The document describes the design of an electromagnetic braking system as an alternative to conventional braking systems. The system uses an 8051 microcontroller to control three electromagnets based on input from a brake pedal. This provides braking force without wear parts and offers potential cost and performance advantages over traditional brakes. The design was tested and shown to work within budget, though stronger magnets may improve performance given a larger budget.

1. Electromagnetic
Braking System
Name: William Gaskey, Sandip Mistry, Duy Nguyen, Jee Yoon
Team No.: 4
Course/Section: ELET4308/12652
Instructor: Dr. Farrokh Attarzadeh
University of Houston
College of Technology
Semester: Fall 2006

2. Outline
• Executive Summary
• Product Requirements
• Design Alternatives
• Design Specifications
• Design Description
• Construction Details
• Costs
• Conclusions
• Questions & Comments
ELET 4308 Team 4 Slide 1 of 13

3. Executive Summary
• Objective: Design an electromagnetic
braking system
– Replacing the conventional braking system
– Less cost with greater performance
– No need for maintenance and/or replacement
• Research: Other types of electromagnetic
braking system
– Electromagnetic braking system with brake pads
– Eddy-current braking system
ELET 4308 Team 4 Slide 2 of 13

4. Product Requirements
• Overall
– Power supply to power the system
– Hub and spindle assembly to simulate the actual
spinning of the rotor
– Custom made rotor with metal arranged for the
most effective result
– Brake pedal to simulate the real environment
– Three electromagnets to generate braking force
ELET 4308 Team 4 Slide 3 of 13

5. Product Requirements (cont’d)
• Hardware and Software
– 8051 microcontroller
• Reading the braking level from pedal
• Varying the braking force through duty cycle
– Custom built circuit board
• Regulating input voltage
• Powering up the 8051 µC
• Amplifying the output voltage to electromagnets
ELET 4308 Team 4 Slide 4 of 13

6. Design Alternatives
• Permanent magnets mounted on the wheel
– Cleaning issue
– Magnet arrangement issue
– Electromagnetic field around other mechanical
components issue
• Metallic material region all around the wheel
– Electromagnetic field dispersion issue
– Not enough braking force
ELET 4308 Team 4 Slide 5 of 13

7. Design Specifications
ELET 4308 Team 4 Slide 6 of 13
• Mini-Max 51-C2 8051 Microcontroller
• 2001 Toyota Corolla hub and spindle
assembly
• Three GP-2030/24VDC electromagnets
• MC2 Microcon pedals

8. Design Specifications (cont’d)
• General view
– Pedal
– 8015 Microcontroller
– Circuit board
– Electromagnets
– DC power supply
Pedal
8051 µC
EM
DC
power
supply
Circuit
board
5 [V]
output
Input
Square
Wave
12 [V]
power
42 [V]
power
Amplified
output
ELET 4308 Team 4 Slide 7 of 13

9. Design Description
• Circuit board
– LM317T voltage
regulator to regulate
input voltage
– BUK-555 60A
MOSFET as a
switch
ELET 4308 Team 4 Slide 8 of 13

10. Design Description
• Programming
– Voltage reading by ADC
– ADC by convert()
function
– ON and OFF state by
setbit() and clrbit()
– Generate delay by
generate_delay()
function
ELET 4308 Team 4 Slide 9 of 13
Start
Parameter Setup
Voltage Reading
Generate Delay
Generate Delay
OFF State
ON State

11. Construction Details
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12. Costs
ELET 4308 Team 4 Slide 11 of 13
Project Cost
Parts
Labor
Equipments
21% 3%
76%
$19,810.78
Total
$ 4,183.43
Equipments
$15,000.00
Labor
$ 627.35
Parts
Cost
Category

13. Conclusions
• Project was completed on schedule and
within budget thanks to donations
• Supplier issues caused the purchase of
weaker magnets than intended for design
• Good results with current design, a larger
budget would improve performance
• The project proves the theory and shows the
potential for a full functional system
ELET 4308 Team 4 Slide 12 of 13

14. Questions & Comments
ELET 4308 Team 4 Slide 13 of 13