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METHODS ENRICHING POWER & ENERGY DEVELOPMENTS (MEPED'13) April 12th, 2013

ISSN:-2230-7850

ORIGINAL ARTICLE

BRAKE PAD ACTUATION USING ELECTROMAGNETIC COILS


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BHARATHRAM M ,2 KIRUBHAHAR PRAVEEN P , 3CHANDRAKALA D , 4 AKSHAY JALAN , 5GOWTHAM RAM N . UG student, **assistant professor electrical and electronics engineering easwari engineering college

Abstract: A brake is a mechanical device which inhibits motion. Most commonly brakes use friction to convert kinetic energy into heat, though other methods of energy conversion are also employed. For example regenerative braking converts much of the energy to electrical energy, which may be stored for later use. Other methods convert kinetic energy into potential in such stored forms as pressurized air or pressurized fluid. Eddy current brakes use magnetic fields to convert kinetic energy into electric current in the brake disc, fin, or rail, which is converted into heat. Nowadays the majority of the automobiles which we use have braking system which operates on the principle of hydraulics or Air-over hydraulics. This paper is about designing a braking system which can be powered using electromagnetic coils. The force produced by the magnetic coils will actuate the brake pads and will in turn stop the rotating disc. This will be yet another method of applying the brake which will be very efficient and accurate. KEYWORDSEddy current, Hydraulics, Electromagnetic coils. I.INTRODUCTION Brakes are one the most essential component of an auto mobile. Brakes are used to inhibit the motion of a vehicle and to bring it to a stop. Brakes are generally applied to rotating axles or wheels. Some vehicles use a combination of braking mechanisms, such as drag racing cars with both wheel brakes and a parachute, or airplanes with both wheel brakes and drag flaps are raised into the air during landing. The most common type of brakes are frictional and electromagnetic each with their own working principle. EXISTING METHOD Braking system is generally classified based upon the principle of operation. The two major type of brake are frictional and electromagnetic retarder Frictional brakes: A friction brake is a type of automotive brake that slows or stops a vehicle by converting kinetic energy into heat energy, via friction. The heat energy is then dissipated into the atmosphere. In most systems, the brake acts on the vehicle's roadwheel hubs, but some vehicles use brakes which act on the axles or transmission. Friction brakes may be of either drum or disc type. Friction brakes are often rotating devices with a stationary pad and a rotating wear surface. Common configurations include shoes that contract to rub on the outside of a rotating drum, such as a band brake; a rotating drum with shoes that expand to rub the inside of a drum, commonly called a "drum brake", although other drum

Indian Streams Research Journal

BRAKE PAD ACTUATION USING ELECTROMAGNETIC COILS

configurations are possible; and pads that pinch a rotating disc, commonly called a "disc brake". The friction brakes are generally applied using hydraulic fluid. Electromagnetic retarder brakes: A retarder or electromagnetic brake is a device used to augment or replace some of the functions of primary friction-based braking systems, usually on heavy vehicles. Retarders serve to slow vehicles, or maintain a steady speed on declines, and help prevent the vehicle 'running away' by accelerating down the decline. They are not usually capable of bringing vehicles to a standstill, as their effectiveness diminishes as vehicle speed lowers. They are usually used as an additional 'assistance' to slow vehicles, with the final braking done by a conventional friction braking system. As the friction brake will be used less, particularly at higher speeds, their service life is increased. PROPOSED METHOD Each braking system has their own individual advantages and disadvantages; while the frictional brake has high braking force its service life is less and requires frequent maintenance. The electromagnetic brake has a rugged design and has a long service life but the braking force produced by them is very less and hence it cannot serve as a primary braking system. The objective of our paper is to encompass the advantages of both the frictional and electromagnetic braking system by designing a hybrid braking system. This braking system will use brake pad which are used in frictional brakes but will use the force generated from electromagnetic coils to drive the brake pads. Thus the brake can serve for a longer period of time with very less maintenance. BLOCK DIAGRAM

Fig1

Fig 2

BRAKE PAD ACTUATION USING ELECTROMAGNETIC COILS

The Fig 1 & 2 consists of the following blocks 1)Electronic control unit: The Primary function of the ECU is to control and regulate the various input signals. The ECU mainly consists of a PIC16F877 microcontroller which is powered by an external +5vDC supply. It receives input signal from the pedal and produces desired output current accordingly. This output current is fed to the electromagnetic coil which produces an output force based upon the input current. 2)Pedal control: The pedal is nothing but a potentiometer foot control pedal. The foot pedal is used for controlling the braking force produced by the coils. The pedal varies the resistance depending upon the amount of pedal force supplied and in turn controls the output current. Electromagnetic coil: The electromagnetic coil used for this application is a solenoid coil. A solenoid is a type of coil which is wound in shape of a helix. A plunger is place in the middle of the helix. This plunger is made of magnetic substance. When the solenoid is energised the plunger is either pulled in or pushed out depending upon the orientation of the solenoid and the poles of the plunger. The brake pads are attached to the ends of the plunger so when the coil is energised the plunger is pushed out on to the brake disc and the disc is stopped due to friction.

DC motor: A DC motor is device which converts input electrical energy (Direct current) into rotating mechanical energy. DC motors are widely used due to its small size and low power consumption. Here we use the DC motor to rotate the brake disc to simulate its operating condition. Relay circuit: A relay is an electrically operated which is operated using another electrical circuit. Relays have a coil which works on 12V dc power supply and provides DPDT action as an output. Here we use a relay to cut the power supply to the motor when the brake is applied. This prevents the motor from getting damaged. Power supply: The power supply is used for powering the microcontroller. The 230v input AC supply is rectified and stepped down to +5v DC which is supplied to the microcontroller. Another power supply is connected to the relay which operates at 12v. Deceleration sensor: It measures the rate at which the disc decelerates and stops. It is used for the monitoring the rotor's position. CALCULATION The force generated by the coil is calculated using the formula F = (Fm)2 0 A / (2 g2) F = (N*I)2 0 A / (2 g2), Where: 0 = 4? 10-7

BRAKE PAD ACTUATION USING ELECTROMAGNETIC COILS

F is the force in Newtons N is the number of turns I is the current in Amps A is the area in length units squared g is the length of the gap between the solenoid and a piece of metal. The force required to stop a vehicle of weight 150kg moving at 65kmph within 6 seconds is 450 newtons Force = mass*acceleration Mass = 150kg Acceleration = (18-0)/6 = 3m/s Force = 150*3 = 450 Newtons In order to stop the vehicle we must design a coil capable of producing force greater the required force Sample calculation I (current in amps) = 25 amps Number of turns = 150 turns Radius of the coil = 0.5 cm Area of the coil = .785398 cm2 Airgap length = 0.1 cm Force produced by solenoid: F = (150*25)2 *4? 10-7 * 0.785398/ (2*0.1)2 F = 694 Newtons SIMULATION This simulation shows the current produced equivalent to the force on the pedal. The input from the pedal is sensed by the microcontroller which sends corresponding output to the MOSFET. The MOSFET varies the output current based upon the input.

The graph shows the output equivalent current waveform for the pedal pressed . OPERATION The operation of the braking system is similar to the traditional braking system where the braking system is controlled using a foot pedal. The DC motor connected to the brake disc will rotate the disc in

BRAKE PAD ACTUATION USING ELECTROMAGNETIC COILS

order to simulate its operating condition. When the foot pedal is pressed it sends out a signal to the PIC16F877 microcontroller. This signal is varied using the potentiometer present within the pedal. The microcontroller senses this input signal and varies the current supplied to the electromagnetic coil accordingly. The coil consists of a plunger with brake pads attached to them in one end. When the coil is energised the plunger is pushed forward and on to the brake disc. The friction between the brake pad and the disc retards the disc and brings the vehicle to a stop. The spring present within the coil will pull back the plunger once the current to the coil is removed. ADVANTAGES Faster response time High efficiency High degree of safety Better control over the system Low maintenance due to ruggedness of parts APPLICATIONS The main intent of this system is to improve the existing brake system by implementing the concept of electromagnetism. This technology can also be applied in any other rotating drive systems. CONCLUSION This paper proves the possibility of designing a novel electromagnetic braking system for automobiles which can be much more efficient than the traditional braking system. By carefully designing the coils we can achieve the required braking force. REFERENCES [1]Ahfock, A., Toowoomba, QLD Wells, C.G. A practical demonstration of electromagnetic braking [2]Power Engineering Conference, AUPEC 2007 Australasian Universities, Date of Conference: 9-12 Dec. 2007. [3]Kumar, K.P., Kadoli, R., Kumar, M.V.A. Mechanical and magnetic analysis of magnetostrictive disc brake system. Industrial and Information Systems (ICIIS), 2010 International Conference on, Date of Conference: July 29 2010-Aug. 1 2010. [4]Collan, H.K., Espoo, Vinnurva, Rapid optimization of a magnetic induction brake Magnetics, IEEE Transactions on Date of Publication: Jul 1996, Volume: 32, Issue: 4, Page(s): 3040 3044. [5]Basics on electromagnetic braking http://en.wikipedia.org/wiki/Electromagnetic_brake [6]General principle of electromagnetic braking http://scholar.lib.vt.edu/theses/available/etd5440202339731121/unrestricted/CHAP1_DOC.pdf [7]Existing alternative braking system http://www.bipom.com/documents/student_projects/fall2006/Electromagnetic%20Braking%20System .pdf [8]An IEEE paper titled Electric pulse magnetic braking using mechatronics http://www.creativeworld9.com/2011/04/abstract-and-full-paper-on-electric.html [9]Construction and working of an electromagnetic coil http://www.projects-forum.com/ThreadFabrication-of-Electro-Magnetic-braking-System-For-Automobile [10]Functions, advantages and disadvantages of hydraulic braking system http://www.ignou.ac.in/upload/Unit-6-61.pdf [11]Working of an electromagnetic retarder http://en.wikipedia.org/wiki/Retarder_%28mechanical_engineering%29 [12]Operation of a disc brake http://auto.howstuffworks.com/auto-parts/brakes/brake-types/discbrake2.html

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