Visvesvaraya Technological University

Belagavi, Karnataka

Mini Project - Report On

“ELECTROMAGNETIC BRAKING SYSTEM”
Submitted
In Partial Fulfillment for the award of degree
Bachelor of Engineering
In
Mechanical Engineering
Submitted by 6th Semester Students
Nrupada Ramesh (1SG19ME036)
Prateek P Jigalore (1SG19ME039)
Sagar T (1SG19ME048)
Santhosh S (1SG19ME050)
Under the Guidance Of

Mr. Chethan B P
Assistant Professor

Department of Mechanical Engineering

SAPTHAGIRI COLLEGE OF ENGINEERING

14/5, Chikkasandara, Hesaraghatta Main Road, Bengaluru-57

FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

SAPTHAGIRI COLLEGE OF ENGINEERING

(Affiliated to VTU Belagavi & Approved by AICTE, New Delhi)
14/5, Chikkasandara, Hesaraghatta Main Road, Bengaluru-57
DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the Mini Project work entitled “ELECTROMAGNETIC BRAKING
SYSTEM” carried out by Nrupada Ramesh (1SG19ME036), Prateek P Jigalore
(1SG19ME039), Sagar T (1SG19ME048) and Santhosh S (1SG19ME050) of 6th
Semester Mechanical Engineering department in partial fulfilment for the award of
degree in Bachelor of Engineering at Sapthagiri College of Engineering affiliated
to Visvesvaraya Technological University, Belagavi for the academic year 2021-
2022. It is certified that all corrections/ suggestions indicated for internal assessment
have been incorporated in the report deposited in the department library. The Mini
Project report has been approved as it satisfies the academic requirements in
prescribed for the said degree.

Signature of the Guide Signature of the HOD

Mr. Chethan B P Dr. P MAHADEVASWAMY

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

CONTENTS

No. DESCRIPTION PAGE NUMBER

1) Abstract 4
2) Acknowledgement 5
3) Figure Heads 6
4) Background 7
5) Introduction to Project 8
6) Literature Review 9 - 10
7) Principle of Electromagnetism 11
8) Components 12 - 15
9) Fabrication Model of Electromagnetic Braking 16
10) Component Specifications 17
11) Methodology 18
12) Scope & Objectives 19
13) Advantages & Limitations 20
14) Project Management 21
15) Result & Discussion 22
16) Conclusion 23
17) References 24

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

ABSTRACT

The project deals with electromagnetic braking system, which is used in elevators, escalators, servomotors,
packaging and food processing machinery etc… The project concentrates on creating an electromagnetic
braking system model capable of applying brakes without any friction loss and without losing the energy
supplied.

Electromagnetic brakes are also known as electro-mechanical brakes, this is a braking system that is used to
slow down or stop the rotation of machine shaft with help of electromagnet. It works on the principle of
electromagnetism; these brakes use both electrical power as well as mechanical power during operation. The
electromagnetic brakes are an excellent replacement of the conventional brakes as these reduces the wear in
automobiles as they are frictionless.

The working principle of this braking system is that when magnetic flux passes through the rotating wheel
the eddy current flows in opposite direction to the rotating wheel. The eddy current is trying to stop the
rotating wheel or rotor as a result the rotating wheel/rotor comes to rest.

Electromagnetic brakes are preferred across a wide range of industries because of their cleanliness, control
and safety when compared to the conventional braking system. It is used in agriculture, aerospace, medical,
military, oil and gas industries and many more. EM brakes have a considerably longer lifespan, low
maintenance, and similar or sometimes better working strength. Hence, their inclusion is another step for the
overall betterment of our lifestyle.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

ACKNOWLEDGEMENT

Any achievement does not depend solely on the individual effect but on the guidance, encouragement and
co-operation of intellectuals, elders and friends. A number of personalities, in their own capabilities have
helped me in carrying out this project work. I would like to take this opportunity to thank them all.

I would like to express my immense gratitude to Dr. H RAMA KRISHNA, Principal of Sapthagiri College
of Engineering, Bangalore for this help and inspiration during the tenure of course.

I also extend my sincere thanks to Dr. P MAHADEVSWAMY, Professor and Head of Department of
Mechanical Engineering, Sapthagiri College of Engineering, Bangalore, for his constant support.

I would like to express my heartfelt gratitude to our project Co-Ordinator Mr. CHETHAN B P, Department
of mechanical Engineering, Sapthagiri College of Engineering, Bangalore, for his timely advice on the
completion of project work.

It gives me a great pleasure in placing on record a deep sense of gratitude to our guide Mr. CHETHAN B
P, Assistant professor, Department of mechanical Engineering, Sapthagiri College of Engineering,
Bangalore, for his expert guidance, initiative and encouragement that led us throughout our Project work.

I would like to express my sincere thanks to Dr. TULSIDAS, Professor, Dr. RAGHAVENDRA
DESHPANDE, Professor and Mr. ANIL KUMAR, Assistant Professor, Department of mechanical
Engineering, Sapthagiri College of Engineering, Bangalore for their constant support and guidance
throughout the project work.

I also extend my sincere thanks to all the faculty members of Mechanical Engineering Department of
Mechanical Engineering, Sapthagiri College of Engineering, Bangalore for their constant encouragement
and support.

I would like to thank all non-teaching staff members of Mechanical Department who have helped us directly
and indirectly during the project.

Finally, I thank my parents and friends for their moral support.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

FIGURE HEADS

LIST OF FIGURES NAME

Fig 1. Principle of Electromagnetism

Fig 2. Sprocket

Fig 3. Chain

Fig 4. Mild Steel Bars

Fig 5. Bicycle Tire

Fig 6. Electromagnet

Fig 7. Motor

Fig 8. Bearings

Fig 9. Regulated Power Supply

Fig 10. Fabrication Of Electromagnetic

Braking System (Right View)

Fig 11. Fabrication Of Electromagnetic

Braking System (Left View)

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

BACKGROUND

It is 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 compared with other retarders. By using electromagnetic brakes, the friction brakes
can be used lessened frequently, and therefore practically never reach high temperatures. The brake linings
would last considerably longer before requiring maintenance and the potentially “brake fade” problem could
be avoided. Furthermore, the electromagnetic brakes prevent the danger that can arise from the prolonged
use of brake beyond their capability to dissipate heat.

Since becoming popular in the mid-20th century especially in trains and trams, the variety of applications
and brakes design has increased dramatically, but the basic operation remains the same. They work on the
principle of electromagnetism.

Types of Braking System

➢ Electromagnetic Brake System

Electromagnetic brakes use an electric motor that is included in the automobile which help the
vehicle come to a stop. These types of brakes are in most hybrid vehicles and use an electric motor to
charge the batteries and regenerative brakes.

➢ Frictional Brake System

Frictional brake system is found in many automobiles. They are service brakes, and typically
found in two forms; pads and shoes. As the name implies, these brakes use friction to stop the automobile
from moving. They typically include a rotating device with a stationary pad and a rotating weather surface.

➢ Hydraulic Brake System

Hydraulic brake system is composed of a master cylinder that is fed by a reservoir of hydraulic
braking fluid. This is connected by an assortment of metal pipes and rubber fittings which are attached to the
cylinders of the wheels. The wheels contain two opposite pistons which are located on the band or drum
brakes which pressure to push the pistons apart forcing the brake pads into the cylinders, thus
causing the wheel to stop moving

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

INTRODUCTION TO PROJECT

Electromagnetic brakes also called as electro-mechanical brakes it is used to slow or stop motion using
electromagnetic force by applying mechanical resistance(friction). The original name was “electro-
mechanical brakes” but over the years the name changes to “electromagnetic brakes” referring to their
actuation method. These brakes have excellently replaced the conventional brakes due to their many added
advantages. The reason for implementing this brake in automobile is to reduce wear in brakes as it is
frictionless. It is very widely used in the present automobile industries.

Electromagnetic brakes have been used as supplementary retardation equipment in addition to the regular
friction brakes on heavy vehicles. Electromagnetic brakes are the brakes working on the electric power &
magnetic power. They work on the principle of electromagnetism. The working principle of this system is
that when the magnetic flux passes through and perpendicular to the rotating wheel the eddy current flows
opposite to the rotating wheel/rotor direction. This eddy current trying to stop the rotating wheel or rotor.
This results in the rotating wheel or rotor comes to rest/ neutral.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

LITERATURE REVIEW

Prof. N.B.Totala et al. The authors have come down to conclusion that an alternative to disc braking where
a high increase in temperature takes place because of the friction between the plates can be prevented by
using electromagnetic braking system where there is no heat generated by friction, no wear of any plates,
which brings a huge impact on maintenance of the brakes since regular changes of brakes is not at all
needed. Even though a very small amount will be generated because of the electromagnet, it can be
thermally stabilized by means of the convection and radiation of the heat energy at high temperature. The
electromagnetic brakes have excellent heat dissipation efficiency. Electromagnetic brakes have better
thermal dynamic performance than regular friction brakes. An alternative and efficient system which can be
used instead of drum brakes, hydraulic brakes and pneumatic brakes is an electromagnetic brake which
proves to be a better solution. Electromagnetic brake control system is an electric switching system which
gives it superior controllability. The installation of an electromagnetic brake is not very difficult. From the
foregoing, it is apparent that the electromagnetic brake is an attractive complement to the safe braking of
heavy vehicles. Good results with current design, a larger budget would improve performance.

Kiran Prakash et al. In this journal, the design of electromagnet for using it in a braking system has been
done. To design an electromagnet braking system the key points or the factors which have to be taken into
consideration are Material Selection, Disc Thickness, Disc Radius, Relative Permeability & Absolute
Permeability, Magnetic Field for the chosen, Braking Torque, Braking Time are to be calculated.

Sevvel P et al. In this journal different types of conventional braking systems have been analysed along with
their disadvantages and difficulties faced by using those braking systems. Also, they have explained
regarding the working principle of electromagnetism Oersted experiment, magnetic effect of the flow of
current in a conductor and the factors affecting the strength of electromagnet are discussed. They have
detailed explained about how an electromagnet can be used in the braking system, thermal dynamics and
working principle of electromagnetic braking system. They finally concluded by saying that with all these
advantages of electromagnetic braking system over the conventional/friction brakes, they have been widely
used in heavy vehicles where brake fading problems occur. They have also briefly spoken about how this
mechanism is been developed for lighter vehicles which is still under development.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

Min Joua et al. In this journal the authors have developed a model to demonstrate the principle of
magnetism. Here, they designed a magnetic braking system using permanent magnets which are used in
elevators for safety features, they used 2 pairs of permanent magnets on front and rear side. Their objective
was to develop FEM to analyse the electromagnetic field for calculation of braking force and to understand
the effect of air gap in magnetic flux density. They made few considerations and assumptions like
rectangular magnets are used in this study which will reduce the model from 3D to 2D and the magnets are
mounted in symmetry in order to reduce the vibrations due to unbalance of forces. Finally, they concluded
that increasing air gap will decrease the average value of magnetic flux density. There verification showed
that the predicted magnetic flux is within 5% difference with the measured value. Therefore, the magnetic
flux density computed by the developed FEM model can be applied during the design stage of magnetic
braking systems

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

PRINCIPLE OF BRAKING SYSTEM

The principle of braking in road vehicles involves the conversion of kinetic energy into thermal energy
(heat). When stepping on the brakes, the driver commands a stopping force several times as powerful as the
force that puts the car in motion and dissipates the associated kinetic energy as heat. Brakes must be able to
arrest the speed of a vehicle in a short period of time regardless how fast the speed is. As a result, the brakes
are required to have the ability to generating high torque and absorbing energy at extremely high rates for
short periods of time. Brakes may be applied for a prolonged periods of time in some applications such as a
heavy vehicle descending a long gradient at high speed. Brakes have to have the mechanism to keep the heat
absorption capability for prolonged periods of time. Electromagnetic Braking system works on the principle
of electromagnetism

Fig 1. Principle of Electromagnetism

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

COMPONENTS
1) Sprocket: -
A sprocket, sprocket-wheel, or chain wheel is a profiled wheel with teeth that mesh with a chain, bar, or
other perforated or notched material. The name “sprocket” applies generally to any wheel on which radial
projections engage in a chain running over it. Sprockets and chains are also used to transfer power from one
shaft to another when slippage is not allowed, using sprockets instead of belts or ropes and sprockets instead
of pulleys. Sprockets are used in bicycles, motorcycles, tracked vehicles, and other machines to either
transmit rotary motion between two shafts where gears are unsuitable or to impart linear motion to a track,
tape, etc.

Fig 2. Sprocket

2) Chain: -
Chains are made of many links connected together in a manner that allows it to bend as it travels through the
drive mechanism. Chain drives are employed for a wide range of power transmission applications, like in
bicycles, motorcycles, rolling mills, agricultural machinery, machine tools, conveyors, coal cutters, etc. A
chain drive consists of a chain and two wheels, called Sprockets. The sprockets are toothed wheels over
which an endless chain is fitted.

Fig 3. Chain

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

3) Mild Steel Bars -

Mild steel bars are plain in surface and have cross sectional diameters varying from 6 to 50 mm. These rods
are manufactured in long lengths and can be cut quickly and be bent easily without damage. Mild steel is a
form of carbon steel which has high tensile and impact stress.

Fig 4. Mild Steel Bars

4) Bicycle Tire: -
A bicycle wheel is a wheel, most commonly a wire wheel, designed for a bicycle. A pair is often called
a wheelset, especially in the context of ready built "off the shelf" performance-oriented wheels. Bicycle
wheels are typically designed to fit into the frame and fork via dropouts, and hold bicycle tires. These wheel
to use the tension in metal spokes during rotation.

Fig 5. Bicycle Tires

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

5) Electromagnet: -
An electromagnet is a type of magnet in which the magnetic field is produced by an electric current.
Electromagnets usually consist of wire wound into a coil. A current through the wire creates a magnetic field
which is concentrated in the hole, denoting the centre of the coil. The magnetic field disappears when the
current is turned off. The wire turns are often wound around a magnetic core made from
a ferromagnetic or ferrimagnetic material such as iron; the magnetic core concentrates the magnetic flux and
makes a more powerful magnet.

Fig 6. Electromagnet

6) Motor: -

A 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 electric current in a wire
winding to generate force in the form of torque applied on the motor's shaft. An electric generator is
mechanically identical to an electric motor, but operates with a reversed flow of power, converting
mechanical energy into electrical energy. Electric motors can be powered by direct current (DC) sources,
such as from batteries, or rectifiers, or by alternating current (AC) sources, such as a power grid, inverters or
electrical generators

Fig 7. Motor

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

7) Bearings: -
A bearing is a machine element that constrains relative motion to only the desired motion, and
reduces friction between moving parts. It provides for free linear movement of the moving part or for
free rotation around a fixed axis; or, it may prevent a motion by controlling the vectors of normal forces that
bear on the moving parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are
classified broadly according to the type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.

Fig 8. Bearings

8) Regulated Power Supply: -

Regulated power supply is an electronic circuit that is designed to provide a constant dc voltage of
predetermined value across load terminals irrespective of ac mains fluctuations or load variations. A
regulated power supply essentially consists of an ordinary power supply and a voltage regulating device, as
illustrated in the figure. The output from an ordinary power supply is fed to the voltage regulating device
that provides the final output. The output voltage remains constant irrespective of variations in the ac input
voltage or variations in output (or load) current.

Fig 9. Regulated Power Supply

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

Fig 10. Fabrication Of Electromagnetic Braking System (Right View)

Fig 11. Fabrication Of Electromagnetic Braking System (Left View)

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

COMPONENT SPECIFICATIONS

❖ Specifications Of Electromagnet

Holding/Suction Force 8 Kg
Operating Voltage 24 V
Max Operating Current 10 A
Power Consumption 3 Watt

❖ Specifications Of Motor

Rated Speed 3000 rpm

Operating Voltage 24 V
Power 250 Watt

❖ Specifications Of Regulated Power Supply

Variable Output Voltage 30 V

Variable Output Current 3A
Input 220 V

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

METHODOLOGY

METHODOLOGY / WORKING: -

❖ The motor of power rating 24v and 250 watts is driven using a Regulated power supply of 25v
5amps.
❖ When the motor is power the motor starts to rotate at an rpm depending upon the potential given, as
the motor starts to rotate the chain mechanism which is connected using 6-inch and 3-inch sprocket
produces the rotation.
❖ When the wheel starts rotating at a certain rpm to stop the rotation of the or in other words to apply
brake to the system the current is passed to the electromagnet.
❖ When the required amount is passed through the electromagnet the electromagnet gets magnetized
and thus due to the magnetic file produced the disc is attracted to the electromagnet because of the
magnetic field produced.
❖ When the magnetic field is produced, it starts providing resistance to the rotating disc which is
connected on the axle thus restricting the rotation of the wheel.
❖ When the electromagnet produces sufficient magnetic field the magnetic field lines completely stop
the rotation on the wheel thus in other terms it applies brakes to the rotating wheel.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

OBJECTIVES & SCOPE

OBJECTIVES
❖ The main objective of our project is to design and fabricate an Electromagnetic Braking System
model.
❖ To understand project planning and execution.
❖ To understand the fabrication techniques in a mechanical workshop.
❖ To understand the usage of various mechanical machine tools and also measuring tools.
❖ To make day to day human life easier by proper use of technology.
❖ To study about different braking system used in automobiles and its design.

SCOPE
❖ Electromagnetic brakes they satisfy all the energy requirements of a braking without the use of
friction. They have better heat dissipation capacity to avoid problems faced by conventional brakes.
❖ They can be used as a supplementary braking system in addition to the conventional braking in
heavy vehicles.
❖ These electromagnetic brakes they are already in use in railways, heavy vehicles etc...
❖ Heavy braking is more comfortable since these brakes are more effective in nature.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

ADVANTAGES & LIMITATIONS

ADVANTAGES

❖ As there is no physical contact required to create friction between the parts, the wear and tear of this
system are less than the other system.
❖ Electromagnetic braking is cheaper and almost no maintenance cost is required.
❖ The heat generated by electromagnetic braking is extremely less compared to any other braking.
❖ In electric braking there is no maintenance cost like replaced brake shoes periodically.
❖ In electric braking negligible amount of heat is generated whereas in mechanical braking enormous
heat is produced during braking.
❖ Construction of electromagnetic brakes is simple.
❖ Less Noise is generated during working.

LIMITATIONS

❖ Due to residual magnetism present in electromagnets, the brake shoe takes time to come back to its
original position.

❖ The installation of an electromagnetic brake is very difficult if there is not enough space between the
gearbox and the rear axle.
❖ Since this system runs on battery, it drains the battery much quicker.
❖ Chances of brake failure due to failure in electrical system.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

PROJECT MANAGEMENT

Project management allows verification of all the project goals being achieved and to what extent under
specific time frame. The primary constraints faced during conducting the project was Research Time,
Estimated Budget and allotment of tasks for available human resources. In this Chapter, the Bill of
Materials and Cost Estimation to complete the Tasks.

SL.NO COMPONENTS QUANTITY SPECIFICATIONS

USED

1) Electromagnets 2 10A – 24v

2) Motor 1 300rpm – 24v

3) Regulated Power Supply 1 30v – 3A

4) Bearings 2 To constrains relative

motion to only the desired
motion

5) Shaft 1 Transmit power from one

source to another.

6) Sprocket 1 For guiding the chain and

transfer power

7) Chain 1 Provide drive mechanism

8) Electrical Wires Multiple To complete the circuit

connections

9) Bicycle Wheel 1 Prove rotational motion

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

RESULT & DISCUSSION

By using the electromagnetic brake as supplementary retardation equipment, the friction brakes can be used
less frequently, and therefore practically never reach high temperatures. The brake linings would last
considerably longer before requiring maintenance, and the potentially “brake fade” problem could be
avoided.

It does not need a subsidiary cooling system. It does not effect on the efficiency of engine, electromagnetic
brake also has better controllability. Thermal stability of the electromagnetic brakes is achieved by means of
the convection and radiation of the heat energy at high temperature. The electromagnetic brakes have
excellent heat dissipation efficiency. Electromagnetic brakes have better thermal dynamic performance than
regular friction brakes.

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FABRICATION OF ELECTROMAGNETIC BRAKING SYSTEM

CONCLUSIONS

The project sums up the performance of an electromagnetic brakes system which provides an optimum
braking effect by effective utilization of the electromagnetic field produced by the coils. By doing this
project we understood how an electromagnet can be used to achieve braking. We got to know that
electromagnetic braking system is more reliable even though there are a few limitations in its usage. The
process of installation of these brakes in the system is very easy compared to other brakes

The electromagnets use about 80% of all the power supplied during operation. These brakes are used as
secondary brakes in heavy vehicles as they operate at a low temperature and generates no friction. This
enhanced brakes not only helps in effective braking but also helps reduce the frequency of accidents.

In this type of braking system abrasion, noise, harmful friction, dust, temperature failure is reduced. With a
much better design a larger budget we can surely improve the performance of the system.

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REFERENCES

[1] Prof. N.B.Totala, Priya Bhosle, Seema Jarhad, Soniya Jadhav, Kamlesh Kuchekar. “Electromagnetic
Braking” 6-8 April 2015.

[2] Dr. S. R. Pawar, Shubham D. Satam, Saif Ali Shaikh, Amit R. Shah. “Analysis Of Electromagnetic
Braking”. Volume 10 Issue 4, 2022, PP. 19-26.

[3] Pratyush Kumar Routh, Prem Sagar, Prince Kumar, Rajesh Kumar, Sarnendu Paul. “Electromagnetic
Braking System” Volume: 06 Issue: 05 | May 2019

[4] Rhythm Dhoot, Sanket Gaikar , Nitish Kulkarni , Ojus Jain. “Design & Theoretical Study of
Electromagnetic Braking System” Volume 13, Issue 6 Ver. VI (Nov. - Dec. 2016), PP 87-96.

[5] Sagar Wagh, Aditya Mahakode, Abhishek Mehta and Vaneela Pyla (2017), “Electromagnetic Braking
System in Automobile” International Journal of Trend in Research and Development, Volume 4(3), 228-
231.

[6] V.B. Bhandari "Design of Machine Elements" Tata McGraw hill.

[7] Prajapati, K., Vibhandik, R., Baria, D., Patel, Y. and Detail, I.G., 2017. “ELECTROMAGNETIC
BRAKING SYSTEM”. International Journal of Scientific Research in Engineering.

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