International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020

ISSN 2229-5518 355

Design and Fabrication of Frictionless Braking System

Md Shujauddin1, Malge Anand1, Mohammed Faizan1, Nikhil R1, Shreyas P S2
School of Mechanical Engineering, REVA University, Bangalore

Abstract: The idea of electromagnetic braking comes with the advantages and disadvantages of stresses in calipers and
dissipation of heat. The electromagnetic braking system entirely depends on magnetic power to move the parts of the braking
system. The system indulges the principle of if a magnetic field is induced in the rotating disc, then the other side produces the
eddy current of the movement or rotation of the disc brake. The major parts of an electromagnetic braking system are braking
discs, solenoid, circuit board, step-down transformer and battery power.

Keywords: Electromagnetic Braking, Control of Current, Electromagnet, Rotating Disc.

Introduction: The stopping force generated by a braking system is more

than the actual energy generated by engines. Nowadays the
The Frictionless Braking system: greater power of engines and greater need for safety has
caused to develop a system to minimize the dangers. Vehicle
A frictionless electromagnetic braking system utilizes linear safety improvement is one area in the automobile industry that
alternators which are controlled by a power electronics is increasingly being emphasized with passing time. Stability
converter interface to capture the car's kinetic energy and of vehicles running on the road is very much dependent on the
generate braking force on the wheel. on-going improvements in brake technology. Currently, for
the purpose of improving braking functionality and to have the

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Electromagnetism: Electromagnetism is one of the four least environmental impact, automotive manufacturers are
fundamental interactions in nature. The other three are the investing in developing EMB (Electromechanical braking
strong interaction, the weak interaction and gravitation. systems). Electromagnetic brakes are simply an mechanical
Electromagnetism is the force that causes the interaction brakes which bring about retardation by applying
between electrically charged particles; the areas in which this electromagnetic induction in the disc brake in direction
happens are called electromagnetic fields. opposite to the rotation of the actual disc i.e. If vehicle is
moving forward then rotation of disc will be clockwise (Frame
Magnetic Effect of Current: The term "Magnetic effect of
of reference is from left hand side of vehicle) then the
current" means that "a current flowing in a wire produces a
magnetic field will be counter clockwise. By this way the
magnetic field around it". The magnetic effect of current was
motion of the brake is retarded by the brakes but there is no
discovered by Ousted in 1820. Ousted found that a wire
physical contact in any case.
carrying a current was able to deflect a magnetic needle.
This is a revolutionary concept. Hence electrical energy from
Electromagnet: An electric current can be used for making
the appropriate power source is used to the purpose. As any
temporary magnets known as electromagnets. An
type of brake, the heat energy is generated in the brakes which
electromagnet works on the Magnetic effect of current. It has
have to be exhausted into environment but wear and tear is
been found that if a soft iron rod called core is placed inside a
minimized. Brakes are imperative for any vehicle and a
solenoid, then the strength of the magnetic field becomes very
substantial vehicle by and large uses grating brakes alongside
large because the iron ore is magnetized by induction.
Electromagnetic brakes. This venture primarily concentrates
on building slowing mechanism, which can be material in bike
Eddy Currents: When the moving conductor is introduced in
at fast and low upkeep cost. This framework utilizes an
the magnetic field then current is generated in the conductor,
electromagnet connected directly to vehicle’s battery.
this phenomenon is called as the Eddy currents.
Electromagnetic brakes are likewise called electro-mechanical
brakes or EM brakes and moderate or stop movement utilizing
1.1 Background of the Project
electromagnetic constrain to apply mechanical resistance.
Automobile industry is a constantly changing industry with
the fast pace of technological developments and
1.2 Significance of the Project
implementations. With introduction of new and powerful
Electromagnetic brakes are a new revolutionary concept. It is
machine the need to stop these machines also arises.
found that electromagnetic brakes generate negative energy
which is twice as that of the Energy generated by engines, and
Not on stopping but increasing the efficiency to maximum in
three times more the exhaust system. Types of braking system
order to keep the energy losses to minimum. Generally,
is Exhaust braking system
friction braking or exhaust braking is used in the automobiles,
friction or exhaust braking system comprises of means to use
Drum Brakes: In drum brakes the motion is retarded by using
friction to convert Kinetic energy of body into Heat energy
a brake pad mounted inside the drum of the wheel. Which
causing the motion to retard.
brakes are applied then the pad lined with frictional material
rubs against the drum and retardation is observed.
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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 356
minimum. Furthermore, the electromagnetic brakes prevent
Disc Brakes: Disc brakes are hydraulic type of braking the danger that can arise from the prolonged use of brake
system. In this braking system which brakes are applied fluid beyond their capability to dissipate heat.
from master cylinder is generates pressure and this pressure is Production costs, time required for product development, time
passed through fluid lines. This fluid applies pressure on slave required for process development are all significantly reduced
cylinders, causing them to rub against the disc. Heads of slave by the proper utilization of tools. Not only the above-
cylinders are also coated with frictional material to increase mentioned benefits but also the simulation techniques that are
the effectiveness. involved in braking systems give a boost to quality assurance
of the final part.
When braking action is brought by the use of electromagnetic
induction rotation Electromagnetic brakes brings about the Moreover, it becomes easier to make cost estimates for
same action as above stated brakes only with greater making business related quotations to customers, specifying
efficiency and effectiveness. In this report we observe the parameters as specifications for technical purposes as all these
studies done on the said topic and various developments the are required in the mechanisms prevalent in the business
field of braking and careful use of energy. world.

1.3 Project Rationale: 1.5 Objectives

Electromagnetic braking systems are a process design activity 1. To assess the tools and techniques for designing,
which is of paramount importance. For this reason, implementing, and evaluating ubiquitous computing
computerized automation is essential to integrate braking Systems used by developers
systems. A literature review of the state-of-the-art trends and 2. To formulate practical solutions that addresses the
approaches for braking system is presented. Some functionality of these systems.

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shortcomings of the current approaches are also discussed new 3. This review considers the various steps that are required
research focus areas are explored. A part that must be for the design. It also presents the various important
machined is held by an assembly or a component. This researches that have been conducted the world over, and
assembly or component is further defined. It must be designed describes the requirements for braking Systems that have
properly so that it would fit the shape of the part and also be developed over time.
compatible to the machining process. 4. Moreover, the paper also dwells on the most important
and related Research that has been carried out in the field
This review would discuss the basics and techniques etc. and which has utilized intelligent techniques and principles
would also dwell on planning, dedicated design, and that relate to this type of work. The review also presents
verification of design and of course how all these can be the CBR approach (case-based reasoning).
integrated with the main process. 5. It has been considered as the most successful he most
successful approach. The presentation of this approach
1.4 Scope of the Project uses information on various applications, the different
Electromagnetic braking system is found to be more reliable
stages of systems based on design. It also describes the
as compared to other braking systems. In oil braking system or
air braking system even a small leakage may lead to complete work principles as well as the relevant approaches that
failure of brakes. have been proposed.

While in electromagnetic braking system as four disc plates,

coils and firing circuits are attached individually on each 2 LITERATURE SURVEY
wheel, even any coil fails the brake does not completely fails 2.1 Sumit Patel,( 2015) [1] : Engineering complications in
remaining three coil works properly. And this system needs actual sense incorporate linguistic information process that
very little of maintenance. proves complex to enumerate through conventional
calculations since it is a representation of subjective
In addition, it is found that electromagnetic brakes make up knowledge. Failure to quantify linguistic information results,
approximately 80% of all of the power applied brake therefore, to assumptions in developing mathematical models.
applications. Electromagnetic brakes have been used as Moreover, in transportation engineering, several values are
supplementary retardation equipment in addition to the regular described through improbability, subjectivity; imprecision’s as
friction brakes on heavy vehicles. The frictions brakes can be well as ambiguity. The electromagnetic braking system uses
used less frequently and therefore practically never reach high magnetic strength to decrease or stop the speed in wheel
temperatures. rotation. The idea of electromagnetic braking comes with the
advantages and disadvantages of stresses in calipers and
The brake linings would last considerably longer before dissipation of heat. The electromagnetic braking system
requiring maintenance and the potentially “brake fade” entirely depends on magnetic power to move the parts of the
problem could be avoided. This enhanced braking system not braking system. The system indulges the principle of if a
only helps in effective braking but also helps in avoiding the magnetic field is induced in the rotating disc, then the other
accidents and reducing the frequency of accidents to a
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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 357
side produces the eddy current of the movement or rotation of The proposed mechanism implements this phenomenon in
the disc brake. developing a braking system. The potential applications of the
The major parts of an electromagnetic braking system are braking system can be a decelerating system to increase the
braking discs, solenoid, circuit board, step-down transformer safety of an elevator or any guided rail transportation system
and battery power. In other words, human operators, As a result it develops a torque and eventually the vehicle
dispatchers, drivers, as well as passengers, gauge the context comes to rest. In this project the advantage of using the
of a situation through idiosyncratic knowledge or linguistic electromagnetic braking system in automobile is studied.
evidence in regular decisions. Electromagnetic braking system These brakes can be incorporated in heavy vehicles as an
is classical example of increased effectiveness of braking auxiliary brake. The electromagnetic brakes can be used in
system while minimizing losses. In this paper the focus is commercial vehicles by controlling the current supplied to
provided on comparison between Electromagnetic braking produce the magnetic flux. Making some improvements in the
system and conventional exhaust braking system. The focus of brakes it can be used in automobiles in future. . It also reduces
Electromagnetic system is to increase the safety of the device the maintenance of braking system. An advantage of this
meanwhile keeping the losses to minimum. The sole aim of system is that it can be used on any vehicle with minor
the research study lies on providing advantages of both the modifications to the transmission and electrical systems.
systems as well as clearly mentioning their ambiguities.
2.4 Tatsuya YAMASAKI, (2007). [4] : An automatic brake
2.2 Sevvel P, Nirmal Kannan V,(2014) [2] : An system for a vehicle consists of an electric motor, related to
Electromagnetic Braking system uses Magnetic force to the motor for transmission motion from the motor to a brake
engage the brake, but the power required for braking is lever that pushes the restraint. This project provides a brand
transmitted manually. The disc is connected to a shaft and the new idea style of the EMPB (electro mechanical parking
electromagnet is mounted on the frame .When electricity is brakes) system that has straightforward and cheap
applied to the coil a magnetic field is developed across the characteristics. This project deals with coming up with and

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armature because of the current flowing across the coil and fabrication of EMPB system. Mechanical device hand brake
causes armature to get attracted towards the coil. As a result it system conjointly remarked as brake by-wire, replace typical
develops a torque and eventually the vehicle comes to rest. In parking braking systems with a totally electrical part system.
this project the advantage of using the electromagnetic This happens by replacement typical linkages with electrical
braking system in automobile is studied. These brakes can be motor-driven units. The braking force is generated directly at
incorporated in heavy vehicles as an auxiliary brake. The every wheel by high performance electrical motors and
electromagnetic brakes can be used in commercial vehicles by automobile management, that area unit controlled by an ECU.
controlling the current supplied to produce the magnetic flux. The electronic hand brake replaces the traditional handbrake.
Making some improvements in the brakes it can be used in It's operated by a switch within the centre console. The
automobiles in future mechanical device hand brake provides the subsequent edges
over the traditional handbrake: easy use-the hand brake is
The electromagnetic diffusion and the electromechanical applied totally no matter the strength of the driving force.
phenomena arising in a solid cylinder rotating inside a Safety-the electrical hand brake applies mechanically once the
magnetic field are here analyzed. The study is developed key is off from the ignition.
through a time stepping Finite Element voltage-driven
formulation, employing the sliding mesh technique for 3 WORKING DESIGN
handling the cylinder motion. The influence on the dynamic 3.1 Block Diagram
behavior and energy dissipation of the material electric and
magnetic properties, the geometrical parameters and the
supply conditions is investigated considering a model
problem. 2006 Elsevier Inc. All rights reserved

2.3 McConnell, H.M,(1954), [3] : Most of the braking

systems utilize friction forces to transform the kinetic energy
of a moving body into heat that is dissipated by the braking
pads. The overuse of friction-type braking systems causes the
temperature of the braking pads to rise, reducing the
effectiveness of the system. An Electromagnetic Braking
system uses Magnetic force to engage the brake, but the power
required for braking is transmitted manually. The disc is
connected to a shaft and the electromagnet is mounted on the
frame .When electricity is applied to the coil a magnetic field
is developed across the armature. The eddy-current is created Fig 3.1 Block Diagram
by the relative motion between a magnet and a metal (or alloy)
conductor. The current induces the reverse magnetic field and ELECTROMAGNETIC BRAKE
results in the deceleration of motion. Electromagnetic brake slows down an object through force
created by an electromagnetic induction, which acts as a

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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 358
resistance to motion of the vehicle. This type of brake applied screw. At last the disc is fitted with the pulley by the use
pressure on two distinct objects to gradually slow the vehicle screws. Dimensions: - Ext. dia. - 97-98mm Thickness -
in a uniform manner. 5.6mm
3.2 Components 3.8 Electromagnet
The following are the components used in the work as
follows, DC Motor, Resistance type current regulator, V Belt
Wheel, Metal Disc, Electromagnet, Vertical holding column
Control Switch, Fasteners / Bearings etc..

3.3 DC Motor

Fig 3.7 Electromagnet

Electromagnet is the device which gets magnetized when the

current is feed into it. Here the electromagnet is designed by
modified a typical transformer. The transformers has double
side outer core around the inner core. This outside core of the
Fig 3.2 DC Motor transformer is removed and then arranged as single side. Now
it is act as an electromagnet.
The rotary motion of the wheel is given by the DC motor.
Working on DC 220 volt

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The electric motor converts electric energy into mechanical
energy by electromagnetic induction. The motor been used Nos of magnet 2 Nos
here is the typical grinder motor of 12 volt, speed of 600 rpm
and Power of 30 watts 3.9 Switch and Wires
ON/OFF switch used to control the power supply to the
3.4 Regulator electromagnet. It is connected with the electromagnet. A
The regulator been used in order to control the speed of the typical common electric switch is used here. When the
electric motor. The speed is controlled by changing the rotation of the pulley is to be stop, the braking is applied by
current of the electric supply to the motor. The current can be turned the switch on. When the free rotation of the pulley is
adjusted to match the need of the process. The higher current required the switch is turned off. To provide the electric
of the output voltage is, the higher the speed of the motor, and supply to the motor and the electromagnet the electric wire is
thus, the output of the process. Here the capacity of the used here. The copper wire has been used here since it has the
regulator is 220V±10% in voltage, 50HZ in frequency and better electrical conductivity and wire is 7nos x 15 swg and 6
400watt is used. mtr.

3.5 Belt 3.10 Bolts and Nuts

A belt is made up of a polymer material used to transmit To join the motor, electromagnet, vertical column with the
power between two or more rotary shafts, mostly parallel in wooden base and to join the metal disc with the pulley the
arrangement. Belts may be used to transmit power effectively. bolts and nuts are used. The 7mm bolts and the 13mm nuts
Belts are fitted over grooves in pulleys and also may have are used for the joints with the wooden base. The 4mm bolts
twists between pulleys, and the shafts need not to be parallel and the 8mm nuts are used for the joint of disc with pulley.
in all conditions. Flat belt, V-belt, Round belt is some
important types of belts. Here the V-belt has been looped over 3.11 Wheel
the driving motor and the driven wheel.

3.6 Pulley
The pulley has been used to mound the metal disc along with
it. It provides the rotary motion from motor to the disc by the
use of V-belt. Here we used a typical pulley with six arms.
The material of the pulley is used as hardened plastic

3.7 Metal Disc Fig 3.10 Wheel

Dimension- Internal dia. - 22mm External dia. - 300mm
The metal disc is one of the important components been used Width - 47mm Iron Bush -5.5mm Material - Vulcanized
here. It is made up of cast iron. The reason for using cast iron rubber. Justification: - It was cheap and easily available.
plate is that the plate is to be magnetic material. it has a hole
in order to reduce the weight. There are four holes drilled for
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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 359
wheel pulley (motor) and the driven wheel pulley are looped
by a typical v-belt. A metallic disc is mounted with the front
of the driven pulley. An electromagnet is fitted in the front of
3-D Model of the Design: the metallic disc which is fitted with driven pulley. The
important thing is that the electromagnet is to be fitted with
the smallest clearance with the metallic disc. The ON/OFF
switch and the regulator are connected with the electromagnet
and the motor respectively with the help of the electric wires
to control the current supply to them.

3.13 Working Principle

The basic work of an electromagnetic brake is to reduce
speed of the vehicle using electromagnetic force to induce a
mechanical frictional resistance within the wheels. These
kinds of brakes operate through an electric actuation, but
transmit torque mechanically.

3.14 Working Methodology

Fig 3.11 Top View of the Design When the power supply is given the motor, the pulley is
driven by the belt. Now the pulley is continuously rotated.
As the steel plate is connected along with pulley it is rotated in
front of the electromagnet. When the braking is required the
control, switch is turned on. So, the current or voltage is

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applied on the electromagnet. A magnetic field is created by
an energizing coil by the application of voltage or current.
This coil develops magnetic lines of flux between the metal
discs thus attracting the armature to the face of the metal disc.
When the current or voltage is removed from the brake
(electromagnet) the metal disc is free to rotate. Here springs
are used as medium to hold the armature winding of the
electromagnet away from the disc. Rotating motion in wheels
is achieved by switching controls of the supply to the coil.
Slippage occurs only during deceleration only when the brake
is engaged; there should not be slippage once the brake comes
Fig 3.12 3D View of the Design to a full halt.

3.15 Software Arduino IDE

Microcontroller ATmega328P
Architecture AVR
Operating Voltage 5 Volts
Flash Memory 32 KB of which 2 KB used
by Boot loader
SRAM 2KB
Clock speed 16 MHz
Analog I/O Pins 8
EEPROM 1 KB
DC Current per I/O Pins 40 milliamps
Input Voltage (7-12) Volt

3.16 What is Arduino

Fig 3.13 Orthogonal View of the Design Arduino is an open-source electronics platform based on easy-
to-use hardware and software. Arduino boards are able to read
3.12 Construction Details inputs - light on a sensor, a finger on a button, or a Twitter
The construction of the system is done by the following message - and turn it into an output - activating a motor,
manner. The system consists of a column. The pulley is turning on an LED, publishing something online. You can tell
mounted at the top of the vertical column. This setup is fitted your board what to do by sending a set of instructions to the
on a wooden board which is act as a base. On the other end of microcontroller on the board. To do so you use the Arduino
the base, the motor is fitted with the help of bolts. The driving programming language (based on Wiring), and the Arduino
Software (IDE), based on Processing.
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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 360
Cross-platform - The Arduino Software (IDE) runs on
Over the years Arduino has been the brain of thousands of Windows, Macintosh OSX, and Linux operating systems.
projects, from everyday objects to complex scientific Most microcontroller systems are limited to Windows.
instruments. A worldwide community of makers - students, Simple, clear programming environment - The Arduino
hobbyists, artists, programmers, and professionals - has Software (IDE) is easy-to-use for beginners, yet flexible
gathered around this open-source platform, their contributions enough for advanced users to take advantage of as well. For
have added up to an incredible amount of accessible teachers, it's conveniently based on the Processing
knowledge that can be of great help to novices and experts programming environment, so students learning to program in
alike. that environment will be familiar with how the Arduino IDE
works.
Arduino was born at the Ivrea Interaction Design Institute as
an easy tool for fast prototyping, aimed at students without a Open source and extensible software - The Arduino
background in electronics and programming. As soon as it software is published as open source tools, available for
reached a wider community, the Arduino board started extension by experienced programmers. The language can be
changing to adapt to new needs and challenges, differentiating expanded through C++ libraries, and people wanting to
its offer from simple 8-bit boards to products understand the technical details can make the leap from
for IoT applications, wearable, 3D printing, and embedded Arduino to the AVR C programming language on which it's
environments. All Arduino boards are completely open- based. Similarly, you can add AVR-C code directly into your
source, empowering users to build them independently and Arduino programs
eventually adapt them to their particular needs. The software,
too, is open-source, and it is growing through the Open source and extensible hardware - The plans of the
contributions of users worldwide. Arduino boards are published under a Creative Commons
license, so experienced circuit designers can make their own

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3.17 Why Arduino version of the module, extending it and improving it. Even
Thanks to its simple and accessible user experience, Arduino relatively inexperienced users can build the breadboard
has been used in thousands of different projects and version of the module in order to understand how it works and
applications. The Arduino software is easy-to-use for save money.
beginners, yet flexible enough for advanced users. It runs on
Mac, Windows, and Linux.

Teachers and students use it to build low cost scientific

instruments, to prove chemistry and physics principles, or to
get started with programming and robotics. Designers and
architects build interactive prototypes, musicians and artists
use it for installations and to experiment with new musical
instruments. Makers, of course, use it to build many of the
projects exhibited at the Maker Faire, for example. Arduino is
a key tool to learn new things. Anyone - children, hobbyists, Fig 3.14 Arduino IDE
artists, programmers - can start tinkering just following the
step by step instructions of a kit, or sharing ideas online with 3.18 Shaft
other members of the Arduino community. Dimension - Length - 2.5 ft. Diameter - 16.5 mm Material?
Iron Justification: - Available only of iron and diameter is
There are many other microcontrollers and microcontroller adjusted keeping in view of wheel inner diameter. The length
platforms available for physical computing. Parallax Basic is adjusted according to the fabrication.
Stamp, Netmedia's BX-24, Phidgets, MIT's Handyboard, and
many others offer similar functionality. 4. DESIGN PARAMETERS
12V DC Motor. (2.3mm shaft diameter, 2pin connection)
All of these tools take the messy details of microcontroller Speed of Motor: 600 RPM
programming and wrap it up in an easy-to-use package. Pulley Reduction Ratio: 1:1
Arduino also simplifies the process of working with
microcontrollers, but it offers some advantage for teachers, 4.1 Force Produced
students, and interested amateurs over other systems: The force between electromagnet and another piece of
ferromagnetic material separated by a gap of distance G is,
Inexpensive - Arduino boards are relatively inexpensive
compared to other microcontroller platforms. The least (IN )2
F= xμA
expensive version of the Arduino module can be assembled by (2G)2

hand, and even the pre-assembled Arduino modules cost less

Where:
than $50
• μ = 4π*10^-7
• F is the force in Newtons
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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 361
•N is the number of turns =
102
(2 x 9.8)
•I is the current in Amps S=5.20m
•A is the area in mm2 8. Average Braking Force to stop vehicle,
•G is the length of the gap between the solenoid and a Work done to stop vehicle = Change in it’s KE
piece of metal FS =0.5MU2
0.5∗20∗102
Note, any units can be used for A and g so long as they are F=
5.1
consistent F’=200 N
Since theoretically calculated force produced by
NOTE: These Calculations is done when ECU is switched off. electromagnets (F) is less than force required to stop the
When ECU is switched on these values will be divided vehicle in 5.1 m so vehicle will stop at 6.2m.
proportionally to each brake.
1. Total Force produced, 4.2 Braking Efficiency
(N∗I)2 μ A
F=
(2 g2) 0.4U2
F= 161.7 N ɳ=
S
ρL 0.4∗102
2. Resistance of wire, R= =
A 5.1
1.7∗10⁻⁸ ∗13.8 ɳ=80.1 %
=
0.503 NOTE: The value of efficiency changes for each velocity and
=0.466 Ω respective stoppage distance.
3. Heat produced, H=I^2*R*T
= 4^2*0.466*60 DESIGN AND CALCULATIONS
= 447.36 J 4.3 Main Pulley speed
4. Power transmitted by the motor,

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P = 20 W N1= 800 R.P.M
5. The twisting moment (T’),
P∗60 N2=? D1= 75 mm
T’ =
2πN
= 1.90 N.m D2= 50 mm
Shafts Subjected to Twisting Moment
T τ N2 D1
= =
J r N1 D2
for round solid shaft, polar moment of inertia,
πd⁴ N2=640 R.P.M
J= ,
32
So above equation becomes, 4.4 Secondary Pulley Torque
πτd3
T’ = ,
16
Power = 200 watts
d =3 mm.
Solid shaft of mild steel was used. Considering factor of 2∗π∗N1∗T1
safety, shaft of 7mm is used. P= =3.66*103 N-mm
60∗103 T1
6. Kinetic energy of vehicle during braking is given by, π
1 T1 = =0.044 N/mm2< fs (perm) = 34 N/mm2
KE= 16∗fs∗d1 3 Fs (Ind)
2∗m∗(U2−V2)

Therefore, Design is Safe

=0.5*1*(102-02)
=50 J 4.5 Main Pulley Torque
Maximum weight transferred from rear to front wheels on Power = 200watts
applying brakes,
2∗π∗N2∗T2
Condition: Wheel base equal to 3 times the height of its P=
60∗103
CG above the ground and adhesion factor of road is 0.6.
T2= 5.49*103N/mm2
μ’∗h∗f∗w
W= , π
(b∗g) T2=
(0.6∗0.6) ∗w 16∗fs∗d2 3 Fs
=
3
=12w (Ind) =0.22 N/mm2 < fs (perm) = 34 N/mm2
Therefore, weight transfer= 12%.
7. Minimum Stoppage Distance Therefore, Design is Safe
When vehicle deaccelerate with g=9.8 m/s2,
U2 4.6 For Load Calculation
S=
2g

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International Journal of Scientific & Engineering Research Volume 11, Issue 6, June-2020
ISSN 2229-5518 362
4P And FOS is factor of safety = 2
Ft =
πd2
210
P = 704 KN So σall= = 105 MPa = 105 N/mm²
2

4.7 Belt calculation Comparing above we get, σb < σall i.e 45.22 < 105 N/mm²

Centre distance of pulley = 2 (D1 + D2) So design is safe.

C= 112.5
Conclusion
(π∗D1∗N1)
S=V= = 3.76 m/s We completed literature survey and fabrication work in
60000
progress. With one major challenge to check the compatibility
1800 –(D1−D2)
Arc of contact (α) = = 1630 330 = 2.85 Radian of electromagnetic braking with Electronic brake distribution
C ∗ 600
EBD as per our design and calculation which in testing phase
2∗C+ π (D1+D2) of our project successfully gave proper brake force
L= 2+ (D1−D2)
4∗c
distribution among two pair of Electromagnetic Brakes and
helps us to know about a new way to use EBD except with
L=422 mm ABS. By doing this project we now know that EBD can
successfully work with EM brakes. Electronic control unit
4.8 Design of Frame also helped EM brake to last longer by only providing
necessary amount of current required for safe braking which
Size of the Frame is 25*25*3 (b*d*t) square angle mild steel results in long lasting braking system.
channel In addition, it is found that electromagnetic brakes make up

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approximately 80% of all of the power applied brake
Consider the maximum load on the frame to be 20 kg. applications. And by using EBD, surely this amount of
percentage will increase which led to more efficient braking
Max. Bending moment = force*perpendicular distance =
20*9.81*400
References
M = 78480 Nmm
[1]. Sumit Patel,” Development of the Electro-Magnetic
We know, M / I = σb / y
Brake”, IJIRST –International Journal for Innovative Research
M = Bending moment in Science & Technology| Volume 1 | Issue 12 | May 2015

I = Moment of Inertia about axis of bending that is; Ixx [2]. Sevvel P, Nirmal Kannan V, Mars Mukesh S, “Innovative
Electro Magnetic Braking System”, IJIRSET, April 2014
y = Distance of the layer at which the bending stress is
consider (We take always the maximum value of y, that is, [3]. Oriano Bottauscio, Mario Chiampi, Alessandra Manzin,
distance of extreme fiber from N.A.) “Modeling analysis of the electromagnetic braking action on
rotating solid cylinders”, Science Direct, December 2006
E = Modulus of elasticity of beam material
[4]. AkshayKumar S. Puttewar, Nagnath U. Kakde, Huzaifa
I = BD^3/12-bd3 /12 A. Fidvi, Bhushan Nandeshwar, “Enhancement of braking
system in automobile using Electromagnetic Braking”, IOSR-
= 25*25^3 / 12 -19*19^3/12 JMCE
[5]. McConnell, H.M, “Eddy current phenomena in
I = 21692 mm4 σb = My ferromagnetic material”, AIEE Transaction, vol.73, part I, pp
226-234, July 1954
78480∗12.5
I= [6]. Tatsuya YAMASAKI, M. E. (2007). Development of an
21692
Electromechanical Brake.NTN Global.
σb = 45.22 N /mm² [7]. Warrendale, Brake technology, ABS/TCS, and controlled
suspensions Society of Automotive Engineers, & SAE World
The allowable shear stress for material is σall = Syt / fos. Congress. (2001)., PA: Society of Automotive Engineers.

Where Syt = yield stress = 210 MPa = 210 N/mm²

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