Design and Fabrication of Electromagnetic Brakes

Project Title

Design and Fabrication of Electromagnetic Brakes

Project Area of Specialization Mechanical EngineeringProject Summary

We Will design and Fabricate a braking system for automobiles whose efficacy is more than the traditional braking system. The Traditional braking system works on the phenomenon of friction while this system works on Electromagnetism.

In traditional Braking System the disc is surrounded by two brake pads on each side of the disc and when the driver presses the brake pedal, brake fluid from brake oil cylinder passes through tubes and pushes the brake pads to touch the disc. Due to this contact a tremendous amount of friction develops and this friction gradually stops the vehicle.

In our project we eliminate this friction with a system whose working is based on Faradays law of electromagnetic induction and lenz law. Following are some of the components that we will be using in our project.

1) Stepper Motor:

This is a type of electromagnet which will retard the motion of tyre( vehicle), using the following mechanism.

The motor contains coils and a shaft that extends out of the motor. When current is applied to it, the coils get magnetized and develops/generate a magnetic field. This magnetic Field gets cutted by the shaft of the stepper motor and according to Faraday law of electromagnetic Induction " a changing magnetic field produces current known as Eddy current." This Eddy current is produced in the shaft and according to lenz law this Eddy current produces magnetic field which is opposite in direction to the original magnetic field( opposite in direction to the motion of the shaft). So in this way it will retard the motion of the shaft and as this shaft is connected to the axle of the tyre so eventually tyre/vehicle will stop.

2) DC Motor:

An external DC Motor will be used to rotate the tyre. This is a prototype so thats why we are using external DC Motor . In real situation this tyre will be driven by engine.

3) Tyre:

This offcourse is used to move and stop the vehicle. Also the stepper Motor is connected to the axle of the tyre.

4) Frame:

In real car each and every component is mounted/situated on its own position and we do not need frame to hold things for us. As this is a prototype so we need a frame to mount the components.

5) Battery:

The DC Motor will be powered by an external battery. This battery will also provide current to the stepper motor when ever we apply brakes.

At a time when we do not need braking the DC Motor will be rotating the tyre and as the axle of the tyre and the stepper motor shaft are also connected to each other so the stepper motor will also be rotating and hence it will produce/generate power. The battery will be charged with this power.     

Project Objectives

Braking is an integral part of any automobile. It plays a vital role in the safety of the passengers and every automobile company foccuses on the safety of the passenger not only because of government regulations across the globe but the customer demands it too.

Before ABS, the braking performance of automobiles was too poor and with the addition of ABS it revolutize the braking of automobiles. Our Objective is to develop such an effective braking system which will revolutize the braking of automobiles once again. The said project will stop the vehicle in 5 seconds from 100 km/h to 0 km/h that is from 2000 rpm to 0 rpm.  Normal ABS installed vehicle will do the same job in 5 to 6 seconds. Another objective is to eliminate the heat generated due to friction and this heat generation can reduce the life of different parts of braking system. With the installation of this system we will be able to reduce/eliminate the regular maintanience cost of braking system, as there will be no friction so no wear and tear of braking parts. No brake fluid/oil will be used. Only there will be maintanience of battery which will be approximately after 2 to 3 years unlike the braking parts maintanience ( brake pad) which is to be done every month.

Project Implementation Method

We will fabricate the project in the following steps:

1) Design of the model

2) Calculations

3) Constructing Frame

4) Purchasing Equipments

5) Assembling the Whole system

6) Testing

First of all we design the model of the project on a piece of a paper. We took dimensions of each and every component and determine its proper place which best fits  on the frame. On the basis of these dimensions we determine the size of the frame that is 3ft in length, 1 ft in width and 1 ft in height.

Then we did calculations for the whole project. Starting with the frame, we find out the stresses in the bars of the frame and according to these values we constructed a frame. Then we did calculations for stepper motor and DC Motor that will run a tyre of 2 to 3 kg upto 2000 to3000 rpm, and then will stop it respectively.

After calculations we made market visit and purchased stepper motor, battery and DC Motor.

We fix the tyre on the frame using bearings. The shaft (axle) that extends from the tyre was welded with the shaft that comes from the stepper motor. The stepper motor is connected with battery using wires. The DC Motor and tyre are connected with each other using belt. The DC Motor is also connected with battery in order to get power.  After integration of all this sytem we started the testing of this braking system. We runned the tyre at 2000 rpm and then energize the stepper motor by pressing the brake pedal. The tyre completely stops in 4 seconds.

Benefits of the Project

As this project is related to health and safety of commuters so i think this project can benefit the community alot if this project gets commercilized. When this braking system gets installed in vehicles, it will increase Braking Performance thus reducing chance of accident. 

As there is no  friction so the chance of wear and tear is low so as a result its maintanience cost decreases and peoples money wouldn't be wasted.

Last but not the least in this braking system each tyre works individually , meaning if one tyre braking system gets failed so the other tyres braking system will be able to stop the car unlike the conventional braking system in which if brake oil gets leaked, the whole braking system gets failed. 

Technical Details of Final Deliverable

Our project comprises of 5 components. Their specifications and technical details of all these components will be discussed in this section.

We run DC Motor to run the tyre. The DC Motor is 24 W. As our purpose is to run a 2 to 3 kg of tyre so we do n't need a heavy duty DC Motor.

The second Component that we use in this project is stepper motor. A Neema stepper motor is used whose purpose is to stop/retard the motion of the tyre.

Tyre is used offcourse for rotatation purpose. We use a bycycle tyre as it is a prototype. The reason for selecting a bycycle tyre is that its a light weight so we will require a DC Motor with less power. ( Hence price is reduced).

Then comes battery. We purchased battery of motorcycle . Then comes frame. A 3 ft x 1ft x 1ft steel frame( angle iron ) is used to support the tyre and other components. Last but not the least a switch , couple of wires will be used to make this project functional.   

Final Deliverable of the Project Hardware SystemCore Industry TransportationOther Industries Manufacturing Core Technology OthersOther TechnologiesSustainable Development Goals Affordable and Clean Energy, Industry, Innovation and Infrastructure, Climate ActionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	47500
Frame	Equipment	1	7000	7000
Frame Painting	Equipment	1	1000	1000
Tyre	Equipment	1	2000	2000
DC Motor	Equipment	1	12000	12000
Stepper Motor	Equipment	2	3000	6000
Battery	Equipment	1	5000	5000
Bearings	Equipment	2	2500	5000
Bearings Couplers	Equipment	2	1500	3000
Switch and wires	Equipment	1	500	500
Blacksmith expense	Miscellaneous	1	3000	3000
Transportation	Miscellaneous	3	1000	3000