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CALIBRATION OF THE ELECTROMAGNETIC BRAKE

Conference Paper · November 2015

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 2015 INTERNATIONAL SCIENTIFIC CONFERENCE
20 – 21 November 2015, GABROVO

CALIBRATION OF THE ELECTROMAGNETIC BRAKE

Marko Šućurović1, Nebojša Mitrović2, Miroslav Bjekić1, Miloš Božić1, Marko Rosić1
1
Faculty of Technical Sciences Čačak, University of Kragujevac, Serbia
2
Faculty of Electronic Engineering, University of Niš, Serbia

Abstract
The procedure of electromagnetic brake calibration is presented in the paper. HBM torque meter is used for
measuring. By processing the measured values of torque and speed, torque functions in correlation to rotation speed
are obtained. Derived functions of the braking torque for the brake with the ferromagnetic disk are compared with
measured values, and their accuracy is confirmed.

Key words: electromagnetic brake, torque meter, mechanical characteristics.

INTRODUCTION Laboratory of electrical machines, drives and

For efficiency class testing of asynhronous regulations [4], has rotating ferromagnetic disc
motor (IE code), it is necessary to provide only on one side of the brake.
their load control. This is performed by
loading motor with braking torque in the CONSTRUCTION OF THE
specific range. ELECTROMAGNETIC BRAKE
One procedure of determination of the The electromagnetic brake consists of the
asynhronous motor energy efficiency is moving part and the stationary part.
presented in [1,2]. It is possible to perform Components of the electromagnetic brake used
load on the motor shaft by an electrical in this work are presented in the paper [5].
machine which is working in the generator The stationary part consists of the pedestal
mode, and by some types of brake. with 8 electrоmagnets and the brake shaft on
There are two types of brakes that can be it. Ferromagnetic disc (Fig. 1a) and aluminum
used for motor loading: contact brakes disc (Fig. 1b) are on the brake shaft.
(friction), and contactless brakes (electro- Mechanical connection of the brake and
magnetic). drive machine is realized by flexible coupling.
Control of the electromagnetic brake is
performed by using DC current which is
passed through the electromagnet coils. Coil
generates a static magnetic field. Disc rotates
in this magnetic field and due to rotation,
electromotive force is generated that produces
eddy current inside the disc. These eddy
currents produce braking torque which slows
down brake disc.
This type of brake usually has two discs set
on both sides, thereby the great axilliare force
and strain of bearings are cancelled. Practical
example of using this construction of the
electromagnetic brake is retarder of „Telma“ a) b)
for slowing down trucks and buses [3]. The Fig. 1. The electromagnetic brake with
electromagnetic brake, constructed in the ferromagnetic disc (a) and aluminum disc (b)

International Scientific Conference “UNITECH 2015” – Gabrovo I-159

PROCEDURE AND RESULTS OF
MEASURING BRAKING TORQUE
Measurement of the mechanical characte- 1
ristics of the brake is realized with the 2
equipment presented on the Fig. 2. DC motor
with power of 1.5 kW, is used for creating the
torque. DC motor is selected because it has
suitable mechanical characteristics, which can
be obtained in the wide range of speeds, by
using different types of settings: in this case,
changing voltage of armature circuit was used.
Fig. 3. Front panel of the application in LabVIEW:
1-numerical values for torque speed, torque and
power, 2-time shape of measured torque

Measuring is done the following way: For

the fixed values of brake current, braking
torque for some values of rotation speed is
measured.
Measuring results of the torque and speed
of the brake with ferromagnetic disc are
presented in the Fig. 4. Presented results refer
to brake current range from 0.2 to 0.8 A.
18

Fig. 2. The equipment used for measuring of the 0.8 A

mechanical characteristics of the electromagnetic 16

brake: 1-electromagnetic brake, 2-drive machine,

3-torque meter, 4-connection box of the torque meter 14 0.7 A

Braking torque and rotation speed of the 12

brake are measured by the HBM T20WN
torque meter [6]. This torque meter is designed 10 0.6 A

for measuring static and dynamic torque,

M [Nm]

rotation speed, and angle of rotation [6]. The 8 0.5 A

torque meter obtains the output voltages in the
range ±10 V. The torque meter is coupled with 6
the motor shaft, on one side, and the shaft of 0.4 A

the brake, on the other side. Coupling is 4

realized with flexible bellow couples (Fig. 2). 0.3 A

The connection box VK20A was used as an 0.2 A

2
additional equipement. It enables easier
connecting and improves security of the torque
0
meter operations [6]. 0 500 1000 1500 2000
n [min-1]
cDAQ-9178 with the acquisition card for
voltage measurement NI 9225 [7] is used for Fig. 4. Measured values of the torque and the
acquisition of voltage signals, representing speed of the brake with ferromagnetic disc (Ik =
torque and speed. Voltage signals are 0.2-0.8 A)
processed by the LabVIEW software. The
current values of braking torque in Nm, speed Measuring results of the torque for brake
of rotation in min-1, electric power in W, and with aluminum disc are presented in the Fig. 5.
the torque shape in time, are presented in the Presented results refer to brake current range
Front panel (Fig. 3). from 0.2 to 2 A.

I-160 International Scientific Conference “UNITECH 2015” – Gabrovo

 As it is expected significantly lower value  A1 B1 C1 D1   −4,74 −0,00316 3,53 −0,0379 
of the braking torque is confirmed compared A B2 C2 D2   26, 41 0,00726 −25,0 0,0194 
 2 =
to the brake with ferromagnetic disc for the  A3 B3 C3 D3   2, 24 −0,00726 −2,75 0,00436 
same values of speed and braking current.    
 A4 B4 C4 D4   −0, 262 0,00110 0,319 −0,0072 
9

2A - for the electromagnetic brake with aluminum

8 disc:
7
1.8 A  A1 B1 C1 D1   0, 413 0,000174 −0, 413 0,000705 
A B2 C2 D2   2,04 −0,000531 −2,06 −0,00322 
6
 2 =
1.6 A  A3 B3 C3 D3   −0,357 0,000176 0,358 0,00599 
   
5  A4 B4 C4 D4   0,647 0,000120 −0,641 −0,00729 
M [Nm]

1.4 A

4 Torque values for any values of braking

1.2 A
speed and current in the measured range, are
3
1A
calculated by the obtained coefficients and
0.8 A
interpolation expressions (1) and (2).
2

0.6 A
Mechanical characteristics of the brake with
1
0.4 A ferromagnetic disc and the brake with
0.2 A
aluminum disc, obtained with the interpolation
0
and measurement, are presented in the Fig. 6
0 200 400 600 800
n [min-1]
1000 1200 1400
and 7.
Fig. 5. Measured values of the torque and the 20
0,8 A

speed of the brake with aluminum disc (Ik=0.2-2A)

18

ANALITICAL EXPRESSION OF THE

16 0,7 A
BRAKING TORQUE
Using MATLAB and its application cftool 14

it is possible to estimate correlation of torque

12
and speed by interpolation for the defined 0,6 A
braking current. Braking torque is defined with
M [Nm]

10

the following exponential function [4]:

8
0,5 A

M k (n) = A ⋅ e ( B ⋅n )
+ C ⋅e (D ⋅n )
(1) 6
0,4 A

Coefficients A, B, C and D depend on the 4 0,3 A

value of braking current. This dependence is 2

0,2 A

defined with the third-order polynomial.

Polynomial coefficients are calculated by the 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
same application in MATLAB. n [min-1]

Fig. 6. Mech. characteristics of the brake with Fe

A = A1 ⋅ I k3 + A2 ⋅ I k2 + A3 ⋅ I k + A4 

B = B1 ⋅ I k3 + B2 ⋅ I k2 + B3 ⋅ I k + B4 

C = C1 ⋅ I k3 + C2 ⋅ I k2 + C3 ⋅ I k + C4 
D = D1 ⋅ I k3 + D2 ⋅ I k2 + D3 ⋅ I k + D4 
The obtained coefficients are presented in
the a matrix form. Coefficients are:
- for the electromagnetic brake with
ferromagnetic disc:
International Scientific Conference “UNITECH 2015” – Gabrovo
disc (○ measured values, ― interpolation
(2) function)
Some differences between measured and
interpolated values could be observed.
According to the main idea in the introduction
of the paper, indirect measurement of the
braking torque was realized by electrical
measuring of the input electric power of the
motor and calculating all losses in the motor.
I-161
 9
measured directly by the torque meter give the
2A higher values than the values obtained
8
indirectly with the DC motor. For the
minimum and maximum braking current (0.2
7
A and 0.7 A), differences in the torque values
are the highest: for 1000 min-1 the values are
1,8 A

14.77% and 15.25%; for 1500 min-1 the values

6

5
1,6 A are 23.47% and 16.33%. These differences are
around 6% in real operating conditions zone,
M [Nm]

4
1,4 A
which is satisfactory.
1,2 A

3 CONCLUSION
1A
This paper compares two ways of
0,8 A
2 determining electromagnetic brake torque:
0,6 A
indirect method – processing measuring results
0,4 A
1 0,2 A of electric parameters, and direct method –
measuring with torque transducer. It has been
0
0 200 400 600 800 1000 1200 1400 1600 shown that difference between these two
n [min-1]
methods is few percent. Dependence of these
Fig. 7. Mech. characteristics of the brake with Al two measuring methods are derived and
disc (○ measured values, ― interpolation function) presented in the analytical form.

Considering that the value of torque was ACKNOWLEDGMENT

determined for the same electromagnetic brake This paper is a result of the project TR33016
with ferromagnetic disc in this paper and in the which is supported by Ministry of Education,
paper [5], obtained results are compared. The Science and Technological Development of the
values of the torque for rotation speed from 1000 Republic of Serbia.
min-1 toward 1500 min-1 are presented in Tab. 1.
REFERENCE
Tab. 1. Torque values obtained by measuring with [1] Koprivica, B., Bozić, M., Rosić, M., Bjekić,M.,
torque meter and DC machine "Application of Standard and Modified Eh-Star
n=1000 min-1 n=1500 min-1 Test Method for Induction Motor Stray Load
Ik Losses and Efficiency Measurement", SJEE,
M1 M2 ΔM% M1 M2 ΔM%
0.2 1.76 1.5 14.77 2.13 1.63 23.47 Vol. 9, No. 3, pp. 277-391, 2012.
0.3 3.2 3 6.25 3.52 3.18 9.66 [2] Božić, M., Rosić, M., Koprivica, B., Bjekić, M.,
0.4 4.92 4.6 6.50 5.16 4.83 6.39 Antić, S., "Efficiency classes of three-phase,
0.5 7.18 6.8 5.29 7.4 7.05 4.73 cage-induction motors (IE-code) software",
0.6 10.21 9.6 5.97 10.58 9.8 7.37 INDEL 2012, pp 87-91, November 1-3, Banja
0.7 14.16 12 15.25 15 12.55 16.33
Luka, Bosna i Hercegovina, 2012.
M1 - Torque measured by the torque meter in Nm
M2 - Torque measured by the DC machine in Nm [3] Telma, Tehnical Specifications, AC 50-80
ΔM% - difference of torques in % Retarder, http://www.metsys.fi/ana/Telma.pdf
[4] Laboratory of electrical machines, drives and
regulations, www.empr.ftn.kg.ac.rs
Torque values for synhronous speeds of 6-
pole and 4-pole asynhronous motor are [5] Bjekić, M., Božić, M., Rosić, M. et al.,
compared. In the first case (M1), torque values "Design, Construction, Calibration and Use of
are obtained by direct measuring with HBM A New Type of Electromagnetic Brake",
torque meter. In the second case (M1), the XLVIII ICEST 2013, 26-29 June 2013 Ohrid,
Macedonia,Vol. 2 pp. 727-730.
values are obtained by processing the results
of measured electrical values. [6]T20WN, http://www.hbm.com/en/menu/product
Table 1 shows percentual differences s/transducers-sensors/torque/t20wn/
between torque values (ΔM%) for two rotation [7] NI 9227 - Data Sheet - National Instruments,
speeds of ferromagnetic disc. Torque values http://www.ni.com/datasheet/pdf/en/ds-194

I-162 International Scientific Conference “UNITECH 2015” – Gabrovo

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