddenly stop the vehicle then press the brake pedal fully,
then the rheostat allos maximum current which is enough to stop the vehicle.
Similarly we can reduce the speed of the vehicle by applying the brake gradually.
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gearbox or on the axle of the vehicle. The axle of a vehicle drives at least one road
wheel, which road wheel drives at least one wheel of the same vehicle.
8. Working Principle-
The working principle of the electric retarder is based on the creation of eddy
currents within a metal disc rotating between two electromagnets, which sets up a
force opposing the rotation of the disc . If the electromagnet is not energized, the
rotation of the disc is free and accelerates uniformly under the action of the weight
to which its shaft is connected. When the electromagnet is energized, the rotation of
the disc is retarded and the energy absorbed appears as heating of the disc. If the
current exciting the electromagnet is varied by a rheostat, the braking torque varies
in direct proportion to the value of the current. It was the Frenchman Raoul Sarazin
who made the first vehicle application of eddy current brakes. The development of
this invention began when the French company Telma, associated with Raoul
Sarazin, developed and marketed several generations of electric brakes based on
the functioning principles described above . A typical retarder consists of stator and
rotor. The stator holds 16 induction coils, energized separately in groups of four. The
coils are made up of varnished aluminum wire mounded in epoxy resin. . The rotor
is made up of two discs, which provide the braking force. when subject to the
electromagnetic influence when the coils are excited. Careful design of the fins,
which are integral to the disc, permit independent cooling of the arrangement.
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close the four groups of coil circuits within the electric brake at either 24 volts or 12
volts, as appropriate (Reverdin 1974 and Omega Technologies).
Features:-
Slim Brakes with good performance and can quickly stop loads
Technical Features:
Simple Construction
Technical Features:
Coil Voltage: 24 V
Torque: 3 N-m to 3600 N-m
Compact design
A friction-plate brake uses a single plate friction surface to engage the input and
output members of the clutch. Single face electromagnetic brakes make up
approximately 80% of all of the power applied brake applications.
Power off brakes stop or hold a load when electrical power is either
accidentally lost or intentionally disconnected. In the past, some companies
have referred to these as "fail safe" brakes. These brakes are typically used on
or near an electric motor. Typical applications include robotics, holding brakes
for Z axis ball screws and servo motor brakes. Brakes are available in multiple
voltages and can have either standard backlash or zero backlash hubs. Multiple
disks can also be used to increase brake torque, without increasing brake
diameter. There are 2 main types of holding brakes. The first is spring applied
brakes. The second is permanent magnet brakes.
(a) Spring type - When no electricity is applied to the brake, a spring pushes
against a pressure plate, squeezing the friction disk between the inner pressure
plate and the outer cover plate. This frictional clamping force is transferred to
the hub, which is mounted to a shaft.
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Both power off brakes are considered to be engaged when no power is applied
to them. They are typically required to hold or to stop alone in the event of a
loss of power or when power is not available in a machine circuit. Permanent
magnet brakes have a very high torque for their size, but also require a constant
current control to offset the permanent magnetic field. Spring applied brakes do
not require a constant current control, they can use a simple rectifier, but are
larger in diameter or would need stacked friction disks to increase the torque.
(5)Particle brake
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Magnetic particle brakes are unique in their design from other electro-
mechanical brakes because of the wide operating torque range available. Like
an electro-mechanical brake, torque to voltage is almost linear; however, in a
magnetic particle brake, torque can be controlled very accurately (within the
operating RPM range of the unit). This makes these units ideally suited for
tension control applications, such as wire winding, foil, film, and tape tension
control. Because of their fast response, they can also be used in high cycle
applications, such as magnetic card readers, sorting machines and labeling
equipment.
Magnetic particles (very similar to iron filings) are located in the powder
cavity. When electricity is applied to the coil, the resulting magnetic flux tries
to bind the particles together, almost like a magnetic particle slush. As the
electric current is increased, the binding of the particles becomes stronger. The
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brake rotor passes through these bound particles. The output of the housing is
rigidly attached to some portion of the machine. As the particles start to bind
together, a resistant force is created on the rotor, slowing, and eventually
stopping the output shaft.
When electricity is removed from the brake, the input is free to turn with the
shaft. Since magnetic particle powder is in the cavity, all magnetic particle units
have some type of minimum drag associated with them.
Electrical hysteresis units have an extremely wide torque range. Since these
units can be controlled remotely, they are ideal for test stand applications where
varying torque is required. Since drag torque is minimal, these units offer the
widest available torque range of any of the hysteresis products. Most
applications involving powered hysteresis units are in test stand requirements.
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When electricity is applied to the field, it creates an internal magnetic flux. That
flux is then transferred into a hysteresis disk passing through the field. The
hysteresis disk is attached to the brake shaft. A magnetic drag on the hysteresis
disk allows for a constant drag, or eventual stoppage of the output shaft.
When electricity is removed from the brake, the hysteresis disk is free to turn,
and no relative force is transmitted between either member. Therefore, the only
torque seen between the input and the output is bearing drag.
Multiple disk brakes are used to deliver extremely high torque within a small
space. These brakes can be used either wet or dry, which makes them ideal to
run in multi-speed gear box applications, machine tool applications, or in off
road equipment.
When electricity is removed from the brake, the armature is free to turn with
the shaft. Springs keep the friction disk and armature away from each other.
There is no contact between braking surfaces and minimal drag.
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.
In a study with a vehicle with 5 axles and weighing 40 tons powered by an engine
of 310 b.h.p traveling down a gradient of 6 percent at a steady speed between 35
and 40 m.p.h, it can be calculated that the braking power necessary to maintain
this speed is the order of 450 h.p. The braking effect of the engine even with a
fitted exhaust brake is approximately 150 h.p. The brakes, therefore, would have to
absorb 300 h.p,
meaning that each brake in the 5 axles must absorb 30 h.p, which is beyond the
limit of 25 h.p. that a friction brake can normally absorb without self destruction.
The electromagnetic brake is well suited to such conditions since it will
independently absorb more than 300 h.p . It therefore can exceed the requirements
of continuous uninterrupted braking, leaving the friction brakes cool and ready for
emergency braking in total safety. The installation of an electromagnetic brake is
not very difficult if there is enough space between the gearbox and the rear axle. It
does not need a subsidiary cooling system. It does not rely on the efficiency of
engine components for its use, as do exhaust and hydrokinetic brakes. The
electromagnetic brake also has better controllability. The exhaust brake is an on/off
device and hydrokinetic brakes have very complex control system. The electro-
magnetic brake control system is an electric switching system which gives it
superior controllability. 11 From the foregoing, it is apparent that the electro-
magnetic brake is an attractive complement to the safe braking of heavy vehicles.
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12-Thermal Dynamics-
Q MCp (2.1)
where:
M = Mass of air circulated;
Cp = Calorific value of air;
= Difference in temperature between the air entering and the air leaving the fan;
The electromagnetic brakes has excellent heat dissipation efficiency owing to the
high temperature of the surface of the disc which is being cooled and also because
the flow of air through the centrifugal fan is very rapid. Therefore, the curie
temperature of the disc material could never been reached .The practical location of
the electromagnetic brakes prevents the direct impingement of air on the brakes
caused by the motion of the vehicle. Any air flow movement within the chassis of
the vehicle is found to have a relatively 12 insignificant effect on the air flow and
hence temperature of both front and rear discs. Due to its special mounting location
and heat dissipation mechanism, electromagnetic brakes have better thermal
dynamic performance than regular friction brakes.
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13-MERITS-
Quick operation
Accuracy is more.
It reduces the manual effort.
In electromagnetic braking system maintenance is very less.
electromagnetic braking system work is done very fast, because of electronic
component. And flowing of current is very fast.
Very less effort is required to apply the brake.
It is reasonable as compare with other brakes.
14-DERMIRTS-
15-APPLICATION -
16- Summary
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With all the advantages of electromagnetic brakes over friction brakes, they have
been widely used on heavy vehicles where the brake fading problem is serious. The
same concept is being developed for application on lighter
vehicles.