ACKNOWLEDGEMENT

First of all we thank and praise the Almighty, without whom nothing is possible,
for the spiritual support, eternal guidance and all blessings bestowed on us.

We would like to express our gratitude to our Principal Dr. Babu Kurian for
his external support and blessings showered on us to make our endeavour a success.

We would like to express our indebtedness to Prof. Arun K, Head of the

Department, Mechanical Engineering under whose valuable guidance we could
complete our mission, for his positive criticism, suggestions and encouragement which
have boosted our spirit to attain the goal.

Further, we have the pleasure to thank Asst. Prof. Shinaz Shahul, Project
Guide, Asst. Prof. Shajahan C M, Project Coordinator & Asst. Prof. Kiran George,
Class Tutor, for their encouraging status and timely help which have constantly
stimulated us to travel eventually towards the completion of this project.

Lastly, we would like to thank Mr Anoop K.K, Technical Officer (EEE),

Mr K.G Mathai, Workshop Superintend (ME), Mr T.A Pathrose, Mr V.K.
Ravinathan, Mr K.M. Abubaker, Raju P.K, Trade Instructors of Mechanical
Department and countless others whom has helped us make our project a success.

i
 ABSTRACT

A conventional launcher uses solid or liquid fuel to generate thrust but due to the
mass of this fuel the payload capacity decreases considerably. So the aim of the future
was to come up with a better alternative.

This is where the introduction of electromagnetic launcher came to be. This

launcher proved to be a better alternative to the conventional system.

Here we are fabricating a scale model which conveys the advantages of this
technology, and also tried ways to reduce the heat generated due to high current used.
A parametric study was also done on the system. This study was done so that the
advantages of this technology over the conventional launching methods is shown to
the world

Keywords: Electromagnetic Launcher, High Velocity, High Current, Heat.

ii
 TABLE OF CONTENTS

I. Acknowledgement i
II. Abstract ii
III. List of Diagrams v

CHAPTER 1 : INTRODUCTION 01

CHAPTER 2 : HISTORY 03

CHAPTER 3 : ELECTROMAGNETIC LAUNCHER THEORY 04

3.1. ELECTROMAGNETIC LAUNCH 04

3.2 CIRCUIT STRUCTURE 07

CHAPTER 4 : DESCRIPTION OF EQUIPMENTS 09

4.1 BARREL 09

4.2 PROJECTILES 10

4.3 POWER SUPPLY 11

4.3.1 CAPACITOR BANK AND CHARGING UNIT 13

4.3.2 HIGH CURRENT SWITCHES 14

4.3.3 SOLENOID PLUNGER 15

CHAPTER 5 : DESIGN 17

5.1. DESIGN OF RAILS 17

5.2. DESIGN OF ARMATURE 17

CHAPTER 6 : EXPERIMENTAL SETUP 24

iii
CHAPTER 7 : TESTING 27

CHAPTER 8 : ANALYSIS 29

CHAPTER 9 : RESULT 33

CHAPTER10 : CONCLUSION 35

CHAPTER11 : FUTURE SCOPE 37

CHAPTER 12 : REFERENCE 39

CERTIFICATES 43

iv
 LIST OF DIAGRAMS
Page
No. Title
No.
3.1 Current And Magnetic Field Interaction(Left) 04
3.1 Lorentz Force (Right) 04
3.2 The Drift Velocity Of A Charge Q Along A Projectile Of Height 05
3.3 The Magnetic Field Created By A Current Passing Through The Rails 06
3.4 Ideal Circuit For A Rail Gun 07
4.1 EM Launcher 10
4.2 Projectile 10
4.3 Circuit Diagram Of Capacitors And Switches 11
4.4 Capacitor Bank And Switches 12
4.5 Capacitor 13
4.6 Transformer 14
4.7 Solenoid Switch 15
4.8 Plunger Solenoid 16
6.1 Assembled View 24
6.3 Assembled View With Control Switches 25
6.2 Schematic Diagram Of EM Launcher 18
7.1 Projectile Inside The Barrel 27
7.2 EM Launcher During Testing 28
8.1 Current vs Capacitor Discharge Time 29
8.2 Acceleration vs Capacitor Discharge Time 30
8.3 Velocity vs Capacitor Discharge Time 31
8.4 Displacement vs Capacitor Discharge Time 32

10.1 Damaged Projectile 34

10.2 Damaged Rail Surface 34

11.1 Military Weapon 37

11.2 Space Launcher 38

v
 ELECTROMAGNETIC LAUNCHER

CHAPTER 1

INTRODUCTION

In recent years there has been a renewed interest in projectile launchers which

utilize electromagnetic energy. An electromagnetic launcher was developed to launch

hypervelocity projectiles using electromagnetic energy. The electromagnetic launcher

contains two parallel conducting plates called rails and a projectile sits so as to

complete the electrical circuit between them. Generally they work under the basic

principle of Lorentz force. A large current is used to generate magnetic field, which

will accelerate the projectile at high speed in a short time. There is no need for any

other components although some designs do have additional rails that seek to augment

the flux generated by the rails and some are further complicated by the addition of

circuits that recover the energy stored in the rails as the projectiles leaves the gun.

When rails were energized by applying a large current and it will starts to flow by

creating a current loop together. In order to get higher velocity of armature, the

launcher needs huge amount of current.

The performance characteristics parameters of the electromagnetic launcher

such as force and velocity acting on the armature, induced voltage, power loss and

magnetic field plots over rail and armature are greatly affected by its current

distribution. These parameters depend on rail and armature dimension, shape, and the

magnitude of current as well as the shape of current supplied to rails.

DEPT OF ME, HKCET 1

 ELECTROMAGNETIC LAUNCHER

Proposals for using EM launchers as weapons include projecting heavy non-

explosive missiles at speeds up to 5000miles per hour. The energy outmatches that of

an explosive shell. The high speed is easy to attain since the force on the projectile is

proportional to the current applied.

In this paper the electromagnetic launcher is compared against other

conventional systems in use today. It is seen that electromagnetic launcher has a high

no of advantages and it has a bright future in the coming future not only in the defence

field but also in the space exploration and energy field since Its also used as Trigger

for inertial confinement fusion i.e., electromagnetic launcher may be able to trigger

fusion by firing energetic plasma from multiple directions. Its also suggested that

they can be used from a high altitude aircraft to fire a small payload into orbit

The scope of this project is to study and examine power supply required for 1

meter long electromagnetic launcher, while accounting for numerous factors such as

muzzle velocity, rail length and current density using MATLAB software. Also

produce a scaled model for analysing what are the difficulties occur while producing

an electromagnetic launcher.

DEPT OF ME, HKCET 2

 ELECTROMAGNETIC LAUNCHER

CHAPTER 2

HISTORY

In 1918, French inventor Louis Octave Fauchon-Villeplee invented electric

cannon which are an early form of electromagnetic launcher. He filed for a US patent

on 1 April 1919, which was issued in July 1922 as patent no. 1,421,435 "Electric

Apparatus for Propelling Projectiles". In 1944, during World War II, Joachim

Hansler of Germany's Ordnance Office proposed the first theoretically viable

electromagnetic launcher. By late 1944, the theory behind his electric anti-aircraft

gun had been worked out sufficiently to allow the Luftwaffe's Flak Command to

issue a specification, which demanded a muzzle velocity of 2,000 m/s and a

projectile containing 0.5 kg of explosive. The guns were to be mounted in batteries

of six firing twelve rounds per minute, and it was to fit existing 12.8 cm Flak 40

mounts. It was never built. When details were discovered after the war it around

much interest and a more detailed study was done, culminating with a 1947 report

which concluded that it was theoretically feasible, but that each gun would need

enough power to illuminate half of Chicago.

During 1950, Sir Mark Oliphant, an Australian physicist and first director of the

Research School of Physical Sciences at the new Australian National University,

initiated the design and construction of the world's largest (500 mega joule)

homopolar generator. This machine was operational from 1962 and was later used to

power a large scale electromagnetic launcher that was used as a scientific

experiment.

DEPT OF ME, HKCET 3

 ELECTROMAGNETIC LAUNCHER

The significance of Equation 3.7 is the term for which we now define in Equation

1.8. L is known as the inductance gradient, which has the units of (henries/meter). It

is important to note that L is not an inductance of the system. Instead, L is a

magnetic field factor, which is only dependent upon the geometry of the

electromagnetic launcher itself. Therefore, L remains constant once the

electromagnetic launcher has been constructed.

L = (0 /2) x ln((R+L)2/L2) (Eq 3.8) [Ref 3]

Now, by substituting Equation 1.8 into 1.7, the magnitude of the Lorentz force can

now be simply expressed as:

F =LI2/2 (Eq 3.9) [Ref 3]

3.2.CIRCUIT STRUCTURE

Apart from directly analysing the Lorentz force, previous studies have

recognized that the electromagnetic launcher system could also reasonably be

modelled as an RLC circuit. John P. Hartke analysed the model shown in Figure 3.4,

and derived an expression for the force exerted by the electromagnetic launcher such

that it would be comparable to the expression in Equation 1.9.

DEPT OF ME, HKCET 7

 ELECTROMAGNETIC LAUNCHER

CHAPTER 4

DESCRIPTION OF EQUIPMENTS

In the most basic form, an electromagnetic launcher consists of two parallel

rails connected to an electrical power source. In this section we are going discuss

about the various parts required for the proper functioning of an electromagnetic

launcher. The launcher consist of

4.1.BARREL

The most important part of electromagnetic weapons is the barrel. The major

parts serving in the barrel are the rails. Here we use launcher setup consist of two

parallel copper stripes of length 490mm.copper is selected due to its high

conductivity.

The copper rails are rigidly bolted to an Acrylic glass plate in parallel with a 10mm

gap between them. The inner sides of the copper stripes are machined to made

smooth and flat to obtain a throughout contact with projectile and also decrease

friction. The rails should be produced from materials having high conductance and

durability. The most ergonomic solution is copper rails. An alternative to decrease

the friction and resistance of copper is to cover its surface with silver. These copper

bars used must have profiles that can transfer the current without any warming. As

the currents passing through the rails are in opposite directions, the electromagnetic

force created between the rails would repulse each other. Therefore the installation

DEPT OF ME, HKCET 9

 ELECTROMAGNETIC LAUNCHER

CHAPTER 5

DESIGN

The Design of the proposed system was done by keeping safety and feasibility

in mind. The length of rails and capacitors used was selected to due to safety reasons.

The detailed explanation of the design process is given below.

5.1. DESIGN OF RAILS

Chosen Rail parameter as

Rail length , L =490mm

Rail width , W =50mm

Rail thickness, T=6mm

Rail separation, d=30mm

Rail material is copper

5.2. DESIGN OF ARMATURE

Projectile dimension

Material used : Aluminium

Density of projectile =2.7g/cm3

Length of projectile l =15mm

DEPT OF ME, HKCET 17

 ELECTROMAGNETIC LAUNCHER

Width of projectile w =10mm

Thickness of projectile h =6mm

Volume Val =l x w x h

=1.5x1x0.6

=0.9cm3.

Mass of projectile m = x Val

=2.7x0.9

=2.43g

5.3. CAPACITOR CALCULATION

Chosen Capacitors = 22000F 80v (2 in parallel)

Calculation total capacitance in the capacitance bank

= 22000F x 2

=44000F

Calculate the resistance that the rails have

= 16.8 x 10-9m

Rr = x (L/A )

DEPT OF ME, HKCET 18

 ELECTROMAGNETIC LAUNCHER

L =.49 m

A =.05 x .006

=3 x 10-4 m2

Rr = 16.8 x 10-9 x .49/3x10-4

=2.774x10-6

For 2 rails Rr =2x25.2*10-6

=5.488x10-6

Calculate the current that should be produced when the capacitor is discharged

into rails

RT =Rr+Resr

=5.488+.011

=.011005

Ir =Vf/RT

=80/.011005

=7269.1A

DEPT OF ME, HKCET 19

 ELECTROMAGNETIC LAUNCHER

With the current, calculation of magnetic flux

Assumption

1) Current passes through the canter of rail

2) Magnetic characteristics of rectangular plate is similar to longround wire

Magnetic Flux B = 0I/4r [Ref 3]

Lorentz force F =B x I x L

Force between rails

F =(0 xI2/4)xln((R+L)2/L2) [Ref 3]

F =(4 x10-7x7269.12/4)xln((50+10)2/502)

=1.92 N

Inductance gradient

L = (0 /2)x ln((R+L)2/L2)

= (4 x10-7/2)xln((50+10)2/502)

= 7.29 x 10-8 H/m

DEPT OF ME, HKCET 20

 ELECTROMAGNETIC LAUNCHER

Acceleration inside rail

F =m x a

=1.926/(2.4x10-3 )

=792.59m/s2

Energy stored in capacitor bank

E =CVs2/2

=44000x10-6x802/2

=140.8J

Time to moves to the end of rail

tr =(2/Io)x(m x l/L')

Assume Ir =Io

tr =(2/7269.1)x(.00243x.49/(7.29 x10-8).5

=.0351 sec

Muzzle velocity v = v0 +at

=5+792.6 x .0351

=32.82 m/s

DEPT OF ME, HKCET 21

 ELECTROMAGNETIC LAUNCHER

To find range

Assuming air resistance is negligible.

Since only horizontal velocity no vertical force acting on the system and the

only affecting factor is gravity.

To find time of flight

S =ut+.5at2

s = 1m

a =729.6 m/s2.

u = 0m/s

1= 0+.5 x 729.6 x t2.

t = .451 s

Distance travelled by projectile, d= vt

=32.82 x .451

= 14.80 m

DEPT OF ME, HKCET 22

 ELECTROMAGNETIC LAUNCHER

To find heat generated

From joules law heat generated

H = I2R t

=7269.12x5.488x10-6x.0351

=10.178 J

To find efficiency

The efficiency of EM launcher depends upon a number of variables. The efficiency of an EM

launcher increases with increasing Electrical conductivity , Velocity v, and rail width w.

1
= L 64 [Ref 14]
(2+( 0 )+( )( l/( v)0.5 )
L xl 15wL

The efficiency depends in a complicated way on the rail length l. In the limit of high

velocity v , the efficiency of the EM launcher has the limiting value.

1
lim = [Ref 14]
2+ 0

Where L0= Stationary self-inductance

Energy inside rail

E=f x l

=1.92 x .49

=0.94 J

DEPT OF ME, HKCET 23

 ELECTROMAGNETIC LAUNCHER

1
Also E= 2
x L0I02 [Ref 14]

L0= 2 x E/ I02

= 2 x 0.94/8269.12

= 3.5579 x10-8 H

Dynamic self inductance L x l =7.29 x 10-8 x .49

= 3.571 x10-8 H

1
Therefore Efficiency = 3.5579108
2+
3.57108

= 0.33

=33%

DEPT OF ME, HKCET 24

 ELECTROMAGNETIC LAUNCHER

Fig 6.3. Schematic Diagram of EM Launcher

DEPT OF ME, HKCET 27

 ELECTROMAGNETIC LAUNCHER

CHAPTER 9

RESULT

The main objective of this project is to design a scaled model of

electromagnetic launcher and analysis of a 1 m long electromagnetic launcher using

MATLAB software. This system which can be used to accelerate a projectile with

high velocities. In order to carry out this study, in this chapter, different types of

electric gun propulsion technology which can be used to accelerate a projectile with

high velocity are studied. Based on energy storage and pulse forming network the

characteristics of each technologies have been studied. It has been concluded that the

design and operating characteristics of electromagnetic launcher make them an

excellent choice because it has high projectile velocity, low system susceptibility,

low firing signature, selectable lethality, simplicity of projectile storage, handling

and resupply, and minimal environmental impact.

DEPT OF ME, HKCET 34

 ELECTROMAGNETIC LAUNCHER

CHAPTER 10

CONCLUSION

Our study has shown that projectiles attain high velocities by using an

electromagnetic launcher. Significant improvement in the efficiency of the

electromagnetic launcher set up is one of the key issues that will determine the use of

electromagnetic launchers for various applications. Hence we carried out modelling

and analysis of the entire electromagnetic launcher system. During testing we found

that the rails and projectile get damage after a number of firing hence need more

investigation to eliminate the friction loss and increase the efficiency of the

electromagnetic launcher.

Although electromagnetic launcher seem quite simple logically, their

calculations are not easy at all since a change in the system necessitates changes in

other parameters. For example, when the projectile mass is desired to be changed

when the speed is constant, capacity and the length of the barrel should also be

changed. These calculations may be made with multivariate equations. In the study

Mat lab codes are prepared in order to make these calculations and present the

results visually with graphs. Instead of solving quite a few equations, these codes are

used and the desired values are entered to get the results. In order to increase the

speed of electromagnetic launcher the following three things should be realized:

DEPT OF ME, HKCET 36

 ELECTROMAGNETIC LAUNCHER

To increase the capacitor value

To decrease the projectile mass

To increase the voltage value

At the test shots no changes are made in the projectile mass or capacity value,

instead by changing the value of voltage test are performed. Besides, some shots

were unsuccessful and the projectiles got out of the barrel with low speeds. Further,

during some shots the projectile clung to the rails and could not leave the rails

DEPT OF ME, HKCET 37

 ELECTROMAGNETIC LAUNCHER

CHAPTER 12

REFERENCES

[1] Alexander Bolonkin and Mark Krinker,Rail gun space Launcher, j Aerospace

engineering 2010

[2] S.G.Tatake, K.J Daniel, K.R. Rao, A.A.Ghosh and I.I Khan, Rail gun, Armament

Research & Develop Establishment, pune 1994

[3] Feliciano, Allan S, Design and Optimization of a power supply for 1.2 m rail gun, naval

postgraduate school California, 2001

[4] P.Balamurali, G Vijila, S. Thiruselvam and D.Saravanakumar, Analysis of the

performance parameter of a navel plasma launcher in rail gun, Dept. of Electronoics and

communication Engg.,karunya university Coimbatore, India 2015.

[5] Wen Liu &Leilei Wang, Optimization calculation and Analysis of moving load of the rail

gun by Newton method, school of science, Yanshanuniversity,Qinhunbangdao, China 2011

[6] P Gilduits, R Kacianaushas, M Scheider, E Stupak, R stonkus, Deformation analysis of

rail gun cross section, Vilnius GediminasTechinical University Lithuania 2012

[7] L Tumonis, M Scheider, R Kacianaushas, A Kacianaushas, Comparison of dynamic

behavior of EMA 3 rail gun under differently induced loading, Vilnius GediminasTechinical

University Lithuania 2009

[8]Yu-tao LOU, Hai-yuan LI, Bao-ming LI, Research on proximity effect of electromagnetic

rail gun, National Key laboratory of Transient physics Nanjing university of science and

technology Nanjing china 2016

DEPT OF ME, HKCET 40

 ELECTROMAGNETIC LAUNCHER

[9] Jin-guo WU, Bo TANG, Qing-hua LIN, Hai-yuan LI, Bao-ming LI, 3D numerical

simulation and analysis of railgun gouging mechanism, National Key laboratory of

Transient physics Nanjing university of science and technology Nanjing china 2016

[10] Qing-hua LIN , Bao-mingLI,Numerical simulation of interior ballistic process of

railgun based onthe multi-field coupled model, National Key laboratory of Transient physics

Nanjing university of science and technology Nanjing china 2016

[11] Saravana Kumar .M .N, Murugan .R , Effective Analysis on Metal-Metal Contact on C-

Shaped Armature-Rail Interface, Department of Electrical and Electronics Engineering, St.

Peters University, Chennai, TN, India 2016

[12] Murugan .R, Saravana Kumar M.N and Azhagar Raj .M, Investigating the effect of

current shape on rail gun design at transient conditions, Electrical and Electronics

Engineering, St. Peters University, Chennai, TN, India 2016

[13] M. Coffo and J. Gallant, Simulation of the Current Distribution and the Heat Load

Of a Brush Projectile in a Railgun with the Finite Element Code ANSYS, Royal Military

Academy, Renaissancelaan 30, Brussels, Belgium, 2009

[14] AfefSlama, Vincent Mazauric, Yves Marchal, Grard Meunier, and Philippe

Wendling,ElectricRailgun 3D Modeling: Computation of Eddy Currents and Lorentz Force,

Schneider Electric, Research Center/A2, 38050-Grenoble Cedex 9, France 2001

[15] S. Fish, C. Phipps and V. Tang, Rail Heating Analysis for Multishot EM Gun Operation

Institute for Advanced Technology, The University of Texas at Austin, 4030-2 W. Braker

Lane, Austin, TX 78759 1999

DEPT OF ME, HKCET 41

 ELECTROMAGNETIC LAUNCHER

[16] Shumei Cui, Qing LiuWeiduo Zhao, Simulation Research of CPA Powered Railgun

System, Department of Electrical Engineering, Harbin Institute of Technology, Harbin,

China 2012

[17] Ira Kohlberg and William 0. Cobum A Solution for the Three Dimensional Rail Gun

Current Distribution and Electromagnetic Fields of a Rail Launcher ,KohlbergAssociates,

Inc., 5375 Duke Street, Unit 1603, Alexandria, VA 22304

U.S. Army Research Laboratory, AMSRL-WT-ND. 2800 Powder Mill Road. Adelphi. MD

20783 1995

[18] Jin Feng, Lu Xiao-fei, Chen Yan-qiao, Three-dimensional Simulation of the

electromagnetic Railgun Range School of Automation, Beijing Institute of Technology,

Beijing, 100081, China 2012

[19] Arindam Banerjee and Dr. P J Radcliffe, Simulation approaches for new experimental

methods to investigate rail gun recoil, School of Electrical and Computer Engineering Royal

Melbourne Institute of Technology Melbourne, Australia 2013

[20]P.Balamurali, G Vijila, S. Thiruselvam and D.Saravanakumar, Analysis of the

performance parameter of a navel plasma launcher in rail gun, Dept. of Electronoics and

communication Engg.,karunya university Coimbatore, India 2015.

DEPT OF ME, HKCET 42