ELECTROMAGNETIC BRAKES

FACULTY ADVISORMr. Dinesh Shukla

TEAM MEMBERS:Sachin (07109048) Faruque(07109056) Rakesh(07109044)

CONTENTS

Limitations of conventional friction brakes Introduction to Electromagnet & EM brakes Existing electro-mechanical brakes Objective Design rig for electromagnetic braking system Material property and selection Force generated in rotating disc Relevant calculation regarding magnetic field and force Variation of engagement time with current Advantages of electromagnetic brakes Concept of integrated braking system Eddy-current brake concept

LIMITATIONS OF CONVENTIONAL FRICTION BRAKES

Friction between contact surfaces leads to generation of heat that
causes temperature rise of components. Rise in temperature cause decrease in friction co-efficient which adversely affect the torque Wear and tear of friction lining during braking. Performance reduction with passage of time ,so require more maintenance. Take large space and have greater weight. It becomes self locking if properly not designed, in which frictional force is strong enough to apply the brake without any external force.

INTRODUCTION TO ELECTROMAGNET AND EM BRAKES

An electromagnet is a type of magnet whose magnetic field is produced by the flow of electric current. The magnetic field disappears when the current ceases. To concentrate the magnetic field, in an electromagnet the wire is wound into a coil, with many turns of wire lying side by side. The magnetic field of all the turns of wire passes through the center of the coil, creating a strong magnetic field there .Strength of magnetic field depend on current through coil and magnetic permeability of the core material. EM brake works when core of the coil is magnetized .The magnetized core tries to pull the disc and that attraction force slows down the rotating disc. As some EM brake work with friction ,which make the disc stop very quickly in 1-3 sec , this kind of EM brake is called Electro-mechanical brake. But when friction part is removed it takes slight more time to stop the disc .

EXISTING ELECTRO-MECHANICAL BRAKES

Power off brakes stop or hold a load when electrical power is either accidentally lost or intentionally disconnected. A permanent magnet holding brake looks very similar to a standard power applied electromagnetic brake. It uses permanent magnets to attract a single face armature. When the brake is engaged, the permanent magnets create magnetic lines of flux, which can turn attract the armature to the brake housing. To disengage the brake, power is applied to the coil which sets up an alternate magnetic field that cancels out the magnetic flux of the permanent magnets .Typical applications include robotics, holding brakes for Z axis ball screws and servo motor brakes. Electromagnetic Particle Brake - 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. The brake rotor passes through these bound particles. As the particles start to bind together, a resistant force is created on the rotor, slowing, and eventually stopping the output shaft.

Electromagnetic Hysteresis Power Brake 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. Since these units can be controlled remotely, they are ideal for test stand applications where varying torque is required. Multiple Disk Brakes When electricity is applied to the coil of an electromagnet, the magnetic flux attracts the armature to the face of the brake. As it does so, it squeezes the inner and outer friction disks together. The hub is normally mounted on the shaft that is rotating. The brake housing is mounted solidly to the machine frame. As the disks are squeezed, torque is transmitted from the hub into the machine frame, stopping and holding the shaft

OBJECTIVE

Due to the problems faced by conventional friction brakes , we intend to design Electromagnetic Brakes which work by applying the magnetic force on a disc mounted on a shaft. Brake is applied when disc stops rotating due the resisting magnetic force exerted by the magnetic field of electromagnets and hence the shaft stops rotating .

METHODOLOGY-ELECTROMAGNETIC BRAKE SYSTEM

How does a magnetic brake system work? Magnetic resistance works by passing a spinning metallic disk through a magnetic field. The magnetic field provides resistance to the spinning disk thus slowing its rotation. The amount of resistance can be increased or decreased by varying the strength of the magnetic field. Field strength is controlled by changing either the power of the magnet or the distance between the magnet and the spinning disk. Resistance Formula: Resistance is determined by three factors: Disk rpm, magnet power and the distance between the magnet and disk. The three factors are expressed as a ratio of one to one to one squared: RPM : MAGNET POWER : DISTANCE = RESISTANCE

The distance value is the most important part of the formula because its value is squared. This means that very small changes in DISTANCE make very large changes in the resistance level.

METHODOLOGY CONTD..

Because distance is such an important part of the resistance formula small variations can make large differences in the amount of resistance.

A consistent distance between magnet and disk produces a smoother resistance curve

high resistance

By placing magnets on the sides of the disk the patented MForce magnetic brake system far maintains a consistent from disk distance between the disk and magnets at all times. variable distance Maintaining a consistent distance allows for fine adjustment of the resistance level simply by adjusting the magnetic field power. This results in a smooth resistance curve. other systems:
distance between magnet and disk varies

low resistance close to disk consistent distance

mforce: maintains a consistent distance

NECESSARY CALCULATIONS

Magnetic flux is found by the relation B = NI / L where is magnetic permeability of the core N is the number of turns I is the current passing through the coil L is the length of core(on which coil is wound) Force is calculated by the relation F=BA/2

EXPERIMENTAL SET UP AND METHODOLOGY USED

Fig:- TEST MODEL

TEST DESIGN BED COMPONENTS

AC motor characteristics
PARAMETERS Nominal armature voltage Nominal armature current Armature resistance Maximum speed Nominal shaft power Maximum torque Torque constant VALUE 220 V 6A 285 Ohm 2800 rpm 18 w 0.0614 N.m 0.0102N.m/A

TEST ELECTROMAGNETIC BRAKE CHARACTERISTICS PARAMETER electromagnet residual flux SYMBOL B VALUE 10.4 T

Number of turns of coil

Resistivity of disc material Number of electromagnet used Arc between north and south pole Airgap width Disc thickness Disc inner radius Disc outer radius

n
p t g e R inner R outer

1900
1.18x10e( -6) Ohm-m. 4 80 degree 2.5 mm 3.5 mm 5.5 cm 9 cm

Material

Ult. Tensile strength

Yield Strength

Poissons Ratio

Shear strength

Electrical Resistivity

1018 Mild (low-carbon) steel

63.8kpsi

53.7kpsi

0.303

2.15 kpsi

1.18x10e-6 ohm-m

6061- T6 Aluminum ASTM A36 Mild (lowcarbon) steel

45.0 kpsi

40.0 kpsi

0.330

3.77 kpsi

0.00000157 ohm-m 7.2x10e6 ohm-m

58-79kpsi

36.3 kpsi

0.300

2.3 kpsi

MATERIALS EVALUATION Disc

an extremely strong material that can withstand the stresses produced by the high rate of rotation. must be made of a slightly conductive material in order to efficiently host eddy currents with the least amount of resistance possible ; should have good magnetic properties. Mild steel (0.1 % C) is chosen as disc material having the following properties: Resistivity 10e-8Ohm m Shear strength=2.1 kpsi Disc Orientation

The disc will have only one orientation. It will mount perpendicularly to the drive shaft and the electromagnets while mounted in the middle of the paired coils

ELECTROMAGNET DESIGN

The construction is having four in number a change of polarity in electromagnets applied to electromagnetic brakes will produce a higher force than only one direction of polarity standard coated aluminum wire coiled around a ferrous metal core. Coating the aluminum 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 coated aluminum around our ferrous material will determine the strength of the induced magnetic field.
a ferrous material, such as mild steel or iron, ideal for a metal core for electromagnets. Mild steel is chosen for our core material.

The electromagnet is mounted in pairs in series connection one after another.

SPECIFICATIONS OF ELECTROMAGNET
Core material mild steel

Number of turns of coil Relative Permeability

Gauge diameter Area on the disc Magnetic strength

1900 800
28 swg 45x32 mm2 10.6 T

Wire material

standard coated aluminum wire

OTHERS COMPONENTS
1.A variable 0220 V ac power source for the motor; 2. A variable 06 A dc power source for the coil; 3. Ammeters and voltmeters;

4. Digital tachometer to accurately measure the angular speed of the motor;

5. Electronic stopwatch; 6. Wooden base for support structure; 7. Regulators for regulating current supply in electromagnet. 8. Rectifier for converting dc into ac for electromagnet.

STRESS DUE TO THE ROTATING DISC

Where
The high rotation rate of the disc will cause enormous stresses within the disc. The rotation is by far the source contributing the largest amount of stress in the disc. stresses act in both the tangential and radial directions where tangential is defined as the direction tangent to the outer edge of the circle created by the silhouette of the disc, and radial is defined as the direction starting at the axis of rotation of the disc and moving outward through the plane of the disc.

[rad/s]

a = inner radius b = outer radius v = Poissons ratio = material density = angular velocity r = radius of interest

Tangential stress = 0.343 N/mm Radial stress = 3.065 N/mm

STRESS DUE TO EDDY CURRENTS

If there is generation of eddy current then the forces that the eddy currents cause on the disc oppose the direction of motion the disc. in the image below the red arrows indicate the direction of rotation of the disc and the E vectors represent the corresponding eddycurrent-forces on the differential ring element of the disc.

EXPERIMENTAL RESULTS AND DISCUSSION

Current verses magnetic field intensity Sl.No. in telsa 01 02 03 04 05 06 07 08 10.60 Current (mA) Magnetic field intensity (B)

90.5 130.5 172 210 250 270 320

2.59 3.74 4.93 6.01 7.16 7.73 9.172 370

Fig ; Graph between current and magnetic field intensity

BRAKING TIME OF THE DISC

(i) Current= 90.5 mA Voltage (v) 126.7 144.1 162.5 (ii) Current= 130 mA Voltage (v) 126.7 144.1 162.5 (iii) Current=172 mA Voltage (v) 126.7 144.1 162.5

rpm 2250 2450 2600

Braking time (s) 2.3 2.8 3.15

rpm 2250 2450 2600 Rpm 2250 2450 2600

Braking time (s) 0.9 1.04 1.13 Braking time (s) 0.64 0.88 0.98

Fig: -Graph between braking time and current

APPLICATIONS
Electromagnetic brake

Circular eddy current brake system is used in trailer cars Linear eddy current brake is used in rails In roller coaster To create a torque on a driveshaft that connects a generator to a gearbox in an aerospace application.

Our design model

Various machines and equipments in gymnasium

CONCLUSION
Despite its tremendous advantages in compactness and effectiveness, friction braking suffers from severe limitations:

- Loss of braking force with increasing temperature (fading phenomenon) - Warping of discs - Wear of pads and rotors - Complexity and fuel consumption of power assistance - Slow response time due to power assistance, especially in trucks, buses and trains - Complexity of controlling each wheels braking independently - Necessity of complex and costly anti-lock controls - Risk of hydraulic fluid leak - Risk of brake fluid contamination by water and subsequent loss of braking power - Challenging integration with anti-lock, traction, and dynamic stability controls

CONCLUSION CONTD
So the design brakes give us following advantages; -Reduced wear
-Reduced -Reduced -Faster

sensitivity to fading fuel consumption of power assistance

control dynamics

-Easier
-Easy

integration with anti-lock, traction, and dynamic stability controls

individual wheel braking control actuation, no fluid

-Electric

FUTURE SCOPE

Eddy Current Brake System By changing the disc material(by using a non magnetic material , Aluminum),eddy current brake can be made. Eddy currents are produced due to relative motion between disc and perpendicular magnetic field These tend to slow down the disc due to opposing force produced by the eddy currents. Integrated Brake It combines a friction brake with an eddy-current brake on the same caliper Reduced wear of friction pads Reduced sensitivity to wheel lock Faster control dynamics

REFERENCES
[1] R. Limpert, Brake Design and Safety. Warrendale, PA: Society of Automotive Engineers, 1999. [2 ] Telma. (2004, December). Nos Produits. [Online]. Available: www.telma.com. [3 ] H. Sakamoto, Design of permanent magnet type compact ECB retarder, Society of Automotive Engineers #973228, pp. 19-25, 1997. [4] J. Bigeon and J.C. Sabonnadiere, Analysis of an electromagnetic brake, IEEE Journal of Electric Machines and Power Systems, vol. 10, pp. 285-297, 1985. . [5] J.H. Wouterse, Critical torque and speed of eddy current brake with widely separated soft iron poles, in IEE Proceedings-B, vol. 138, no. 4, pp. 153-158, 1991.

wikipedia: http://en.wikipedia.org/wiki/Eddy_current_brake wikipedia: http://en.wikipedia.org/wiki/Electromagnetic_brake

Youtube : http://www.youtube.com/watch?v=TxYh6TodacM&feature=related

[9] A text book of machine design by

R S KHURMI & J K GUPTA

Thank U