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Design and Fabrication of Electromagnetic Braking System

Article in International Journal of Innovative Research in Science Engineering and Technology · July 2021
DOI: 10.15680/IJIRSET.2021.1007008|

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 Volume 10, Issue 7, July 2021

Impact Factor: 7.569

International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

Design and Fabrication of Electromagnetic

Braking System
Krushabh Chaudahri1, Nayan Varudkar2, Sachin Sonwane3, Rakesh Kawale4, Nishikant Shaymkuwar5, Rohit
Fukat6, Prof. Vijay Talhodikar7
U.G. Student, Department of Mechanical Engineering, Tulsiramji Gaikwad-Patil College Of Engineering and
Technology, Nagpur, India1-6
Associate Professor, Department of Mechanical Engineering, Tulsiramji Gaikwad-Patil College Of Engineering and
Technology, Nagpur, India7

ABSTRACT: An electromagnetic brake is a new and revolutionary concept. Electromagnetic braking system is a
modern technology braking system used in light motor & heavy motor vehicles. This system is a combination of
electro-mechanical concepts. It is electromagnetic brake is an essential complement to the safe braking of heavy
vehicles. It aims to minimize the brake failure to avoid the road accidents. It also reduces the maintenance of braking
system. An advantage of this system is that it can be used on any vehicle with minor modifications to the transmission
and electrical systems. An Electromagnetic Braking system uses Magnetic force to engage the brake, but the power
required for braking is transmitted manually. The disc is connected to a shaft and the electromagnet is mounted on the
frame when electricity is applied to the coil a magnetic field is developed across the armature because of the current
flowing across the coil and causes armature to get attracted towards the coil.
The electromagnetic brakes can be used in commercial vehicles by controlling the current supplied to produce the
magnetic flux. Making some improvements in the brakes it can be used in automobiles in future. O

KEYWORDS: Electromagnetic brake, Safe breaking, Armature, Magnetic flux.

I. INTRODUCTION
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. Here we are using an electromagnetic coil and a plunger. There is an electromagnetic effect which
moves the plunger in the braking direction.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.
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.

Sr Title Of The Paper Authors Name Of Journal Proposed Concept And Details
no. / ISSN No. / Volume
Number /Year

1. Innovative P. Sevvel, International Journal An Electromagnetic Braking system

electromagnetic braking N. Kannan, of Innovative uses Magnetic force to engage the brake,
system S.Marsmukesh Research in Science, but the power required for braking is
Engineering and transmitted manually. The electromagnetic
Technology 2014 brakes can be used in commercial vehicles
by controlling the current supplied to

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International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

produce the magnetic flux

II. LITERATURE SURVEY

Sr Topic Of The Paper Authors Name Of Proposed Concept And Details

no. Journal / ISSN No.
/ Volume Number
/Year

2 Automatic Braking J.V.Sai Ram, International When compared with olden days life span
System Using G.Pavanth, Journal of of human is reduced. Death rate due to
Ultrasonic Sensor B.Jagadeep , Innovative Science accident is drastically increased because
Dr.B.Raghu and Research vehicles usage is increasing by day by day.
Kumar Technology ISSN Due to brake failure so many accidents are
No: - 2456 - 2165 occurring so when we control the brake by
automatically we can reduce the effect of
accident.
3 Fabrication of Auto- Eung Soo Kim International The auto-braking system was designed by
Braking System for Div. Digital Journal of Control VHDL and fabricated to keep a distance
Pre-Crash Safety Using Media and Automation between two cars. It provides pre-crash
Sensor Engineering, Vol. 2, No. 1, safety system for intelligent car. This
Pusan March, 2009 module can detect the distance between
University of front vehicle and driver’s vehicle to keep a
Foreign Studies, constant distance using a sensor and operate
Busan, Korea the brake system forcibly if the driver does
not decrease the speed of car.

III. METHODOLOGY
Basically, this project was to study and analyse electromagnetic braking system as a secondary measure for the
hydraulic braking system. First, the base for the electromagnets and the stand for fitting the wheel, is made.
Then, a wheel is made and attached to the spook whereas the spook is attached to the stand by the help of bearings an
electromagnet is made by winding the copper wire with the cylindrical body and attached to its base. Furthermore, a U
shaped metal rod is welded with a L shaped metal bar forming a brake shoe and then its end are rest inside the
electromagnet.
The motor is attached to the base. So the electromagnet and the motors of wheel are circuited to an external battery and
by turning it on, they work respectively.
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 he 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.
B. 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 centre of the coil. The wire turns are often wound around a magnetic
corn Shoe: main b. Brake Shoe: It is part that will stop the wheel when the electromagnet is turned on.

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International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

Figure 1: DC motor

Windshield wipers are powered by a small electric motor, usually mounted on the firewall or under the cowl (the area
under the windshield's base). The motor activates linkage that moves the wiper arms back and forth. On vehicles with a
rear window wiper, a separate motor powers the one in the rear.

BEARING
A bearing is a machine element that constrains relative motion to only the desired motion, and reduces friction
between moving parts. The design of the bearing may, for example, provide for free linear movement of the moving
part or for free rotation around a fixed axis, or, it may prevent a motion by controlling the vectors of normal forces that
bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are classified
broadly according to the type of operation, the motions allowed, or to the directions of the loads (forces) applied to the
parts. Rotary bearings hold rotating components such as shafts or axles within mechanical systems, and transfer axial
and radial loads from the source of the load to the structure supporting it The simplest form of bearing, the plain
bearing, consists of a shaft rotating in a hole.

Figure 2: Bearing
SPROCKET
A sprocket or sprocket-wheel is a profiled wheel with teeth, or cogs, that mesh with a chain, track or other perforated
or indented material. The name 'sprocket applies generally to any wheel upon which radial projections engage a chain
passing over it. It is distinguished from a gear in that sprockets are never meshed together directly, and differs from a
pulley in that sprockets have teeth and pulleys are smooth. Sprockets are used in bicycles, motorcycles, cars, tracked
vehicles, and other machinery either to transmit rotary motion between two shafts where gears are unsuitable or to
impart linear motion to a track, tape etc.

Figure 3: sprocket

CHAIN
Chain drive is a way of transmitting mechanical power from one place to another. It is often used to convey power to
the wheels of a vehicle, particularly bicycles and motorcycles It is also used in a wide variety of machines besides
vehiclesMost often, the power is conveyed by a roller chain, known as the drive chain or transmission chain, passing

IJIRSET © 2021 | An ISO 9001:2008 Certified Journal | 8619

International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

over a sprocket gear, with the teeth of the gear meshing with the holes in the links of the chain. The gear is turned, and
this pulls the chain putting mechanical force into the system. Another type of drive chain is the Morse chain, invented
by the Morse Chain Company of Ithaca, New York, United States. This has inverted teeth

Figure 4: Chain

DISC
Disc are familiar from automotive applications where they are used extensively for car and motorcycle wheels. These
typically consist of a cast iron disc, bolted to the wheel hub. This is sandwiched between two pads actuated by pistons
supported in a caliper mounted on the stub shaft. When the brake pedal is pressed, hydraulically pressurized fluid is
forced into the cylinders, pushing the opposing pistons and brake pads into frictional contact with the disc

Figure 5: Disc

IV. CALCULATION

Calculation for Force to operate Brake shoe

(F) F = (m + M)/C
Allowable pressure for Asbestos = 0.7b N/mm²

Total moment of Normal force (M)

M = ½ p br OA [(Ø₂- Ø₁) + ½ (sin2Ø₁-sin2Ø₂)]
= ½ x 0.75 x 5 x 97 x 85 [(1.83 – 0.175) + ½ (sin20-sin216]
= 39959.47 N-mm.
Total momentum of the friction force (M)
M = µ pbr [r (cosØ₁-cosθ₂) + OA/4 (cos2θ₂-cos 2θ₁)
= 31947.52 N mm
Therefore Force (F) = (M + M)/C
= (39959.47-31947.52)/155 = 51.69 N.
Force to operate brake shoe = 51.69N.

Calculation for Diameter of shaft

Subjected to torque
Material = Carbon steel (C14)
Force = 51.69 N = 5.269 kgf.
Radius = 0.097 m.
Torque = Force x Radius (kgfm)
= 5.269 x 0.097
= 0.511 kgfm

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International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

dia of the shaft =20.5 mm (From PSG-Design Data book)

Calculation of force exerted by the solenoid

No of turns of copper = N = 400
Current = I = 10A
MMf = M * I = 400 * 10 = 4000 AT
Reluctance of force =
=250.88*103

Flux =
=15.94m wb

Flux density = B = Flux/cs area

B = 70.53 wb/m2

Force =
Force = 570 N

V. FABRICATION OF MODEL
In electro-magnetic braking system we use electromagnetic property due to which action of braking will be done. in
this system we used electro magnet iron plate, liners, tension spring, disc brake plate.The brake liners are attached with
electro-magnet and iron plate individually and both plates insert the disc plate as shown in figure and this plate is fixed
with wheels. The battery of minimum 12 volts is used for external power supply. In electro-magnetic braking system
we use silicon control rectifier (SCR) The gate pulse of SCR is fired and the output of SCR is given to electro-magnet
for braking the wheels. This SCR provides high current to our electro-magnetic braking system, electro-magnet and
attracts the iron plate towards itself. This method opposes the motion of wheels, here we have designed electro-
magnetic coil and liner system.

Figure 7: Diagram Of Electromagnetic Braking System

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International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

Figure 8: Firing Circuit

The various stages of fabrication of the prototype model is as follows:

Fabrication of frame

Attachment of wheel to frame Coil with braking plate & chain drive along with motor is added to the frame
Finally, control circuit box with battery is assembled and connected to the limit switches.
Final assembly

Figure 9: CAD Model

VI. CONCLUSION

An electromagnetic braking for automobiles like bike, car has an effective braking system. In addition, by using
these electromagnetic brakes, we can increase the life of the braking unit the working principle of this system is that
when the electromagnetic flux passes though and perpendicular to the notating wheel the eddy current is induced in the
rotating wheel Eddy current flows opposite to the routing wheel? This eddy current tries to stop the rotating wheel or
TX
This results in the rotating wheel or rotor comes to rely Electromagnetic braking system is found to be more reliable
as compared to other braking systems.

IJIRSET © 2021 | An ISO 9001:2008 Certified Journal | 8622

International Journal of Innovative Research in Science, Engineering and Technology (IJIRSET)

| e-ISSN: 2319-8753, p-ISSN: 2320-6710| www.ijirset.com | Impact Factor: 7.569|

|| Volume 10, Issue 7, July 2021 ||

|DOI:10.15680/IJIRSET.2021.1007008|

In oil braking system or air baking system, even a small leakage may lead to complete failure of brakes. While in
electromagnetic braking system as four disc plates, col and firing circuits are attached individually on each wheel,
electromagnetic brakes make up approximately 80% of all of the power applied brake applications. Electromagnetic
brakes have been used as supplementary retardation equipment in addition to the regular friction brakes on beany
vehicles.
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September 2008, Retrieved On 13 April 2009.
2. "Next: The Voltswagon?" Time Magazine, 22 December 1967, Retrieved On 13april 2009.
3. GM Patents 5775467 -Floating Electromagnetic Brake System.Roger Ford (July 2, 2007). "Regenerative Braking
Boosts Green Credentials".
4. Railway Gazette International
Http://Www.Railwaygazette.Com/Features_view/Article/ 2007/07/7577/Regenerative_braking Boosts_green_
Credentials.Html.Delhi Metro Prevents 90,000 Tons Of CO2. Http:// Economictimes.Indiatimes.Com/Earth/Delhi-
metro-cuts 90000-tons-ofco2/Articleshow/41
5. Andreen, J.H., Gibson, J.W. and Wetmore, O.C., 1953. Fabric evaluations based on physiological measurements
of comfort. Textile Research Journal, 23(1), pp.11-22. 2.
6. Totala, N.B., Bhosle, P., Jarhad, S., Jadhav, S. and Kuchekar, K., 2015, April. Electromagnetic Braking System. In
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Innovative Research in Science, Engineering and Technology (IJIRSET),Volume-3 in April 2014
8. Flybird System
9. Torotrak

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