Introduction

The key objective of this project is to introduce and

prepare a working model of eddy current brakes. The
problems faced in conventional frictional brakes; i.e.
fading, overheating, very short life span etc. precedes
the motivation of the work, presented in the report,
followed by the statement of problem and objectives.

A brake is a device which inhibits motion. 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.
Other methods convert kinetic energy into potential
energy in such stored forms as pressurized air or
pressurized oil. Still other braking methods even
transform kinetic energy into different forms, for
example by transferring the energy to a rotating
flywheel.
Brakes are generally applied to rotating axles or
wheels, but may also take other forms such as the
surface of a moving fluid (flaps deployed into water or
air). 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 raised into the air during
landing.
Since kinetic energy increases quadratically with
velocity (K = mv2 / 2), an object traveling at 10
kilometers per second has 100 times as much energy
as one traveling at 1 kilometer per second, and
consequently the theoretical braking distance, when
braking at the traction limit, is 100 times as long. In
practice, fast vehicles usually have significant air
drag, and energy lost to air drag rises quickly with
speed.
Friction brakes on automobiles store braking heat in
the drum brake or disc brake while braking then
conduct it to the air gradually. When traveling downhill
some vehicles can use their engines to brake.
When the brake pedal is pushed the caliper containing
piston pushes the pad towards the brake disc which
slows the wheel down. On the brake drum it is similar
as the cylinder pushes the brake shoes towards the
drum which also slows the wheel down.
General Principle of Brake System
The principle of braking in road vehicles involves
the conversion of kinetic energy into thermal energy
(heat). When stepping on the brakes, the driver
commands a stopping force several times as powerful
as the force that spots the car in motion and
dissipates the associated kinetic energy as heat.
Brakes must be able to arrest the speed of a vehicle in
short periods of time regardless how fast the speed is.
As a result, the brakes are required to have the ability
to generating high torque and absorbing energy at
extremely high rates for short periods of time. Brakes
may be applied for a prolonged periods of time in
some applications such as a heavy vehicle
descending a long gradient at high speed. Brakes
have to have the mechanism to keep the heat
absorption capability for prolonged periods of time.
Conventional Friction Brake
The conventional friction brake system is composed of
the following basic components:
The “master cylinder” which is located under the hood
is directly connected to the brake pedal, and converts
the drivers’ foot pressure into hydraulic pressure.
Steel “brake hoses” connect the master cylinder to the
“slave cylinders” located at each wheel. Brake fluid,
specially designed to work in extreme temperature
conditions, fills the system. “Shoes” or “pads” are
pushed by the slave cylinders to contact the “drums”
or “rotors,” thus causing drag, which slows the car.
Two major kinds of friction brakes are disc brakes and
drum brakes.
Disc brakes use a clamping action to produce friction
between the “rotors” and the “pads” mounted in the
“caliper” attached to the suspension members. Disc
brakes work using the same basic principle as the
brakes on a bicycle: as the caliper pinches the wheel
with pads on both sides, it slows the vehicle.
Drum brakes consist of a heavy flat-topped cylinder,
which is sandwiched between the wheel rim and the
wheel hub. The inside surface of the drum is acted
upon by the linings of the brake shoes.
When the brakes are applied, the brake shoes are
forced into contact with the inside surface of the
brake drum to slow the rotation of the wheels.
Air brakes use standard hydraulic brake system
components such as braking lines, wheel cylinders
and a slave cylinder similar to a master cylinder to
transmit the air-pressure-produced braking energy to
the wheel brakes. Air brakes are used frequently when
greater braking capacity is required.
Brake Fading Effect
The conventional friction brake can absorb and
convert enormous energy values (25h.p. Without self-
destruction for an 5-axle truck, Reverdin 1974), but
only if the temperature rise of the friction contact
materials is controlled. This high energy conversion
therefore demands an appropriate rate of heat
dissipation if a reasonable temperature and
performance stability are to be maintained.
Unfortunately, design, construction, and location
features all severely limit the heat dissipation function
of the friction brake to short and intermittent periods
of application. This could lead to a ‘brake fade’
problem (reduction of the coefficient of friction, less
friction force generated) due to the high temperature
caused by heavy brake demands. The main reasons
why conventional friction brakes fail to dissipate heat
rapidly are as follows:
- Poor ventilation due to encapsulation in the road
wheels,
- Diameter restriction due to tire dimensions,
- Problems of drum distortion at widely varying
temperatures.
It is common for friction-brake drums to exceed 500 °C
surface temperatures when subject to heavy braking
demands, and at temperatures of this order, a
reduction in the coefficient of friction (‘brake fade’)
suddenly occurs (Grimm, 1985). The potential hazard
of tire deterioration and bursts is perhaps also serious
due to the close proximity of overheated brake
drums to the inner diameter of the tire.
Applications of Eddy Currents
Working of induction furnace is based on the heating
effects of Eddy Currents.

 Induction motors

 In Electromagnetic brakes

 In speedometers

 Electromagnetic shielding
  In Paddle Machine Brake

 In Turbine Brake

Voltage is induced when a magnet moves towards or

away from a coil, inducing a current in the coil. Faster
the magnet’s motion, the greater the induced current.

FIG 3.3 INDUCTION OF EDDY CURRENT

The induced voltage in a coil is proportional to the
product of the number of loops and rate at which the
magnetic field changes within the loops.
Advantages

1. The device should be used in heavy automobiles

as an accessory.

2. It is highly suitable at high speed.

3. It works on electricity and consumes very small

amount of power for a tiny time period.

4. Can be easily controlled and resettable.

5. Very light weight and low maintenance.

6. Consumes small space therefore installation is

easy.
 7. Running cost is small.

Disadvantages

1. Higher initial cost.

2. Very large amount of heat generation.

Conclusion

1. The eddy current brakes can be used as an

accessory in heavy automobiles with conventional
friction brakes; because it is the remedy of
problems faced by conventional brakes like
fading, skidding, high maintenance requirement,
low reliability, requirement of servo mechanisms,
breaking, higher weights etc.

2. This device is easy to install an cost incurred is

small so can be used in the automobiles
manufactured.