A Design Study of Electromagnetic Clutch and Brake
Mechanism for Wind Generators (3 Bladed HAWTG)
Rolando G. Gironella, III*, Mike Rowen S. Bañares, Janlesther O. Cañada, Elmer B. Dollera
Abstract – With the rise of climate change, the demand for
better renewable energy grows.[1] Nations such as the
Philippines experience high winds and frequent tropical
storms and hurricanes. Due to this, harnessing the energy of
the wind must be utilized in order to make use of such an
inexhaustible resource. It can also be scaled down to power
a house or a single room/ However, with the presence of
dangerous winds, there is a constant prevalent threat to the
internal and external components of the wind turbine.
Modern horizontal axis wind turbine generators utilize
several safety features that prevent failure to the mechanical
and electrical components of the system. [2] The main
innovation of this study is the addition of an electromagnetic
clutch and brake mechanism as an additional safety
measure for the wind turbine generator. The clutch is
placed between the turbine shaft and the generator which
disengages as cut-out speed is reached to prevent damaging
the most expensive part of the system which is the
generator. On the other hand, the electromagnetic brake is
located in front of the motor which serves as a replacement
for wind. With a testing rig, an RPM proximity sensor and
relay which was installed in the system is triggered
disengage the clutch and engages the brake once the cut-off
speed has been reached. A non-contact infrared
temperature module then measures the temperature rise of
the clutch during operation. Finally, a power meter/logger
will monitor the energy consumption of the brake and clutch
during operation.
Keywords: electromagnetic brake, electromagnetic clutch,
infrared temperature module, power meter/logger, rpm
proximity sensor
I. INTRODUCTION
Wind energy, which is a form of solar energy, as a
whole is a sustainable and cost-effective source of
power generation. Winds are caused by the uneven
heating of the atmosphere by the sun, the irregularities
of the earth's surface, and rotation of the earth. Wind
flow patterns are modified by the earth's terrain, bodies
of water, and vegetative cover. These winds are
harvested by wind turbines and are converted to
electricity. In the Philippines, particularly in the region
of Ilocos Norte, has utilized its tactical surroundings to
make use of an efficient wind farm. This was done by
strategically placing them on the mountain side where
plenty of wind that comes from the sea flows through.
However, wind energy is frequently dangerous when
the weather turns for the worse. This comes in the
*Rolando G. Gironella, III is currently a
graduating student of Xavier University,
Ateneo de Cagayan, CDO, Philippines,
Email: randy@gironella-cdo.com
form of extreme weather and high winds. This is
prevalent in the Philippines as it is prone to tropical
storms that batter the land.
In order to combat this, modern wind turbines
utilize several safety features in order to prevent a
catastrophic failure to the mechanical and electrical
components of the system. Examples of these are the
yawing mechanism and brake that mitigate the
overbearing power of the winds.
II. METHODOLOGY
A. Introduction
The main objective of this study is tackling the
symptoms of high winds such as overheating of the
internal components. The most notable danger is the
high rotational speed coming from the blades and
transferring to the generator shaft. In order to address
this, the study proposes a design which integrates an
electromagnetic clutch as a buffer between the two
shafts. The design will have this clutch automatically
disengage the blade shaft from the generator shaft
whenever an installed RPM sensor sends signals to the
controller reads a wind speed that is beyond the
limiting value, using a program made from Arduino
which utilizes standard cut-off and cut-in speeds. By
doing this, blade shaft will be in freewheel state,
preventing it from transmitting the overload power
which is damaging to the generator.
To clarify, the second part of the design is the
electromagnetic brake. Another danger for the wind
turbine is the effect of the high winds on the blades
themselves. One such symptoms is the likelihood that
the high rotational speed will tear the blades apart and
break. Hence, a braking system must be implemented
for the wind turbines in order to stop it. Wind turbine
brakes are important for maintenance, for emergencies,
or even for something as simple as managing risk and
protecting investment in the case of high wind speeds.
The study aims to gather the data for power
consumption of the clutch and brake as well as the
temperature rise of the clutch. Lastly, to determine
through calculation the efficiency of the generator.
 Figure 1. Flow Chart
Research
Design and
Fabrication B. Selection of Materials

Design Testing
The materials for fabrication and data gathering
and Data
Logging
were canvased prior to the fabrication of the design.
Local as well as online sources were used to find
Calculation of
suitable parts and components. [6] In order to accurately
Efficiencies gather data, it was decided to use Arduino, so as to use
designs, single-board microcontrollers and
Economic microcontroller kits for building digital devices. The
Analysis
study requires sensors and modules that are able to
relay signals, monitor temperature via infrared, log
Risk and Risk energy consumption and monitor the RPM of the
Management
motor.
 Electromagnetic Clutch: 24-volt dc power supply,
2 N-m torque.
 Electromagnetic Brake: 24-volt dc power supply,
2 N-m torque.
 Shafts: Stainless steel
 Generator: Permanent Magnet DC Generator, 12-
volt, 6 Watts
 Induction Motor Drive: Single Phase, 220-volt, 0.5
Horsepower, 60 Hertz, 4 poles
 Variable Frequency Drive: 1 Horsepower, 220-
volt
 MLX90614 Non-Contact Infrared Temperature
Module
 Adafruit INA219 Current Sensor Breakout

C. Research Fabrication
With the assemblage of materials and electrical
components, it was critical to correctly code and
connect each individual sensor and relay so as to get
accurate results and accomplish the desired goals. In
order to accomplish this, a schematic diagram of the
circuit and sensor was made using CircuitMaker
design software for the temperature module and power
meter, and Fritzing for the RPM proximity sensor and
relay.

Figure 2. Schematic of Non-Contact Infrared

Temperature Module

In order to measure the rise of temperature on the

electromagnetic clutch, it was decided to utilize a

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MLX90614 non-contact infrared temperature module. drive reaches the desired cut-in and cut-out
[3]
speeds.

Figure 3. Schematic of Power Meter/Logger

In order to measure the voltage, current and

power of the clutch, brake and generator, it was
decided to utilize an Adafruit INA219 Current
Sensor Breakout.[4] The vin+ pin is connected to
the +terminal of the supply voltage, while the Figure 5. Testing Rig Side View
vin- pin is connected to the +terminal of the
load.

Figure 6. Electromagnetic Clutch Isometric

View and Dimension (mm)

Figure 4. Circuit Diagram of RPM Proximity

Sensor and Relay
The RPM Proximity Sensor and Relay has the task
to monitor the rpm of the motor shaft. The way this is
done is by having the IR detect infrared rays that are
reflected by light colored surfaces, in this case, parts of
the shaft has been taped with masking tape in order for
the sensor to detect it. The module is set to send a
signal to engage the brake and disengage the clutch
once it reaches the set RPM.
Figure 7. Electromagnetic Brake Isometric
D. Testing Rig
View and Dimension (mm)
The miniature testing rig utilizes these
components for testing. As such, a dc motor drive III. EXPERIMENTAL
was used to simulate the variating turbine
rotational power produced from the gust of the After the integration of a pre-existing
wind. The dc motor drive was then coupled to the electromagnetic clutch and the electromagnetic break,
shafts of the brake, clutch and generator. An rpm the system is subjected to testing. In this testing
proximity sensor that is programmed in Arduino dependent variables such as temperature for the clutch
will be gathered in 3 modes. 20Hz, 30Hz and 60Hz.
was installed in the system in order to trigger the
Using the sensors and modules, the voltage, current
engaging and disengaging mechanism of the and power consumed by the clutch and brake once
electromagnetic clutch and break as the dc motor
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activated will be logged. This will be the same for the The results and findings depend on the data logger
voltage, current and power generated by the generator. which will analyze the variables of the study. This is
done with the discussed Arduino sensors. The
To assist the convenience of data comparison for electromagnetic clutch and brake system was tested at
each trial and for the sake of convenient visualization the Mechanical Engineering Laboratory using a Motor
as well, graphs and data tables are to be obtained. All in place of natural wind through wind turbine blades.
data will measured in real time every 3 seconds for 3
minutes each trial. This will be repeated for 30 trials
with a 5-minute break in-between trials to allow the
motor and the Variable Frequency Drive to cooldown.
Graph will contain:
1. Temperature Rise
a. Temperature of Clutch with Respect to Time

This was obtained by pointing the MLX90614

infrared sensor at the clutch with a distance of 0.5
inches from the surface. The Arduino board will
process this data and collect it every 3 seconds for 3
minutes. This will be repeated for 30 trials for 3
different shaft rpm each, which is 575rpm, 875rpm and
1715rpm.
2. Power Consumption
a. Voltage, Current and Power vs Time
Figure 8. Temperature of Clutch with respect to
Time
The temperature rise of the clutch varies between
RPM. Using the Variable Frequency Drive, the study
was done for 20Hz (575RPM), 30Hz(875RPM) and
60Hz(1715RPM). As shown in the data, the higher the
frequency, the higher the temperature rise of the
clutch. At the end of the 3-minute mark, at 20Hz the
temperature reached 55.65°C. At 30Hz the temperature
reached 61.09°C. At 60Hz the temperature reached
78.59°C.

This was obtained using the Adafruit INA219 and

is connected to the clutch or brake. The vin+ pin is
connected to the +terminal of the supply voltage, while
the vin- pin is connected to the +terminal of the load.
And the ground of the load is connected to the ground
of the measuring device.

. 3. Power Generated of System with clutch

a. Voltage, Current and Power vs Time

This was obtained using the Adafruit INA219 and

is connected to the generator. In this case the vin+ pin Figure 9. Clutch and Brake Voltage Chart
is connected to the +terminal generator while the vin-
pin is connected to the -terminal of the generator. Figure 9 shows the voltage chart of the brake and
clutch. The electromagnetic brake showed minimal
4. Power Generated of System without clutch variation as it only needs to engage and the motor will
stop. The electromagnetic clutch on the other hand has
a. Voltage, Current and Power vs Time a larger fluctuation in voltage. This is due to its nature
to engage and continue spinning. The fluctuation is
Similar to the obtaining the power generated of the caused by friction and possible slip.
system with the clutch, this was obtained using the
Adafruit INA219 and is connected to the generator. In
this case the vin+ pin is connected to the +terminal
generator while the vin- pin is connected to the -
terminal of the generator.

IV. RESULTS AND DISCUSSION

4

Figure 10. Clutch and Brake Current Chart
Figure 10. shows the current chart of the
electromagnetic brake and clutch. The electromagnetic
brake showed minimal variation as it only needs to
engage and the motor will stop. The electromagnetic
clutch showed minimal variation in current.
Figure 11. Clutch and Brake Power
Consumption
Figure 11 shows the amount of power by the
electromagnetic brake and clutch. The electromagnetic
brake consumes approximately 9900mW of power
once engaged. The electromagnetic clutch consumes
approximately 8900mW of power once engaged.
Figure 12. Generator Voltage Chart
Figure 12 shows the amount of voltage the
generator produces with and without the
electromagnetic clutch. The voltage produced by the
generator with the clutch mechanism fluctuates on
around 7.74V. When compared to the manufacturer
voltage of 12V, the system is approximately 64%
efficient. On the contrary, the voltage produced by the
generator without the clutch fluctuates on around
10.06V. When compared to the manufacturer voltage
of 12V, the system is approximately 83% efficient.
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Figure 13. Generator Current Chart
Figure 13 shows the amount of current the
generator produces with and without the
electromagnetic clutch. The current produced by the
generator with the electromagnetic clutch fluctuates on
around 488.52mA. However, the current produced by
the generator without the electromagnetic clutch
fluctuates on around 489.94mA. As shown in the data,
there is minimal variation between the current of the
system.
Figure 14. Generator Power Chart
Figure 14 shows the amount of power the generator
produces with and without the electromagnetic clutch.
The power produced by the generator with the
electromagnetic clutch is on average 3.88W. When
compared to the manufacturer power output of the
generator, which is 6W, the system is approximately
64% efficient. In contrast, the power produced by the
generator without the electromagnetic clutch is on
average 5.03W. When compared to the manufacturer
power output of the generator, which is 6W, the
system is approximately 83% efficient.
V. CONCLUSION AND RECOMMENDATION
Wind energy is frequently dangerous when the
weather turns for the worse. This comes in the form of
extreme weather and high winds. In order to combat
this, modern wind turbines utilize several safety
features in order to prevent a catastrophic failure to the
mechanical and electrical components of the system.
The study determined that the temperature rise of the
electromagnetic clutch maxes out at 78.59°C and is
well below the Curie Point, which is the point for a AUTHORS’ PROFILE
magnetic material to lose its magnetic property, for
low carbon steel which is 770°C. In the study, the
fabricated system that incorporates an electromagnetic
clutch and brake mechanism as an additional safety
feature for a wind turbine generator (3-Bladed
HAWTG) is compared to the same system without said
mechanism. The system was able to produce on
average 3.88W of power with the electromagnetic
clutch and brake attached, and 5.03W of power
without it. The results show that the combined and
mechanical efficiency of the system with the feature is
64 and 71 percent efficient respectively. In contrast the
combined and mechanical efficiency of the system
without the feature is 83 and 92 percent efficient. It is
known beforehand that the addition of components to
any system will incur mechanical losses. This is the
case for this study as there is 19% combined efficiency
and a 21% mechanical efficiency difference between
the system with and without the electromagnetic
clutch. Though this is the case, the addition of safety
features a wind turbine generator is essential to extend
its operating life and prepare it for extreme scenarios
such as hurricanes and heavy tropical storms.
It is recommended that future studies incorporate a
motor that is able to reach 5000RPM which the DC
generator can run up towards. As well as utilizing a
gear box in order to come closer to the ideal rpm at the
cost of mechanical losses.

ACKNOWLEDGMENT
The authors would like to express our gratitude to
our friends, family and the faculty of the Mechanical
Engineering Department of Xavier University, Ateneo
de Cagayan.
REFERENCES
[1] Lee, G.-C., & Jung, T.-U. (2013). Design of dual
structural axial flux permanent magnet generator for
small wind turbine. IEEE 2013 Tencon - Spring.
[2] Angustia, M. R. (n.d.). Efficiency, rating, and
applications of dynamos. Retrieved from https://
www.slidesharenet/MariaRominaAngustia/efficiency-
rating-and-applications-of-dynamos
[3] Yasa, Y., Sincar, E., Ertugrul, B. T., & Mese, E.
(2014). Design considerations of electromagnetic
brakes for servo applications. 2014 IEEE 23rd
International Symposium on Industrial Electronics
(ISIE).
[4] Tanzo, W. T., & Pacheco, B. M. (n.d.). New Wind
Load Provisions in Philippine Structural Code.
Retrieved from http://www.wind.arch.t-kougei.ac.jp/

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Rolando G. Gironella, III is currently a
graduating student of Bachelor of
Science in Mechanical Engineering,
Xavier University, Ateneo de Cagayan
from SY2015-2020. He studied in
Xavier University High School,
Pueblo, CDO from SY2011-2015. He
finished elementary in Xavier
University Grade School in CDO from
SY2005-2011.

Mike Rowen S. Bañares, is currently a

graduating student of Bachelor of
Science in Mechanical Engineering,
Xavier University, Ateneo de Cagayan
from SY2015-2020. He studied in
Misamis Oriental General
Comprehensive High School in CDO
from SY2011-2015. He finished
elementary in Fr. William F.
Masterson SJ in CDO from SY2005-
2011.

Janlesther O. Cañada, is currently a

graduating student of Bachelor of
Science in Mechanical Engineering,
Xavier University, Ateneo de Cagayan
from SY2015-2020. He studied in
Balulang National High School, CDO
from SY2011-2015. He finished
elementary in Macasandig Elementary
School, CDO from SY2005-2011.

Elmer B. Dollera is currently working

as a professor in Mechanical
Engineering Department, Xavier
University, Cagayan de Oro City,
Philippines. He earned his degree in
Doctor of Engineering in MSU-Iligan
Institute of Technology (2015) and
Master of Science in Mechanical
Engineering (1995) in University of
the Philippines, Quezon City,
Philippines. He attended a Post
Masteral Program in Mechanical
Engineering (1997) in University of
New South Wales, Sydney, Australia.