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ABSTRACT
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The topic of magnetic braking has dramatically increased in
popularity in recent years. Since 1987, numerous articles about magnetic
braking were published. These articles describe both experiments dealing
with magnetic braking, as well as the theory behind the phenomenon.
Magnetic braking works because of induced currents and Lenz's law. If you
attach a metal plate to the end of a pendulum and let it swing, its speed will
greatly decrease when it passes between the poles of a magnet.
When the plate enters the magnetic field, an electric field is induced in
metal and circulating eddy currents are generated. These currents act to
oppose the change in flux through the plate, in accordance with Lenz's Law.
The currents in turn heat the plate, thereby reducing its kinetic energy. The
practical uses for magnetic braking are numerous and commonly found in
industry today. This phenomenon can be used to damp unwanted nutations
in satellites, to eliminate vibrations in spacecrafts, and to separate
nonmagnetic metals from solid waste
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When the driver applies force on the brake pedal the magnitude is
sensed by the pressure transducer which in turn sends the actuating signals
to microprocessor. This intelligent device sends pulsating D.C. current from
the capacitor to the power pack. The power pack develops sufficient torque
to decelerate or stop the vehicle as per the driver's requirement. The torque
produced is directly proportional to the force applied on the brake pedal, as
the intensity of the actuating signal from the pressure transducer is directly
proportional to the pulsating D.C. current supplied to the power pack.
Another important aspect of this braking system is that the power
pack also acts as a generator, which results in additional power generation.
We have also incorporated artificial intelligence. Logic gates for backup-
circuit for safety and shift current for shifting the power pack from
generating mode to braking mode and vice-versa to generator power.
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Chapter 1
Introduction
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1.0 Introduction
1.1 Brakes
Brakes are generally applied to rotating axles or wheels, but may also take
other forms such as the surface of a moving fluid (flaps deployed into water
or air). Some vehicles use a combination of braking mechanisms, such as
drag racing cars with both wheel brakes and a parachute, or airplanes with
both wheel brakes and drag flaps raised into the air during landing.
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Since kinetic energy increases quadratically with velocity (K = mv2 / 2), an
object traveling at 10 kilometers per second has 100 times as much energy as
one traveling at 1 kilometer per second, and consequently the theoretical
braking distance, when braking at the traction limit, is 100 times as long. In
practice, fast vehicles usually have significant air drag, and energy lost to air
drag rises quickly with speed.
Friction brakes on automobiles store braking heat in the drum brake or disc
brake while braking then conduct it to the air gradually. When traveling
downhill some vehicles can use their engines to brake.
When the brake pedal is pushed the caliper containing piston pushes the pad
towards the brake disc which slows the wheel down. On the brake drum it is
similar as the cylinder pushes the brake shoes towards the drum which also
slows the wheel down.
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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.
The “master cylinder” which is located under the hood is directly connected
to the brake pedal, and converts the drivers’ foot pressure into hydraulic
pressure. Steel “brake hoses” connect the master cylinder to the “slave
cylinders” located at each wheel. Brake fluid, specially designed to work in
extreme temperature conditions, fills the system. “Shoes” or “pads” are
pushed by the slave cylinders to contact the “drums” or “rotors,” thus
causing drag, which slows the car. Two major kinds of friction brakes are
disc brakes and drum brakes.
Disc brakes use a clamping action to produce friction between the “rotors”
and the “pads” mounted in the “caliper” attached to the suspension
members. Disc brakes work using the same basic principle as the brakes
on a bicycle: as the caliper pinches the wheel with pads on both sides, it
slows the vehicle.
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When the brakes are applied, the brake shoes are forced into contact with the
inside surface of the brake drum to slow the rotation of the wheels.
Air brakes use standard hydraulic brake system components such as braking
lines, wheel cylinders and a slave cylinder similar to a master cylinder to
transmit the air-pressure-produced braking energy to the wheel brakes. Air
brakes are used frequently when greater braking capacity is required.
The conventional friction brake can absorb and convert enormous energy
values (25h.p. Without self-destruction for an 5-axle truck, Reverdin 1974),
but only if the temperature rise of the friction contact materials is
controlled. This high energy conversion therefore demands an appropriate
rate of heat dissipation if a reasonable temperature and performance stability
are to be maintained. Unfortunately, design, construction, and location
features all severely limit the heat dissipation function of the friction brake
to short and intermittent periods of application. This could lead to a ‘brake
fade’ problem (reduction of the coefficient of friction, less friction force
generated) due to the high temperature caused by heavy brake demands.
The main reasons why conventional friction brakes fail to dissipate heat
rapidly are as follows:
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this order, a reduction in the coefficient of friction (‘brake fade’) suddenly
occurs (Grimm, 1985). The potential hazard of tire deterioration and bursts
is perhaps also serious due to the close proximity of overheated brake
drums to the inner diameter of the tire.
Chapter 2
Literature Survey
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2.1 Introduction
This chapter pertains to the literature survey on magnetic properties of
materials and there classification.
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FIG. 2.1 TOROID
B= (µ*N*i)/(2Пr)
Where,
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2.2.1 Magnetic Flux, Φ
1. Diamagnetic materials:
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field and orbital motion of electrons. Examples: Bismuth, Cu, H2O,
gold.
2. Paramagnetic materials:
3. Ferromagnetic material:
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Examples: iron, cobalt, nickel.
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2.2.6 Hysteresis
Hysteresis refers to systems that have the effects of the current input (or
stimulus) to the system are experienced with a certain delay in time. Such a
system may exhibit path dependence, or "rate-independent memory".
Hysteresis phenomena occur in magnetic materials, ferromagnetic materials
and ferroelectric materials, as well as in the elastic, electric, and magnetic
behavior of materials, in which a lag occurs between the application and the
removal of a force or field and its subsequent effect. Electric hysteresis
occurs when applying a varying electric field, and elastic hysteresis occurs
in response to a varying force.Many physical systems naturally exhibit
hysteresis.
A piece of iron that is brought into a magnetic field retains some
magnetization, even after the external magnetic field is removed.Once
magnetized, the iron will stay magnetized indefinitely. To demagnetize the
iron, it would be necessary to apply a magnetic field in the opposite
direction. This is the effect that provides the element of memory in a hard
disk drive .
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d B
As by Faraday’s Law, E ds V , where B is the magnetic flux, t
dt
is time, and V is voltage. Additionally, using the basic relationship of
V
V IR I, it is assumed that the current induced in each differential
R
V d B 1
said differential piece. Thus, I induced and the radial flowing
R dt R
current is calculated in each element. As by the equation F IL B , where in
this case I is the induced differential current, L is the length of the element in
the direction of radial current flow, and B is taken to be the average strength
of the magnetic field over each differential element. The resulting quantity
by multiplying average braking or eddy current force acting on shaft with its
radius is the total torque exerted on the disk.
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Working of induction furnace is based on the heating effects of Eddy
Currents.
Induction motors
In Electromagnetic brakes
In speedometers
Electromagnetic shielding
In Paddle Machine Brake
In Turbine Brake
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Chapter 3
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Block Diagram
Working Principle
The eddy current brake consists of a magnetic yoke with electrical coils
positioned along the rail, which are being magnetized alternating as south
and north magnetic poles. This magnet does not touch the rail, as with the
magnetic brake, but is held at a constant small distance from the rail. It does
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not move along the rail, exerting only a vertical pull on the rail. When the
magnet is moved along the rail, it generates a non-stationary magnetic field
in the head of the rail, which then generates electrical tension (Faraday's
induction law), and causes eddy currents. These disturb the magnetic field in
such a way that the magnetic force is diverted to the opposite of the direction
of the movement, thus creating a horizontal force component, which works
against the movement of the magnet. The braking energy of the vehicle is
converted in eddy current losses which lead to a warming of the rail.
Advantages
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Applications of Eddy Currents
Induction motors
In Electromagnetic brakes
In speedometers
Electromagnetic shielding
In Paddle Machine Brake
In Turbine Brake.
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 stator assembly is
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supported resiliently through anti-vibration mountings on the chassis frame
of the vehicle. 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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and 40mph, it can be calculated that the braking power necessary to maintain
this speed is the order of 450hp. The braking effect of the engine even with a
fitted exhaust brake is approximately 150h.p. The brakes, therefore, would
have to absorb 300hp, 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 300h.p
(Reverdin 1974). It therefore can exceed the requirements of continuous
uninterrupted braking, leaving the friction brakes cool and ready for
emergency braking in total safety.
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of a current in such a way that it resists the cause of change of magnetic
flux; this current is known as Eddy current.
Eddy Currents are induced current that exist in a solid. A changing magnetic
flux over an area of the solid will produce an Eddy Current which will create
a magnetic field opposing the field producing the Eddy Currents. The
opposition of this generated magnetic field is dependent on the changing
area. As the area of flux increases the Eddy Current generation is in a
“negative” direction. With a decreasing area exposed to the flux the
generated Eddy Currents will act in the opposite, “positive”.
The figure shows one plate at two instances in time. The first instant models
the plate just entering the magnetic field directed into the page. The swirl
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indicated on the plate illustrates the direction of the Eddy Current. The
Eddy Current in position one has a “negative” direction or counter clockwise
direction. The second position shows the Eddy current swirl going in the
“positive” direction, or clockwise, as the plate has a decreasing area passing
through the flux. Essentially, at the middle of the field there is no Eddy
Current generation and also acts as the point in which the Eddy Current
generation changes direction. The diagram also shows a force, Fb , which
represents the force created by the Eddy Currents that are generated. The
force created by the Eddy Currents will always oppose the direction of
motion. The magnetic field generated by the Eddy Currents will oppose one
another in position one of figure 1, and attract each other as the area is
decreasing, thereby creating a force that always opposes the direction of the
plate’s motion. The force produce by the Eddy Current generation is
proportional to the conductivity of the material, the speed of plate or the rate
of change of flux and the magnitude of the magnetic field, B.
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creates eddy currents in the discs. These eddy currents generate an opposing
magnetic field, which then resists the rotation of the discs, providing braking
force. The net result is to convert the motion of the rotors into heat in the
rotors.
These disturb the magnetic field in such a way that the magnetic force is
diverted to the opposite of the direction of the movement. The braking
energy of the vehicle is converted in eddy current losses which lead to a
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warming of the rail.
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When electromagnets are used, control of the braking action is made
possible by varying the strength of the magnetic field. A braking force is
possible when electric current is passed through the electromagnets. The
movement of the metal through the magnetic field of the electromagnets
creates eddy currents in the discs.
These eddy currents generate an opposing magnetic field, which then resists
the rotation of the discs, providing braking force. The net result is to convert
the motion of the rotors into heat in rotors.
Eddy current brakes at the Intamin roller coaster Goliath in Walibi World
(Netherlands) The first train in commercial circulation to use such a braking
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is the ICE 3.Modern roller coasters use this type of braking, but utilize
permanent magnets instead of electromagnets, and require no electricity.
However, their braking strength cannot be adjusted.
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Chapter 4
Equipments Used
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4.1 Selection of Equipment
Voltage 12 Volts DC
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FIG 4.1 PRIME MOVER
4.1.2 Electromagnet
We required producing the magnetic field around the shaft; therefore we are
using electromagnet to get magnetic field around shaft only when desired to
stop the shaft. We are using 24 volt DC current supply through battery used
in trucks. Keeping the voltage same we have to draw more current to
achieve powerful magnetic field.
It can be achieved by using a thick wire or wire of AWG 20 or AWG 22
grade to reduce the resistance and increase the current drawn.
No of turns 500
External radii mm
Internal radii mm
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Length mm
The electromagnets will be built and assembled by our team. We will use
standard coated copper wire AWG gauge 36 coiled around a ferrous metal
core. Coating the copper wire will prevent corrosion and increase the life of
the electromagnets and maintain the efficiency of the overall braking system.
The number of turns of copper around our ferrous material will determine
the strength of the induced magnetic field.
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FIGURE 4.4 MAGNETIC FIELD LINES OF COIL PAIRS
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Chapter 6
Results and Discussion
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6.1 Result
1. The maximum speed of shaft is 1000rpm (approx).
2. Reduction in speed after application of brakes from 1000rpm to
700rpm in 2.83seconds.
Percentage reduction in speed = 30%
3. Reduction of speed after 700rpm is not considerable or very small
because of very small rate of change of flux.
6.2 Advantages
6.3 Disadvantages
1 Higher initial cost.
2 Very large amount of heat generation.
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6.3 Conclusion
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6.4 Future Enhancement
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REFERENCES
Websites:
1. www.freepatentonline.com
2. www.wikipedia.com
3. www.telmaretarders.com
4. Prof. Peter R. Saulson “Electrical Power, Magnetism and
Electromagnetic Motors” aulson@physics.syr.edu
http://physics.syr.edu/courses/PHY101/Physics 263-4
5. Prof. S.K. Sahdev and Prof. R.K. Chaturvedi Dhanpat Rai & Co.
edition 1988 Page(2.1-2.49)
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