AUTOMATED ELECTROMAGNETIC

BRAKING SYSTEM

PROJECT REPORT

Submitted in partial fulfillment of the requirements

for the award of the Degree of Bachelor of Technology
in Mechanical Engineering
of the APJ Abdul Kalam Technological University

SUBMITTED BY

ABIN AJ (ACE19ME001)
ADHINAN UMAR U (ACE19ME002)
DEVADUTH A B (ACE19ME005)
VAISHAKH S KUMAR (ACE19ME024)

DEPARTMENT OF MECHANICAL ENGINEERING

ACE COLLEGE OF ENGINEERING

Thiruvallam, Thiruvananthapuram- 695027
2022 – 2023
 DEPARTMENT OF MECHANICAL ENGINEERING

ACE COLLEGE OF ENGINEERING

Thiruvallam, Thiruvananthapuram- 695027

CERTIFICATE
This is to certify that this Project Report titled "AUTOMATED ELECTROMAGNETIC
BRAKING SYSTEM” is a bonafide record of the work done by Abin A J (ACE19ME001),
Adhinan Umar U (ACE19ME002), Devaduth A B (ACE19ME005), Vaishakh S Kumar
(ACE19ME024) under our guidance towards the partial fulfillment of the requirements for the
award of the Degree of Bachelor of Technology in Mechanical Engineering of the APJ Abdul
Kalam Technological University during the year 2022-2023.

Mr. Babumon S Mr. Arun Raj R

Assistant Professor Assistant Professor
Project Guide Project Coordinator

Prof. Arun Raj R

Head of the Department
 ACKNOWLEDGEMENT

I would like to express my deep sense of gratitude to Dr. Farrukh Sayeed, Principal, for
rendering all the facilities for the completion of my project. I am gratefully indebted to Asst Prof
Arun Raj R, Head of the Department of Mechanical Engineering and Project Coordinator, for his
valuable advice and encouragement which enabled me to complete this project successfully.

With profound respect and immense gratitude, I wish to thank Mr.Babumon S, Assistant
Professor, Mechanical Engineering Department, for giving source of ideas and encouragement
throughout the course of the Project.

I also thank all other Faculty members and Staff of Mechanical Engineering Department for
their timely help and advice.

Above all I praise and thank the God Almighty for the support, guidance and blessings
bestowed up on me throughout the Project.

ABIN A J
ADHINAN UMAR U
DEVADUTH A B
VAISHAKH S KUMAR
 ABSTRACT

This project aims to design and implement an electromagnetic braking system for automobiles,
focusing on enhancing safety and energy efficiency. Traditional braking systems have limitations in
terms of response time, precision, and energy regeneration. The proposed electromagnetic braking
system addresses these limitations by utilizing an electromagnet to control braking force.

The project utilizes an Arduino microcontroller and various components to develop a working
prototype of the electromagnetic braking system. An infrared sensor is incorporated to detect the
presence of objects, triggering the activation of the braking system. The system consists of an
electromagnet, motor, fan, and LED, each serving a specific function in the braking process.

Through careful control logic, the system responds rapidly to the sensor input, ensuring quick and
precise braking. It showcases the advantages of faster response times, precise control, and energy
regeneration compared to traditional braking systems. Furthermore, it highlights the potential for
integration with autonomous vehicles, advanced control algorithms, and vehicle-to-vehicle
communication for further improvements.
 TABLE OF CONTENTS

SL NO. TITLE PAGE NO.

1 Introduction 1

2 Literature Survey 3

3 Methodology 5

4 Introduction To Components 6

5 Construction 13

6 Working 15

7 Calculation 18

8 Theoretical Analysis 20

9 Result 24

10 Conclusion 31

11 Future Scope 32

12 Reference 33
 LIST OF FIGURES

FIGURE NO. TITLE OF FIGURE PAGE NO.

1 3D model of Electromagnetic Braking System 1

2 Prototype 4

3 Cycle Wheel 6

4 Iron Disc 6

5 Electromagnet 7

6 Electric Motor 8

7 Potentiometer 8

8 Arduino UNO 9

9 Relay Module 9

10 IR Sensor 9

11 Frame 10

12 Li-io Battery 10

13 Assembled view of Components 11

14 Circuit Diagram 12

15 Theoretical and Actual analysis 24

16 Result of Theoretical analysis 25

17 Theoretical Analysis using two Electromagnets 30

18 Theoretical Analysis with two Electromagnets 30

 LIST OF TABLES

TABLE TITLE PAGE NO.

NO.

1 Result of Theoretical and Actual analysis 24

2 Result of Theoretical analysis 25

3 Result of Theoretical analysis using two electromagnets 29

 CHAPTER 1

INTRODUCTION

A brake is a device, where it restricts motion. It is commonly known that the brakes use
friction to convert kinetic energy into heat. But the Electromagnetic brakes have been used as
supplementary retardation equipment in addition to the regular friction brakes on heavy
vehicles. 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 creates an
opposing force to the wheel rotation and in turn slows down the wheel. Thus we achieve
electromagnetic braking as a better braking system for future automobiles. By using the
electromagnetic brake as supplementary retardation equipment, the frictions brakes can be
used less frequently and therefore practically never reach high temperatures. In this research
work, with a view to enhance to the braking system in automobile, a prototype model is
created and analyzed. It aims to minimize the brake failure to avoid the road accidents. It
also reduces the maintenance of braking system

ELECTROMAGNET DISC

MOTOR
CHAIN

GEAR

FRAME

Fig.1, 3D model of electromagnetic braking system

Electromagnetic braking system increases the life span and reliability of brakes since no
friction leads to less wearing out of brakes. Also it requires less maintenance and oiling. This
is an upcoming technological replacement for traditional braking systems. The main purpose
behind the proposed use of these brakes in vehicles is that it is frictionless. This leads to a
sizably less maintenance cost due to no friction and no oiling. Also traditional braking
systems are prone to slipping while this one is guaranteed to apply brakes to the vehicle. So
without friction or need of lubrication this technology is a preferred replacement for
traditional braking. Also it is quite smaller in size compared to the traditional braking
systems.

1
Here we aim on reducing road accidents due to the consciousness of drivers. for this, an
automated circuit is created to automate the braking system. here we couple the
electromagnetic braking system with the automated circuit. the circuit consists of several
sensors such as proximity sensor, Passive infrared sensor, Infrared sensor, CMOS sensors,
etc.. with the help of these sensors the circuit can able to measure nearby vehicle or object
distance, road structures, several Zones such as school zone, accident-prone areas, etc.., the
circuit will continuously monitor the vehicle surrounding. when a necessary situation occurs
the circuit will automatically provide braking force through the electromagnetic braking
system

2
 CHAPTER 2

LITERATURE SURVEY

Our team goes through various review papers to learn about other people working on
different brakes. we find some very useful papers that are listed below.

[Varun Kumar reddy malipeddi, ramcharan vuygala, and premsagar perumala] [October 2018]
They had done research based on the role of EBS in an automobile. During this research,
they showed that the EBS is found to be more reliable than before. In this paper, the authors
have tried to show that electromagnetic brakes operate via an electric Actuation but produce
torque mechanically when voltage or current is applied to the brake the coil becomes on
electromagnet and produces magnetic lines of flux. Also, they showed that electromagnetic
braking coils and firing circuits are attached individually on each wheel, even if any coil fails
the brake does not completely fails remaining three coils works properly.

[Dr. S.R. Pawar, Shubham D Satan, Saif Ali Shaik and Amit R Shah] [April 2022]
They had done research based on an analysis of electromagnetic braking systems. During this
research, they showed that the electromagnetic braking model is capable of applying brakes
without any friction loss and without losing the energy supplied. It uses two electromagnets
run by the power supply from the circuit. A metal bar is in the vicinity of the electromagnets
and wheel so when the electromagnets produce eddy currents it stops the rotating wheel or
rotor.

[Srinivasa Gupta Gambali, A.N Brahmeswara Rao, and H Naresh] [January 2021]
They had done Research on the design and Experimental Analysis of an Electromagnetic
Braking System. During this research work. they have done a theoretical and actual
experiments to determine the stopping time for different speeds. after experimentation, they
showed that the vehicle slows down but cannot stop instantaneously, as we increase the no.
of magnets the stopping distance and stopping time would reduce. but they cannot have a
sudden and instantaneous brake like friction brakes.

[B. Koushik Kannan, B. Praveen Ram, and Mrs.M.S Kavitha] [March 2019]
They had done Research on IR (Infrared) Based on Enhanced safety In automobiles. During
this Research work, the designed system not only displays the obstacles to the driver but also
automatically slows down the vehicles if the obstacle is too close using an Infrared sensor.
through this research, it helps to avoid accidents.

3
[Rahul P. Haridas2, Somnath M. Kamble3, Shubham D.Kamble4, Rohan S. Jadhav] [2020]
Contactless Electromagnetic Braking System
They found out that an electromagnet is often considered better than a permanent magnet
because it can produce very strong magnetic fields and its strength can be controlled by
varying the number of turns in its coil or by changing the current flowing through the coil.
Electromagnetic brakes operate electrically, but transmit torque mechanically. This is why
they used to be referred to as electro-mechanical brakes. The variety of applications and
brake designs has increased dramatically, but the basic operation remains the same. Single
face electromagnetic brakes make up approximately 80% of all of the power applied brake
applications. It was 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.
[1 Sudarshan T A, 2 Sefeej, 3 Swathin,Nikith T, Nidhin] [2018] Design And Fabrication Of
Electromagnetic Braking 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 because of the current flowing across the coil and
causes armature to get attracted towards the coil. As a result, it develops a torque and
eventually the vehicle comes to rest. These brakes can be incorporated in heavy vehicles as an
auxiliary brake. The electromagnetic brakes can be used in commercial vehicles by
controlling the current supplied to produce the magnetic flux. Making some improvements in
the brakes it can be used in automobiles in future.

Fig.2, Prototype

[Srinivasa Gupta Gembali, A.N. Brahmeswara Rao, H. Naresh] [2021] Design and
Experimental Analysis of Electro Magnetic Braking System
They proposed a concept on magnetic braking system has been introduced, basis for which is
Lenz’s law. An aluminium disc is used to fit into the wheel of a bicycle and the influence of
different parameter on braking torque have been analysed analytically as well as
experimentally in this proposal.

4
To fabricate the model it all begins with a systematic plan where the fabrication is of a
seven steps of solving process. The steps are as follows:

CHAPTER 3

METHODOLOGY

To fabricate the model it all begins with a systematic plan where the fabrication is of a seven
steps of solving process. The steps are as follows:

ANALYSING THE RESEARCH PAPERS: Collect all the relevant data about the
problems and the research programs which are happening around and the outcomes of
them and evaluate them by comparing with the other research programs where to sort
out the demerits of the conventional types of braking systems in a more effective.

SELECTION OF THE ELECTROMAGNETIC BRAKES TO OVERCOME THE

PROBLEMS: Selection of the electromagnetic braking system is to minimize the
problems which normally occur in the conventional type of braking system where to
overcome some problems like efficiency, maintaining parameters, safety. Hence to
overcome these problems the electromagnetic braking system is been selected for the
further process.

ANALYSIS OF THE ELECTROMAGNETIC BRAKING SYSTEM: To study and

analyze about the system where by focusing on to the working principle and the
fabrication materials and design required for the model to be done and even a study
towards the functioning of the braking system according to the design planned.

PREPERATION OF DESIGN: In this step it is more concentrated on to the design part

where looking on to several alternatives of designs according to the installation
specifications as planned in the previous steps.

FABRICATION: In this step the process consist of working on to the chosen design and
approach into the reality. The model is then fabricated as per the specifications given and
check if all the mechanisms work perfectly.

TESTING: The model is tested to check if it meets all the objectives and the model is
again made to test weather there has to be done any improvement or any modifications
to it. After the test is done completely the model is then made to implement.

RESULT: The output of the model is taken down and tabulated and the result is
presented by calculating and submitted .

5
 CHAPTER 4

INTRODUCTION TO COMPONENTS

WHEEL

Fig.3, Cycle wheel

The wheel is a circular component that rotates on an axle bearing which is one of the key
components of the braking system with a radius of 17cm.

DISK

Fig.4, Iron Disc

One of the main key component in the braking system is the disk where it is attached to the
wheel and transfers the retardation force to the wheel as well. The disk is the component
where it receives retardation force and produces opposing torque force.
Iron is commonly used as the material for metal discs in electromagnetic braking systems due
to its specific properties and characteristics. Here are some reasons why iron is preferred:
1. Magnetic Permeability: Iron exhibits high magnetic permeability, which means it can
easily conduct magnetic fields. This property is crucial in electromagnetic braking
systems where the metal disc needs to interact effectively with the magnetic field
generated by the brake assembly.
2. Thermal Conductivity: Iron has good thermal conductivity, allowing it to dissipate heat
efficiently. Iron's ability to conduct heat helps in dissipating the generated heat,
preventing overheating and maintaining optimal braking performance.

6
3. Strength and Durability: Iron is a strong and durable metal, making it capable of
withstanding the mechanical stresses and forces experienced during braking.
4. Cost-effectiveness: Iron is readily available and relatively inexpensive compared to other
metals with similar properties.
5. Machinability: Iron is relatively easy to machine and shape, allowing the metal discs to be
manufactured in various sizes and designs to fit different brake system requirements.
Iron has several advantages over other materials such as copper and aluminum. Here are
some of the advantages:
1. High magnetic permeability: Iron has a higher magnetic permeability compared to
copper and aluminum. This means that it can more effectively concentrate and channel
magnetic flux when subjected to a magnetic field. This property is crucial for creating a
strong magnetic interaction in an electromagnetic braking system.
2. High saturation magnetization: Iron has a high saturation magnetization, which means
it can be magnetized to a greater extent compared to copper and aluminum. This
property allows for stronger magnetic forces and greater braking power in the system.
3. Good thermal conductivity: Iron has better thermal conductivity compared to copper
and aluminum. Iron can efficiently dissipate this heat, helping to prevent overheating
and ensuring the braking system's performance and reliability.
4. Cost-effective: Iron is generally less expensive compared to copper and aluminum.

ELECTROMAGNET

Fig.5, Electromagnet

Since the name itself says “Electromagnetic braking system” and the main component
required is the electromagnet. When the current is passed the coils inside are excited and the
magnetic field is produced from the electromagnet. The electromagnets works in the base of
induction. Where the process induction causes electrical field to produce magnetic field thus
the electromagnet uses the source of power from the electrical field into the magnetic field.
Specifcation : 40mm x 20mm , 24 v (Market availability)

7
 MOTOR

Fig.6, Electric Motor

Motor is a device used to convert electrical energy to mechanical energy. It operates based on
the principles of electromagnetism and electromagnetic induction.

AUTOMATED CIRCUIT

The automated circuit board is one important component in the system where it connects the
mechanical components electrically to perform the action. Where the circuit consists of

POTENTIOMETER
ARDUINO
RELAY
IR SENSOR

Potentiometer: A potentiometer is a three-terminal resistor with a sliding or rotating

contact that forms an adjustable voltage divider. If only two terminals are used, one end
and the wiper, it acts as a variable resistor or rheostat.

Fig.7, Potentiometer

8
Arduino: Arduino is a popular open-source electronics platform that consists of a
microcontroller board and a development environment for creating and programming
electronic projects.

Fig.8, Arduino UNO

Relay: Relays are the switches that open and close the circuit by electrically or
electromechanically, they control the circuit by engaging and disengaging and even the
contacts between another circuit.

Fig.9, Relay module

IR SENSOR: An infrared (IR) sensor is an electronic device that measures and detects
infrared radiation in its surrounding environment.

Fig.10, IR Sensor

9
FRAME

Fig.11, Frame
The frame is the structural system that supports components of the physical construction
such as the axle, wheel, clamps connecting the electromagnet, and the automated circuit
board holder.
Size: 50cmx30cmx38cm

BATTERY

Fig.12, Li-on Battery

A battery is a device that converts chemical energy directly to electrical energy which is used
to power up the whole system, especially to the circuits.

10
ASSEMBLY OF COMPONENTS

Side View

Top View

Fig.13, Assembled view of components

11
CIRCUIT DIAGRAM

RELAY

FAN

RELAY ELECTROMAGNET

ARDUINO UNO
BATTERY

DC MOTOR

IR SENSOR
Fig.14, Cicuit diagram of automated electromagnetic braking system

Ground
5V Supply
12V Supply
24V Supply
Arduino input and output signal

12
 CHAPTER 5

CONSTRUCTION

The Iron disc is manufactured by using a CNC lathe, CNC milling, and drilling machines.
The system consists of a rectangular shaped frame, the steel frame is designed according to
the requirement and required size. For making the frame 1-inch square steel pipe is used,
which is cut and welded using a cutting machine and welding plant. The two vertical columns
are mounted on the frame by welding. The wheel is being held in between the two vertical
columns and tightened using threaded nuts. The holes in the frame are drilled using a drilling
machine to attach the electromagnet and wheelbase. The material used to make the frame is
steel. Once the framework is completed we closed all the openings of the frame using plastic
end caps and painted the frame using black enamel paint. The iron disc is mounted on the
wheel hub at a specific distance. DC-type electromagnets are situated near the iron disc and
mounted on the frame. For the smoother transmission of power from the DC motor to the
wheelbase through a chain drive, the DC motor is placed corresponding to the position of the
wheelbase. DC motor is attached to the frame using plastic tags. after placing the motor and
wheelbase onto the frame chain links are attached to the chain sprocket at the required
length. The torque is provided to the sprocket through a chain drive driven by a motor,
mounted on the frame. a mini cooling fan is glued near the electromagnet. . A base is
provided on the surface of the frame, to support all the electronic components that have been
used for the project. After placing each component onto the surface properly, proper
electrical connections are made through the components using copper wire. Once the
assembly of parts, and electronic components is completed, an Arduino code is uploaded to
the Arduino. Arduino code is uploaded to the board by the help of Arduino IDE software.
The system is also equipped with an IR sensor on the frame's edge to detect disturbances
around the sensor.

13
Arduino code which has been uploaded to the Arduino board

14
 CHAPTER 6

WORKING

WORKING PRINCIPLE
The rotation of a ferromagnetic material in a magnetic field can indeed cause a change in its
rotation speed, but it depends on the specific circumstances and properties of the material.
When a ferromagnetic material is placed in a magnetic field, it can become magnetized and
develop its own magnetic field. The interaction between the external magnetic field and the
induced magnetic field in the material can create forces that affect its motion.

If the ferromagnetic material is freely rotating without any external forces acting on it, the
interaction with the magnetic field can cause what is known as "magnetic damping" or "eddy
current braking." This phenomenon occurs when the changing magnetic field induces electric
currents (eddy currents) within the material. These currents, in turn, generate their own
magnetic fields that oppose the original magnetic field, creating resistance to the rotation of
the material. The result is that the rotation slows down over time.

The magnitude of the magnetic damping effect depends on several factors, including the
strength of the external magnetic field, the magnetic properties of the material, the geometry
and mass distribution of the object, and the speed of rotation. For instance, a stronger
magnetic field or faster rotation speed can increase the damping effect.

WORKING
Electromagnetic brakes work electrically but transmit torque mechanically. The system is
powered by a 24V DC supply where magnetic flux is used to supply the brake machine.
When the circuit is turned on, the motor starts to rotate and transmit mechanical energy to
the wheelbase. Hence the wheelbase and motor are connected through the chain links the
wheelbase will also start to rotate when the circuit is turned on. If there is no disturbance
around the IR sensor the wheel will continue to rotate. If there is any disturbance around the
sensor the IR sensor will detect the disturbance. Here the IR sensor converts physical
movement into an electrical signal and transmits the signal to the Arduino board through
jumper wires. The Arduino board acts as the head of the whole circuit. Once the electrical
signal is received from the sensor, the Arduino board will send a signal to three different relay
modules. Relays are the switches that aim at closing and opening the circuits electronically as
well as electromechanically, It controls the opening and closing of the circuit contacts of an
electronic circuit. When the signal reaches to relays disconnect the 12V DC supply of the
motor and provides a 24V DC supply to the electromagnet and also provide a 5V DC supply
to the cooling fan to cool down the temperature of the electromagnet.

15
If the electromagnetic magnet is not powered, the disk rotation is free. When electromagnetic
is enabled, magnetic flux is produced in such a way that the brakes are applied to the disc in
rotation. The DC motor causes the disc to rotate on the wheel hub using gears and chain
links connected to the wheel hub. The IR sensor is located on the edge of the frame. This IR
sensor detects distance from the adjacent objects and passes the signal to the automated
circuit. This automated circuit provides the DC supply to the electromagnet if it is necessary.
When the electromagnet receives the DC supply it produces a magnetic flux to the disc. This
causes the brakes to be applied to the disc in rotation and the retardation of the wheel takes
place.

16
 NOTATION

F = Force In Newton
I = Moment of Inertia
B = Magnetic Flux Density
μₒ = Permeability Of Free Space
H = Magnetic Field Intensity
A₁ = Surface Area of the Magnet
σ = Specific Conductivity Of The Material
d = Width Of The Disc
R = Effective Radius
ω = Angular Speed
m = Mass Of The Wheel And Disc
n = No.Of Magnets
D₁= Diameter of pulley in m
Rᵥᵥ= Wheel Radius in m
R = Effective Radius

17
 CHAPTER 7

CALCULATIONS
Calculation For =
d= 8cm Disc:
0.08m
r= 0.04m
N= Speed of pulley in rpm
D₁= Diameter of pulley in m
N= 500rpm
D₁= 15cm = 0.15m
Angular speed (ω) = (500 rpm) * (2π/60) rad/s = 52.36 rad/s
Torque on the disc (T)
T=I x ω
I=1/2 mr²
=1/2 1.5 x 0.075² = 0.00534375 kgm²
T= 52.36 x 0.00534375 = 0.28Nm

Calculation For Motor:

Torque generated in the motor

single phase DC motor
Power (P) = 60 w
Speed (N) = 500rpm
T = Px60
2πN

T= 1.14Nm

Calculation For Electromagnet:

Power= 7.5 w
Area of the electromagnet= 0.00125 m²
Voltage Supplied (V) = 24V
Current Supplied (i) = 400mA
Suction Force = 30kg
Dimensions = 40 x 20 mm (D x H)
Radius (r) = 20mm = 20 x 10⁻³m
Surface area of electromagnet = πr² = 0.00126m²
No. of turns in coil = 300

18
 Magnetic Flux Density

B² = 2μₒxF
A₁
μₒ = 4πx10⁻⁷Hm⁻¹ [permeability of free space]
m = 1.5 kg (Total mass)
F = 1.5 x 9.81 = 14.76 N
B² = (2 x 4π x 10⁻⁷ x 14.76)/ 0.00126
B = 0.1716 wb/m²

Total Magnetic Flux In Core

Φ = BxA₁
=0.1716 x 0.00126
=0.000216216 wb
Magnetic Field Intensity (H)

H = B
μₒ

= 0.1716 / 4π x 10⁻⁷
= 136554.94 A/m

19
 CHAPTER 8

THEORETICAL ANALYSIS

Braking Torque (T₂)

T₂=nxA₁xσxdxB²xR²xω
where,
n = Number of Magnets
A₁ = Surface Area of the Magnet
σ = Specific Conductivity of material
d = Width of the Disc
B = Magnetic Field Intensity
R = Effective Radius
ω = Angular Velocity

Specific Conductivity of Iron (Fe) = 1.04x10⁷ S/m

Acceleration (a)

a = F
m
where,
F = Force required to stop the wheel
m = Mass of Iron Disc and Wheel
m = 1.5kg

Iteration (i)

When the speed of the wheel is 10 km/hr, the corresponding rpm will be 176.83 rpm
ω = (2πn₁)/60
= (2π x 176.83)/60
= 18.51 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
= 1 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 18.52
= 0.07Nm
F = T₂ / Rᵥᵥ
= 0.07/0.15
= 0.46 N

20
a=F
m
=0.46/1.5
=0.306m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 18.51
= 1.388 m/s
t = u-v (since, final velocity is 0)
a
= (1.388 - 0)/0.306
= 4.53s
S₁=ut+1/2at²
=1.388 x 4.53+1/2 x 0.306 x 4.53²
=9.42m (stopping distance)

Iteration (ii)
When the speed of the wheel is 12 km/hr, the corresponding rpm will be 212.2 rpm
ω = (2πn₂)/60
= (2π x 212.2)/60
= 22.22 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
= 1 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 22.22
= 0.09Nm
F = T₂ / Rᵥᵥ
= 0.09/0.15
= 0.60 N
a=F
m
=0.60/1.5
=0.34m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 22.22
= 1.66 m/s
t = u-v
a (since, final velocity is 0)

= (1.66- 0)/0.34
= 4.88s
S₂=ut+1/2at²
=1.66 x 4.88+1/2 x 0.34 x 4.88²
=12.15m

21
Iteration (iii)
When the speed of the wheel is 14 km/hr, the corresponding rpm will be 247.56 rpm
ω = (2πn₃)/60
= (2π x 247.56)/60
= 25.9 rad/s

T₂ = n x A₁ x σ x d x B² x R² x ω
=0.11Nm
F = T₂ / Rᵥᵥ
= 0.73 N
a=F
m
= 0.4m/s²

u=rxω
where, r = radius of the disc
u = 0.075 x 25.9
= 2.04 m/s
t = u-v (since, final velocity is 0)
a
= (2.04- 0)/0.40
= 5.18s
S₃=ut+1/2at²
=2.04 x 5.18+1/2 x 0.40x 5.1²
=15.6 m
Iteration (iv)

When the speed of the wheel is 16 km/hr, the corresponding rpm will be 282.9 rpm
ω = (2πn₄)/60
= (2π x 282.9)/60
= 29.6 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
=0.123 Nm
F = T₂ / Rᵥᵥ
= 0.82 N
a=F
m

= 0.5m/s²

22
u=rxω
where, r = radius of the disc
u = 0.075 x 29.6
= 2.7 m/s

t = u-v (since, final velocity is 0)

a

= (2.7- 0)/0.5
= 5.52 s

S₄ = ut+1/2at²
= 2.7 x 5.52+1/2 x 0.5x 5.4²
= 21.87 m

Iteration (v)

When the speed of the wheel is 18 km/hr, the corresponding rpm will be 318.3 rpm
ω = (2πn₅)/60
= (2π x 318.3)/60
= 33.33 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
=0.14 Nm
F = T₂ / Rᵥᵥ
= 0.93 N
a=F
m
=0.62 m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 33.33
= 3.65 m/s
t = u-v (since, final velocity is 0)
a
= (3.65- 0)/0.62
= 5.97 s

S₅ = ut+1/2at²
=3.65 x 5.97+1/2 x 0.62 x 5.9²
=27.65 m

23
 CHAPTER 9

RESULTS

Sl. Speed Theoretical Time Actual Time

No. (kmph) (sec) (sec)

1 10 4.53 3.84

2 12 4.88 4.01

3 14 5.18 4.28

4 16 5.45 4.39

5 18 5.97 4.52

Tab.1, Result of Theoretical and Actual analysis

6
t ica l
T h eo r e

Actual
→

4
Time(sec)

0
10kmph 12kmph 14kmph 16kmph 18kmph
Speed(kmph) →
Fig.15, Theoretical and Actual analysis

24
 RESULTS

Speed Stopping Distance

Sl.No.
(kmph) (m)

1 10 9.42

2 12 12.15

3 14 15.6

4 16 21.8

5 18 27.65

Tab.2, Result of Theoretical analysis

THEORETICAL
30
→
Stopping Distance(m)

20

10

0
10kmph 12kmph 14kmph 16kmph 18kmph
Speed(kmph) →
Fig.16 , Result of Theoretical analysis

25
From the above results, We notice that as the speed increases stopping time and stopping
distance also increases.
For making the braking system more efficient, we need to add more electromagnets to
increase the braking force, as the brake force increases the stopping time and distance
decrease
For checking this we conducted a theoretical analysis by increasing the number of
electromagnets in the experimental setup.
Theoretical analysis by using 2 electromagnets
Iteration (i)
When the speed of the wheel is 10 km/hr, the corresponding rpm will be 176.83 rpm
ω = (2πn₁)/60
= (2π x 176.83)/60
= 18.52 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
= 2 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 18.52
= 0.154Nm
F = T / Rᵥᵥ
= 0.154/0.15
= 1.03 N
a=F
m
=1.03/1.5
=0.55m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 18.52
= 1.389 m/s
t = u-v
a (since, final velocity is 0)

= (1.389- 0)/0.55
= 2.5s
S₁=ut+1/2at²
=1.389 x 2.5+1/2 x 0.55 x 2.5²
=5.1m

26
Iteration (ii)
When the speed of the wheel is 12 km/hr, the corresponding rpm will be 212.2 rpm
ω = (2πn₂)/60
= (2π x 212.2)/60
= 22.22 rad/s
T₂ = n x A₁ x σ x d x B² x R² x ω
= 2 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 22.22
= 0.185Nm
F = T₂ / Rᵥᵥ
= 0.185/0.15
= 1.233 N
a=F
m
=1.233/1.5
=0.60m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 22.22
= 1.66 m/s
t = u-v
a (since, final velocity is 0)

= (1.66- 0)/0.60
= 2.88s
S₂=ut+1/2at²
=1.66 x 2.88+1/2 x 0.60 x 2.88²
=7.27m

Iteration (iii)
When the speed of the wheel is 14 km/hr, the corresponding rpm will be 247.56 rpm
ω = (2πn₂)/60
= (2π x 247.56)/60
= 25.9 rad/s
T₃ = n x A₁ x σ x d x B² x R² x ω
= 2 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 25.9
= 0.22Nm
F = T₃ / Rᵥᵥ
= 0.22/0.15
= 1.46 N
a=F
m
=1.46/1.5
=0.658 m/s²

27
u=rxω
where, r = radius of the disc
u = 0.075 x 25.9
= 2.04 m/s
t = u-v
a (since, final velocity is 0)

= (2.04- 0)/0.60
= 3.10s
S₃= ut+1/2at²
= 2.04 x 3.10+1/2 x 0.658 x 3.10²
= 9.48m

Iteration (iv)

When the speed of the wheel is 16 km/hr, the corresponding rpm will be 282.9 rpm
ω = (2πn₄)/60
= (2π x 282.9)/60
= 29.6 rad/s
T₄ = n x A₁ x σ x d x B² x R² x ω
= 2 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 29.6
= 0.25 Nm
F = T₄ / Rᵥᵥ
= 0.25/0.15
= 1.65 N
a=F
m
=1.65/1.5
=0.73m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 29.6
= 2.7 m/s
t = u-v
a (since, final velocity is 0)

= (2.7- 0)/0.60
= 3.67s
S₄=ut+1/2at²
=2.7 x 3.67+1/2 x 0.73 x 3.67²
=14.8m

28
Iteration (v)

When the speed of the wheel is 18 km/hr, the corresponding rpm will be 318.3 rpm
ω = (2πn₅)/60
= (2π x 318.3)/60
= 33.33 rad/s
T₅ = n x A₁ x σ x d x B² x R² x ω
= 2 x 0.00126 x 1.04 x 10⁷ x 0.003 x 0.06² x 0.1716² x 33.33
= 0.28 Nm
F = T₅ / Rᵥᵥ
= 0.28/0.15
= 1.87 N
a=F
m
=1.87/1.5
=0.87m/s²
u=rxω
where, r = radius of the disc
u = 0.075 x 33.33
= 3.65 m/s
t = u-v
a (since, final velocity is 0)

= (3.65- 0)/0.60
= 4.17s
S₅=ut+1/2at²
=4.17 x 4.17+1/2 x 0.87 x 4.17²
=22.78m

Sl. Speed Theoretical Time Stopping Distance

No. (kmph) (sec) (m)

1 10 2.5 5.1

2 12 2.88 7.27

3 14 3.10 9.48

4 16 3.67 14.8

5 18 4.17 22.78

Tab.3, Result of Theoretical analysis using two electromagnets

29
 5

4
→
Stopping Time(m)

0
10kmph 12kmph 14kmph 16kmph 18kmph
Speed(kmph) →
Fig.17, Theoretical analysis with 2 electromagnets

25

20
→
Stopping Distance(m)

15

10

0
10kmph 12kmph 14kmph 16kmph 18kmph
Speed(kmph) →
Fig.18, Theoretical analysis with 2 electromagnets

30
 CONCLUSION

In conclusion, the electromagnetic braking system is a significant advancement in the

automobile industry. It provides a safer and more efficient braking mechanism compared to
traditional systems. By utilizing an electromagnet, this braking system offers several
advantages, such as faster response times, precise control, and improved energy regeneration.
The project aimed to implement an automatic electromagnetic braking system using an
Arduino microcontroller and various components.
This project has practical applications in the automotive industry, especially in electric and
hybrid vehicles.Additionally, the precise control provided by the electromagnetic braking
system improves safety by enabling smoother and more accurate braking. It reduces the risk
of skidding and provides a more comfortable driving experience.
Further development of the project could involve integrating additional sensors, such as
speed or distance sensors, to enhance the system's functionality. It could also include more
advanced control algorithms to optimize the braking performance based on various driving
conditions.
As the number of magnets increased, stopping distance and stopping time got reduced but
there was a drastic change will occur by increasing the number of magnets. The reason is as
the number of magnets increase, magnetic field intensity will increase, the variation of torque
with magnetic field intensity is non-linear as square of magnetic field intensity is used in
torque equation.
After experimentation we observed that the wheel slows down but cannot stop
instantaneously, as we increase the number of magnets the stopping distance and stopping
time would reduce but we cannot have a sudden and instantaneous brake like friction brakes.

Overall, the electromagnetic braking system has the potential to revolutionize braking
technology in the automobile industry, providing enhanced safety, energy efficiency, and
control.

31
 FUTURE SCOPE

Integration with Autonomous Vehicles: As autonomous vehicles become more prevalent,

there is an opportunity to integrate electromagnetic braking systems with the vehicle's
autonomous driving system. This integration can enable more precise and adaptive
braking control based on the vehicle's surrounding environment and driving conditions.

Energy Regeneration Optimization: The energy regeneration capability of

electromagnetic braking systems can be further optimized. Research and development
efforts can focus on maximizing the amount of energy recovered during braking and
improving the efficiency of energy storage systems, such as batteries or supercapacitors.
This would contribute to increased overall energy efficiency and extend the vehicle's
driving range.

Integration with Vehicle-to-Vehicle Communication: In the era of connected vehicles,

electromagnetic braking systems can be integrated with vehicle-to-vehicle communication
protocols. This integration can enable cooperative braking, where vehicles communicate
with each other to coordinate braking actions, thereby enhancing safety and reducing the
risk of collisions.

Integration with Active Safety Systems: The electromagnetic braking system can be
integrated with other active safety systems, such as anti-lock braking systems (ABS) and
electronic stability control (ESC). By combining these systems, the overall safety and
stability of the vehicle can be enhanced, providing better control during emergency
maneuvers and challenging road conditions.

Overall, the future scope of electromagnetic braking systems in the automobile industry is
vast and holds great potential for advancements in safety, energy efficiency, and overall
driving experience. Continued research, development, and innovation in this field can lead to
significant improvements and contribute to the ongoing evolution of automotive
technologies.

32
 REFERENCE

[1] [Dr. S. R. Pawar Shubham D. Satam Saif Ali Shaikh Amit R. Shah] Analysis Of
Electromagnetic Braking System, [2022].
[2] [Srinivasa Gupta Gembali, A.N. Brahmeswara Rao, H. Naresh] Design and
Experimental Analysis of Electro Magnetic Braking System, [2021].
[3] [ Kare Gurudev Ramchandra , Gosavi Rushikesh Rajesh , Shriram Sourabh Amrut ,
Jagtap Rutvik Sambhaji, Vibhute Chandrakant Ningappa] Electromagnetic Braking
System, [2021].
[4] [Sudarshan T A, Sefeej, Swathin,Nikith T, Nidhin] Design And Fabrication Of
Electromagnetic Braking System, [2018].
[5] [Ashutosh Kumar B.Tech Scholar(ME),Swati Sachdev Assistant Professor (ME) , Ali
Mehdi B.Tech Scholar (ME) , Adarsh Sharma4 B.Tech Scholar (ME) , Abhishek Anand5
B.Tech Scholar (ME) , Brijesh Chaurasiya B.Tech Scholar (ME)] A Comparative Study of
Electromagnetic Braking System , [2021].
[6] [Pratyush Kumar Routh, Prem Sagar, Prince Kumar, Rajesh Kumar, Sarnendu Paul]
Electromagnetic Braking System, [2019].
[7] [Rahul P. Haridas2 , Somnath M. Kamble3 , Shubham D. Kamble4 , Rohan S.
Jadhav5] Contactless Electromagnetic Braking System [2020]

33