Synopsis

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. As a result it develops a torque and
eventually the vehicle comes to rest. In this project the advantage of using the
electromagnetic braking system in automobile is studied. These brakes can be incorporated in
heavy vehicles as an auxiliary brake. 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
 INTRODUCTION

Baking system is necessary in an automobile for stopping the vehicle. Brakes are applied on
the wheels to stop or to slow down the vehicle.

There are two main functions of brakes:

(a) To slow down or stop the vehicle in the shortest possible time at the time of need.

(b) To control the speed of vehicle at turns and also at the time of driving down on a hill
slope.

Braking of a vehicle depends upon the static function that acts between tyres and road
surface. Brakes work on the following principle to stop the vehicle:

“The kinetic energy due to motion of the vehicle is dissipated in the form of heat energy due
to friction between moving parts (wheel or wheel drum) and stationary parts of vehicle (brake
shoes)”.

The heat energy so generate4d due to application of brakes is dissipated into air.

Brakes operate most effectively when they are applied in a manner so that wheels do not lock
completely but continue to roll without slipping on the surface of road.

CLASSIFICATION OF BRAKES

On the Basis of Method of Actuation

(a) Foot brake (also called service brake) operated by foot pedal.

(b) Hand brake – it is also called parking brake operated by hand.

On the Basis of Mode of Operation

(a) Mechanical brakes

(b) Hydraulic brakes

(c) Air brakes

(d) Vacuum brakes

(e) Electric brakes.

On the Basis of Action on Front or Rear Wheels

(a) Front-wheel brakes

(b) Rear-wheel brakes.

On the Basis of Method of Application of Braking Contact

(a) Internally – expanding brakes

(b) Externally – contracting brakes.

Construction and Working of Mechanical Brakes

Internal expanding shoe brakes are most commonly used in automobiles. In an automobile,
the wheel is fitted on a wheel drum. The brake shoes come in contact with inner surface of
this drum to apply brakes. The construction of internal expanding mechanical brake is shown
in Figure. The whole assembly consists of a pair of brake shoes along with brake linings, a
retractor spring two anchor pins a cam and a brake drum. Brake linings are fitted on outer
surface of each brake shoe. The brake shoes are hinged at one end by anchor pins. Other end
of brake shoe is operated by a cam to expand it out against brake drum. A retracting spring
brings back shoes in their original position when brakes are not applied. The brake drum
Braking System closes inside it the whole mechanism to protect it from dust and first. A plate
holds whole assembly and fits to car axle. It acts as a base to fasten the brake shoes and other
operating mechanism.

How brakes are applied and released

When brake pedal is pressed, the cam turns through brake linkages. Brake shoes expand
towards brake drum due to turning of cam. The brake linings, rub against brake drum and
therefore motion of wheels is stopped. The pedal force is transmitted to the brake shoes
through a mechanical linage. This mechanism also multiplies the force to apply the brakes
effectively. When force on brake pedal is removed, the retractor spring brings back shoes in
original position and brakes are released.
Disc Brakes

Modern motor cars are fitted with disc brakes instead of conventional drum type brakes. In
Santro car and Maruti-800, front wheels are provided with disc brakes whereas rear wheel are
provided with drum brakes.

A disc brake consists of a rotating disc and two friction pads which are actuated by hydraulic
braking system as described earlier. The friction pads remain free on each side of disc when
brakes are no applied.

They rub against disc when brakes are applied to stop the vehicle. These brakes are applied in
the same manner as that of hydraulic brakes. But mechanism of stopping vehicle is different
than that of drum brakes.

Advantage of Disc Brakes

(a) Main advantage of disc brakes is their resistance to wear as the discs remain cool even
after repeated brake applications.

(b) Brake pads are easily replaceable.

(c) The condition of brake pads can be checked without much dismantling of brake system.

Disadvantage of Disc Brakes

(a) More force is needed be applied as the brakes are not self emerging.
(b) Pad wear is more.

(c) Hand brakes are not effective if disc brakes are used in rear wheels also. (Hand brakes are
better with mechanical brakes).

Hydraulic Brakes

The brakes which are actuated by the hydraulic pressure (pressure of a fluid) are called
hydraulic brakes. Hydraulic brakes are commonly used in the automobiles.

Principle

Hydraulic brakes work on the principle of Pascal’s law which states that “pressure at a point
in a fluid is equal in all directions in space”. According to this law when pressure is applied
on a fluid it travels equally in all directions so that uniform braking action is applied on all
four wheels.

Construction and Working of Hydraulic Brakes

When brake pedal in pressed, the force is transmitted to the brake shoes through a liquid
(link). The pedal force is multiplied and transmitted to all brake shoes by a force transmission
system. Figure 6.1 shows the system of hydraulic brake of a four wheeler automobile. It
consists of a master cylinder, four wheel cylinders and pipes carrying a brake fluid from
master cylinder to wheel cylinder.
The master cylinder is connected to all the four-wheel cylinders by tubing or piping. All
cylinders and tubes are fitted with a fluid which acts as a link to transmit pedal force from
master cylinder to wheel cylinders. Brake Fluid The fluid filled in the hydraulic brake system
is known as brake fluid. It is a mixture of glycerine and alcohol or caster oil and some
additives. Master cylinder consists of a piston which is connected to peal through connecting
rod. The wheel cylinder consists of two pistons between which fluid is filled. Each wheel
brake consists of a cylinder brake drum. This drum is mounted on the inner side of wheel.
The drum revolves with the wheel. Two brake shoes which are mounted inside the drum
remain stationary. Heat and wear resistant brake linings are fitted on the surface of the brake
shoes.

Application of Brakes

When brake pedal is pressed to apply the brakes, the piston in the master cylinder forces the
brake fluid. This increases the pressure of fluid. This pressure is transmitted in all the pipes
and upto all wheel cylinders according to Pascal’s law. This increased pressure forces out the
two pistons in the wheel cylinders. These pistons are connected to brake shoes. So, the brake
shoes expand out against brake drums. Due to friction between brake linings and drum,
wheels slow down and brakes are applied. Two pipes carrying braked fluid are connected to
front wheel cylinders which may be same as rear wheel cylinders. The front wheels may also
have same type of brakes (drum brakes) as shown in the rear wheels. But, in modern cars,
there are disc brakes in the front wheels and drum brakes in the rear wheels. Figure 6.2 :
Mechanical Brake (Internal Expanding Type)

Release of Brakes

When pedal is released, the piston of master cylinder returns to its original position due to
retractor spring provided in master cylinder. Thus, fluid pressure drops to original value. The
retractor spring provided in the wheel cylinders pulls the brake shoes and contact between
drum and brake linings is broken. Therefore, brakes are released.

ADVANTAGES AND DISADVANTAGES OF HYDRAULIC BRAKES

Advantages

(a) Equal braking action on all wheels.

(b) Increased braking force.

(c) Simple in construction.

(d) Low wear rate of brake linings.

(e) Flexibility of brake linings.

(f) Increased mechanical advantage.

Disadvantages

(a) Whole braking system fails due to leakage of fluid from brake linings.

(b) Presence of air inside the tubings ruins the whole system.
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. 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

Characteristics of Electromagnetic Brakes

It was 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 performances of electromagnetic brakes make
them much more competitive candidate for alternative retardation equipment’s compared
with other retarders. The brake linings would last considerably longer before requiring
maintenance, and the potentially “brake fade” problem could be avoided. In research
conducted by a truck manufacturer, it was proved that the electromagnetic brake assumed 80
percentage of the duty which would otherwise have been demanded of the regular service
brake. Furthermore, the electromagnetic brake prevents the dangers that can arise from the
prolonged use of brakes beyond their capability to dissipate heat. This is most likely to occur
while a vehicle descending a long gradient at high speed.
CONSTRUCTION

The parts of Electromagnetic Disc Brake are:

AC Motor

Internal Expanding Brake

Frame

Solenoid switches

Pulleys & Belt Shaft

Motor

An electric motor is an electrical machine that converts electrical energy into mechanical
energy. Most electric motors operate through the interaction between the motor's magnetic
field and winding currents to generate force in the form of rotation. Electric motors can be
powered by direct current (DC) sources, such as from batteries, motor vehicles or rectifiers,
or by alternating current (AC) sources, such as a power grid, inverters or electrical
generators.

A DC motor is any of a class of rotary electrical machines that converts direct current
electrical energy into mechanical energy. The most common types rely on the forces
produced by magnetic fields. Nearly all types of DC motors have some internal mechanism,
either electromechanical or electronic; to periodically change the direction of current flow in
part of the motor.

Internal Expanding Brake

Internal expanding brakes are used almost exclusively as wheel brakes, but can be found on
some cranes. This type of brake permits a more compact and economical construction. The
brake shoes andbrake-operating mechanism is supported on a backing plate or brake shield
attached to the vehicle axle, as shown in figure. The brake drum attached to the rotating
wheel, acts as a cover for the shoe and operating mechanism and furnishes a frictional surface
for the brake shoes. The brake shoe of an internal expanding brake is forced outward against
the drum to produce the braking action. One end of the shoe is hinged to the backing plate by
an anchor pin, while the other end is unattached and can be moved in its support by the
operating mechanism. When force from the operating mechanism is applied to the unattached
end of the shoe, the shoe expands and brakes the wheel. A retracting spring returns the shoe
to the original position when braking action is no longer required.

Solenoid switches

Solenoid switches are used to switch high power circuits on and off using a much smaller
electrical control signal to actuate the switching. This allows extensive logic and decision
making circuitry to be performed on inexpensive microchips and small electronic parts, with
the actual switching of the high power signals being limited to the very last step. The result is
cooler running of less sophisticated equipment. It also enables the high power switching
equipment to be limited to a remote location. Solenoid switches are typically used on
automotive engine starting systems.
Solenoids are wound wire magnetic coils with an open core to receive a sliding cylindrical
plunger. When the coil is energized with an electrical current, a magnetic field is created in
the hollow opening which pulls the plunger into it or pushes it out, based on the orientation of
the solenoid and the poles of the plunger. The plunger is mechanically connected to a set of
switch contacts, which perform the high power switching. The there are a minimum of four
connector terminals on a solenoid switch. The coil requires two and is most often isolated
from all the other terminals, which keeps the coil wires completely independent of the current
being switched. The switched current terminals are usually substantially heavier than the coil
terminals.

Working of Electromagnetic Brake

The electromagnet is energized by the AC supply where the magnetic field produced is used
to provide the braking mechanism. When the electromagnet is not energized, the rotation of
the disc is free and accelerates uniformly under the action of weight to which the shaft is
connected. When the electromagnet is energized, magnetic field is produced thereby applying
brake by retarding the rotation of the disc and the energy absorbed is appeared as heating of
the disc. 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. The AC motor makes the
disc to rotate through the shaft by means of pulleys connected to the shaft.

Engagement Time

There are actually two engagement times to consider in an electromagnetic brake. The first
one is the time it takes for a coil to develop a magnetic field, strong enough to pull in an
armature. The second one is air gap, which is the space between the armature and the coil
shell.
 Applications

In locomotives, a mechanical linkage transmits torque to an electromagnetic braking

component.

Trams and trains use electromagnetic track brakes where the braking element is pressed by
magnetic force to the rail. They are distinguished from mechanical track brakes, where the
braking element is mechanically pressed on the rail.

Electric motors in industrial and robotic applications also employ electromagnetic brakes.

Recent design innovations have led to the application of electromagnetic brakes to aircraft
applications. In this application, a combination motor/generator is used first as a motor to
spin the tires up to speed prior to touchdown, thus reducing wear on the tires, and then as a
generator to provide regenerative braking.
 ADVANTAGES

1. There is no need to change brake oils regularly.

2. There is no oil leakage.
3. Electromagnetic brake systems will reduce maintenance cost
4. The problem of brake fluid vaporization and freezing is eliminated
5. Potential hazard of tire deterioration and bursts due to friction is eliminated.
 DISADVANTAGES

1. Dependence on battery power to energize the brake system drains down the battery
much faster.
2. Due to residual magnetism present in electromagnets, the brake shoe takes time to
come back to its original position.
3. A special spring mechanism needs to be provided for the quick return of the brake
shoe.
 CONCLUSION

With all the advantages of electromagnetic brakes over friction brakes, they have been widely
used on heavy vehicles where the ‘brake fading’ problem exists. The same concept is being
developed for application on lighter vehicles. The concept designed by us is just a prototype
and needs to be developed more because of the above mentioned disadvantages. These
electromagnetic brakes can be used as an auxiliary braking system along with the friction
braking system to avoid overheating and brake failure. ABS usage can be neglected by
simply using a micro controlled electromagnetic disk brake system .These find vast
applications in heavy vehicles where high heat dissipation is required. In rail coaches it can
used in combination of disc brake to bring the trains moving in high speed. When these
brakes are combined it increases the life of brake and act like fully loaded brakes. These
electromagnetic brakes can be used in wet conditions which eliminate the anti-skidding
equipment, and cost of these brake are cheaper than the other types. Hence the braking force
produced in this is less than the disc brakes if can be used as a secondary or emergency
braking system in the automobiles.