DESIGN AND FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

1. SHRI RAMSWAROOP MEMORIAL COLLEGE OF ENGINEERING AND MANAGEMENT,LUCKNOW
DESIGN AND FABRICATION OF
ADVANCED ELECTROMAGNETIC
BRAKING SYSTEM
PROJECT GUIDE : GROUP MEMBERS :
Mr. K. K. YADAV AMARJEET YADAV (1312240034)
ASST. PROF. ANUPAM SINGH (1312240055)
ME-DEPARTMENT ANURAG YADAV (1312240056)
GROUP NO.- 15

2. INTRODUCTION
 This projects intends to the design and implementation of new
system of retardation (braking) for automobiles
 The design of the new brakes is based upon the phenomenon of
electromagnetic induction and eddy currents
 The design basically consists of very strong magnet and rotating
metallic wheel
 The wheel develops eddy currents due to the change in magnetic
flux associated to the wheel due to its rotation
 The eddy current development obeys Maxwell’s law of
electromagnetic induction and Lenz’s law of direction of induced
current
 The current in turn dissipates the rotational energy of the wheel
as heat bringing the wheel to a stop
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3. UTILITY OF THE PROJECT
In this project we are trying to make a braking system. which can be
applicable in two wheeler at high speed and low maintenance cost,
replacing the conventional braking system. Here we are using an
electromagnetic coil and a plunger. There is an electromagnetic
effect which moves the plunger in the braking direction.
It has been proven that electromagnetic brakes create a
negative flow of energy twice as the power of any combustion
engine and at least three times stronger than regular friction brake
systems. While innovations in technology lead to a broader use of
electromagnetic brakes now-a-days.
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4. LITERATURE REVIEW
*Project based on this research
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TITLE CONCLUSION
*01. Innovative Electro Magnetic Braking System by Sevvel P and S
Mukesh published in International Journal of Innovative Research in
Science, Engineering and Technology (IJIRSET),Volume-3 in April
2014, Second National Conference on Trends in Automotive Parts
Systems and Applications (TAPSA-2014) at Sri Krishna College of
Engineering & Technology, Kuniamuthur, Coimbatore,Tamilnadu,
India
Mr. Sevvel P and S Mukesh Et al find that the electromagnetic brakes
can be used as an auxiliary braking system along with the friction
braking system to avoid overheating and brake failure. ABS usage can
be neglected by simply using a micro controlled electromagnetic disk
brake system . When these brakes are combined with mechanical
brakes, it increases the life of brake and act like fully loaded brakes.
These electromagnetic brakes can be used in wet conditions which
eliminate the anti-skidding equipment. Hence, the braking force
produced in this is less than the disc brakes if can be used as a
secondary or emergency braking system in the automobiles.
02. Enhancement of Braking System in Automobile Using
Electromagnetic Braking by Akshya S.Puttewar and Nagnath U.
published in IOSR Journal of Mechanical and Civil Engineering (IOSR-
JMCE) ,in 2009, conference held at
Dr.Babasaheb Ambedkar College of Engineering & Research,
Wanadongri,Nagpur
Mr. Akshya S.Puttewar and Nagnath U. Et al analyse that
Electromagnetic braking system is found to be more reliable as
compared to other braking systems. In oil braking system or air braking
system even a small leakage may lead to complete failure of brakes.
While in electromagnetic braking system as four disc plates, coils and
firing circuits are attached individually on each wheel, even any coil
fails the brake does not completely fails remaining three coil works
properly. This enhanced braking system not only helps in effective
braking but also helps in avoiding the accidents and reducing the
frequency of accidents to a minimum.

5. NEED FOR ALTERNATIVE
 All conventional systems of braking in road vehicles uses
development of contact friction for retardation
 These systems are probe to the wear and tear on usage
 Conventional braking systems produces continuous power
dissipation as heat and may fail if the temperature rises too high
 Friction based braking methods are also not efficient under wet
conditions
 Weight brakes add additional weight to the automobile serving no
other purpose and significantly reducing traction under certain
circumstances
 Brakes usually creates small noise on application and may also
create loud screeches on hard usage
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6. GENERAL PRINCIPLES
Electromagnetic brakes work in a relatively cool condition and satisfy all
the energy requirements of braking at high speeds. It is generally based on
electromagnetic induction principle.
According to this principle when current passes through any electromagnetic coil, it
produces a magneto motive force and the coil works as a permanent magnet.
This magneto motive force is proportional to the current flowing in electromagnetic
coil.

7. METHODOLOGY
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PROBLEM IDENTIFICATION OF
CONVANTIONAL BRAKES
FIND THE PARAMETER
OF DESIGN
ANALYSIS OF THE
DESIGN
PREPARE IDEA
GENERATION
SELECT ELECTROMAGNETIC BRAKES TO OVERCOME THE PROBLEMS
ANALYSIS OF
ELECTROMAGNETIC BRAKING
SYSTEM
DESIGN USING CATIA
FABRICATION OF
ELECTROMAGNETIC BRAKE
FIND AND ANALYSE THE RESEARCH PAPER

8. ASSUMPTIONS
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1. Intensity of magnet used is assumed to be constant at specified
current
2. Effect of heat on brake effectiveness is assumed to be neglected
3. There is no decrease in braking force with slight decrease in
speed of vehicle
4. Eddy-current brakes can only used to modified system.

9. WORKING
When 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.
In this type of electromagnetic braking system, electromagnet is fixed in
the back plate in this way the unequal braking effect at one shoe are balanced, even if
the lining on one shoe is worn more than other the plunger will move to one side so
that shoe still share equal acting force.
In this braking system, any one shoe out of two will remove & instead
of it we will use the electromagnetic coil. As the current passes through this
electromagnetic coil, it will produce the magnetic flux, this flux will attract the shoe
with much force, and brake will apply.

10. FIGURES RELATED TO EM
BRAKING SYSTEM
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4.Final assembly
1.Fabrication Of Frame 2.Addition of solenoid
coil & chain drive to
frame
3.Addition of control circuit box

11. 10/23/16
1.Diagram of electromagnetic breaking system
2.Constructional
diagram

12. PROS
 High impact
 Low maintenance requirement
 Less noise
 Simple in design
 High degree of safety
CONS
 Usage of electric power for braking
 Less effective under very low velocities
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13. APPLICATIONS
Already in use under some railway system
Can be used for any road vehicles
Equally applicable to heavy and light vehicles
Can be used as additional retarder for aircrafts
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14. MATERIAL REQUIREMENT AND COST ESTIMATION
Sr. No. Components Nos. *Cost ( Rs.)
1 Limit Switches 2 100
2 DC Motor (12 V) 1 350
3 Electromagnetic Solenoid 1 1750
4 Battery (12 V, 7.5 Ah) 1 600
5 Control Relay 1 250
6 Firing Circuit 1 400
7 Micro Controller 1 350
8 Disc Plate 1 600
9 Aluminium Wheel and Mild-
steel Shaft
1-1 175
10 Free Wheel 2 100
11 Frame and Machining 1 1500
********** Total Cost 14 6175
**Approximate Costs of Components

15. PLAN OF ACTION
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Sr. No. Action Scheduled Dates Semester
1 Literature survey Till 15 Sep.,2016 VII
2 Requirement of parts and its
availability
Till 30 Sep.,2016 VII
3 Collection and the study of
required parts
Till 15 Oct.,2016 VII
4 Design of an EM braking system Till 15 Nov.,2016 VII
5 Plan of fabrication according to
design and specification
Till 30 Jan.,2017 VIII
6 Procurement of materials and
components from market
Till 15 Feb., 2017 VIII
7 Assemble all parts of project
together
Till 15 March,2017 VIII
8 Experimentation of the project Till 30 March,2017 VIII

16. CONCLUSIONS
During the making of this project presentation “Fabrication of
Electromagnetic brake”, we got a lot of information and knowledge about
this brake, its construction, working and principle and how the brake action
takes place.
We are sure that while doing this project we will came across various
manufacturing process which we learn in books and their actual meaning.
Techniques of this braking system save the effort of the human
being at the maximum level which provide the comfort to the rider of the
vehicle.
As this brake is require external power source of battery and it require to
charge every time, to overcome this problem one can use dynamo for the
charging of the power source is generated itself by the vehicle.
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17. REFERENCES
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01. Innovative Electro Magnetic Braking System by Sevvel P and S Mukesh
published in International Journal of Innovative Research in Science, Engineering
and Technology (IJIRSET),Volume-3 in April 2014, Second National Conference on
Trends in Automotive Parts Systems and Applications (TAPSA-2014) at Sri Krishna
College of Engineering & Technology, Kuniamuthur, Coimbatore,Tamilnadu, India
02. Enhancement of Braking System in Automobile Using Electromagnetic
Braking by Akshya S.Puttewar and Nagnath U. published in IOSR Journal of
Mechanical and Civil Engineering (IOSR-JMCE) ,in 2009, conference held at
Dr.Babasaheb Ambedkar College of Engineering & Research, Wanadongri,Nagpur
03. Yunda HU “The Research on Test-Bed Test System of Automobile Eddy
Current Retarder” 2012

18. Thanks to our faculty and project-guide for
their precious suggestions!!
THANK YOU…!