Kathmandu University

School of Engineering
Department of mechanical engineering

PROJECT PROPOSAL ON

STUDY AND FABRICATION OF ELCTROMAGNETIC BRAKING SYSTEM

Nitesh Kumar Yadav (12090)

Posan Sah (12081)

Samip Timilsina (12088)

Sujan Shrestha (12086)

Suman Thapa (12087)

 May 2017

Date: 28.05.2017

To
The Project Supervisor,
Department of Mechanical Engineering
Kathmandu University

SUBJECT: Request for approval of porposal.

Dear Sir/Madam,
Submitted for your review is our proposal entitled “( STUDY AND FABRICATION OF
ELECTROMAGNETIC BRAKING SYSTEM).”The report is submitted as requirement of
course entitled Engineering Project ENGG 102. Within this document you will find the basic
introductions, objectives, methodology and expected outcome from the proposed work (Listed in
detail in the table of content section).
We hope for your keen review and future assistance in this work along with the approval.

Sincerely,
Nitesh Kumar Yadav
Posan Sah
Samip Timilsina
Sujan Shrestha
Suman Thapa
 TABLE OF CONTENTS

LIST OF FIGURES........................................................................................................4
LIST OF TABLES..........................................................................................................5
LIST OF ABBREVIATIONS.........................................................................................6
LIST OF SYMBOLS.......................................................................................................7
CHAPTER 1 INTRODUCTION....................................................................................8
1.1 Context/Rationale/Background.............................................................................8
1.2 Objectives...........................................................................................................10
1.3 Significance/Scope..............................................................................................10
1.4 Limitations..........................................................................................................10
CHAPTER 2  METHODOLOGY................................................................................11
2.1 Theoretical/Conceptual Framework....................................................................11
2.2 Working Mechanism…………………………………………………………….13
2.3Study Design........................................................................................................13
2.3 Gantt Chart/Work Schedule/ Activity Plan.........................................................18
CHAPTER 3 BUDGET ESTIMATION.......................................................................19
 CHAPTER 4  EXPECTED OUTCOME.......................................................................21
CHAPTER 5 REFRENCES..............................................................................................22
 • LIST OF FIGURES

Figure 1. 1 Principle of Electromagnetic braking system…...........................................9

Figure 2.2 Flowchart showing working mechanism…………………………………….13

Figure 2.5.a Base plank.....................................................................................................14

Figure 2.5.b Working motor……………………………………………………………..14

Figure 2.5.c Connecting chains…………………………………………………………..15

Figure 2.5.d Chain rings………………………………………………………………….15

Figure 2.5.e Metallic disc…………………………………………………………………16

Figure 2.5.f Simple electromagnet……………………………………………………….16

Figure 2.5.g Speed controller ……………………………………………………………..16

 LIST OF TABLES

Table 2.9 Gnatt chart/work schedule/activity plan.......................................................18

Table 3.1 Table for Budget estimation…………………………………………………19
 • LIST OF ABBREVIATIONS

bhp Brake horse power

mhp Miles per hour
EMBS Electromagnetic Braking System
cm centimeter
RPM Revolution per minute
 LIST OF SYMBOLS

A Ampere [A]
R Radius [L]
V Voltage 2 -3 -1
[ML T A ]
 CHAPTER 1 INTRODUCTION

1.1 Background and Rational

Electromagnetic brakes (also called electro-mechanical brakes or EM brakes) slow or stop

motion using electromagnetic force to apply mechanical resistance (friction). The original name
was "electro-mechanical brakes" but over the years the name changed to "electromagnetic
brakes", referring to their actuation method. Since becoming popular in the mid-20th century
especially in trains and trams, the variety of applications and brake designs has increased
dramatically, but the basic operation remains the same. Electromagnetic brakes are the brakes
working on the electric power & magnetic power. They works on the principle of
electromagnetism.
These brakes are an excellent replacement on the convectional brakes due to their many
advantages. The reason for implementing this brake in automobiles is to reduce wear in brakes as
it frictionless. Electromagnetic brakes are of today’s automobiles. The working principle of this
system is that when the magnetic flux passes through and perpendicular to the rotating wheel the
eddy current flows opposite to the rotating wheel/rotor direction. This eddy current trying to stop
the rotating wheel or rotor. This results in the rotating wheel or rotor comes to rest/ neutral.

History

It is found that electromagnetic brakes can develop a negative power which represents
nearly twice the maximum power output of a typical engine, and at least three times the braking
power of an exhaust brake. (Reverdin 1994). These performance of electromagnetic brakes make
them much more competitive candidate for alternative retardation equipments compared with
other retarders. By using by using the electromagnetic brakes are supplementary retardation
equipment, the friction brakes can 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% of the duty
which would otherwise have been demanded of the regular service brake (Reverdin 1974).
Further more the electromagnetic brakes prevents the danger that can arise from the prolonged
use of brake beyond their capability to dissipate heat. This is most likely to occur while a
vehicle descending a long gradient at high speed. Ina study with a vehicle with 5 axles and
weighting 40 tones powered by a powered by an engine of 310 b.h.p travelling down a gradient
of 6% at a steady speed between 35 and 40 m.h.p, it can be calculated that the braking power
necessary to maintain this speed ot the order of 450 hp. The brakes, therefore, would have to
absorb 300 hp, meaning that each brake in the 5 axels must absorb 30 hp, that a friction brake
can normally absorb with selfdestruction. The magnetic brake is wall suited to such conditions
since it will independently absorb more than 300 hp (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. The installation of an electromagnetic brake is not very
difficulty if there is enough space between the gearbox and the rear axle. If did not need a
subsidiary cooling system. It relay on the efficiency of engine components for its use, so do
exhaust and hydrokinetic brakes. The exhaust brake is an on/off device and hydrokinetic brakes
have very complex control system. The electromagnetic brake control system is an electric
switching system which gives it superior controllability.

Fig 1.1 Principle of Electromagnetic Braking System

1.2 Objectives
 Primary Objective

 The main objective of this project is to design and fabricate Electromagnetic

Braking System with greater performance replacing conventional braking system.

Secondary Objective

 To achieve great performance with less cost.

 To achieve brake system with no heat loss.

1.3 Significance/Scope

 Trams and trains use electromagnetic track brakes where the braking element is pressed
by magnetic force to the rail.

 Electric motors in industrial and robotic applications also employ electromagnetic brakes.

 Recent design innovations have led to the application of electromagnetic brakes to

aircraft applications. In this application, a combination motor/generator is used first as a
motor to spin the tires up to speed prior to touchdown, thus reducing wear on the tires,
and then as a generator to provide regenerative braking.

 Electromagnetic brakes work in a relatively cool condition and satisfy all the energy
requirements of braking at high speeds, completely without the use of friction.

1.4 Limitations

Some of the possible limitations that we may encounter while doing the projects can be listed
as:-
 The installation of an electromagnetic brake is very difficult if there is not enough space
between the gearbox and the rear axle.
 Maintenance of the equipment components such as hoses, valves has to done
periodically.
  Need a separate compressor.

                          CHAPTER 2 METHODOLOGY

The model will be designed using locally available resources and working as a team.

We shall be working several weeks to accomplish our project within our time and budget starting with
consultation with books, teachers, project supervisor along with internet surfing.

The methods used in the development of projects are as follows;

2.1 Theoretical/Conceptual Framework

Our model is divided mainly into two different units ;

1) Driving Unit

a)Electric Motor

An Electric motor is an electrical device that converts electrical energy into mechanical
energy. In normal motoring mode, most electric motors operate through the interaction between an
electric motor's magnetic field and winding currents to generate force within the motor. Electric motors
may be classified by electric power source type, internal construction, application, type of motion output,
and so on.

b)Wheel

Wheel gets in motion with the help of running motor.Both motor and wheel is connected with
the help of connecting chain and chain ring.

c)Power control

This division consists of power supply to whole system and a separate power control
system to control the motion of motion.
2) Braking Unit

a) Electromagnet

An electromagnet is a type of magnet in which the magnetic field is produced by an electric

current .The magnetic field disappears when the current is turned off. Electromagnets usually consist of
insulated wire wound into a coil. A current through the wire creates a magnetic field which is
concentrated in the hole in the center of the coil. The wire turns are often wound around a magnetic core
made from a ferromagnetic or ferrimagnetic material such as iron; the magnetic core concentrates
the magnetic flux and makes a more powerful magnet.

b) Stopping disc

It is magnetic disc that will slow down once electromagnet is turned on and will stop the main wheel.
2.2 WORKING MECHANISM
Fig:2.2 Flowchart showing working principle of EMBS

2.3 Study Design

             The design of  EMBS is simple.When power is supplied to motor,it starts to move the 
wheel and when needed we supply power to electromagnet that will create magnetic field and 
will stop magnetic disc.

2.4 Literature Review

 Jae-Woong Lee, Seoul, Rep. of Korea Disclosed is a magnetic brake system for a
vehicle. comprising: a plurality of brake disk solenoids for generating the magnetic force; a
plurality of brake pad solenoids for generating the magnetic force; a braking sensor for detecting
whether a brake pedal is applied; a wheel speed sensor for detecting wheel speed; a magnetic
polarity sensor for detecting magnetic polarity of the brake disk solenoids; and a control unit for
controlling the brake pad solenoids using signals from the braking sensor. The wheel speed
sensor and the magnetic polarity sensor.

2.5 Preliminary Calculation and Design

a)Base plank
It consists of rectangular wooden plank which will act as a base for all the component of EMBS.
It will have dimension of 80*50*1 cm.

Fig2.5.a Base plank

b) Electric motor
Wiper motors will be used to move the wheel .

Fig 2.5.b Working motor

c) Connecting Chains
 Two connecting chains will be used . One will be used to deliever motion from motor to wheel and other
will use that motion to run magnetic disc.

fig 2.5.c Connecting chains

d) Chain Ring

Two chain rings will be either side of rotating wheel which will act as support for connecting
chains.

Fig 2.5.d Chain ring

e) Metallic disc

This disc will be stopped with the help of electromagnet.

Fig 2.5.e Metallic disc

F) Electromagnet

We will be using electromagnet made by ourself in lab.

Fig 2.5.f Simple Electromagnet

g) Speed Controller

We Will be using one speed controller for driving motor.

Fig 2.5.g speed controller

 2.6 Fabrication

We will be fabricating our model in following order;

 First we will make electromagnets as it is the main component of our project.

 We will then fix wheel and driving motor.
 Then metallic disc and electromagnet will be attached.
 After that whole model will be installed on the wooden plank.

2.7 Preliminary Test

 Every step of fabrication will be followed by testing the mechanisms or component.
 After all mechanisms are fitted properly, the machine will be given power and the
machine will be tested.
 If everything went as we proposed, the machine will be ready for demonstration and
final presentation.

2.8 Final Report and Presentation

When final test is completed, we will create a final report of the project and final presentation to
the judges and demonstrate the machine.

2.9 Gantt Chart/Work Schedule/ Activity Plan

Table 2.9: Gantt Chart for Second Semester

Weeks 1 2 3 4 5 6 7 8
Literature review

Proposal submission
Material selection and
purchase.
Model design and
Construction
Data Analysis and
improvement
Midterm presentation
Testing and
Debugging
Demonstration
Report submission
and final submission

Table 2.9: Index

Work
Completed

Work
Remaining
    

CHAPTER 3  BUDGET  ESTIMATION

Table 3.1: Table for Budget estimation

S/N Particulars Specification Rate Unit Total

(NRs)
1. Ply Wood 1 sq.ft. 50per sq.ft. 1 200

2. Motor 500RPM 500 1 500

3. Chain 1.5m 200 2 400
4. Chain ring R4 150 2 300
3. Electromagnet 350 2 700
4. Metallic disc iron 100 1 100
5. Wheel 300 1 300
6. Battery Li-Po, 12v, 3A 2000 1 2,000
7. Speed controller 220v 2000w 250 1 250
8. Switch 50 1 50
9. Others 70
(wires,gum……) 0
Total 5500
CHAPTER 4 EXPECTED OUTCOME

     Following things we expect from our model;

 As our brake system is contactless with rotating wheel, we expect negligible production 
of heat.
 The brake linings would last considerably longer before requiring maintenance and the 
potentially “brake fade” problem could be avoided. 
 Good results with current design, a larger budget would improve performance.
 REFERENCES

[1] RK Mohanty ,Automobile Engineering­2

[2] https://en.wikipedia.org/wiki/Electromagnet

[3] http://automobiletechinfo.blogspot.com/2013/05/electromagnetic-brake.html

[4] http://www.dbrake.com/braking-history.php

[5] http://papers.sae.org/2013-01-2543/

[6] http://eblogbd.com/wht-is-solenoid-and-its-basic-working-principle/