ELECTROMAGNETIC BRAKING SYSTEM

A PROJECT REPORT

Submitted by

PRIYANK KUMAR GUPTA [Reg No: RA1511002010289]

VIKASH CHAUDHARY [Reg No: RA1511002010390]
MOHIT SINGH [Reg No: RA1511002010563]

Under the guidance of

Dr. JITENDRA KUMAR KATIYAR, Ph.D
(Assistant Professor, Department of Mechanical Engineering)

in partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
of

FACULTY OF ENGINEERING AND TECHNOLOGY

S.R.M. Nagar, Kattankulathur, Kancheepuram District

MAY 2019
 SRM INSTITUTE OF SCIENCE &
TECHNOLOGY
(Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this project report titled “ELECTROMAGNETIC BRAK-

ING SYSTEM” is the bonafide work of “ PRIYANK KUMAR GUPTA
[Reg No: RA1511002010289], VIKASH CHAUDHARY [Reg No:
RA1511002010390], MOHIT SINGH [Reg No: RA1511002010563]”,
who carried out the project work under my supervision. Certified further, that
to the best of my knowledge the work reported herein does not form any
other project report or dissertation on the basis of which a degree or award
was conferred on an earlier occasion on this or any other candidate.

SIGNATURE
SIGNATURE

Dr. JITENDRA KUMAR KATIYAR, Dr. S. PRABHU

Ph.D HEAD OF THE DEPARTMENT
GUIDE Dept. of Mechanical Engineering
Assistant Professor
Dept. of Mechanical Engineering

Signature of the External Examiner

Signature of the Internal Examiner
 ABSTRACT

The aim of this project is to develop an electromagnetic breaking system

which is of non-friction in nature. This project uses two electromagnets
for the purpose of braking and a battery used as a power supply to power
electromagnets. Also, we have aluminum disc in the project which acts as
a wheel and is rotated at higher speeds with the help of Battery. Then we
have metal bars which acts as support for different elements in our project
.we took the help of various manufacturing techniques such as drilling,
welding etc. which also made us aware about hands on of different
manufacturing techniques. This model will find its application in form of
a supplementary braking system and can be used widely along with
friction braking which will reduce maintenance to a larger extent.
 ACKNOWLEDGEMENTS

We are grateful to the Mechanical Engineering Department at SRM Institute of Science

and Technology, Kattankulathur, HOD Dr. S. Prabhu, and our project guide Dr.
Jitendra Kumar Katiyar for providing us the opportunity to do the major project under
their guidance and full cooperation. We take immense pleasure in thanking our project
guide, Dr. Jitendra Kumar Katiyar (Assistance Professor) for his rightful guidance,
constant motivation, personal advice, precious time and giving us with an outstanding
atmosphere for completing the research based project. Throughout the work, we ac-
knowledge his cooperation and continuous support to us in completion of this research
work.

Authors

iv
 TABLE OF CONTENTS

ABSTRACT iii

ACKNOWLEDGEMENTS iv

LIST OF TABLES vii

LIST OF FIGURES viii

ABBREVIATIONS ix

LIST OF SYMBOLS x

1 INTRODUCTION 1
1.1 BACKGROUND AND RATIONAL . . . . . . . . . . . . . . . . . 1

2 LITERATURE SURVEY 2

3 SYSTEM DESIGN DISCRIPTION AND APPROACH 4

3.1 PROBLEM STATEMENT . . . . . . . . . . . . . . . . . . . . . . 4
3.2 NEED FOR STUDY . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.3 OBJECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 TECHNICAL REQUIREMENTS . . . . . . . . . . . . . . . . . . 5
3.5 DATA COLLECTION METHODS . . . . . . . . . . . . . . . . . . 5
3.5.1 PRIMARY MODE OF DATA COLLECTION . . . . . . . 5
3.5.2 SECONDARY MODE OF DATA COLLECTION . . . . . 6
3.6 TYPE OF RESEARCH/PROJECT WORK . . . . . . . . . . . . . 6
3.7 TOOLS UTILISED . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.7.1 SOFTWARE SPECIFICATIONS ............. . 6
3.7.2 STATISTICAL TOOL . . . . . . . . . . . . . . . . . . . . 6
3.8 IMPACT OF OUR PROJECT ON DIFFERENT SECTORS . . . . . 7

v
 3.8.1 ECONOMIC SECTOR . . . . . . . . . . . . . . . . . . . . 7
3.8.2 ENVIRONMENTAL SECTOR . . . . . . . . . . . . . . . 7
3.8.3 SOCIAL SECTOR . . . . . . . . . . . . . . . . . . . . . . 7
3.8.4 HEALTH AND SAFETY SECTOR . . . . . . . . . . . . . 7
3.8.5 MANUFACTURABILITY SECTOR . . . . . . . . . . . . 7
3.8.6 SUSTAINABILITY SECTOR . . . . . . . . . . . . . . . . 7

4 SYSTEM DESIGN FLOW 8

4.1 DESIGN SCHEMATIC AND FIGURES . . . . . . . . . . . . . . . 8
4.2 CAD MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 SIGNFICANCE AND SCOPE . . . . . . . . . . . . . . . . . . . . 9
4.4 LIMITATIONS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 METHODOLOGY 11
5.1 STRUCTURAL FRAMEWORK . . . . . . . . . . . . . . . . . . . 12
5.1.1 DRIVING UNIT . . . . . . . . . . . . . . . . . . . . . . . 12
5.1.2 BRAKING UNIT . . . . . . . . . . . . . . . . . . . . . . . 13
5.1.3 OTHER PARTS . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 MATERIALS AND REASON OF USE . . . . . . . . . . . . . . . 16
5.3 THEORETICAL ANALYSIS . . . . . . . . . . . . . . . . . . . . . 17
5.4 THEORETICAL CALCULATIONS . . . . . . . . . . . . . . . . . 18
5.5 WORKING MECHANISM . . . . . . . . . . . . . . . . . . . . . . 19

6 FABRICATION 20
6.1 MANUFACTURING PROCESSES UTILISED . . . . . . . . . . . 20
6.2 STEPS OF FABRICATION . . . . . . . . . . . . . . . . . . . . . 21
6.3 COSTING OF FABRICATION . . . . . . . . . . . . . . . . . . . . 24
6.4 GANTT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7 OBSERVATION AND GRAPHS 26

7.1 FINAL PROJECT IMAGE . . . . . . . . . . . . . . . . . . . . . . 29

8 CONCLUSION 30
 LIST OF TABLES

6.1 Cost Involved In the Experiment. . . . . . . . . . . . . . . . . . . 24

7.1 RPM Vs Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.2 RPM Vs Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 RPM Vs Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

vii
 LIST OF FIGURES

4.1 Schematic Diagram of Principle of Electromagnetic Braking Sys-

tem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 CAD Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.1 Electric DC motor. . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5.2 Aluminium Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 12V Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4 Electromagnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.5 Wooden Plank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.6 Fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.7 Housing of Electromagnets . . . . . . . . . . . . . . . . . . . . . 16
5.8 Electromagnet Support Analysis . . . . . . . . . . . . . . . . . . 17
5.9 Aluminium Disc Analysis. . . . . . . . . . . . . . . . . . . . . . . 17
5.10 Flowchart Depicting Working Mechanism. . . . . . . . . . . . . 19

6.1 Gantt Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

7.1 RPM Vs Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7.2 RPM Vs Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3 Revolution per minute (RPM) Vs Time. . . . . . . . . . . . . . . 28
7.4 Actual Project Setup. . . . . . . . . . . . . . . . . . . . . . . . . 29

viii
 ABBREVIATIONS

EMBS Electromagnetic Braking System

RPM Revolution per minute

ix
 LIST OF SYMBOLS

I Current in Amperes.

N1 Number of turns of larger electromagnet.

N2 Number of turns of smaller electromagnet.

A Cross sectional area in m2.

G Gap between electromagnet and iron.

R Resistance of copper wire in ohms.

L Length of copper wire in meters.

ρ Resistivity of copper.

T Time in seconds.

x
 CHAPTER 1

INTRODUCTION

1.1 BACKGROUND AND RATIONAL

The conventional braking system being bulky and has a very low power to weight ra-
tio. On the other hand, an Electromagnetic Braking System (EMBS) is capable to serve
the purpose with a less complicated design. This project focuses on minimizing the
brake failure in order to avoid the accident and also reducing the maintenance of brak-
ing system.The main aim of designing Electromagnetic Braking System is to act as
a supplement upon the existing braking System which can be utilized effectively for
various applications. There are certain specifications for braking, which become pre-
requisites for maximum efficiency in the available choices. The non-contact braking
majorly involves the concept of Eddy Currents being induced on the disc leading to the
deceleration of the disc.
 CHAPTER 2

LITERATURE SURVEY

Wang et al. (2018) deals with the Design of Eddy Current Magnet Brakes is written and
published by the Japanese Research Scholar named Bica (2004) in âĂIJ- Transactions of
The Canadian Society for Mechanical EngineeringâĂ İ. Main objective of this paper
includes the concept of Non-Contact Braking. The non- contact braking majorly involves
the concept of Eddy Currents Being Induced on the plate leading to the deceleration of the
plate. The design of eddy current brakes is presented in the paper.

Second Paper titled as Electromagnetic Braking System emphasizes on non-contact

Braking presented by International Research
of Volume 05 and Issued on 04- Apr-2018. This paper shows Electromagnetic brakes
having numerous preferences over frictional slowing mechanism, as in conventional
braking system.Yasa et al. (2016) additionally focuses on comparison between friction
braking and non-frictional braking and highlighting the advantages of non-friction braking
over friction-braking.

Third Paper Presented by Haiqi et al. (2008) on Enhancement of Braking System in

Automobile Using Electromagnetic Braking was published in IOSR Journal of Mechanical
and Civil Engineering (IOSR-JMCE).The main objectives found out from the extraction of
paper tells about an electromagnetic brake which is a new and revolutionary concept.
Electromagnetic braking is a braking system which is used in light motor and heavy motor
vehicles like car, jeep, truck, busses etc.The major findings provides a glimpse on the
knowledge about structural setup.The Major Constructional features includes four disc
plates, coils and firing circuits.These all are attached individually on each wheel,and this
system needs very little of maintenance.
Fourth Paper is put forward by Kalikate et al. (2018) titled as Electromagnetic Braking
System,was Published in the National Conference on Innovations in Mechanical
Engineering, which was held during 6-8 April in the year 2015. The Main Objective of this
paper is to represent about minimizing of the brake failure in order to avoid the accident
which will in turn save the monetary and social loss also. It also reduces the maintenance
of braking system as, due to frictional braking pads gets rubbed off and requires more often
maintenance. One of the Major Findings of this research paper presents comparison about
Hydraulic brakes and pneumatic brakes and infers that electromagnetic brake can be a
better supplement and reliable solution.

3
 CHAPTER 3

SYSTEM DESIGN DISCRIPTION AND APPROACH

3.1 PROBLEM STATEMENT

The major problem(s) intended to solve with this project includes the conventional brak-
ing system being bulky and has a very low power to weight ratio. On the other hand, an
electromagnetic braking system is capable to serve the purpose with a less complicated
design. The project focuses on minimizing the brake failure in order to avoid the acci-
dent and also reducing the maintenance of braking system.

3.2 NEED FOR STUDY

The main aim of designing Electromagnetic Braking System is to act as a supplement

upon the existing braking System which can be utilized effectively for various applica-
tions. There are certain specifications for the Braking, which become pre-requisites for
maximum efficiency in the available choices.

• No Contact
• Low Braking Time
• Less transmission loss

3.3 OBJECTIVE

To increase the reliability of the braking system and to design a cost effective system.
This can be used as a supplement with conventional braking system to enhance its ef-
ficiency. Other objectives includes objectives such that Designing and Manufacturing
electromagnetic braking system model and to understand project planning and execu-
tion. Furthermore this project will also help us understand the fabrication techniques in
a mechanical workshop and the usage of various mechanical machine tools and mea-
suring tools. Our project also emphasises on making day to day human life easier by
proper use of technology.

3.4 TECHNICAL REQUIREMENTS

• Knowledge of behavior of material used.

• Concept of Eddy Currents.

• Electromagnets working Criteria.

• Deceleration mechanisms in Non-Contact Braking.

• Transmission losses in Braking.

• Gap determination between the Electromagnets and disc.

• Parameters like diameter of plate, Current and Voltage values, variation of current
leading to change in eddy Currents on the plate.

3.5 DATA COLLECTION METHODS

The data collection is done for three designs in the same orientation i.e. linearly ar-
ranged holes on the surface of horizontal bar supporting Disc. Distance between the
plate and electromagnet is varied during the manufacturing, The best confinement is
considered for every value and correspondingly the values of effective Eddy Currents
being induced on coil, that contain both real and imaginary parts considering the atten-
uation constants.

3.5.1 PRIMARY MODE OF DATA COLLECTION

The primary data taken from the simulation results are effective current and voltage
values, Magnetic Field produced by electromagnets altogether.

5
3.5.2 SECONDARY MODE OF DATA COLLECTION

The secondary data which is calculated with the help of primary data is the confinement
Heat loss and the Eddy Current produced on the plate. At the end, the data obtained and
calculated are put together and plotted.

3.6 TYPE OF RESEARCH/PROJECT WORK

The project undertaken is electro-mechanical project. The study is based on the re-
search work done on the Electromagnetic Braking System, its mechanisms, properties,
parameters, design considerations and its applications in braking of light/heavy auto-
mobiles.

3.7 TOOLS UTILISED

3.7.1 SOFTWARE SPECIFICATIONS

Analysis of these specifications can be done with the help of various softwares available
across different platforms like Ansys, Creo, Solidworks, Hypermesh. The prime reason
of choosing Hypermesh is due to the fact that its uniqueness can be extended for its
ability to solve coupled phenomena and comparison of various parameters like force,
displacement etc.

3.7.2 STATISTICAL TOOL

The tool used in this project for plotting values obtained after analysis is ORIGIN 9.0.
The software helps in plotting the huge database with ease and gives a user with wide
variety of options like line plot, contour plot, scatter plot and many others.

6
3.8 IMPACT OF OUR PROJECT ON DIFFERENT SEC-
TORS

3.8.1 ECONOMIC SECTOR

Cost of fabrication of fiber is economical and material is easily available.

3.8.2 ENVIRONMENTAL SECTOR

This project does not tend to produce any harmful pollutants and gases in the environ-
ment after fabrication.

3.8.3 SOCIAL SECTOR

This project aims for designing braking system which would serve the purpose of in-
creased reliability of brake services, and other allied applications.

3.8.4 HEALTH AND SAFETY SECTOR

This project is not expected to entail health and safety constraints.

3.8.5 MANUFACTURABILITY SECTOR

This project can be easily replicated only when he/she is well acquainted with the work-
conditions.

3.8.6 SUSTAINABILITY SECTOR

The resources used in this project are environment friendly, sustainable in nature and
recoverable in use.

7
 CHAPTER 4

SYSTEM DESIGN FLOW

4.1 DESIGN SCHEMATIC AND FIGURES

Figure 4.1: Schematic Diagram of Principle of Electromagnetic Braking System.

4.2 CAD MODEL

The above figure depicts the CAD model of Experimental Setup of Electromagnetic
Braking System. The above model is made in Cero pertaining to our Specifications.
Our model helped us immensely in positioning the elements when we started the man-
ufacturing .The major components visible in Design includes -

• Supporting Pillar for electromagnet

• Housing For Electromagnets

• Aluminium Disc

• Flange

• Support for Disc

 Figure 4.2: CAD Model.

4.3 SIGNFICANCE AND SCOPE

The following are the significances:

 Electromagnetic Braking System uses all its energy for non-contact braking,
i.e. for generation of eddy Currents on the plate which leads to less generation
of heat and also good dissipation of heat as well.

 Electromagnetic Braking can act as an excellent supplement to friction braking

in heavy automobiles.

 Total Cost of Electromagnetic Braking System turns out be very less as

compared to Conventional Braking System.

 This braking system can also reduce the use of Crude oil which is decreasing
day by day.

9
 4.4 LIMITATIONS:

The following are the limitations:

 Installation of Electromagnetic Braking System requires large space.

 Lubricants such as Grease or Oil cannot be used simultaneously as it can damage

Electromagnetic Breaking System.

 Electromagnetic Braking System cannot used as a âĂ IJonlyâĂ İ braking mechanism

as it can only slow it down not completely stop it.

10
 CHAPTER 5

METHODOLOGY

Our project was designed as an alternative to the Frictional Braking System. The
methodology utilized was primarily comprised of following steps. The Project Method-
ology began with the setting up of base plank, the second Step followed was the setting
up of horizontal and Vertical arms, which had a series of holes for variable adjutancy
of the distance of electromagnet from the rotating disc. The Horizontal and the Verti-
cal arms were welded on the base plate. The Base plate along with the Vertical arm is
bolted on the Base Plank. The horizontal arm is then bolted to vertical arm.
The Second phase of Setup Involves the populating up the skeleton structure. The first
and foremost step of the second phase goes to the creation of electromagnet. The elec-
tromagnet used in our project is made up by winding copper wire of approx. 40 meters
on each iron core. The Housing of Electromagnets is welded with the Vertical arm.
The electromagnets are kept on the housing. A Support Pillar for placement of motor
is made. The motor is placed on the pillar. Our rotor, the aluminium disc was a cir-
cular cutout of the aluminium plate. A hole was made into the disc at the geometrical
center and it was bolted to motor using a flange coupling. The motor was connected
to the battery and then to a switch. Similarly connection to the Electromagnets was
done. The Two Electromagnets was given connection to a 12V Battery, and then to the
switch. The wires were properly cleaned and arranged on the board neatly with the help
of tapes. Metallic Components were cleaned with emery paper. Cleaning was followed
by painting which completes the sets of methodology employed for this project.
5.1 STRUCTURAL FRAMEWORK

Our Structural Framework is divided into 2 major Categories

1. Driving Unit.

2. Braking Unit.

3. Other Parts.

5.1.1 DRIVING UNIT

MOTOR

Motor is an electrical component that converts Mechanical energy into Electrical En-
ergy. It works on the Principle of Faraday Law, which states that when an electric
conductor is placed in magnetic field it experiences a force in the direction perpendic-
ular to both current and magnetic current. We have used a motor of 300 rpm in our
project, which is used to rotate our aluminium disc.

Figure 5.1: Electric DC motor.

12
ALUMINIUM DISC

The Aluminium Disc is one and only moving element in our Project. The aluminium
disc is cut through an aluminium sheet with the help of power tool. This disc is rotated
at approx. 300 rpm with the help of electric motor.

Figure 5.2: Aluminium Disc.

BATTERY

Battery is the power house of our project. It supplies the current to motor as well as
electromagnets. We have used a battery of 12V in our project.

Figure 5.3: 12V Battery.

13
5.1.2 BRAKING UNIT

ELECTROMAGNET

The electromagnet is an electrical component which becomes a magnet when electric

current is passed through it, when current is switched off it behaves as the normal iron
metal piece. The electromagnet used in our project is made up by winding copper wire
of approx. 40 meters on each iron core.

Figure 5.4: Electromagnet

14
5.1.2 OTHER PARTS

WOODEN BASE

Wooden base is a wooden plank which is a base for all the components of the electro-
magnetic braking system having dimensions as 40*22*1 cm.

Figure 5.5: Wooden Plank

FASTENERS

A mechanical object that affixes or joins two mechanical objects.

Figure 5.6: Fastener

15
HOUSING OF ELECTROMAGNETS

Housing of electromagnets exhibits a scoop like structure as shown in figure

Figure 5.7: Housing of Electromagnets

5.2 MATERIALS AND REASON OF USE

1. Mild Steel.
Reasons:

• Excellent Weldeblity.

• Excellent Machinability.

• Ambient Availability.

• Pocket Friendly.

2. Aluminium.
Reasons:

• Light Weight.

• Magnetic Under Normal Conditions.

• Better and Faster Reaction to Eddy Currents.

• Doesn’t attract magnet.

16
5.3 THEORETICAL ANALYSIS
• Electromagnet Support Analysis.

Figure 5.8: Electromagnet Support Analysis

• Aluminium Disc Analysis.

Figure 5.9: Aluminium Disc Analysis.

17
5.4 THEORETICAL CALCULATIONS

1. Magnetic force produced for larger electromagnet (B) = µIN1

= 4π ∗ 10−7 ∗ 7 ∗ 550
= 0.00483 T which is magnetic force produced by one electromagnet as we are
using two electromagnets.

2. Magnetic force produced for larger electromagnet (B) = µIN2

= 4π ∗ 10−7 ∗ 7 ∗ 225 = 1.979 ∗ (10−3)T

Total Magnetic Force Produced = (0.00483T + 0.00197) = 0.0068T

3. Resistance of wire(R)= ρL/A

Area= (π ∗ 3 ∗ 3)/4 = 7.06 ∗ (10−6)m2

Length= 40m

Resistivity of Copper= 1.7 ∗ 10−8Ωm

R= 1.7 ∗ 10−8 ∗ 40/(7.06 ∗ 10−6)

R= 0.0963Ω

4. V=IR
I=V/R
= 12/0.0963
I= 124.6 A

18
5.5 WORKING MECHANISM

Figure 5.10: Flowchart Depicting Working Mechanism.

19
 CHAPTER 6

FABRICATION

6.1 MANUFACTURING PROCESSES UTILISED

• Drilling.

Drilling is a manufacturing process utilised to cut a hole in a solid materials using a

drilling bit and a drilling machine

• Metal Cutting.

. Metal Cutting is a manufacturing process utilised to remove extra or unnecessary

metal from the metal block in forms of chips.

• Grinding.

. Grinding in an manufacturing process utilised to remove small amounts of metal

from metal block which uses a wheel made up of abrasives as the cutting tool.

• Buffing.

. Buffing is a surface finishing process used for smoothening the surface of metal
block using a buffing wheel.

• Welding.

. Welding is a manufacturing process which is used to join two similar or dissimilar

metals. The process involves high heat which leads to melting of metals and ultimately
joining them.
6.2 STEPS OF FABRICATION

Fabrication starts just after designing phase gets over, followed by theoretical analysis
and calculation. The fabrication Steps follows as mentioned below:

• Selection of base plank.

. The base plank is selected such that it can survive the load and should be of su-
perior quality. The base plank of size 40*22*1 cm was finalized. The Base Plank was
properly cleaned and holes are drilled on the previously desired positions. The Plank
was again cleaned and kept aside.

• Formation of bars and plates.

. Horizontal and vertical bars are cut from the mild steel plate. Furthermore mild
steel plates are cut from the large mild steel plate. These mild steel plates are cut was
of the size (8*4*1 )cm and 2 in number.6 Small mild Steel plates of the size (3*2*1)cm
was also cut from the larger leftover plate. These small plates are welded in order to
create a scoop like structure leading to housing of electromagnets ultimately.

• Drilling of holes.

. Holes of size M4 are drilled on the vertical as well as horizontal bar on regular
intervals. The Drilled holes are cleaned using grinding operation. A hole is also drilled
in the geometrical centre of aluminium disc.

• Formation of Skeletal Structure.

. All the components formed from the above processes are brought together with
the various manufacturing processes already discussed above like welding, grinding and
fastening with bolts. So each set of horizontal and vertical bar are bolted and then these
bars are welded with the base plate. These base plates are fastened through nuts and

21
bolts to the wooden plank. So we are ready with the housing of electromagnets. An-
other set of horizontal and vertical bar after welding to base plate are similarly fastened
to the wooden base. This makes our housing of Motor and so here we are here finally
with the skeletal structure of Electromagnetic Breaking System.

• Formation of Electromagnets.

. The electromagnet is an electrical component which becomes a magnet when elec-

tric current is passed through it, when current is switched off it behaves as the normal
iron metal piece. The electromagnet used in our project is made up by winding copper
wire of approx. 40 meters each on each iron core. So for determining optimum number
of turns required to achieve desired strength of Electromagnet, we have done iterations
for both the electromagnets separately, as shown below -
Iteration for coil 1

Iteration 1:
Number of Turns= 75
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 75 = 6.597 ∗ (10−4) T

Result: No Reduction in speed seen
Iteration 2:
Number of Turns= 125
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 125 = 1.09 ∗ (10−3) T

Result: Reduction in speed seen but reduced speed was not up to the desired mark
Iteration 3:
Number of Turns= 225
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 225 = 1.979 ∗ (10−3) T

Result: Reduction in speed seen up to the desired mark, so approved.
Iteration for coil 2
Iteration 1:
Number of Turns= 175

22
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 175 = 1.53 ∗ (10−3) T

Result: No Reduction in speed seen.
Iteration 2:
Number of Turns= 325
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 325 = 2.85 ∗ (10−3) T

Result: Reduction in speed seen but reduced speed was not up to the desired mark.
Iteration 3:
Number of Turns= 550
Magnetic force produced(B) = µIN

= 4π ∗ 10−7 ∗ 7 ∗ 550 = 4.83 ∗ (10−3) T

Result: Reduction in speed seen up to the desired mark, so approved.
So after iterations we came to know that 225 no. of turns is required for coil 1 and 550
number of turns for coil 2 to get our desired output.

• Final Connection and Assembly

So we have skeletal structure ready, we just need to connect them and properly put
the things at place. Firstly the aluminium plate was bolted to electric motor and electric
motor was clamped to the housing. The electromagnet was placed on the housing and
was firmed using zip-tie. A connection starting from the battery connecting the two
terminals of each electromagnet .Similarly connection to the electric motor is done.
The terminals were soldered properly.All the open terminals were connected through
a switch. The connections were properly stuck with tape properly making it to look
decent. It was finally painted leading to completion of our project.

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6.3 COSTING OF FABRICATION

Table 6.1: Cost Involved In the Experiment.

S.No. Name Of The Components Quantity Price (in Rs.)

1 Supporting Rods (Mild Steel) 1m 400
2 Base Plate(Mild Steel) 3 kg 195
3 Fasteners:M4-Nut and Bolt 6 nos. 190
4 Fasteners:M8-Nut and Bolt 10 nos. 280
5 Fasteners: Self Driving Screw 4 nos. 15
6 Aluminium Metal Sheet - 80
7 Electromagnetic coil 80 m 600
8 Iron Core - 100
9 Electric Motor - 140
10 Miscellaneous - 100

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6.4 GANTT CHART

Figure 6.1: Gantt Chart.

25
 CHAPTER 7

OBSERVATION AND GRAPHS

The Tabular column(s) displayed below shows the deceleration of the wheel i.e instan-
taneous decreasing rpm is recorded with respect to time under different conditions.
1. In Table electromagnet having 175 turns is being tested. So in this iteration we can
evidently see that it takes least time when compared to time taken with electromagnet
having 325 or 550 turns, and same is conveyed graphically in Graph-2.

Table 7.1: RPM Vs Time

Time (in seconds) RPM of aluminium disc

0 625
7 352
14 176
21 105
28 52
35 0

Figure 7.1: RPM Vs Time.

 2. In Table electromagnet having 325 turns is being tested. So in this iteration we
can evidently see that it takes intermediate time when compared to time taken with elec-
tromagnet having 175 or 550 turns, and same is conveyed graphically in Graph-2.

Table 7.2: RPM Vs Time

Time (in seconds) RPM of aluminium disc

0 625
5 320
10 173
15 95
20 48
25 0

Figure 7.2: RPM Vs Time.

27
 3. In Table electromagnet having 325 turns is being tested. So in this iteration we
can evidently see that it takes intermediate time when compared to time taken with elec-
tromagnet having 175 or 550 turns, and same is conveyed graphically in Graph-2.

Table 7.3: RPM Vs Time

Time (in seconds) RPM of aluminium disc

0 625
2 341
4 163
6 82
8 37
10 0

Figure 7.3: RPM Vs Time.

28
7.1 FINAL PROJECT IMAGE

Figure depicting our completed project.

Figure 7.4: Actual Project Setup.

29
 CHAPTER 8

CONCLUSION

Following Conclusions are made after the exhilarant exploration of our Project (ELEC-
TROMAGNETIC BREAKING SYSTEM):

 Electromagnetic Breaking System can act as an Excellent Supplement of

conventional Breaking System.

 Aluminium discs are nonmagnetic so it would be best suitable as compared to

the other materials available with us.

 Furthermore, this project presents the performance of an electromagnetic

braking system which includes various components with its cost effectiveness
and efficient methodologies to utilize the supplied energy. With the application
of the effective and strong electromagnet we can have greater efficient braking
system.
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3. Haiqi, Y., Baofeng, W., Huiqin, L., and Jianchao, L. (2008). “Influence of electromag-
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