Journal

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056
Volume: 03 Issue: 04 | Apr-2024 www.irjet.net p-ISSN: 2395-0072

International Conference on Recent Trends In Engineering Technology-2024 (ICRTET-3)
Organised by VSM College of Engineering, Ramachandrapuram
FABRICATION OF CONTACTLESS EDDY CURRENT BRAKING

SYSTEM
Mr. T Kumar Raju1, D Ganesh2, S.Y.Sanyasi Naidu3, M Pawan Kalyan4, P Uma Mahesh5, G Manikanta6
Assistant Professor1, UG Students2,3,4,5,6, Department of Mechanical Engineering, V.S.M College of engineering,

Ramachandrapuram, Andhra Pradesh, India
***
ABSTRACT- Majority of braking systems work on the The braking force can be adjusted to control higher
principle of dissipation of kinetic energy to heat energy. torque loads by varying the coil turns or by
This method has its own drawbacks and must be replaced increasing the voltage. This gives flexibility of operation of
with a more reliable braking system that is quick in the system and makes it reliable even in changing loading
response, doesn’t heat up and is maintenance free. In this patterns. A study of eddy current braking system is
project the design an eddy current braking system and performed to find out the practical limit of using an
optimization for various operational parameters has been electromagnetic braking system.
done. These parameters have been previously iterated in
cited projects and papers and also in the simulation 1.2 OBJECTIVES:
models and are to be cross-checked with the
experimental setup. Primary Objective :
Keywords – Brakes, Metal Wheel , frictionless Brake disc, The main objective of our project is to design and
Eddy Current, Electromagnet, Electro motive force, fabricate an Electromagnetic Braking System model.
Magnets.
Secondary Objective:
1.1 INTORDUCTION Besides the main objective, following are our secondary
objectives:
In the operation of any machinery the most primary
safety system is the braking system. The most basic 1. To understand project planning and execution
designs of the braking system involve the conversion of
kinetic energy to heat energy by friction. This is 2. To understand the fabrication techniques in a
accomplished by friction between two rubbing surfaces. mechanical workshop
These brakes pose several problems i.e. significant wear,
fading, complex and slow actuation, lack of fail-safe 3. To understand the usage of various mechanical
features, increased fuel consumption due to power machine tools and also measuring tools
assistance, and requirement for anti-lock controls. To
4. To make day to day human life more easier by proper
solve these problems, a contactless magnetic brake has
use of technology
been developed. This concept includes a metals disk
which will conduct eddy currents generated by magnets.
2. LITERATURE REVIEW
This brake is wear-free, less-sensitive to temperature
than friction brakes, has fast and simple actuation, and
has a reduced sensitivity to wheel lock. Contactless Oscar Rodrigues et al. [2016] [1], The purpose of
brakes can be applied to any machinery like the study was to perform a comparative study of
automobiles, locomotives, roller coasters, hydraulic and theoretical and practical braking time and establish a
turbo machinery, machine tools, elevators, etc. The wide practical air gap limit beyond which the electromagnetic
range applicability of these brakes strongly imply the brakes lose their effectiveness.
effectiveness and ease of operation.
© 2024, IRJET ISO 9001:2008 Certified Journal Page 809
p-ISSN: 2395-0072
Volume: 03 Issue: 04 | Apr-2016 www.irjet.net

max air gap limit of 3 mm is obtained beyond with 3. METHODOLOGY

electromagnetic brakes are found to be ineffective.
Basically, this project was study of electromagnetic
Baoquan Kou et al [2015] [2], in this paper, a novel braking system as a secondary measure for the hydraulic
hybrid excitation linear eddy current brake was braking system. First, the base for the electromagnets and
presented. The hybrid excitation linear eddy current brake the stand for fitting the wheel, is made. Then, a wheel is
has the advantages of high force density and low made and attached to the spook whereas the spook is
excitation loss compared to the electric excitation linear attached to the stand by the help of bearings. An
eddy current brakes. The validity of the analytical model electromagnet is made by winding the copper wire with
was verified by the FEM and experimental tests, therefore the cylindrical body and attached to it’s base.
the analytical model can be used in the preliminary design Furthermore, an U shaped metal rod is welded with a L
shaped metal bar forming a brake shoe and then its end
of eddy current brakes.
are rest inside the electromagnet. Also a fan is also
Arunesh Kumar Singh et al [2014] [3] this paper attached to motor and the motor is attached to the base.
presented a detailed study of different types Eddy So the electromagnet and the motors of wheel and fan are
circuited to an external battery and by turning it on, they
Current Braking System. Various applications of ECBS
work respectively.
such as retarders in high speed trains, in automobiles,
dampers, couplers and in the air bearing system have been
studied. Various design parameters on which the
4. FABRICATION
performance of ECBS depends have been discussed. It
has been observed that some parameters like air gap
The fabrication process of an eddy braking system
length, the electrical conductivity of conductor, the speed
involves creating a setup where a conductive material,
of conductor are common in all the applications
often a metal disc or plate, is subjected to a changing
Yasuaki Sakamoto et al [2008] [4], they have magnetic field to induce eddy currents. These currents
estimated the performance of the eddy current brake using create resistance, generating braking force. Fabrication
typically includes designing the electromagnetic
a LIM for dynamic braking from experimental results of
components, such as coils and magnets, and assembling
a fundamental test machine. We confirmed that the LIM
them with the conductive material in a way that allows for
under constant current excitation has an approximately efficient energy conversion and braking performance.
constant braking force regardless of both the velocity and Additionally, attention to materials, precision in
frequency, for relatively low frequencies. construction, and testing for effectiveness and safety are
essential steps in the fabrication process.
Sohel Anwar and Bing Zheng [2007] [5], they have
a nonlinear sliding-mode-type controller is presented for
slip regulation in a braking event for an eddy-current-
based BBW system in this paper. It is also shown that the
closed-loop system is stable in the sense of Lyapunov.
Experimental results show very good slip regulation in a
braking system.

3.1 ALUMINIUM DISC 3.3 DC MOTOR
Aluminum discs are circular pieces made from aluminum A DC motor, short for direct current motor, is a type of
alloy. They are commonly used in various industries for electrical machine that converts electrical energy into
applications such as manufacturing components, mechanical energy. It operates on the principle of Lorentz
cookware, signage, and decoration. The properties of force, where a current-carrying conductor placed in a
aluminum, including its lightweight, corrosion resistance, magnetic field experiences a force. DC motors consist of
and conductivity, make it a popular choice for a wide a stator containing magnets or electromagnets and a rotor
range of products. Aluminum discs are typically (rotating part) consisting of a coil of wire or conductive
produced through processes like casting, extrusion, or material. When an electric current is passed through the
machining, depending on the desired shape and coil, it generates a magnetic field that interacts with the
specifications magnetic field of the stator, causing the rotor to rotate.
3.2 NEODYMIUM MAGNETS 3.4 SMPS
Switched Mode Power Supply (SMPS) is a type of power

Neodymium magnets are incredibly strong permanent
supply that efficiently convert electrical power from one
magnets made from an alloy of neodymium, iron, and
form to another using switching devices such as
boron. They are widely used in various applications such
transistors or MOSFETs. SMPSs are commonly used to
as electric motors, generators, headphones, and magnetic convert AC power from the mains electricity supply into
therapy devices due to their high magnetic strength.
regulated DC power for electronic devices such as
Neodymium magnets, also known as NdFeB magnets,
computers, televisions, and smartphones. The smoothed
were developed in the 1980s and are the strongest type of DC voltage is fed into a switching circuit, which rapidly
permanent magnets available commercially. They have a
switches the voltage on and off at a high frequency. This
high resistance to demagnetization and can produce
switching action allows for efficient voltage conversion
significant magnetic fields, making them indispensable in
and regulation
modern technology.


3.5 METAL FRAME 4. SIMULATION

In a contactless eddy braking system, a metal frame The aim of the simulation was to verify the actual results
serves as a foundational component that supports and and to generate the deceleration plot. The deceleration
houses various elements of the braking mechanism. The plot shows an early drop in velocity due to high torque
metal frame provides structural integrity and stability to developed by eddy current present in the disc. The initial
the braking system, ensuring that it can withstand the parameters were loaded in the study. A stationary study
forces and vibrations encountered during operation was done to evaluate the eddy current generated in the
disc. Also a time dependent study was done to show the
development of the same eddy currents in the disc with
declaration.
4.1 MESHING
The meshing must be more concentrated in the junction
were the magnetic field lines transferred into the disc
from the magnet. The mesh shape was selected to be free
tetrahedral andtriangular edge elements. [18]
OVERALL FABRICATION
Methodology to Fabrication of electromagnetic braking
system model
1. Analyze the problems in the fabrication of
electromagnetic braking system
2. Designing the required components.
3. Selection of required materials.
4. Purchasing the materials.
5. Fabrication of the electromagnet.
6. Preparation of report and submit
The junction had been meshed to an average element
size of 0.9mm whereas the rest of the geometry was
meshed up to 24mm mesh size.
4.2 PARAMETRIC SWEEP
To understand the behavior of the ECB under varying
conditions varying a parameter had to be done. The initial
speed and airgaps were physically possible to vary and
hence the simulation was done by varying the initial disc
speed and the airgap
The airgaps 1, 2, 3, 4 mm were swept against initial
speeds of 2500, 2250, 2000, 1750, 1500 rpms. The
deceleration plot is illustrated in the chart 1, 2, 3 and 4
Chart -1: Deceleration graphs for 1mm air gap Chart -3: Deceleration graphs for 3mm air gap
Chart -2: Deceleration graphs for 2mm air gap Chart -4: Deceleration graphs for 4mm air gap

Table 1 shows the braking time obtained by theoretical There was a little difference between simulated and
calculation and by simulation and the observed actual graphs which can be accounted for bearing and
percentage deviation. air friction of the disc and the shaft. Therefore, it is
Table -1:Theoretical and Simulated Braking Time
found the after 4mm airgap there is very little effect of
the electromagnets on the disc which reduces braking
Air Gaps
effectiveness. Also, the established design procedure
Initial
Speed Study type for ECB design performs as per the simulated data.
(Rpm) 1
mm 2 mm 3mm 4 mm
Theoretical 14.57 15.89 16.23 16.59 shows the fabricated experimental setup.
2500 Simulation 13.3 14.7 15.2 16.9
Deviation (%) 8.71 7.48 6.34 1.86
Theoretical 13.29 14.38 14.65 14.95
2250 Simulation 12.1 13.1 13.7 15.8
Deviation (%) 8.95 8.90 6.48 5.68
Theoretical 11.97 12.85 13.07 13.3
2000 Simulation 10.2 11.5 12.2 13.9
Deviation (%) 14.78 10.50 6.65 4.5113
Theoretical 10.62 11.3 11.47 11.65
1750 Simulation 9.2 9.9 11.7 12.9
Deviation (%) 13.37 12.34 2.00 10.73
Theoretical 9.23 9.74 9.87 10
1500 Simulation 8.2 8.8 10.1 12
Deviation (%) 11.15 9.65 2.33 20
Results and conclusion

The deceleration plot was extracted and studied under the Experimental Setup
experimentation phase. A close resemblance was found
between the deceleration plot from the experiment and the
simulation. Speeds drops for all parameter setting were Experiments are performed on setup at speed of 2500,
found and compared. 2250, 2000, 1750 and 1500 rpm taking 1 mm, 2mm,
3mm air gap for each speed.
Based on experiments, the following graph is
extrapolated as shown in figure
Eddy Current density plot

© 2024,IRJET ISO 9001:2008 Certified Journal Page 814
Table 2 shows the results of braking time obtained

similarly for various speeds and air gap settings and their
relative difference in percentage.
Table -2:Experimental Braking Time
Air Gaps
Initial
Speed Study type
(Rpm)
1 mm 2 mm 3mm 4 mm
Without Brake 15.10 15.10 15.10 15.10
2500 With brake 11.98 12.33 13.10 13.70
Reduction (%) 23.97 18.36 13.26 9.29
Without Brake 14.32 14.32 14.32 14.32
2250 With brake 10.90 11.33 12.42 12.98
Reduction (%) 23.9 20.90 13.29 9.48

Chart -6: Braking Time with 2 mm Air Gap
Without Brake 12.89 12.89 12.89 12.89
2000 With brake 9.86 10.28 10.75 12.06
Reduction (%) 23.55 20.25 16.60 6.48
Without Brake 11.38 11.38 11.38 11.38
1750 With brake 8.97 9.78 10.09 10.87
Reduction (%) 21.22 14.06 11.34 4.48
Without Brake 10.15 10.15 10.15 10.15
1500 With brake 7.95 8.21 9.17 9.73
Reduction (%) 21.65 19.14 9.67 4.11
Chart 5, 6, 7 and 8 shows the comparison of braking

time without braking system and with braking system
with air gap of 1mm, 2mm, 3mm and 4mm respectively.

6. REFERENCE
[1]. Max Baermann, (1970) “Permanent Magnet Eddy
Current Brake or Clutch”, USPO3, 488,535
[2]. P. Hanyecz, (1982), “Calculation of Braking force in
Eddy current brakes”, Department of Theoretical
Electricity. Technical University Budapest
[3]. Pushkin Kachroo, (1997), “Modelling and control
of Electromagnetic brakes”, Faculty Publications,
University of Nevada, Las Vegas
[4]. Tohuru Kuwahara, (1999), “Permanent type eddy
current braking system”, USPO5944149
[5]. Marc T. Thompson, “Permanent Magnet
Electrodynamic Brakes Design Principles and
Scaling laws”, Worcester Polytechnic
[6]. Kyi Wan Park; Kap J in Lee, (2001), “Contactless
5. CONCLUSION
eddy current brake for cars”, USPO6286637
[7]. Marc T. Thompson, Edward Pribonic, (2003),”
In conclusion, contactless eddy braking systems offer
Eddy current braking apparatus”, USPO6533083
numerous advantages such as smooth braking, reduced
wear and tear, high efficiency, precise control, low [8]. Min Jou, Jaw-Kuen Shiau, Chi-Chian Sun, (2006),
maintenance, and enhanced safety. However, they also Design of magnetic braking system”, Journal of
come with limitations including higher initial cost, limited Magnetism and Magnetic Materials-Sep 2006.
applicability, dependency on electrical power, heat [9]. Der-Ming Ma, Jaw-Kuen Shiau, (2010), “Design of
dissipation concerns, complexity of design, and potential eddy- current magnet brakes”, Department of
limitations in regenerative braking. Despite these Aerospace Engineering, Tamkang University,
drawbacks, contactless eddy braking systems remain a Danshuei, Taiwan.
valuable choice for applications where smooth, efficient, [10]. G. Priyandoko, M.Z. Baharom, (2011), “Eddy
and reliable braking performance is paramount,
Current Braking Study for Brake Disc of
especially in high-speed or high- performance scenarios.
With ongoing technological advancements and aluminium, Copper and Zink, Regional
optimization efforts, these systems continue to evolve, Engineering Postgraduate
addressing challenges and expanding their potential Conference (EPC) 2011
applications in various industries. [11]. Yuichi Tashiro, Tokyo, Mitsuyoshi Oba, (2011),
“Electromagnetic Type Retarder”, United States
6. FUTURE SCOPE AND WORK Patent Application Publication US 2011/0214954
A1.
The future scope of eddy current braking systems lies in
their potential applications in various industries, including
transportation, renewable energy, and manufacturing.
These systems offer advantages such as energy efficiency,
reduced wear and tear, and precise control, making them
attractive for future development. Additionally, integrating
these systems into emerging technologies.




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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395 -0056

Volume: 03 Issue: 04 | Apr-2024 www.irjet.net p-ISSN: 2395-0072

FABRICATION OF CONTACTLESS EDDY CURRENT BRAKING

Assistant Professor1, UG Students2,3,4,5,6, Department of Mechanical Engineering, V.S.M College of engineering,

International Conference on Recent Trends In Engineering Technology-2024 (ICRTET-3)

max air gap limit of 3 mm is obtained beyond with 3. METHODOLOGY

© 2024, IRJET ISO 9001:2008 Certified Journal Page 810

3.1 ALUMINIUM DISC 3.3 DC MOTOR

3.2 NEODYMIUM MAGNETS 3.4 SMPS

Switched Mode Power Supply (SMPS) is a type of power

© 2024, IRJET ISO 9001:2008 Certified Journal Page 811

International Conference on Recent Trends In Engineering Technology-2024 (ICRTET-3)

3.5 METAL FRAME 4. SIMULATION

© 2024, IRJET ISO 9001:2008 Certified Journal Page 813

Results and conclusion

Eddy Current density plot

Table 2 shows the results of braking time obtained

Without Brake 15.10 15.10 15.10 15.10

2500 With brake 11.98 12.33 13.10 13.70

Reduction (%) 23.97 18.36 13.26 9.29

Without Brake 14.32 14.32 14.32 14.32

2250 With brake 10.90 11.33 12.42 12.98

Reduction (%) 23.9 20.90 13.29 9.48

2000 With brake 9.86 10.28 10.75 12.06

Reduction (%) 23.55 20.25 16.60 6.48

Without Brake 11.38 11.38 11.38 11.38

1750 With brake 8.97 9.78 10.09 10.87

Reduction (%) 21.22 14.06 11.34 4.48

Without Brake 10.15 10.15 10.15 10.15

1500 With brake 7.95 8.21 9.17 9.73

Reduction (%) 21.65 19.14 9.67 4.11

Chart 5, 6, 7 and 8 shows the comparison of braking

Chart -7: Braking Time with 3 mm Air Gap

Chart -5: Braking Time with 1 mm Air Gap

© 2024, IRJET ISO 9001:2008 Certified Journal Page 815

© 2016, IRJET ISO 9001:2008 Certified Journal Page 816

© 2024, IRJET ISO 9001:2008 Certified Journal Page 817

© 2016, IRJET ISO 9001:2008 Certified Journal Page 818

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