JURNAL SISTEM REM

(Enhancement Of Braking System In Automobile Using Electromagnetic

Braking)

Disusun oleh :

Vendi Dwi Pamungkas (17504241035 / A22)

PENDIDIKAN TEKNIK OTOMOTIF

FAKULTAS TEKNIK
UNIVERSITAS NEGERI YOGYAKARTA
2017
 Enhancement Of Braking System In Automobile Using Electromagnetic
Braking
Akshyakumar S.Puttewar1, Nagnath U. Kakde2, Huzaifa A. Fidvi3, Bhushan Nandeshwar4

Abstract

An electromagnetic brake is a new and revolutionary concept. Electromagnetic braking

system in a modern tecnology braking system used in light motor and heavy motor vehicles
like car, jeep, truck, busses, etc. This system is a combination of elctro-mechanical concepts.
The frequency of accidents is now-a-days increasing due to inefficient braking system.in this
research work, with a view to chance to the braking system in automobile, a prototype model
is fabricated and analyzed. It is apparent that the 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.

Keywords: Accidents, Electromagnetic, Braking, Eddy current braking system, Hydraulics,

Energy Flow

I. INTRODUCTION

With the technological enhancement a lot of new technologies are arriving in the world.
Many industries got their faces due to the arrival of these technologies. An automobile
technology is one of them. As a part of automobile, there are also innovations in brake. The
commonly used types of brakes used in automobiles are drum and disc brakes[1]. Various
types of braking system used are hydraulic [2] ,pneumatic etc. Magnetic braking forms the
basis of growing technology [3]. Braking system is generally classified based upon the
principle of operation. The two major type of brake are frictional and electromagnetic
retarder [4]. The principle of braking in road vehicles involves the conversion of kinetic
energy into thermal energy (heat).When stepping on the brakes, the driver commands a
stopping force several times as powerful as the force that puts the car in motion and dissipates
the associated kinetic energy as heat. Ineffective braking results in a lot of accidents. Brakes
must be able to arrest the speed of a vehicle in a short period of time regardless how fast the
speed is. As a result, the brakes are required to have the ability to generating high torque and
absorbing energy at extremely high rates for short periods of time. Brakes may be applied for
a prolonged periods of time in some applications such as a heavy vehicle descending a long
gradient at high speed. Brakes must have the mechanism to keep the heat absorption
capability for prolonged periods of time. The frequency of accidents is now-a-days increasing
due to inefficient braking system. Hence braking system needs to be enhanced for effective
and efficient braking. Electromagnetic brake is as new revolutionary concept [5]. It is found
that electromagnetic brakes can develop a negative power which represents nearly twice the
maximum power output of a typical engine, and at least three times the braking power of an
exhaust brake. These performance of electromagnetic brakes make them much more
competitive candidate for alternative retardation equipments compared with other retarders.
In this research work, with a view to enhance to the braking system in automobile, a
prototype model is created and analyzed. 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.

ELECTROMAGNETIC BRAKING
1. Introduction
Electromagnetic brakes operate electrically, but transmit torque mechanically[6]. This is
why they used to be referred to as electro-mechanical brakes[7]. 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. Electromagnetic brakes have been used as supplementary retardation equipment
in addition to the regular friction brakes on heavy vehicles. Various Other types of
Electromagnetic Braking System are: Electromagnetic Braking System With Brake Pads,
Eddy-Current Braking System[8].

2. Construction
There are three parts to an electromagnetic brake: field, armature, and hub (which is the
input on a brake)[9]. 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.

3. Working Principle
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”. The strength of the magnetic field can be
changed by changing both wire size and the amount of wire (turns). 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. 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 20°C. 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 + aCu × (Tf - T)]
Where Rf = final resistance, Ri = initial resistance, aCu = copper wire’s temperature
coefficient of resistance, 0.0039 °C-1, Tf = final temperature, and Ti = initial temperature.

4. Instalation Location
Electromagnetic brakes work in a relatively cool condition and satisfy all the energy
requirements of braking at high speeds, completely without the use of friction. Due to its
specific installation location (transmission line of rigid vehicles), electromagnetic brakes
have better heat dissipation capability to avoid problems that friction brakes face as
mentioned before. Typically, electromagnetic brakes have been mounted in the transmission
line of vehicles. The propeller shaft is divided and fitted with a sliding universal joint and is
connected to the coupling flange on the brake. The brake is fitted into the chassis of the
vehicle by means of anti-vibration mounting.

Details Of Components Used

The various components used include Disc brake plate, Disc liner, breaking coil,
Tension spring, Battery, Alloy wheel & Electro-magnet. The arrangement of all these
components can be best explained using the following block diagram:

1. Disk brake plate

2. Disk liner
The lining is the portion of the braking system which converts the vehicle's kinetic
energy into heat. The lining must be capable of surviving high temperatures without
excessive wear (leading to frequent replacement) or out gassing (which causes brake fade, a
decrease in the stopping power of the brake). Brake linings are composed of a relatively soft
but tough and heat-resistant material with a high coefficient of dynamic friction (and ideally
an identical coefficient of static friction) typically mounted to a solid metal backing using
high-temperature adhesives or rivets.
3. Braking coil
An electromagnetic coil (or simply a "coil") is formed when a conductor (usually an
insulated solid copper wire) is wound around a core or form to create an inductor or
electromagnet. When electricity is passed through a coil, it generates a magnetic field. One
loop of wire is usually referred to as a turn or a winding, and a coil consists of one or more
turns. For use in an electronic circuit, electrical connection terminals called taps are often
connected to a coil. Coils are often coated with varnish or wrapped with insulating tape to
provide additional insulation and secure them in place. A completed coil assembly with one
or more set of coils and taps is often called windings.

4. Tension Spring
A spring is an elastic object used to store mechanical energy. Depending on the design
and required operating environment, any material can be used to construct a spring .When a
spring is compressed or stretched, the force it exerts is proportional to its change in length.
The rate or spring constant of a spring is the change in the force it exerts, divided by the
change in deflection of the spring. That is, it is the gradient of the force versus deflection
curve. An extension or compression spring has units of force divided by distance, for example
lbf/in or N/m.

5. Battery
A battery is a device that converts chemical energy directly to electrical energy. It
consists of a number of voltaic cells; each voltaic cell consists of two half cells connected in
series by a conductive electrolyte containing anions and cations. One half-cell includes
electrolyte and the electrode to which anions (negatively charged ions) migrate, i.e., the
anode or negative electrode; the other half-cell includes electrolyte and the electrode to which
cations (positively charged ions) migrate, i.e., the cathode or positive electrode. In the redox
reaction that powers the battery, reduction (addition of electrons) occurs to cations at the
cathode, while oxidation (removal of electrons) occurs to anions at the anode.
The electrodes do not touch each other but are electrically connected by the
electrolyte. Some cells use two half-cells with different electrolytes. A separator between half
cells allows ions to flow, but prevents mixing of the electrolytes. Each half cell has an
electromotive force (or emf), determined by its ability to drive electric current from the
interior to the exterior of the cell. The net emf of the cell is the difference between the emf of
its half-cells, as first recognized by Volta. Therefore, if the electrodes have emf and, then the
net emf is in other words, the net emf is the difference between the reduction potentials of the
half-reactions.
6. Alloy wheel
Alloy wheels have become considerably more common since 2000. Alloy wheels are
automobile (car, motorcycle and truck) wheels which are made from an alloy of aluminum or
magnesium. They are typically lighter for the same strength and provide better heat
conduction and improved cosmetic appearance over steel wheels. The earliest light alloy
wheels were made of magnesium alloys. Alloy wheels have long been included as standard
equipment on higher-priced luxury or sports cars, with larger-sized or "exclusive" alloy
wheels being options. The high cost of alloy wheels makes them attractive to thieves; to
counter this, automakers and dealers often use locking wheel nuts which require a special key
to remove. Most alloy wheels are manufactured using casting, but some are forged.

7. Electro-magnet
An electromagnet is a type of magnet in which the magnetic field is produced by the
flow of electric current. An electric current flowing in a wire creates a magnetic field around
the wire. To concentrate the magnetic field, in an electromagnet the wire is wound into a coil
with many turns of wire lying side by side. The magnetic field of all the turns of wire passes
through the center of the coil, creating a strong magnetic field there. The direction of the
magnetic field through a coil of wire can be found from a form of the right-hand rule. The
main advantage of an electromagnet over a permanent magnet is that the magnetic field can
be rapidly manipulated over a wide range by controlling the amount of electric current.

II. FABRICATION OF MODEL

In electro-magnetic braking system we use electro-magnetic 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.

Fig. 8 Constructional diagram Fig. 9 Firing Circuit Diagram

Fabrication Stages
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

Cost Estimation
 III. CONCLUSION
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. And this system needs very
little of maintenance. In addition, it is found that 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 heavy vehicles. The frictions brakes can be used less frequently and therefore
practically never reach high temperatures. The brake linings would last considerably longer
before requiring maintenance and the potentially “brake fade” problem could be avoided.
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. Furthermore the
electromagnetic brakes prevent the danger that can arise from the prolonged use of brake
beyond their capability to dissipate heat.

REFERENCES
http://www.iosjournals.org/iosr-jmce/papers/ICAET-2014/me//volume-2/14.pdf