MAGNETIC BRAKING SYSTEM

ABSTRACT

The topic of magnetic braking has dramatically increased in popularity in

recent years. Since 1987, numerous articles about magnetic braking were published.

These articles describe both experiments dealing with magnetic braking, as well as the

theory behind the phenomenon. Magnetic braking works because of induced currents

and Lenz's law. If you attach a metal plate to the end of a pendulum and let it swing,

its speed will greatly decrease when it passes between the poles of a magnet.

When the plate enters the magnetic field, an electric field is induced in metal

and circulating eddy currents are generated. These currents act to oppose the change

in flux through the plate, in accordance with Lenz's Law. The currents in turn heat the

plate, thereby reducing its kinetic energy. The practical uses for magnetic braking are

numerous and commonly found in industry today. This phenomenon can be used to

damp unwanted nutations in satellites, to eliminate vibrations in spacecrafts, and to

separate nonmagnetic metals from solid waste

Mechatronics is a hybrid technological field which evolved from the

combination of mechanical, electronics & Software engineering. Automobiles need

high degree of safety to protect the occupants and their property. Bearing this in

senses we come up with a new concept of Electric pulse Magnetic Braking

(E.P.M.Braking).

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

When the driver applies force on the brake pedal the magnitude is sensed by

the pressure transducer which in turn sends the actuating signals to microprocessor.

This intelligent device sends pulsating D.C. current from the capacitor to the power

pack. The power pack develops sufficient torque to decelerate or stop the vehicle as

per the driver's requirement. The torque produced is directly proportional to the force

applied on the brake pedal, as the intensity of the actuating signal from the pressure

transducer is directly proportional to the pulsating D.C. current supplied to the power

pack.

Another important aspect of this braking system is that the power pack also

acts as a generator, which results in additional power generation. We have also

incorporated artificial intelligence. Logic gates for backup-circuit for safety and shift

current for shifting the power pack from generating mode to braking mode and vice-

versa to generator power.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

CONTENTS

1. INTRODUCTION

2. PRINCIPLE OF OPERATION

3. CONSTRUCTION

4. WORKING

5. MAGNETIC BRAKING SYSTEM IN TRAINS

6. BRAKING POWER CALCULATIONS

7. MAGNETIC BRAKING SYSTEM REQUIREMENTS

8. MOUNTING AND INSTALLATION

9. ADVANTAGES

10. DISADVANTAGES
Dept. of Mechanical Engineering P.K.C.E.T, Kandala
 MAGNETIC BRAKING SYSTEM

11. APPLICATIONS

12. CONCLUSION

13. REFERENCES

INTRODUCTION

Many of the ordinary brakes, which are being used now days stop the vehicle

by means of mechanical blocking. This causes skidding and wear and tear of the

vehicle. And if the speed of the vehicle is very high, the brake cannot provide that

much high braking force and it will cause problems. These drawbacks of ordinary

brakes can be overcome by a simple and effective mechanism of braking system The

magnetic braking system. It is an abrasion-free method for braking of vehicles

including trains. It makes use of the opposing tendency of eddy current.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Eddy current is the swirling current produced in a conductor, which is subjected to a

change in magnetic field. Because of the tendency of eddy currents to oppose, eddy
Dept. of Mechanical Engineering P.K.C.E.T, Kandala
 MAGNETIC BRAKING SYSTEM

currents cause energy to be lost. More accurately, eddy currents transform more useful

forms of energy such as kinetic energy into heat, which is much less useful. In many

applications, the loss of useful energy is not particularly desirable. But there are some

practical applications. Such an application is the magnetic brake.

Magnetic brake in trains

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

PRINCIPLE OF OPERATIONS

Magnetic brake works according to Faradays law of electromagnetic

induction. According to this law, whenever a conductor cuts magnetic lines of forces,

an emf is induced in the conductor, the magnitude of which is proportional to the

strength of magnetic field and the speed of the conductor. If the conductor is a disc,

there will be circulatory currents i.e. eddy currents in the disc. According to Lenzs

law, the direction of the current is in such a way as to oppose the cause, i.e. movement

of the disk.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Essentially the magnetic brake consists of two parts, a stationary magnetic field

system and a solid rotating part, which include a metal disc. During braking, the metal

disc is exposed to a magnetic field from an electromagnet, generating eddy currents in

the disc. The magnetic interaction between the applied field and the eddy currents

slow down the rotating disc. Thus the wheels of the vehicle also slow down since the

wheels are directly coupled to the disc of the magnetic brake, thus producing smooth

stopping motion.

EDDY CURRENT INDUCED IN A CONDUCTOR

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

CONSTRUCTION

Essentially a magnetic brake consists of two members, a stationary

magnetic field system and a solid rotary member, generally of mild steel, which is

sometimes referred to as the secondary because the eddy currents are induced in it.

Two members are separated by a short air gap, theyre being no contact between the

two for the purpose of torque transmission. Consequently there is no wear as in

friction brake.

Stator consists of pole core, pole shoe, and field winding. The field

winding is wounded on the pole core. Pole core and pole shoes are made of cast steel

laminations and fixed to the state of frames by means of screw or bolts. Copper and

aluminium is used for winding material the arrangement is shown in fig. 1. This

system consists of two parts.

1. Stator

2. Rotor

Stator:-

It is supported frame members of the vehicle chassis. It has introduced

magnetic poles energized by windings. Current is supplied to the winding from the

battery.

Rotor:-

It is a rotating disc, which is fitted on the line of crankshaft with small air gap to

stator. When disc rotates a flux change occur in the section of the disc passing the

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

poles of stator. Due to the flux change there is a circulatory or eddy current in the

disc around the magnetic lines of force. The effect of this eddy current induces N

and S poles at the surface of the disc. Then there will be a drag or braking effect

in between eddy current induced poles and magnetic poles in the stator. By

changing current from the battery we can change the braking force. In this breaking

system kinetic energy of the vehicle is converted to heat and this heat is dissipated

through the rotating disc.

Total resistance of field winding

R = L/A

where, L = total length of field winding in meter.

= Resistivity of the wire in ohm meter

A = the area of cross section of field winding in m2

Total no: of terms = total length /mean length of one term

The rotor is a rotating disc on shaft, which is placed very near to the stator

with small air gap (1 mm to 2 mm). Rotating disc may be one or both side of stator.

The two units have common ring member, poles cores on which winding are

provided being fixed to ring number. If a malleable casting is employed, then the pole

core could be cast integrally with the right. After fitting the windings on the cores,

poles shoes are fitted to provide pole faces of appropriate shape and area. The rotor

disc should be provided with properly designed fins for faster heat removal. The

magnetic circuits of the two units are substantially the same, non-undue and thrust

would be imposed on the motor bearings. Slight axial displacement of rotor could

however, cause quite appreciable discrepancy, the air gap of two units. The

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

effect would be to increase the magnetic pull in one air gap and diminish it on other

which could give to rise to excessive and thrust on rotor bearing to overcome the

inherent defect, the air gaps of both units could be put in series by making the central

number non magnetic and providing a continues pole core for each pair axially

opposite poles. This modification could possibly reduce the length of the combined

pole course or permits a larger winding length.

The maximum diameter of the magnetic brake is decided by

1. The spacing of vehicle chassis frame

2. Vehicle floor clearance

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

WORKING

When the vehicle is moving, the rotor disc of magnetic brake which is coupled

to the wheels of the vehicle rotates, in close proximity to stationary magnetic poles.

When we want to brake the vehicle, a control switch is put on which is placed on the

steering column in a position for easy operation.

When the control switch is operated, current flows from a battery to the field

winding, thus energizing the magnet. Then the rotating disc will cut the magnetic

field. When the disc cuts the magnetic field, flux changes occur in the disc which is

proportional to the strength of the magnetic field. The current will flow back to the

zero field areas of the metal plate and thus create a closed current loop like a whirl or

eddy. A flow of current always means there is a magnetic field as well. Due to Lenzs

law, the magnetic field produced by the eddy currents works against the movement

direction. Thus instead of mechanical friction, a magnetic friction is created. In

consequence, the disc will experience a drag or the braking effect, and thus the disc

stops rotation. The wheels of the vehicle, which is directly coupled to the disc, also

stop rotation. Faster the wheels are spinning, stronger the effect, meaning that as the

vehicle slows, the braking force is reduced producing a smooth stopping action.

The control switch can be set at different positions for controlling the

excitation current to several set values in order to regulate the magnetic flux and

consequently the magnitude of braking force. i.e. if the speed of the vehicle is lpw, a

low braking force is required to stop the vehicle. So the control switch is set at the

lowest position so that a low current will be supplied to the field winding. Then the

magnetic field produced will be of low strength, so that a required low braking force

is produced.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

When the control switch is operated during the standby position of the vehicle, the

magnet will be energized and magnetic field is created. But since the wheels are not

moving, magnetic lines of force are not cut by it, and the brake will not work.

However, a warning lamp is provided on the instrument panel to indicate whether

the brake is energized. This provides a safe guard for the driver against leaving the

unit energized.

When control switch is put in any one of the operating positions, the

corresponding conductor in the contractor box is energized and current flows from the

battery to the field winding to the contractor box. This current magnetizes the poles

in stator, which placed very near to the rotor. When rotor rotates it will cut magnetic

lines and eddy current will set up in the rotor. The magnetic field of this eddy current

produces a breaking force or torque in the opposite direction of rotation disc. This

kinetic energy of rotor is converted as heat energy and dissipated from rotating disc to

surrounding atmosphere. Current in the field can change by changing the position of

the controls switch. Thus we can change the strength of the braking force.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Magnetic field lines across the magnetic material inside a copper tube

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Direction of magnetic lines of force due to magnet in copper tube

Induction of Eddy current due to the motion of magnet in the copper tube

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Direction of magnetic lines of force produced by induced eddy current

MAGNETIC BRAKING SYSTEM IN TRAINS

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

In the case of trains, the part in which the eddy current is induced is rail. The

brake shoe is enclosed in a coil, forming an electromagnet. When the magnet is

energized, eddy currents are induced in the rail by means of electromagnetic

induction, thereby producing braking action.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

MAGNETIC BRAKING SYSTEM IN TRAINS

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

TYPES OF MAGNETIC BRAKE

There are two types of magnetic brakes according to the method of excitation.

1. Electrically excited - magnetic brake

2. Permanent magnet - magnetic brake

1. ELECTRICALLY EXCITED - MAGNETIC BRAKE

Electrically excited - magnetic brakes are abruption-free method for

braking. In high-speed trains they offer a good alternative to the mechanical rail

brakes which are being used now a days. During braking, the brake comes in contact

with the rail, and the magnetic poles of brakes are energized by a winding supplied.

Magnetic poles of brakes are energized by a winding supplied with current from the

battery. Then the magnetic flux is distributed over the rail. The eddy currents are

generated in the rail, producing an electromagnetic braking force. This types of

braking need an additional safety power supply when there are breakdowns in the

electrical power supply.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

ELECTRICALLY EXCITED - MAGNETIC BRAKE

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

2. PERMANENT MAGNET- MAGNETIC BRAKE

Recently, permanent magnet - magnetic brakes have been developed for

subways, trams and local trains. These brakes need a mechanical actuator to turn the

magnets in an on and off position. The main advantage of this type of brake is safety.

i.e. it does not need electrical power supply to energize the magnet.

PERMANENT MAGNET- MAGNETIC BRAKE

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

BRAKING POWER CALCULATIONS

Sophisticated calculation methods for the determination of braking forces of

magnetic brakes are important for the design of the brakes.

For a simple magnetic brake employing a thin non-magnetic disc as copper the

drag or braking force on the disc.

where

H = Magnetic field strength in Webers.

A = Pole force area in cm2.

V = Velocity in cm/sec of mean radius of disc under the poles.

T = disc thickness in cm.

= specific resistance of disc material at its operating temperature in micro

ohms/cm3.

Torque = F * R Nm

Where R = mean pole radius in meter.

Power P = 2 NT/60 watts.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

MAGNETIC BRAKE REQUIREMENTS

An magnetic brake is an energy converter functions is to convert the kinetic

energy of a vehicle into heat and dissipate it such a rate to maintain the temperature of

unit with in reasonable limits under maximum and prolonged braking conditions. The

energy absorbed by the brake is transformed into heat by the currents induced in the

motor, and this is heat manly dissipated in surrounding air through the medium of

suitable designed fins the rotating member.

In mountains area, continues braking force is needed for a long time (say

about half an hour), at this condition, magnetic braking is more suitable to function

without over heating. The use of these retarders is by no means limited to mountain

on country. They can be advantageously employed on public service vehicles on city

routes without frequent stops. But in this braking system there with out be any

braking force in the vehicle is rest. So the magnetic brake is used as an auxiliary

heavy-duty retarder. By using auxiliary retarder very smooth retardation is assumed

and likely hood of skidding on slippery roads surfaces is minimized. Smooth braking

action cuts down tier were and since brake is used as an auxiliary heavy-duty retarder.

By using auxiliary retarder very smooth retardation is assumed and likely hood of

skidding on slippery roads surfaces is minimized. Smooth braking action cuts down

tier were and since the conventional brakes are relieved of heavy duty being required

only to bring vehicles to rest.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

MOUNTING AND INSTALLATION

A typical mounting of an eddy current brake consists of two discs in which

pole salient type, supported between the frame numbers of a vehicle chassis. Rotor is

coupled to road wheels being often mounted on a shaft that is interposed between the

gearbox and propeller shaft and stator is mounted on the frame of the vehicle.

The driver who can select one or four excitation settings according to the

breaking effect required mounts a control switch on a steering column in a position

for easy operation. In the operative positions of this switch 1, 2, 3, 4 contractors are

energized to supply current to the excitation windings of the retarder. Warning lamp is

also provided on the instrument panel to indicate when the retarder is energized. This

provides a safe guard for the driver against leaving the unit energized when the

vehicle is stationary.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

ADVANTAGES

Less maintenance

Wide range of braking force available within the temperature limit

Prolonged braking is possible

Long life

Less strain to the operation

Smooth retardation, which cuts down, the tire wears

Independent of wheel/rail adhesion.

No noise or smell.

Adjustable brake force.

High brake forces at high speeds.

Used also as service brake.

It uses electromagnetic force and not friction.

Non-mechanical (no moving parts, no friction.

Can be activated at will via electrical signal.

Light weight.

Magnetic brakes offer smooth retardation of vehicles without skidding. It is

totally free of wear and tear. So it has long life compared to ordinary brakes. These

need less maintenance.

In mountain areas continuous braking is needed for a long time. At this

condition, magnetic braking is more suitable to function without overheating.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

By changing the excitation current to the field winding, i.e. by adjusting the

position of the control switch, we can vary the braking force to required range. The

operation of magnetic brake is very simple. i.e. the control switch is a soft switch

which can be operated without any strain.

Magnetic brakes works even under the toughest environmental conditions. For

example, in larger water slides and water coasters where the humidity would

immediately result in reduction of friction and thus impair the effectiveness of

ordinary brakes. It works even in highly corrosive environments and heavily

contaminated areas.

DISADVANTAGES

No breaking force at rest, braking force diminishes as speed diminishes with

no ability to hold the load in position at standstill.

Need of electric power

It can not be used at low speed vehicles or vehicle running at low speed.

Magnetic brakes are used with ordinary mechanical brakes.

Nowdays Magnetic brakes is using only for safety purpose.

The main disadvantage of the magnetic brake is that it needs electric power to

work. Researches are going on to overcome this disadvantage by making the brake

regenerative i.e. by converting the kinetic energy of the vehicle into electric energy

and storing it back into the battery.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

APPLICATIONS

For additional safety on long decants in mountain area

For high speed passenger and goods vehicle

It is used as a stopping mechanism in trains.

It is also used in the smooth breaking and functioning of roller coasters and

such fast moving machines

Magnetic brakes are best substitutes for ordinary brakes, which are being used

nowadays in road vehicles even in trains, because of their jerk-free operation. In

mountain areas where continuous braking force is needed, for a long time, the

magnetic braking is very much useful for working without overheating. Magnetic

brakes are very much useful for high-speed passengers and good vehicles. It can also

be used to slow down the trolleys of faster roller coasters.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Conclusion

Magnetic brakes are the best choice when demands for reliability and safety

are the highest. They work even in the toughest environmental conditions. Even the

strike of lightning will not result in the loss of the braking force.

Magnetic braking system is not popular now a days. But we hope that the

magnetic braking system which is simpler and more effective will take the place of

the ordinary braking system and we can do expect it to be the norm one in few years

of time.

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

REFERENCES

1. Manual 1 Gonzalez, Volume 25,Issue 4,July 2004

2. IEEE Transactions on magnetics, Volume 34, Issue 4, July 1998

3. Analysis of eddy current brake for high-speed railway by Wang.P.J.&

Chiuch.S.J.

4. Automobile electrical equipments by Young &Griffith.

5. Automatic engineering by Kripal Sing.

6. Clutches and brakes by William.C.Orthwin.

7. www.reelectromagneticbrakes.com

8. www.lineareddycurrentbrakes.com

Dept. of Mechanical Engineering P.K.C.E.T, Kandala

 MAGNETIC BRAKING SYSTEM

Dept. of Mechanical Engineering P.K.C.E.T, Kandala