This document describes the design and fabrication of an electromagnetic braking system. It uses magnetic force to engage the brake by applying electricity to an electromagnetic coil. When current flows through the coil, a magnetic field is created that attracts a plunger. The plunger then moves the brake shoe against the rotating drum, slowing the vehicle. The objectives are to control vehicle speed and stop quickly using electromagnetic braking to reduce braking reaction time. It provides calculations for the required braking force and shaft diameter. A CAD model and conclusions on improved braking performance are also included.

1. DESIGN & FABRICATION OF
ELECTROMAGNETIC
BRAKING SYSTEM
BY
SURIYA PRAKASH
SURYA KUMAR
TAMILARASAN
VIGNESH V

2. ABSTRACT
• Electromagnetic Braking system uses Magnetic force to
engage the brake, but the power required for braking is
transmitted manually.
• When electricity is applied to the coil a magnetic field is
developed across the plunger because of the current flowing
across the coil and causes plunger to get attracted towards the
coil.
• As a result it moves the brake shoe against the rotating drum
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.

3. OBJECTIVE
• The main objective of our project is to control the
speed of the vehicle as well as to stop it when and
where quickly and efficiently without sticking. By
using electromagnetic braking, we can reduce the
reaction time of braking.

4. INTRODUCTION
• A brake is a device by means of which artificial frictional
resistance is applied to a moving member, in order to retard or
stop the motion of a machine.
• The principle of braking is the reverse of that applied during
accelerating a vehicle.
• In the process of performing this function, the brake absorbs
either kinematic energy of moving member or potential energy
given up by objects lowered by hoists, elevators etc.
• Electromagnetic brake relay on the attractive force generated
by the magnetic coil to move the brake shoe against the inside
of the drum.

5. WORKING
• In this project, we propose a new type of electromagnetic
brake using solenoid switch.
• It has one solenoid coil operated at 12V DC supply. There is a
metal rod centrally mounted in the coil under spring force.
• When the supply is given to the coil, the solenoid core rod
moves inward in the coil and the metal rod pulls the brake
shoe to apply brake to the rotating wheel.
• The coil is connected to the power supply through a pedal.

6. LITERATURE SURVEY
S.no Year Author Name
Journal
Name
Area of Interest
Result and
remarks
1 2014
HE Ran
HU Donghai
Zhang Duanfin
Journal of
automotive
safety and
energy
Brakes are applied in
commercial vehicles
External and
internal
characteristics
of Electro
magnetic brakes
2 2013 ajay yadav
Journal on
electromagne
tic brakes
Electromagnetic in two
wheeler at high speed
and low maintance cost
Characteristics
of
electromagnetic
brakes

7. S.no Year Author Name
Journal
Name
Area of interest
Results &
Remarks
3 2008
WilliamGaskey
Sandip mistry
Jee Yon
Electromagn
etic braking
system
Develop brakes with low
cost and greater
performance
Electromagneti
c field
dispersion
4 2007
Hong Je Ryoo
Geun Hie Rem
Design and
analysis of
an eddy
current brake
for high
speed
railway track
Electromagnetic magntic
braking in high speed
railway train
Constant torque
is generated all
over the speed
range

8. S.no Year Author Name
Journal
Name
Area of Interest
Results &
Remarks
5 2006
Minjou jaw
kuen shiau,
chi-chian sun
Journal of
magnetic and
magnetic
materials
Eddy current braking
Effect of air gap
on the magnetic
flux density
6 2005 Jure Hribar
Magnetic
Braking
Magnetic braking of
rectangular sheet moving
linearly through the
magnet
Effect of
magnetic drag
force on
moving
magnets

9. DESIGN CALCULATIONS
Calculation for Force to operate Brake shoe (F)
F = (m + M)/C
Allowable pressure for Asbestos = 0.7b N/mm²
Total moment of Normal force (M)
M = ½ p br OA [(Ø₂- ₁) + ½ (sin2Ø₁-sin2Ø₂)]
= ½ x 0.75 x 5 x 97 x 85 [(1.83 – 0.175) + ½ (sin20-sin216]
= 39959.47 N-mm.
Total momentum of the friction force (M)
M = µ pbr [r ( cosØ₁-cosθ₂) + OA/4 (cos2θ₂-cos 2θ₁)
= 31947.52 N mm.
Therefore Force (F) = (M + M)/C
= (39959.47-31947.52)/155
= 51.69 N.
Force to operate brake shoe = 51.69N.

10. DESIGN CALCULATIONS
Calculation for Diameter of shaft
Subjected to torque
Material = Carbon steel (C14)
Force = 51.69 N = 5.269 kgf.
Radius = 0.097 m.
Torque = Force x Radius (kgfm)
= 5.269 x 0.097
= 0.511 kgfm
dia of the shaft =20.5 mm (From PSG-Design Data book)

11. DESIGN CALCULATIONS

12. CAD MODEL

13. CONCLUSION
• This project is an experimental effort to demonstrate a new
type of Electromagnetic braking system using a solenoid coil.
The necessity for this brake arises from the fact that there is a
time lag even in the case of air brakes between the pressing of
the brake pedal and the applier action of the brakes. In
electromagnetic brakes there is practically no lag.
• The brake was also successfully applied in the experimental
setup for testing the arrangement.

14. FUTURE SCOPE OF THE
PROJECT
A strong electromagnet can be used to operate the shifting
mechanism of an overrunning clutch drive, when current is sent
through the solenoid coil (electromagnet windings) it attracts a
soft iron core called a plunger which operates the shift lever. The
solenoid unit is mounted solidly on the frame of the starting
motor. The movement of the shift plunger also operates the
contact disc which completes the circuit between the starting
motor and the battery. The solenoid assembly contains two
windings a shunt winding (hold in coil) and a series winding (pull
in coil).

15. REFERENCES
• [01] Prof. P.L.Balleny, “Theory of Machines and Mechanism”. Page
no.574, Twenty second edition 2001, khanna Publication, New
Delhi.
• [02] Joseph E. Shingley & Charles R Mischke, “Mechanical
Engineering Design ( in SI units)”.Page no.986,sixth edition
2003,TaTa McGraw Hill Publication Company Limited, New Delhi.
• [03] G.B.S.Narang, “Automobile Engineering”. Page no.275, fifth
edition 2004, khanna Publication, New Delhi.
• [04] Harbans Singh Reyat, “The Automobile”. First edition
1962,S.Chand Publication, New Delhi.
• [05] K.M.Gupta. “Automobile Engineering”. Volume 2, Page No.80,
Umesh Publication, New Delhi.
• [06] S.M. Jang, S.H. Lee, and S.S. Jeong, “Characteristic analysis of
eddy-current brake system using the linear Hallbach array,” IEEE
1578”

16. REFERENCES
• [07] Bruno Lequense, “Dynamic model of solenoids under impact
excitation, Including Motion and eddy currents,” IEEE Trans. On
Magnetics, Vol 26,1990.
• [08] Richard Shemanske, “Electronic Motor Braking,” IEEE Trans. On
Industry Applications, vol.IA-19,pp.824-831,Apr.1983.
• [09] Timo T. Vekara, Jarl-Thure Eriksson and Juha T.Tanttu,”Dynamic
model of an Electromagnetic Massive Core Brake Actuator,” IEEE
Trans. On Magnetics, Vol. 32, 1996.
• [10] M.A. Heald, “Magnetic Braking: Improved Theory,” American
journal of physics, vol.56, no.6, pp.521-522,1988.

17. THANK YOU