Electromagnetic Braking System Design

This project document details the design and development of an electromagnetic braking system for a vehicle model. It covers the challenges faced during the process, such as overheating of the core and wobbling of the bicycle chain used initially. The author discusses the implementation of a ferromagnetic core and a rubber belt solution to overcome these issues. Collaboration with a teammate is highlighted, especially in calculations and project discussions. Finally, the advantages of electromagnetic brakes over friction brakes are outlined, emphasizing their effectiveness in various conditions.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 2
KUPPA KRISHNA CHAITANYA

CE 2.1 Project Information
Name of the project: Electromagnetic Braking System
Location of the project: [Please fill]
Project Duration: [Please Fill]
Organization: [Please Fill]
Role and Designation during the time: Team Leader
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
The process of implementation of an electromagnetic braking system for a project is a
modern theory. The project has been implemented in a lot of light motor vehicle (LMV) as well
as in high motor vehicle (HMV). The use of the electromagnetic braking system would be able to
minimize the number of accidents that happen around the world. The braking system uses the
power of magnetic force on the wheels when the brakes are applied with the help of manual
force. The rake disc of the wheel is connected to the shaft and an electromagnetic kit along with
the frame. The braking system draws power in the form of electricity.
CE 2.2.2 Objectives developed for the project
I had worked as a team member and had worked on my portion of the project with correct
theoretical knowledge. Accidents on the roads due to brake failure or due to mistiming of the

application of the brakes has greatly increased in the recent days. This is the reason I had taken
an interest is the project and successfully developed it. I had helped my team mates to come up
with the best objectives which can be followed by us to complete the project in the given
timeline as well as provide the best quality work.
 To develop a braking system based on the theory of the working of electromagnets.
 To develop a strong force exerting braking system that can stop a fast moving vehicle in less
amount of time.
 To develop the best working emergency braking system for high motor vehicles and for short
vehicles.
CE 2.2.3 My area of work
I had helped in the understanding of the working model of the braking system of a
vehicle to my team mate and then acted as the team leader for the project. I had helped in the
designing of the braking system model. I had worked on the development of the electromagnetic
disc brakes based on the assumptions and calculation of my team mate. Apart from this I had
also tested the project when completed and then written out the clear documentation of the
working procedure of the project as well as the specifications of the project.

CE 2.2.4 Project Group
Figure 1: Team Member associated in this project
CE 2.2.5 My responsibilities throughout the project
For the completion of the project I was responsible for the development of the
electromagnetic braking system based on the specifications found by my team mate. Based on
the assumptions and calculations done by him I had collected the materials and designed the
braking system. I had also worked as the team leader to produce the best quality project. At the
end of the development of the project I had tested out the model made and then tabulated the test
results. I had then worked on the writing of the documentation of the project.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
On switching the project on the electromagnet gets energized from the AC supply of
battery. This helps in providing the braking system of the project. When the disc is not
energized, it is free to move and accelerates along with the weight of the shaft. When the energy
is supplied the disc is attracted to the electromagnet and the friction produced acts as the braking
system of the vehicle. The armature of the wheel moves as long as there is heat being generated
from the braking system. When the armature of the wheel gets the force applied on it the frame
of the wheel decelerates. The AC motor is used for rotating the shaft of the wheel with the means
of pulley system and rubber belt which is connected between the motor and the wheel of the
model.
CE 2.3.2 Engineering knowledge and skills applied in the project
The working theory of mechanical engineering was applied on the project for the
completion of the model. I had studied different research papers on the topic of electromagnetic
braking system to understanding the exact working criteria of the project. I had designed the
complete working model of the project. I had also initiated the team meetings with my team mate
and my project supervisor to clear out the issues which were being encountered during the
implementation of the project.
CE 2.3.3 Accomplishment and task performed
I had decided to design a working model with the help of motor and wheels to produce a
dummy working model of a vehicle. The model was designed based on the calculation work of
my team mate. Based on this I had used an AC motor, a disc, frame for the support of the model,

electromagnet for the braking system, belt for the rotation of the wheel with the help of the motor
and a long shaft to support the rotating wheel. The motor is to be considered as the engine of the
vehicle. I had implemented a rheostat along with the power supply and the motor. This helped
me to control the speed of the motor to understand if the braking system would work on all the
speed levels.
Figure 2: The 3D design of the frame of the project model.
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
The first issue which I had faced with the implementation of the electromagnets was the
heating up of the core of the magnet. This was causing the core to get expanded and contract
when the electricity was turned off. I found that the problem with the core would harm the
vehicle when implemented in large scale.

2.3.4.2 Solutions
For the problem with the heating up of the core, I had changed the core with different
materials. The core which I was using was of pure iron disc which was causing it to get heated
up. I then did a bit of research and found that the best core for electromagnets was to use a
ferromagnetic core. Once the ferromagnetic core was implemented and changing the turns of the
coil helped in reducing the heating up of the core.
CE 2.3.5 Plan to produce creative and innovative work
I had planned the use of rubber belt for the rotation of the wheel which is to demonstrate
a dummy vehicle wheel. The use of bicycle chain was making it difficult to move above a certain
speed level. On higher speed levels the chain was wobbling and broke off from the joints. I then
found the solution of using a rubberised belt which would keep a strong grip on the rotating
wheel. On higher speed levels the belt kept strong and did not break off.
CE 2.3.6 Collaborative work
I had collaborated with my team mate for the implementation of the electromagnetic
braking system. My team mate had helped in the working of the calculation part of the project
which was required to find the best products to use for the project and also to understand the
amount of force that is to be required for bringing the car at rest. I had also received help from
my project supervisor in understanding the problems which I had faced during the development
of the project. I had also initiated many of the team meetings with my team mate and my project
supervisor to discuss the progress of the project work.

CE 2.4 Project Review
CE 2.4.1 Project Overview
The major advantage of using the electromagnetic brakes in place of friction brakes is the
reduction of the “brake fading” problem with heavy vehicles. The implementation of the braking
system can be used as a secondary option for the use of the friction brakes in the vehicles. The
brakes can be used when the friction brakes fail to work. The braking system can also be
implemented in trains along with the friction brakes to bring trains moving at high speed to rest.
Apart from all the advantages these brakes can be used in wet condition which has been a major
risk factor in the form of skidding during rains. Thus the electromagnetic braking system can be
said to be an emergency braking system for all types of automobiles.
CE 2.4.2 My contribution to work
For the completion of the project I had helped in the designing and development of the
braking system based on the working specifications of my team mate. I had collected the
equipment’s and the parts of the project and compiled them into a single model. The components
that were collected were based on the specification which had been calculated by my team mate.
Apart from this I had also helped in the testing of the device once completed. I had also helped in
the documentation of the complete project which was then submitted to my university.