ELECTRO MAGNETIC BRAKES

GROUP MEMBERS :

KSHITIJ K. WEER. GAYNOR GRATION LEWIS . SANKET S. TAVSALKAR. SANJEEV A. BAWASKAR.

INDEX

Summary Introduction Concept & product detail Types of electromagnetic brake Product detail Product requirements Machinery required Future scope Conclusion references

: SUMMARY :

Now days, the lots of new technologies are arriving in world. They create a lot of effect. Most of industries got their new faces due to this arrival of technologies. Automobile industry is also one of them. There is a boom in worlds automobile industry, so lots of research is also going here. As an important part of automobile, there are also innovations in brakes. Electromagnetic brakes is one of them. Electromagnetic brakes is a new revolutionary concept. Electromagnetic brakes are the brakes working on electric power & magnetic power. They works on the principle of electromagnetism. These are totally frictionless. Due to this, they are more durable & have longer life span. Less maintenance is there. These brakes are an excellent replacement on the conventional brakes due to their many advantages. The reason for implementing this brake in automobiles is to reduce wear in brakes as it is frictionless. Therefore there will also be no heat loss. It can be used in heavy vehicles as well as in light vehicles. The electromagnetic brakes are much effective than conventional brakes & the time taken for application of brakes are also smaller. There is very few need

of lubrication. Electromagnetic brakes gives better performance with less cost which is todays need. There are also many more advantages of Electromagnetic brakes. Thats why Electromagnetic brakes are an excellent replacement on conventional brakes. Electromagnetic brakes are the need of todays automobiles. A electromagnetic braking system for automobiles like cars, an effective braking system. And, by using this electro magnetic brakes, we can increases the life of the braking unit. The working principle of this system is that when the magnetic flux passes through and perpendicular to the rotating wheel the eddy current is induced in the rotating wheel or rotor. This 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. Construction : The construction of the electromagnetic braking system is very simple. The parts needed for the construction are electro magnets, rheostat, sensors and magnetic insulator. A cylindrical ring shaped electro magnet with winding is placed parallel to rotating wheel disc/

rotor. The electro magnet is fixed, like as stator and coils are wounded along the electromagnet. These coils are connected with electrical circuit containing one rheostat which is connected with brake pedal. And the rheostat is used to control the electric current flowing in the coils which are wounded on the electro magnet and a magnetic insulator is used to focus and control the magnetic flux. And also it is used to prevent the magnetisation of other parts like axle and it act as a support frame for the electromagnet. The sensors used to indicate the disconnection in the whole circuit. If there is any error it gives an alert, so we can avoid accident. Working principle : At the initial stage the brake pedal and rheostat are in rest. When we apply the brake through the brake pedal, the rheostat allows the current to flow through the circuit and this current energise the electromagnet. The amount of current flow is controlled by the rheostat. Depending on the current flow different amount of magnetic flux can be obtained. By this varying magnetic flux, different mode of brakes can be obtained. For example, if we want to suddenly stop the vehicle then press the brake pedal fully, then the rheostat allows maximum current

which is enough to stop the vehicle. Similarly we can reduce the speed of the vehicle by applying the brake gradually.

: INTRODUCTION :
Currently the automobile safety norms are going strict & strict which is important for saving occupants life in case of emergency. Brakes are one of the safety systems in automobiles. These days, many types of brakes are in use. Lets first see what are brakes. Brake : Brake is a device which inhibits motion or stops motion. They are the essential & important part of safety system of automobile. The primary functions of brakes are as follows. 1. To stop the vehicle in minimum possible distance. 2. To park the vehicle on slops.

For these purposes, brakes are used. Many developments are made in design of brakes. The brakes are classified as, According to purpose :

1) 2) 1) 2)

Primary or service brake. Secondary or Parking brakes. According to construction : Drum Brake. Disc Brake. According to method of actuation :
1) 2) 3) 4) 5)

Mechanical brake. Hydraulic brake. Air brake. Electric brake. Vacuum brake.

Brakes are generally applied to rotating axles or wheels. Some vehicles use a combination of braking mechanisms, such as drag racing cars with both wheel brakes and a parachute, or airplanes with both wheel brakes and drag flaps raised into the air during landing. Let us see some commonly used brakes in automobiles.

Drum Brake :

It uses the principle of Friction which is caused by a set of shoes or friction

pads that press against a rotating part known as brakes. The modern automobile drum brake was invented in 1902, though a less-sophisticated drum brake had been used a year earlier. It consists of a brake drum which is concentric to the axle hub whereas on the axle casing is mounted a back plate. The back plate is made up of pressed steel sheet and it provides support for the expander, anchor and brake shoes. It also protects the drum and shoe from mud and dust. Two brake shoes are anchored on the back plate, friction linings are mounted on brake shoe. One or more retractor springs are used which serves to keep the brake shoe away from the drum when the brake is not applied the brake shoe is anchored at one end whereas at other end force is applied by some other actuating mechanisms. When force is applied at one end of brake shoe it moves against the revolving drum thereby applying the brakes. These brakes has disadvantages like greater wear & tear. Also heat dissipation is poor. Diameter restriction due to tire dimensions, width restrictions imposed by the vehicle spring designer, problems of drum

distortion at widely varying temperatures. These brakes are less effective than other types.

DRUM BRAKES

Disc Brake :

Disc brakes work using the same basic principle as the brakes on a bicycle as the calliper pinches the wheel with pads on both sides, it slows the vehicle. Development of Disc-style brakes and use began in England in the 1890s. The first calliper-type automobile disc brake was patented by Fedrick William Lanchester in his Birmingham factory in

1902 and was used successfully on Lanchester cars. It consist of a cast iron disc bolted to the wheel hub and a stationary housing called calliper. The calliper is connected to the axial facing or stub axle and is cast in two parts. Each part contains a piston and in between each piston and the disc there is a fricyion pad held in position by retaining pins and spring plates. There are passages drilled in the calliper for fluid to enter or lead the housing. The passages are also connected to one another for bleeding. When the brakes are applied hydraulically actuated piston moves the friction pads in contact with the disc applying equal and opposite force on the disc, on releasing the brakes, the rubber sealing rings act as return spring and retract the pistons and friction pads away from the disc. These brakes are more costlier & effective than drum brakes.

DISC BRAKE

Air Brake :

Air brakes use standard hydraulic brake system components such as braking lines, wheel cylinders and a slave cylinder similar to a master cylinder to transmit the air-pressureproduced braking energy to the wheel brakes. Air brakes are used frequently when greater braking capacity is required.

AIR BRAKE

Hand Brake :

Hand brakes are the parking or emergency brakes. They helps a vehicle to park on a slope or during emergencies when primary brakes are disabled. They works independently of primary brakes.

HAND BRAKE

Electromagnetic Brake :

Electromagnetic brakes operate electrically, but transmit torque mechanically. This is why they are used to be referred to as electro-mechanical brakes. Over the years, EM brakes became known as electromagnetic, referring to their actuation method. There are three parts in an electromagnetic brake: field, armature and hub (which is the input on a brake). Usually the magnetic field is bolted to

the machine frame (or uses a torque arm that can handle the torque of the brake). So when the armature is attracted to the field the stopping torque is transferred into the field housing and into the machine frame decelerating the load. This can happen very fast (0.1-3sec). `Disengagement is very simple. Once the field starts to degrade flux falls rapidly and the armature separates. A spring holds the armature away from its corresponding contact surface at a predetermined air gap.

ELECTROMAGNETIC BRAKE

: CONCEPT & PRODUCT DETAIL :

CONCEPT : Voltage/Current - And the Magnetic Field

RIGHT HAND RULE

If a piece of copper wire was wound, around the nail and then connected to a battery, it would create an electro magnet. The magnetic field that is generated in the wire, from the current, is known as the right hand thumb rule. (V-1) The strength of the magnetic field can be changed by changing both wire size and the amount of wire (turns). EM clutches are similar; they use a copper wire coil (sometimes aluminum) to create a magnetic field. The fields of EM brakes can be made to operate at almost any DC voltage and the torque produced by the brake will be the same as long as the correct operating voltage and current is used with the correct brake. If a 90 volt brake had 48 volts applied to it, this would get about half of the correct torque output of that brake. This is because voltage/current is almost linear to torque in DC electromagnetic brakes. A constant current power supply is ideal for accurate and maximum torque from a brake. If a non regulated power supply is used the magnetic flux will degrade as the resistance of the coil goes up. Basically, the hotter the coil gets the lower the torque will be produced by about an average of 8% for

every 20C. If the temperature is fairly constant, and there is a question of enough service factor in the design for minor temperature fluctuation, by slightly over sizing the brake can compensate for degradation. This will allow the use of a rectified power supply, which is far less expensive than a constant current supply. Based on V = I R, as resistance increases available current falls. An increase in resistance, often results from rising temperature as the coil heats up, according to: Rf = Ri [1 + Cu (Tf - Ti)] Where Rf = final resistance, Ri = initial resistance, Cu = copper wires temperature coefficient of resistance, 0.0039 C-1, Tf = final temperature, and Ti = initial temperature. Electromagnetic brakes is a new revolutionary concept. They works on the principle of electromagnetism. These are totally frictionless.

Types of Electromagnetic Brakes

Electromagnetic Power Off Brake :

Electormagnetic Power Off Brake Spring Set

Introduction - Power off brakes stop or hold a load when electrical power is either accidentally lost or intentionally disconnected. In the past, some companies have referred to these as "fail safe" brakes. These brakes are typically used on or near an electric motor. Typical applications include robotics, holding brakes for Z axis ball screws and servo motor brakes. Brakes are available in multiple voltages and can have either standard backlash or zero backlash hubs. Multiple disks can also be used to increase brake torque,

without increasing brake diameter. There are 2 main types of holding brakes. The first is spring applied brakes. The second is permanent magnet brakes. How It Works : Spring Type - When no electricity is applied to the brake, a spring pushes against a pressure plate, squeezing the friction disk between the inner pressure plate and the outer cover plate. This frictional clamping force is transferred to the hub, which is mounted to a shaft. Permanent Magnet Type A permanent magnet holding brake looks very similar to a standard power applied electromagnetic brake. Instead of squeezing a friction disk, via springs, it uses permanent magnets to attract a single face armature. When the brake is engaged, the permanent magnets create magnetic lines of flux, which can turn attract the armature to the brake housing. To disengage the brake, power is applied to the coil which sets up an alternate magnetic field that cancels out the magnetic flux of the permanent magnets. Both power off brakes are considered to be engaged when no

power is applied to them. They are typically required to hold or to stop alone in the event of a loss of power or when power is not available in a machine circuit. Permanent magnet brakes have a very high torque for their size, but also require a constant current control to offset the permanent magnetic field. Spring applied brakes do not require a constant current control, they can use a simple rectifier, but are larger in diameter or would need stacked friction disks to increase the torque.

Electromagnetic Particle Brake :

Electromagnetic Particle Brake

Introduction : Magnetic particle brakes are unique in their design from other electro-mechanical brakes because of the wide operating torque range available. Like an electro-mechanical brake, torque to voltage is almost linear; however, in a magnetic particle brake, torque can be controlled very accurately (within

the operating RPM range of the unit). This makes these units ideally suited for tension control applications, such as wire winding, foil, film, and tape tension control. Because of their fast response, they can also be used in high cycle applications, such as magnetic card readers, sorting machines and labeling equipment.

How It Works : Magnetic particles (very similar to iron filings) are located in the powder cavity. When electricity is

applied to the coil, the resulting magnetic flux tries to bind the particles together, almost like a magnetic particle slush. As the electric current is increased, the binding of the particles becomes stronger. The brake rotor passes through these bound particles. The output of the housing is rigidly attached to some portion of the machine. As the particles start to bind together, a resistant force is created on the rotor, slowing, and eventually stopping the output shaft.

When electricity is removed from the brake, the input is free to turn with the shaft. Since magnetic particle powder is in the cavity, all magnetic particle units have some type of minimum drag associated with them.

Electromagnetic Hysteresis Power Brake :

Electromagnetic Hysteresis Power Brake

Introduction : Electrical hysteresis units have an extremely wide torque range. Since these units can be controlled remotely, they are ideal for test stand applications where varying torque is required. Since drag torque is minimal, these units offer the widest available torque range of any of the hysteresis products. Most applications involving powered hysteresis units are in test stand requirements. How It Works : 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. When electricity is removed from the brake, the hysteresis disk is free to turn, and no relative force is transmitted between either member. Therefore, the only torque seen between the input and the output is bearing drag.

Multiple Disk Brakes :

Introduction : Multiple disk brakes are used to deliver extremely high torque within a small space. These brakes can be used either wet or dry, which makes them ideal to run in multi speed gear box applications, machine tool applications, or in off road equipment.

Electromagnetic Multiple Disk Brake

How It Works : Electro-mechanical disk brakes operate via electrical actuation, but transmit torque mechanically. When electricity is applied to the coil of an electromagnet, the magnetic flux attracts the armature to the face of the brake. As it does so, it squeezes the inner and outer friction disks together. The hub is normally mounted on the shaft that is rotating. The brake housing is mounted solidly to the machine frame. As the disks are squeezed, torque is transmitted from the hub into the machine frame, stopping and holding the shaft.

When electricity is removed from the brake, the armature is free to turn with the shaft. Springs keep the friction disk and armature away from each other. There is no contact between breaking surfaces and minimal drag. Particle brakes are unique in their design from other electro-mechanical brakes because of the wide operating torque range available. Like an electromechanical brake, torque to voltage is almost linear; however, in a magnetic particle brake, torque can be controlled very accurately (within the operating RPM range of the unit). This makes these units ideally suited for tension control applications, such as wire winding, foil, film, and tape tension control. Because of their fast response, they can also be used in high cycle applications, such as magnetic card readers, sorting machines and labeling equipment. How It Works : Magnetic particles (very similar to iron filings) are located in the powder cavity. When electricity is applied to the coil, the resulting magnetic flux tries to bind the particles together, almost like a magnetic particle slush. As the electric current is increased, the binding of the particles becomes stronger. The brake rotor

passes through these bound particles. The output of the housing is rigidly attached to some portion of the machine. As the particles start to bind together, a resistant force is created on the rotor, slowing, and eventually stopping the output shaft. When electricity is removed from the brake, the input is free to turn with the shaft. Since magnetic particle powder is in the cavity, all magnetic particle units have some type of minimum drag associated with them.

: PRODUCT DETAIL :
Electromagnetic brakes operate electrically, but transmit torque mechanically. This is why they used to be referred to as electro-mechanical brakes. Over the years, EM brakes became known as electromagnetic, referring to their actuation method. Since the brakes started becoming popular over sixty years ago, the variety of applications and brake designs has

increased dramatically, but the basic operation remains the same. Single face electromagnetic brakes make up approximately 80% of all of the power applied brake applications. This article mainly concentrates on these brakes. Alternative designs are shown at the end of this article.

Basic Operation :
There are three parts to an electromagnetic brake: field, armature, and hub (which is the input on a brake) (B-2). Usually the magnetic field is bolted to the machine frame (or uses a torque arm that can handle the torque of the brake). So when the armature is attracted to the field the stopping torque is transferred into the field housing and into the machine frame decelerating the load. This can happen very fast (.1-3sec).

Disengagement is very simple. Once the field starts to degrade flux falls rapidly and the armature separates. A spring(s) hold the armature away from its corresponding contact surface at a predetermined air gap.

Working principle :
The working principle of the Electromagnetic brakes is based on the creation of currents within a metal disc rotating between two electromagnets, which sets up a force opposing the rotation of the disc .If the electromagnet is not energized, the rotation of the disc is free and

accelerates uniformly. When the electromagnet is energized, the rotation of the disc is retarded and the energy absorbed appears as heating of the disc. If the current exciting the electromagnet is varied by a rheostat, the braking torque varies in direct proportion to the value of the current. Electromagnetic brakes satisfy all the energy requirements of braking at high speeds, completely without the use of friction. Electromagnetic brakes have better heat dissipation capability to avoid problems that friction brakes face as we mentioned before. The brakes are fitted to vehicle by means of anti vibration mounting.

Construction :
A horseshoe magnet (A-1) has a north and south pole. If a piece of Iron contacts both poles, a magnetic circuit is created. In an electromagnetic brake, the north and south pole is created by a coil shell and a wound coil. In a brake, the armature is being pulled against the brake field. (A-3) The frictional contact, which is being controlled by the strength of the magnetic field, is what causes the rotational motion to stop. All

of the torque comes from the magnetic attraction and coefficient of friction between the steel of the armature and the steel of the brake field. For many industrial brakes, friction material is used between the poles. The material is mainly used to help decrease the wear rate. But different types of material can also be used to change the coefficient of friction (torque) for special applications. For example, if the brake was required to have an extended time to stop or slip time, a low coefficient material can be used. Conversely, if the brake was required to have a slightly higher torque (mostly for low RPM applications), a high coefficient friction material could be used. In a brake, the electromagnetic lines of flux have to attract and pull the armature in contact with it to complete brake engagement. Most industrial applications use what is called a singleflux two-pole brake. The coil shell is made with carbon steel that has a combination of good strength and good magnetic properties. Copper (sometimes aluminum) magnet wire, is used to create the coil, which is held in shell either by a bobbin or by some type of epoxy/adhesive.

To help increase life in applications, friction material is used between the poles. This friction material is flush with the steel on the coil shell, since if the friction material was not flush, good magnetic traction could not occur between the faces. Some people look at electromagnetic brakes and mistakenly assume that, since the friction material is flush with the steel, that the brake has already worn down, but this is not the case.

Advantages :
1. Electromagnetic brakes are more durable. 2. Electromagnetic brakes has a longer life span. 3. Electromagnetic brakes are much more effective. 4. Electromagnetic brakes works totally frictionless. 5. Better cooling of brakes. 6. There is less amount of wear. 7. Maintenance required is negligible.

CIRCUIT DIAGRAM

: Product Requirements :
Copper (For Winding). Aluminum or Cast Iron (for casing). 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 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 c Amplifying the output voltage to electromagnets

: Machinery Required :

Drilling. Welding.

: FUTURE SCOPE :
A revolutionary invention is made in the field of brakes. The Electromagnetic brakes are excellent replacement for conventional automobile brakes. The use of Electromagnetic brakes can be done for lighter vehicles also. With some modification, a regenerative braking system can be equipped with the Electromagnetic brakes. The Electromagnetic brakes are the future of automobile brakes.

: CONCLUSION :
Electromagnetic brakes can be used for modern Light as well as heavy vehicles. They give better performance with enhanced safety.

: REFRENCES :
Google search. Wikipedia.com Howstuffworks.com