Black book

on

ELECTRO-MAGNETIC BREAKING

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 Abstract

As we all know that the road to a fully electric future was paved in 2020 with potential new
partnerships between automakers and Electric Vehicle (EV) start-ups, advancements in
battery range and heightened government efforts to reduce CO2 emissions. Since braking is
also the most essential part of automobile it’s also needs to get changed with respect to time
as Automobiles get changed from running onto fossil fuels to EV.For such a great change
Electromagnetic Braking System is one of the best option for us to introduce in EV.
Electromagnetic braking system means applying brakes using electronic and magnetic power.
Here we use the principle of electromagnetism to achieve friction less braking. This tends to
increase 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 system.
To make electromagnetic brakes work, a magnetic flux when passed in a direction
perpendicular to the rotating direction of the wheel, we see eddy current flowing in a direction
opposite to the rotation of the wheel. 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.

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 TABLE OF CONTENT
Sr. No. TITLE Page no.

1. Introduction 1-5

1.1 Background and History 3

3-4

4-5

2. Literature Survey 6-9

6-7

7-8

3. Problem Definition and Methodology 10-20

3.1 Problem Definition 10

3.2 Objectives 11

3.3 Methodology 11-12

3.4 Time Activity Chart 12

3.5 Expected Outcomes 13

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References 56

LIST OF FIGURES

Figure. No. Figure Name Page no.

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LIST OF TABLES

Table. No. Table Name Page no.

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Chapter 1

Introduction

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New advances are landing in this world. Numerous enterprises got profited because of the
entry of these new innovations. A vehicle industry is one of them. As brake is an essential
piece of car innovation, there are developments in brakes as well. The generally utilized
brakes in cars are drum and circle brakes. Electromagnetic braking is an imaginative
innovation and furthermore frames the premise of developing innovation. The break is a
mechanical gadget which includes the change of dynamic vitality into a warm vitality by
halting vehicle in a movement. The working principle of the system is that when the magnetic
flux passes through and perpendicular to the rotating wheel the eddy current flows opposite to
the rotating wheel direction.

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1.1 Background and History

Background and Rational Electromagnetic brakes (also called electro-mechanical brakes or

EM brakes) slow or stop motion using electromagnetic force to apply mechanical resistance
(friction). The original name was "electro-mechanical brakes" but over the years the name
changed to “electromagnetic brakes", referring to their actuation method. Since becoming
popular in themid-20th century especially in trains and trams, the variety of applications and
brake designs has increased dramatically, but the basic operation remains the same.
Electromagnetic brakes are the brakes working on the electric power & magnetic power. They
works on the principle of electromagnetism. These brakes are an excellent replacement on the
convectional brakes due to their many advantages. The reason for implementing this brake in
automobiles is to reduce wear in brakes as it frictionless. Electromagnetic brakes are of
today’s automobiles. 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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1.4 Summary :-

This chapter mainly gives brief idea the A brake is a device which inhibits motion. Its
opposite component is a clutch. Most commonly brakes use friction to convert kinetic energy
into heat, though other methods of energy conversion may be employed. For example
regenerative braking converts much of the energy to electrical energy, which may be stored
for later use. The brakes are different to use in stopped the reciprocating parts and motion
automobile vehicles. The new technology is produced in automobile engineering. An
automobile industry is developing new technology of braking system. These worlds are new
possibility and new thinking of braking system. The automobile industry are also developed
new braking system like to drum brake, disc brake, hydraulic brake, pneumatic brake, air
brake and electromagnetic brake. The different brakes are working on different principle
operation. Future is used in time of hydraulic and disc or drum brake. The different types of
friction brake and electromagnetic brake use. The main principle of electromagnetic brake to
induced kinetic energy into heat energy. Braking system is used to automobile vehicle speed
reduced in slowly. The brake are applied the manually force on a brake pedal to the
mechanical linkage operate and applied the brake drum wheel and motion is slowly reduced
and applied the brake. Brake applied to the vehicle speed reduced in several time and vehicle
to rest. The electromagnetic brakes are new technology of automobile industry for future
concept to use for automobile vehicle and other industry level. Brakes are new technology to
use for vehicle required specification. Automobile vehicle to use for required use in purpose
for like sports car, light motor vehicle, heavy motor vehicle, bikes, sports bikes and off road
vehicles. Heavy motor vehicle is use brakes this time of air brakes. The electromagnetic
brakes are new developed in braking system in automobile engineering. This type brake
mainly working principle is one rotating metal disc in between the two magnets to apply the
brake to induced electric current in circuit to induced magnetic field in armature to attract the
magnet to the rotating metal disc and stopped the rotation in several time while applied brake.

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 Chapter 2

Literature Survey

It includes, the data of the published journal papers related to our projects. We have described
the work of respective authorities published in their books. This papers are related to our
project topic, which have help us to learn various process, methods and design factors used in
respective work.

1. MOHD SHAHRIZAN B. SAHRI, ULTRASONIC CAR BRAKING SYSTEM

An ultrasonic car braking system includes; an ultra sonic wave emitter provided in a
front portion of an automatic braking car producing and emitting ultrasonic waves
frontward in a predetermined distance in front of the car.

2. Eung Soo Kim Fabrication of Auto-Braking Sy stem for Pre-Crash Safety Using
Sensor This module can detect the distance between front vehicle and driver’s vehicle
to keep a constant distance using a sensor and operate the brake system forcibly if the
driver does not decrease the speed of car

3. SahilJitesh1* THAKUR ANTILOCK BRAKING SYSTEM ABS generally offer

advanced vehicle control and minimize the stopping distance in slippery and dry
surface, conversely on loose surface like gravel or snow covered pavement, ABS can
significantly increase braking distance, although still improving vehicle control.

4. SevvelP1, NirmalKannanV2, Mars MukeshS3 Innovative Electro Magnetic Braking

System An Electromagnetic Braking system uses Magnetic force to engage the brake,
but the power required for braking is transmitted manually. 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.

5. Sivasubramanian R, Siva sundar S, Umakhesan A, Rajavel M, Saravanan M Design

and Development of Electromagnetic Braking System An electromagnetic brake
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 system could substantially increase braking efficiency while reducing friction brake
wear. Bringing this technology to market would create extra revenue for automobile
companies, and could increase client base. It reaffirms the company‟s commitment to
safety and quality. By producing this brake will be possible to sell it for substantially
less than outsourced systems while still making a profit. Most potential truck owners
will consider this option, since it reduces the upkeep and cost of traditional brakes and
increases truck safety. Electromagnetic braking systems represent the future of brake
technology.

6. Krunal Prajapati, 2Rahul Vibhandik, 3Devendrasinh Baria, 4Yash Patel Student,

Automobile department, Laxmi institute of Technology, Sarigam-Valsad. Gujarat
ELECTROMAGNETIC BRAKING SYSTEM With all the advantages of
electromagnetic brakes over friction brakes, they have been widely used on heavy
vehicles where the „brake fading‟ problem exists. The same concept is being
developed for application on lighter vehicles. The concept designed by us is just a
prototype and needs to be developed more because of the above mentioned
disadvantages. These electromagnetic brakes can be used as an auxiliary braking
system along with the friction braking system to avoid overheating and brake failure.
ABS usage can be neglected by simply using a micro controlled electromagnetic disk
brake system .These find vast applications in heavy vehicles where high heat
dissipation is required

7. 1Purohit Harish Laljibhai ,2Thakor Divyang Javansinh ,3Vankar Dipak Dahyabhai ,

4Prajapati Jaimin Rameshbhai Electromagnetic Braking system As we discussed
about the limitations of drum brakes, hydraulic brakes and pneumatic brakes
electromagnetic brake is a better and reliable 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.
8. Yogesh Kumar Yadav1, Aadarsh Kumar Shah2, Jitendra Kumar Yadav3, Jitendra
Pratap Patel4 Electromagnetic Braking System Electromagnetic brakes have numerous
preferences over frictional slowing mechanism. The blend of swirl present and
attractive powers makes this brake more successful. This brake can be utilized as
assistant stopping mechanism in vehicle. The utilization of abs can be dismissed by

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 utilizing a smaller scale controlled electromagnetic framework. it can be utilized as a
part of rail mentors to decelerate the prepare moving in fast. Mix

9. Name: William Gaskey, Sandip Mistry, Duy Nguyen, Jee Yoon Electromagnetic
Braking System Project was completed on schedule and within budget thanks to
donations • Supplier issues caused the purchase of weaker magnets than intended for
design • Good results with current design, a larger budget would improve performance
• The project proves the theory and shows the potential for a full functional system

10. Romin Patel Dept. of Mechanical, SSASIT, Gujarat Technological University, India
Development of Electro-Magnetic Brake System From our experiment we conclude
that this mechanism is very suitable at high speed. With all the advantages of
electromagnetic brakes over friction brakes, they have been widely used on heavy
vehicles where the ‘brake fading’ problem exists. The same concept is being
developed for application on lighter vehicles. The concept designed by us is just a
prototype and needs to be developed more because of the above mentioned
disadvantages. These electromagnetic brakes can be used as an auxiliary braking
system along with the friction braking system to avoid overheating and brake failure.

11. 11 1Sudarshan T A, 2Sefeej, 3Swathin,Nikith T, Nidhin 1Assistant Professor,

2Student, 3Student 1Department of Mechanical Engineering, 1New Horizon College
Of Engineering, Bengaluru, India DESIGN AND FABRICATION OF
ELECTROMAGNETIC BRAKING SYSTEM The Electromagnetic braking system is
found to be more reliable as compared to other braking systems. In addition, it is
found that electromagnetic brakes make up approximately 80% of all of the power
applied brake applications. Electromagnetic brakes have been used as supplementary
retardation equipment in addition to the regular friction of the brakes. This enhanced
braking system not only helps in effective braking but also helps in avoiding the
accidents and reducing the frequency of accidents to a minimum. Furthermore the
electromagnetic brakes prevent the danger that can arise from the prolonged use of
brake beyond their capability to dissipate heat. ABS usage can be neglected by simply
using a micro controlled electromagnetic disk brake system. For the brake distribution
of the electromagnetic braking system, the abrasion, noise, harmful friction dust, and

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the risk of thermal failure in braking system were reduced obviously. These
electromagnetic brakes can be used in wet conditions which eliminate the anti-
skidding equipment, and cost of these brake are cheaper than the other types. The
concept designed by us is just a prototype and needs to be developed more. It can not
only be used in the field of automotive but also in the field of aeronautics. Hence the
electromagnetic braking system can be a better technological revolution in the future
application

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 Chapter 3

Problem Definition and Objective

3.1 Problem Definition :-

The idea of using an electromagnet as a brake has been mainly used in large vehicles and
machines. Electromagnets can also be used to make frictionless brakes which is what we are
interested in. Further,

1. we are interested in reducing the rotation of a wheel and hence, angular velocity. Thus, the
desired brake involves dissipating rotational energy.
2. In theory, if a magnetic field is induced in a rotating disc, it will produce eddy currents
within the disc. These currents will then oppose the rotation of the disc by dissipating kinetic
energy in the form of heat (causing the temperature of the disc to increase).
3. To me, this concept did not seem intuitive, so we decided to test it. The magnetic field is
usually generated by an electromagnet. Hence, we interested in knowing if an electromagnet
could really affect the rotation of the wheel.

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3.2 Objectives :-

1. The main objective of our project is to design of an Electromagnetic Braking System

model
2 .Besides the main objective, following are our secondary objectives:-
2.1 To understand project planning and execution
2.2 To understand the fabrication techniques in a mechanical workshop
2.3. To understand the usage of various mechanical machine tools and also measuring
tools
2.4 To make day to day human life more easier by proper use of technology

3. Our design overcomes the previous system which was very in very high cost
3.1 Simple in construction
3.2 Less space required
3.3 Low energy consumption
3.4 No need of skilled persons

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3.3 Methodology :-

For 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:
Analyzing 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.

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.

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3.4 Time Activity Chart :-

Task Start Date End Date Duration

1. Proposal Stage 1 20-06-20 15-07-20 25
1.1 Project title selection 20-06-20 24-06-20 4
1.2 Project research 25-06-20 05-07-20 10
1.3 Discussion with adviser about the project 06-07-20 07-07-20 1
1.4 Project proposal preparation 08-07-20 13-07-20 5
1.5 Project proposal submission 14-07-20 15-07-20 1
2. Stage 2 16-07-20 05-09-20 51
2.1 Study of basics of electromagnetic braking system 16-07-20 26-07-20 10
2.2 Types of brakes 27-07-20 01-08-20 5
2.3 study of How can we use braking energy works 02-08-20 08-08-20 6
2.4 Selection Of The Electromagnetic Brakes To 09-08-20 12-08-20 3
Overcome The Problems
2.5 study of different parts in automobile 13-08-20 05-09-20 23
3. Stage 3 06-09-20 15-10-20 39
3.1 Study of literates, various research Papers , 06-09-20 15-09-20 9
Analyzing Research Papers
3.2 Design 3D cad model preparation 16-09-20 29-09-20 13
3.3 Motor torque calculations 30-09-20 15-10-20 15
4. Stage 4 16-10-20 15-11-20 30
4.1 Preparing a PowerPoint Presentation 16-10-20 05-11-20 20
4.2 Study of presentation 06-11-20 15-11-20 9

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Preparation 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.
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.

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Types of Braking System

Electromagnetic Brake System

A rising style of 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. On
occasion, some buses will use it as a secondary retarder brake.

Frictional Brake System

A 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 rotating device with a stationary
pad and a rotating weather surface. On most band brakes the shoe will constrict and rub
against the outside of the rotating drum, alternatively on a drum brake, a rotating drum with
shoes will expand and rub against the inside of the drum.

Hydraulic Brake System

A 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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Design Work

Cad model prepared using catia v5

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Block Diagram:-

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Working :

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When the power supply is given the motor, it will rotate the main shaft by using belt pulley
system, aluminum plate is welded with shaft 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
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 disc thus attracting the armature to the
face of the disc.

When the current or voltage is removed from the brake (electromagnet) the disc is free to
rotate.

Chapter 5

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Components Specifications:

Electromagnet is the device which get magnetized when the current is feed into it. Here the
electromagnet is designed by modified a typical transformer. The transforms has double side
„E‟ shape outer core around the inner core. This outside „E‟ shape core of the transformer is
removed and then arranged as single side. Now it is act as a electromagnet.

Aluminum Disc The disc is one of the important component been used here. It is made up of
aluminum plate of 5 mm thickness. The diameter of the disc is 255 mm. At last the disc is
fitted with the pulley by the use of 4 mm screws.

Switch And Wires ON/OFF switch used to control the power supply to the electromagnet. It
is connected with the electromagnet. A typical common electric switch is used here. When the
rotation of the pulley is to be stop, the braking is applied by turned the switch on. When the
free rotation of the pulley is required the switch is turned off. To provide the electric supply to

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the motor and the electromagnet the electric wire is used here. The copper wire has been used
here since it has the better electrical conductivity.

Ac Motor The rotary motion of the wheel is given by the AC motor. The electric motor
convert electric energy into mechanical energy by electromagnetic induction. The motor been
used here is the typical grinder motor.

MATERIAL SELECTION

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The proper selection of material for the different part of a machine is the main objective in the
fabrication of machine. For a design engineer it is must that he be familiar with the effect,
which the manufacturing process and heat treatment have on the properties of materials. The
Choice of material for engineering purposes depends upon the following factors:

1. Availability of the materials.

2. Suitability of materials for the working condition in service.

3. The cost of materials.

4. Physical and chemical properties of material.

5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability of the

material to resist mechanical forces and load. We shall now discuss these properties as

follows:

1. Strength : It is the ability of a material to resist the externally applied forces

2. Stress: Without breaking or yielding. The internal resistance offered by a part to an

externally applied force is called stress.

3. Stiffness: It is the ability of material to resist deformation under stresses. The modules

of elasticity of the measure of stiffness.

4. Elasticity: It is the property of a material to regain its original shape after deformation

when the external forces are removed. This property is desirable for material used in

tools and machines. It may be noted that steel is more elastic than rubber.

5. Plasticity: It is the property of a material, which retain the deformation produced under
load permanently. This property of material is necessary for forging, in stamping
images on coins and in ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percent
reduction in area. The ductile materials commonly used in engineering practice are
mild steel, copper, aluminum, nickel, zinc, tin and lead.
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 7. Brittleness: It is the property of material opposite to ductile. It is the property of
breaking of a material with little permanent distortion. Brittle materials when
subjected to tensile loads snap off without giving any sensible elongation. Cast iron is
a brittle material.
8. Malleability: It is a special case of ductility, which permits material to be rolled or
hammered into thin sheets, a malleable material should be plastic but it is not essential
to be so strong. The malleable materials commonly used in engineering practice are
lead, soft steel, wrought iron, copper and aluminum.
9. Toughness: It is the property of a material to resist the fracture due to high impact
loads like hammer blows. The toughness of the material decreases when it is heated.
It is measured by the amount of absorbed after being stressed up to the point of
fracture. This property is desirable in parts subjected to shock an impact loads.
10. Resilience: It is the property of a material to absorb energy and to resist rock and
impact loads. It is measured by amount of energy absorbed per unit volume within
elastic limit. This property is essential for spring material.
11. Creep: When a part is subjected to a constant stress at high temperature for long
period of time, it will undergo a slow and permanent deformation called creep. This
property is considered in designing internal combustion engines, boilers and turbines.
12. Hardness: It is a very important property of the metals and has a wide verity of
meanings. It embraces many different properties such as resistance to wear scratching,
deformation and mach inability etc. It also means the ability of the metal to cut another
metal. The hardness is usually expressed in numbers, which are dependent on the method
of making the test. The hardness of a metal may be determined by the following test.
a) Brinell hardness test
b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test and
d) Share scaleroscope.
The science of the metal is a specialized and although it overflows in to realms of knowledge
it tends to shut away from the general reader. The knowledge of materials and their properties
is of great significance for a design engineer. The machine elements should be made of such a
material which has properties suitable for the conditions of operations. In addition to this a
design engineer must be familiar with the manufacturing processes and the heat treatments
have on the properties of the materials. In designing the various part of the machine it is

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necessary to know how the material will function in service. For this certain characteristics or
mechanical properties mostly used in mechanical engineering practice are commonly
determined from standard tensile tests. In engineering practice, the machine parts are
subjected to various forces, which may be due to either one or more of the following.

1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that are set up during
operation. The material selected should with stand it. Another criteria for selection of metal
depend upon the type of load because a machine part resist load more easily than a live load
and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.

1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
7. The extent loss of life if failure occurs
8. The extent of loss of property if failure occurs

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Materials selected in m/c

Base plate, motor support, sleeve and shaft

Material used

Mild steel

Reasons:

1. Mild steel is readily available in market

2. It is economical to use
3. It is available in standard sizes
4. It has good mechanical properties i.e. it is easily machinable
5. It has moderate factor of safety, because factor of safety results in unnecessary
wastage of material and heavy selection. Low factor of safety results in unnecessary
risk of failure
6. It has high tensile strength
7. Low co-efficient of thermal expansion

Properties of Mild Steel:

M.S. has a carbon content from 0.15% to 0.30%. They are easily wieldable thus can be
hardened only. They are similar to wrought iron in properties. Both ultimate tensile and
compressive strength of these steel increases with increasing carbon content. They can be
easily gas welded or electric or arc welded. With increase in the carbon percentage weld
ability decreases.

Mild steel serve the purpose and was hence was selected because of the above purpose

BRIGHT MATERIAL:

It is a machine dawned. The main basic difference between mild steel and bright metal is that
mild steel plates and bars are forged in the forging machine by means is hot forged. But the
materials are drawn from the dies in the plastic state. Therefore the material has good surface
finish than mild steel and has no carbon deposits on its surface for extrusion and formation of

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engineering materials thus giving them a good surface finish and though retaining their
metallic properties

MANUFACTURING
The process of conversion of raw material in to finished products using the three resources
as Man, machine and finished sub-components. Manufacturing is the term by which we
transform resource inputs to create Useful goods and services as outputs. Manufacturing
can also be said as an intentional act of producing something useful . The transformation
process is shown below-

input conventional process out put

Element Transformation Useful product

Material Machines Products
Data Interpretation Knowledge
Energy Skill Services
Variable cost Fixed cost Revenue

It s the phase after the design. Hence referring to the those values we will plan The
various processes using the following machines:-
i) Universal lathe
ii) Milling machine
iii) Grinding machine
iv) Power saw
v) Drill machine
vi) Electric arc welding machine

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 CHAPTER NO

MACHINE DESIGN

Introduction: This chapter describes some of the mathematical technique used by designers of

complex structures. Mathematical models and analysis are briefly described and detail

description is given of the finite – element method of structural analysis. Solution techniques

are presented for static, dynamic & model analysis problems. As part of the design procedure

the designer must be analyses the entire structure and some of its components. To perform

this analysis the designer will develop mathematical models of structure that are

approximation of the real structure, these models are used to determine the important

parameters in the design. The type of structural model the designer uses depends on the

information that is needed and the type of analysis the designer can perform.

Three types of structural models are

1. Rigid Members: The entire structure or parts of the structure are considered to be

rigid; hence no deformation can occur in these members.

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2. Flexible members: The entire structure or parts of the structure are modeled by

members that can deform, but in limited ways. Examples of this members trusses, beams

and plates.

3. Continuum: A continuum model of structure is the most general, since few if any

mathematical assumptions about the behavior of the structure need to be made prior to

making a continuum model. A continuum member is based on the full three – dimensional

equations of continuum models. In selecting a model of the structure,

The designer also must consider type of analysis to be performed. Four typical analysis

that designers perform are:

1. Static equilibrium: In this analysis the designer is trying to the determine the overall

forces and moments that the design will undergo. The analysis is usually done with rigid

members of model of structure and is the simplest analysis to perform.

2. Deformation: This analysis is concerned with how much the structure will move when

operating under the design loads. This analysis is usually done with flexible members.

3. Stress: In this analysis the designers wants a very detailed picture of where and at

what level the stresses are in the design. This analysis usually done with continuum

members.

4. Frequency : This analysis is concerned with determining the natural frequencies and

made shape of a structure. This analysis can be done with either flexible members of a

structure. This analysis can be done with either flexible members or continuum members

but now the mass of the members is included in the analysis

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Consideration in Machine Design

When a machine is to be designed the following points to be considered: -

i) Types of load and stresses caused by the load.

ii) Motion of the parts and kinematics of machine. This deals with the
type of motion i.e. reciprocating . Rotary and oscillatory.

iii) Selection of material & factors like strength, durability, weight,

Corrosion resistant, weld ability, machine ability is considered.

iv) Form and size of the components.

v) Frictional resistances and ease of lubrication.
vi) Convince and economical in operation.
vii) Use of standard parts.
viii) Facilities available for manufacturing.
ix) Cost of making the machine.
x) Numbers of machine or product are manufactured.

GENERAL PROCEDURE IN MACHINE DESIGN

The general steps to be followed in designing the machine are as followed.

i) Preparation of a statement of the problem indicating the purpose of the machine.

ii) Selection of groups of mechanism for the desire motion.
iii) Calculation of the force and energy on each machine member.
iv) Selection of material.
v) Determining the size of component drawing and sending for
manufacture.

vi) Preparation of component drawing and sending for manufacture.

vii) Manufacturing and assembling the machine.
viii) Testing of the machine and for functioning.

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 How do we design ?

Newcomers to design often feel unsure of themselves because the problems encountered are
unlike those previously solved successfully in other units such as Dynamics, Strength of
Materials &c. Although there is no mechanistic series of steps leading to the 'correct' solution
of a design problem, there are techniques which may be learned for tackling design with
confidence and with reasonable expectation of achieving a 'close- to- optimum' solution.
The illustrated Design Processes one such technique, and will form the model for design
throughout this course - however the success of the process, like that of any human endeavor,
depends largely on the attitude, skill and effort of the practitioner(s).

 It is not enough to unthinkingly accept the problem as given, instead the designer must
amplify and state the problem in terms which are both :
o broad, in not being constrained unnecessarily, and
o complete, in identifying everyone and everything likely to be affected by any
solution.

The problem statement contains information relevant to the next two activities :

 The designer, assisted by methods which enhance creativity, generates ideas for
possible solutions to the problem. This activity is inventive and often comprises a free
association of ideas based upon the designer's knowledge of solutions to analogous
problems. Ideas are recorded but not criticized in any way - the activity must be totally
non-judgmental since criticism cripples creativity.
When idea generation is exhausted, the result of this activity is a bank of many
potential solution candidates - some are later found to be good, some bad, some ugly.

 The designer must then specify the various :

o constraints ( such as 'must be shorter than 1m' ) to which every candidate must
conform if it is to be a viable solution, and
o criteria ( such as 'cost' and 'degree of safety' ) by means of which candidates
may later be compared with one another.

The constraints and criteria reflect the wish lists of all those identified as having a stake in the
problem, so this very detailed activity is really one of completing the problem in unequivocal
terms. This activity is left until after ideation has finished, thereby avoiding the stifling of
ideation by prior nit-picking detail.

34
 Design calculations
Design of Motor:

The purpose of a motor, regardless of the application, is to change electrical power to mechanical
power in order to provide rotational movement. Every application will have its own distinct
parameters for input and output power.

The diagram in Figure 1 provides a visual representation of the input and output parameters of a
motor.

The input electrical power can be in the form of a DC battery, AC line voltage, rectified AC line
voltage, or a wide variety of controls. Affected by application and environmental constraints
along with the necessary power needed to move a load, the input power will be volts, amps, and
frequency.

The output power is the motor speed and torque response required to accomplish the task. Figure
1: Motor Input and Output Functions

According to our project design we need variable speed motor , so as per manufactures catalogues
, we have studied the rpm factor and as per our costing we have selected sewing machine 1
motor .
35
Motor specification from ;

https://www.amazon.in/Al-Machine-Winding-Quality-
Controller/dp/B083C2XSWB/ref=asc_df_B083C2XSWB/?tag=googleshopdes-
21&linkCode=df0&hvadid=403986742714&hvpos=&hvnetw=g&hvrand=162854338757017
62726&hvpone=&hvptwo=&hvqmt=&hvdev=c&hvdvcmdl=&hvlocint=&hvlocphy=9062095
&hvtargid=pla-862282021134&psc=1&ext_vrnc=hi

Power transmitted by motor shaft, 

2πNT

P = -----------------

60

Where, N→ Rpm of shaft 1 = 8500

T →Torque transmitted

P→ Power Available = 50w

2π x 8500 x T

50 = ----------------------

60 ×1000

T =56.24 NM = 56 240.00 newton millimeters (N mm)

36
This is torque of motor

2 Speed Reduction of Motor

Belt drive transmission:

N1N 1=speed of motor shaft = 8500

N2N 2= speed of Output shaft
D1D 1=diameter of smaller pulley = 20mm
D2D 2= diameter of larger pulley = 40mm
Output Rpm = To find ?
We know,

N 1 D2
=
N 2 D1

37
 8500 40
=
N2 20

N2=4250 RPM

Power transmitted by shaft, after belt reduction , 

2πNT

P = -----------------

60

Where, N→ Rpm of shaft 1 = 4250

T →Torque transmitted

P→ Power Available = 50w

2π x 4250 x T

50 = ----------------------

60 ×1000

T =112.41 NM = 112000 newton millimeters (N mm)

38
 DESIGNING OF SHAFT

BENDING:

The material forces that are developed on any cross section of the shaft give rise to

stresses at every point. The internal or resisting moment gives rise to so called

bending stresses.

TORSION:

When the shaft is twisted by the couple such that the axis of the shaft and the axis

of the couple coincides, the shaft is subjected to pure torsion and the stresses at

any point of cross section is torsion or shear stresses.

COMBINED BENDING AND TORSION:

In practice the shaft in general are subjected to combination of the above two types

of stresses. The bending stresses may be due to following

1. Weight of belt

2. Pull of belts
39
3. Eccentric Mounting

4. Misalignment

The torsional movement on the other hand may be due to direct or indirect

twisting. Thus any cross-section of the shaft is subjected simultaneously of both

bending stresses and torsional stresses.

Following stresses are normally adopted in shaft design

Material = C 45 (mild steel)

σ ut = 320 N/mm2 ------------ PSG design data book.

factor of safety = 2

σt = σb = σ ut/ fos

= 320/2

= 160 N/mm2

σs = 0.5 σt

= 0.5 x 160

= 80 N/mm2

σs is less then allowable so our shaft design is safe.

T = 112000 from above shaft transmitted torque

40
 Fs allowable = 80 N/mm2

112000 = (3.14 / 16) x σs x d^3

The principal, real, root of:

d^3 = 7142.853

d = 19.2585614=20 mm

But standard size available is 20mm, therefore, from manufacturing CatLog . we

selected 20mm shaft .

Selection of bearing ;

For 20mm Shaft diameter we take standard breaking no. P204

P=pedestal bearing

2=spherical ball

=04=5 * 4 = 20mm Bore diameter of bearing

41
 V- Belt

The V-belts are made of fabric and cords molded in rubber and covered with fabric and rubber
as shown in Fig. These belts are molded to a trapezoidal shape and are made endless. These
are particularly suitable for short drives. The included angle for the V-belt is usually
from 30° to 40°. The power is transmitted by the wedging.

The wedging action of the V-belt in the groove of the pulley results in higher forces of
friction. A little consideration will show that the wedging action and the transmitted torque
will be more if the groove angle of the pulley is small. But a small groove angle

will require more force to pull the belt out of the groove which will result in loss of power and
excessive belt wear due to friction and heat. Hence the selected groove angle is a compromise
between the two. Usually the groove angles of 32° to 38° are used.

42
Components of Projects:

Sr.no Components Qty material Cost

1. shaft 1 MS 400/-

2. Motor 1 STD 1800/-

3. Frame 1 MILD 4000/-

STEEL
4. electromagne 2 - 1200/-
t
6. Belt pulley 1 std 2000/-
7. bearing 2 MS 600/-

10 Wires 1 - 500/-

11 Extras - - 4000/-
Total cost 17,500/
-

43
Results;
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. In research conducted by a truck
manufacturer, it was proved that the electromagnetic brake assumed 80 percent of the duty
which would otherwise have been demanded of the regular service brake.
Furthermore, the electromagnetic brake prevents the dangers that can arise from the
prolonged use of brakes beyond their capability to dissipate heat. This is most likely to occur
while a vehicle descending a long gradient at high speed. The installation of an
electromagnetic brake is not very difficult. 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.

44
 Advantages:
• No friction loss
• Less heat loss Less wear of components
• Fully electromagnetically controlled
• Great braking efficiency potential to regain energy lost in braking
• No need to change brake oils regularly
• No oil leakage Problem of brake fluid vaporization and freezing is eliminated
• Less maintenance cost
• Longer life span compare to other brakes

Applications:
• Failure to act as a holding device
• Usage of electric power for braking
• Less effective under very low velocities

45
 Future Scope:

• Electromagnetic brakes have numerous preferences over frictional slowing

mechanism. The blend of swirl present and attractive powers makes this brake more
successful. This brake can be utilized as assistant stopping mechanism in vehicle.
• The utilization of abs can be dismissed by utilizing a smaller scale controlled
electromagnetic framework. it can be utilized as a part of rail mentors to decelerate the
prepare moving in fast. Mix of these brakes expands the brake life and act like
completely stacked brakes.
• These brakes can be utilized as a part of wet condition, so there is no utilization of
against slipping instrument. it is completely electrically controlled which brings about
less mishaps. The braking power delivered in this brake is not as much as the plate
brakes. Subsequently, it can be utilized as an auxiliary or crisis slowing.
• This brake system can be use in two wheeler.
• Electromagnetic braking system can be used as a modern technology of braking in
automobile.
• Electromagnetic braking system will be used in all types of light motor vehicle like car
and heavy motor vehicle.

46
 REFERENCE

1. Avilov Andrey Gumenyuk Michael Rethmeier (2014), Experimental And Numerical

Investigation Of An Electromagnetic Weld Pool Support System For High Power
Laser Beam Welding Of Austenitic Stainless Steel, Elsevier ,Vol. 214, No. 3, Pp.578-
591.

2. Putman, P.T, (1986) „Capture Dynamics Of Coaxial Magnetic Brakes‟ Vol.6

3. G. Guna* , S. Dinesh ,()2016),Electro Magnetic Braking System, Journal Of Chemical
And Pharmaceutical Sciences,Issue No -5,Pp.427-428.
4. Sagar Wagh, 2Aditya Mahakode, 3Abhishek Mehta And 4Vaneela Pyla
(2017),”Electromagnetic Braking System In Automobile” International Journal Of
Trend In Research And Development, Volume 4(3),228-231.
5. John Willard Tielking, (1926) „Electromagnet Braking‟ Vol.3.
6. U. M. Saravanan1 T. R. Manoj 2 P. Meiyazhagan3 R. Mathi4 M. Murali
Manoharan5,I2018),‟ Design And Fabrication Of Contactless Braking System With
Eddy Current‟, International Journal For Scientific Research & Development| Vol. 6,
Issue 02,Pp.3623-3625.
7. Drkirpal Singh. Automobile Engineering And Technology, Vol 1
8. R.A.Barapte "Electromagnetic Engineering" Technova Educational Publication
9. Khurmi& Gupta “Machine Design” S Chand Publication.
10. Http://En.Wikipedia.Org/Wiki/Eddy_Current_Brake.
11. (M. Fujita, T. Tokumasu, T. Yamada, T. Hirose) Multidisciplinary Design Approach
For Electromagnetic Brakes. Ieee

47
12. Trans. Magn. 34 (5 Part 1) (1998) 3544–3547
13. (Kumar, K.P., Kadoli, R., Kumar, M.V.A.).Enhancement Of Braking System In
Automobile Using Electromagnetic Braking.
14. Industrial And Information Systems (Iciis), 2010 International Conference, July 29
2010-Aug. 1 2010.
15. (S. Anwar And B. Zheng) Brake Performance Analysis Of Abs For Eddy Current And
Electro-Hydraulic Hybrid Brake System”.

48