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UPES Dept. Mechanical Engineering B.

tech Minor End Sem report

Minor Project Report

On

ELECTRIC ENERGY GENERATIVE BRAKE


Submitted in partial fulfillment of requirements for the award of the

Degree of

Bachelor of Technology

In

Automotive Design Engineering

Under the guidance of

Mrs.Geetanjali Raghav Nagpal

(Assistant Professor)

Submitted By

Sanyam Goel Latchi Reddy Shubham

Rishi Rajak Muditum Nigam

Vibhor Girdhar

DEPARTMENT OF MECHANICAL ENGINEERING

UNIVERSITY OF PETROLEUM AND ENERGY STUDIES

Bidholi, Via Prem Nagar, Dehradun, Uttarakhand 248007

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UPES Dept. Mechanical Engineering B.tech Minor End Sem report

CONTENTS

Contents ........................................................................................................................................ ii

Chapter 01 FABRICATION PROCESSES INVOLVED IN EEGB .................................. 3

1.1 Ball Bearing ................................................................................................... 4

1.2 Electromagnet ................................................................................................ 7

1.3 Coil................................................................................................................. 8

Chapter 02 CALCULATING PARAMETERS ................................................................... 9

2.1 Design of Electromagnets .............................................................................. 10

2.2 Design of single coil ...................................................................................... 12

2.3 Design of charging circuit .............................................................................. 13

Chapter 03 LITERATUR REVIEW .................................................................................... 18

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UPES Dept. Mechanical Engineering B.tech Minor End Sem report

CHAPTER 1

FABRICATION PROCESSES INVOLVED IN EAB

1.1 Ball Bearings .......................................................................................................................... 4

1.2 Electromagnet ........................................................................................................................ 7

1.3 Coil......................................................................................................................................... 8

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1.1 BALL BEARING

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races.
The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads.
It achieves this by using at least two races to contain the balls and transmit the loads through the
balls. In most applications, one race is stationary and the other is attached to the rotating
assembly (e.g., a hub or shaft). As one of the bearing races rotates it causes the balls to rotate as
well.

PARTS OF BALL BEARING

1. ROLLER
The main parts of the ball bearing are the races and the balls. There is an outer race,
which goes into a bore, and the inner race, in which the shaft rides. The balls are placed
in between these two parts to create the rolling properties of the ball bearing.

2. CAGE
Cages, keep the balls separated and equally spaced. Cages are selected based on the
bearing size as well as the required performance.

MANUFACTURING
I. BEARING MFG BASIC PROCESS

Bearing Ring
Material Forging Turning Heat Treatment Grinding Assemble

Roller
Material Turning Heat Treatment Grinding Assemble

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Cage
Material Casting Turning Milling Deburring Assemble

II. FORGING

Forging is a manufacturing process involving the shaping of metal using


localized compressive forces. The blows are delivered with a hammer (often a power
hammer) or a die. Forging is often classified according to the temperature at which it is
performed: cold forging (a type of cold working), warm forging, or hot forging (a type
of hot working)

OBJECTIVES OF FORGING

To obtain the semi-finished ring.


To eliminate inner defect of metal.

BEARING RING FORGING PROCEDURE

Material

Heating Cutting Heating Press Staving Shaper Anneal Product

800-1100 C 800-1100 C 780-810 C

III. TURNING

Turning is a form of machining, a material removal process, which is used to create


rotational parts by cutting away unwanted material. The turning process requires
a turning machine or lathe, work piece, fixture, and cutting tool.

OBJECTIVES OF TURNING

To make bearing ring and roller be same shape with finished product.
To create good condition for grinding process.

BEARING RING TURNING

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Ring Inner face Outer face Grinding Marking Roller rail Oil groove
Product

ROLLER TURNING

Material Outer face Cutting Outer face Curvature Chamfer Product

IV. HEAT TREATMENT

Heat treating is a group of industrial and metal working processes used to alter the
physical, and sometimes chemical, properties of a material. The most common
application is metallurgical. ... Heat treatment techniques include annealing, case
hardening, precipitation strengthening, tempering, normalizing and quenching.

OBJECTIVES OF HEAT TREATMENT

To enhance mechanical performance.


To enhance bearing inner quality and hence life span.

BEARING RING AND ROLLER HEAT TREATMENT PROCESS

Ring Quenching Cleaning Tempering 2nd quenching Quenched semi-


finished

800-840 C 190-210 C Products

V. GRINDING

Grinding is an abrasive machining process that uses a grinding wheel as the cutting
tool.

OBJECTIVES OF GRINDING

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To make bearing ring and roller in accordance with the design requirements in size
and shape.
To prepare qualified rings and roller for bearing assembly.

BEARING RING GRINDING PROCESS

Quenched semi- Facing Inner or Roller Tempering Roller


Finished

Finished ring outer dia Channel channel

Grinding

1.2 ELECTROMAGNET MANUFACTURING

Magnets are formed using a modified powdered metallurgy process in which finely powdered
metal is subjected to pressure, heat, and magnetic forces to form the final magnet.

Powdered metal Pressing Heating Annealing Finishing Magnetizing

COPPER WIRE/COIL MANUFACTURING PROCESS

Drawing Process :
We take EC Grade Continuous Cast Copper rod of 8 mm dia , for drawing on our wire
drawing in to different gauge wires.

Annealing Process :
After drawing operation the coils of drawn wire are put in Electric Furnace in a pot for
getting it annealed soft wire.

Bunching / Stranding Process :


After the wire is annealed , it is wound on reels and are put for bunching / Stranding on
the wire Stranding / bunching machines for getting different size range of bunched
/Stranding wires and then passed through nozzling process for better surface of wire.

Braiding :

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After annealing process, the wire is wound on reels and put Braiding / Twisting machines
for making different sizes of braided wire in accordance with the specifications.

1.3 AXLE MANUFACTURING PROCESSES

PRE HEATING

It includes heating a billet at a heating station to a predetermined temperature.

FORGING
This involves forging the heated billet to the shape of axle

MACHINING
The product here transforms from the axle to the machined axle.

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CHAPTER 2

CALCULATING PARAMETERS

CONTENTS

2.1 Design of Electromagnet........................................................................................................ 10

2.2 Design of Single coil .............................................................................................................. 12

2.3 Design of Shaft ...................................................................................................................... 13

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UPES Dept. Mechanical Engineering B.tech Minor End Sem report

2.1 DESIGN OF ELECTROMAGNET

Electromagnets are important components in design of any circuitry. For successful design of
any electromagnets we require magnetic field, number of turns of coil, current in coil and its
shape and cross-section. For this reason following procedure is employed:

1. Assuming electromagnet as a toroid.

Toroid is a circular core on which large number of turns of wire is wound. If a solenoid is bent in
a circular shape it is known as toroid. It is the closest approximation horse shoe magnet. Hence it
is employed for calculation of magnetic field in EEGB.

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Figure 1: Magnetic field of toroid

The magnetic field in toroid can be easily calculated using Ampere circuital law. Suppose we
have to find the field at a distance r from center of toroid. By symmetry, the field will have equal
magnitude at all points of circle. Also the field is every where tangential to circle thus ,

Hence the magnetic field of the electromagnet is given by above expression where,

denotes permeability of iron core= 0.50133 x 105 H

N represents total number of turns.

I denote current in coil

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R represent radius of curvature of toroid.

2. Now, due to space limitations the radius of curvature can be maximum taken as 4 cm.

Therefore, if coil diameter is taken as 0.064516cm

Magnetic field is equal to B=

2.2 DESIGN OF SINGLE COIL

The coil is the rotating part of EEGB that produces current due to change of flux in it. It is
designed to yield maximum current and retarding field. It is shown in figure below:

Since if both AB and CD are placed in constant magnetic field, the emf induced in both wires is
same and hence no current is generated, there fore we must place one in magnetic field and other
must remain in air.

So, considering AB is placed in constant magnetic field B.

Since motor is running at a constant speed of 3000 rpm.

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Figure 2 Coil

Distance of E from center OE= r - l/2

Velocity with which E is rotating about O (v) = wr = 3000(r l/2)

Motional EMF = B(AB) v

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2.3 DESIGN OF CHARGING SYSTEMS

To prepare an efficient charging system which can charge a vehicles electric power source by
regenerating brake energy. Parts required are Capacitor, inductor, resistor, PCB (Printed circuit
board), Switch.
Processing includes Designing circuitry on PCB.

1. Charger for Electric Energy Generative Brake:

Conventional type: charging system includes a circuit consisting of rectifier, step up transformer,
battery, and EEGB assembly.

The current generated from the EEGB is AC But the output voltage will be low therefore a step
up transformer will step up the output voltage and And by using a bridge rectifier the AC output
will be converted into DC and will charge the battery.

Disadvantages:
Core losses are more in the transformer.
Circuitry includes implementation of transformer like electrical parts.

Charging system with chopper circuit: this system will include a circuit with resistor, battery,
voltage regulator, chopper circuit, EEGB assembly.
Because of the disadvantages of the above system we are applying a chopper circuit.Firstly a full
wave bridge rectifier will convert the AC output into DC then with the help of a DC to DC
chopper circuit the voltage will be stepped up.This is very compact and easy way of charging as
compared to above and have following advantages.

Advantages:
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No energy losses.
Can convert a low voltage.
Circuitry doesnt include heavy electrical parts.

This system will be an assist system as described earlier in reports. Hence it will work with our
vehicles main systems.
EEGB assembly which is our main device is also an assistance device with respect to our main
systems. It will work only in conditions when a driver wants to stop his vehicle. The energy
which is getting lost while taking the brakes now can be generated in form of energy which will
help in charging the main electrical power supply and decrease the load on actuators.

2. CIRCUITS

Figure 3 Charging circuit

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3. WORKING OF A DC TO DC STEP UP CHOPPER

The above figure shows the circuit diagram of a step up chopper.it consist of a switch, an
inductor, a source, a diode and a load.
Terms used in the circuit are:
TON It is the interval in which chopper is in ON state.
TOFF It is the interval in which chopper is in OFF state.
VS Source or input voltage.
VO Output or load voltage.
T Chopping period = TON + TOFF

When CH is ON it short circuits the load. Hence output voltage during TON is zero. During this
period inductor gets charged. So, VS = VL

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Where I is the peak to peak inductor current. When CH is OFF inductor L discharges through
the load. So, we will get summation of both source voltage VS and inductor Voltage VL as
output voltage, i.e.

Now, by equating (iii) & (iv).

As we can vary TON from 0 to T, so 0 D 1. Hence VO can be varied from VS to . It is


clear that output voltage is always greater than the input voltage and hence it boost up or increase
the voltage level.

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LITERATURE REVIEW

H.P. Agrawal et al [1]: This paper presentation explores the working principle of eddy current
brake mechanism, which can be analyzed by Maxwell 3D Transient solver. An eddy current
brake, like a conventional friction brake, is responsible for slowing an object, such as a train or a
roller coaster etc. Unlike the friction brakes, which apply pressure on two separate objects, eddy
current brakes slow an object by creating eddy currents through electromagnetic induction which
create resistance, and in turn either heat or electricity. For such a breaker, we give analytical
formulas considering end effects for its magnetic field, eddy current distribution, forces
according to the secondary relative permeability, and conductivity. The results given here are
purely analytic & applicable.

In this various types of eddy current damping mechanisms and the future of eddy currents with
some potential uses have been seen when a non-magnetic conductive material experiences a
time-varying magnetic field, eddy current continuous change in flux that induces an
electromotive force (e.m.f.), allowing the induced currents to regenerate and in turn produce a
repulsive force that is proportional to the velocity of the conductive metal. Since the currents are
dissipated, energy is being removing from the system, thus allowing the magnet and conductor to
function like a viscous damper.

Electromagnetic brakes are similar to electrical motors; non-ferromagnetic metal discs (rotors)
are connected to a rotating coil, and a magnetic field between the rotor and the coil creates a
resistance used to generate electricity or heat. When electromagnets are used, control of the
braking action is made possible by varying the strength of the magnetic field. A braking force is
possible when electric current is passed through the electromagnets. The movement of the metal
through the magnetic field of the electromagnets creates eddy currents in the discs. These eddy
currents generate an opposing magnetic field, which then resists the rotation of the discs,
providing braking force.

Nirmal Kannan et al [2]: An Electromagnetic Braking system uses Magnetic force to engage
the brake, but the power required for braking is transmitted manually. The disc is connected to a
shaft and the electromagnet is mounted on the frame .When electricity is applied to the coil a
magnetic field is developed across the armature because of the current flowing across the coil
and causes armature to get attracted towards the coil. As a result it develops a torque and
eventually the vehicle comes to rest. In this project the advantage of using the electromagnetic
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braking system in automobile is studied. These brakes can be incorporated in heavy vehicles as
an auxiliary brake. 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. An electric current can be used for making
temporary magnets known as electromagnets. An electromagnet works on the magnetic effect of
current. It has been found that if a soft iron rod called core is placed inside a solenoid, then the
strength of the magnetic field becomes very large because the iron ore is magnetized by
induction.

Electromagnetic brakes operate electrically, but transmit torque mechanically. This is why they
used to be referred to as electro-mechanical brakes. Over the years, EM brakes became known as
electromagnetic, referring to their actuation method. The variety of applications and brake
designs has increased dramatically, but the basic operation remains the same. Single face
electromagnetic brakes make up approximately 80% of all of the power applied brake
applications.

Bhushan Nandeshwar et al [3]: There are three parts to an electromagnetic brake: field,
armature, and hub (which is the input on a brake)[9]. Usually the magnetic field is bolted to the
machine frame (or uses a torque arm that can handle the torque of the brake). So when the
armature is attracted to the field the stopping torque is transferred into the field housing and into
the machine frame decelerating the load. This can happen very fast (1-3sec).Disengagement is
very simple. Once the field starts to degrade flux falls rapidly and the armature separates. A
spring(s) hold the armature away from its corresponding contact surface at a predetermined air
gap.

In electro-magnetic braking system we use electro-magnetic property due to which action of


braking will be done. In this system we used electro magnet iron plate, liners, tension spring and
Disc brake plate. The brake liners are attached with electro-magnet and iron plate individually
and both plates insert the disc plate as shown in figure and this plate is fixed with wheels. The
battery of minimum 12 volts is used for external power supply. In electro-magnetic braking
system we use silicon control rectifier (SCR). The gate pulse of SCR is fired and the output of
SCR is given to electro-magnet for braking the wheels. This SCR provides high current to our
electro-magnetic braking system, electro-magnet and attracts the iron plate towards itself. This
method opposes the motion of wheels. Here we have designed electro-magnetic coil and liner
system.

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