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SUPER MAGNET BRAKING SYSTEM

A PROJECT REPORT Submitted by

S.RUBAN K.SURESH KUMAR G.BHARTH KUMAR

090111605042 090111605049 100411605001

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

K.S.R. COLLEGE OF ENGINEERING, TIRUCHEGODE

ANNA UNIVERSITY: CHENNAI 600 025


MAY 2012

ANNA UNIVERSITY: CHENNAI 600 025


BONAFIDE CERTIFICATE
Certified that this project report SUPER MAGNET BRAKING SYSTEM is the bonafide work of

S.RUBAN K.SURESH KUMAR G.BHARTH KUMAR


who carried out the project work under my supervision.

090111605042 090111605049 100411605001

SIGNATURE DR.P.SENTHIL KUMAR HEAD OF THE DEPARTMENT Department of Mechanical Engineering K.S.R.College of Engineering, Tiruchengode-637215.

SIGNATURE MR.N.SHIVASANKARAN SUPERVISOR ASSOCIATE PROFESSOR Department of Mechanical Engineering K.S.R.College of Engineering, Tiruchengode-637215.

INTERNAL EXAMINER

EXTERNAL EXAMINER

SYNOPSIS:

Super magnet brake is the innovative concept based on the magnetic attraction of the conducting metals. A super magnet brake, like a conventional friction brake, is responsible for slowing an object, such as a train or a roller coaster. Unlike 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.

CHAPTER-1

INTRODUCTION
Brake (device), device used to slow and stop a rotating wheel and thus a moving vehicle. Brakes such as those on automobiles, trucks, trains, and bicycles use friction between a wheel and another object to slow the motion of the vehicle. The friction created by the rubbing together of two objects generates a large amount of heat. A brake system must be capable of dissipating the heat as rotating wheels slow, because excess heat can cause the brakes to lose their grip and fail.
TYPES OF BRAKES: Brakes may be broadly classified as 1.Friction Brake 2.Pumping Brake 3.Electromagnetic Brakes FRICTIONAL BRAKES: Frictional brakes are most common and can be divided broadly into "shoe" or "pad" brakes, using an explicit wear surface, and hydrodynamic brakes, such as parachutes, which use friction in a working fluid and do not explicitly wear.Typically the term "friction brake" is used to mean pad/shoe brakes and excludes hydrodynamic brakes, even though hydrodynamic brakes use friction. Friction (pad/shoe) 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 configurations are possible; and pads that pinch a rotating disc, commonly called a "disc brake". PUMPING BRAKES:

Pumping brakes are often used where a pump is already part of the machinery. For example, an internal-combustion piston motor can have the fuel supply stopped, and then internal pumping losses of the engine create some braking. Some engines use a valve override called a Jake brake to greatly increase pumping losses. Pumping brakes can dump energy as heat, or can be regenerative brakes that recharge a pressure reservoir called a hydraulic accumulator. ELECTROMAGNETIC BRAKES: Electromagnetic brakes are likewise often used where an electric motor is already part of the machinery. For example, many hybrid gasoline/electric vehicles use the electric motor as a generator to charge electric batteries and also as a regenerative brake. Some diesel/electric railroad locomotives use the electric motors to generate electricity which is then sent to a resistor bank and dumped as heat. Some vehicles, such as some transit buses, do not already have an electric motor but use a secondary "retarder" brake that is effectively a generator with an internal short-circuit. Related types of such a brake are eddy current brakes, and electro-mechanical brakes (which actually are magnetically driven friction brakes, but nowadays are often just called electromagnetic brakes as well).

CHARACTERISTICS OF BRAKES: Brakes are often described according to several characteristics including:

Peak force The peak force is the maximum decelerating effect that can be obtained. The peak force

is often greater than the traction limit of the tires, in which case the brake can cause a wheel skid.

Fade As a brake heats, it may become less effective, called brake fade. Some designs are inherently

prone to fade, while other designs are relatively immune. Further, use considerations, such as cooling, often have a big effect on fade.

Smoothness A brake that is grabby, pulses, has chatter, or otherwise exerts varying brake force

may lead to skids. For example, railroad wheels have little traction, and friction brakes without an anti-skid mechanism often lead to skids, which increases maintenance costs and leads to a "thump thump" feeling for riders inside.

Durability Friction brakes have wear surfaces that must be renewed periodically. Wear surfaces

include the brake shoes or pads, and also the brake disc or drum. There may be tradeoffs, for example a wear surface that generates high peak force may also wear quickly.

Weight Brakes are often "added weight" in that they serve no other function. Further, brakes are

often mounted on wheels, and unsprung weight can significantly hurt traction in some circumstances. "Weight" may mean the brake itself, or may include additional support structure.

Noise Brakes usually create some minor noise when applied, but often create squeal or grinding

noises that are quite loud. LIMITATIONS OF PRESENT BRAKING SYSTEM: Since there is direct metal to metal contact, it causes more friction. This high friction leads to wear and tear. Due to high wear and tear, the durability of brake is reduced.

When the drum are heated by hard braking, the diameter of the drum increases slightly due to thermal expansion, this means the brakes shoes have to move farther and the brake pedal has to be depressed further. It causes more noise due to friction. In electromagnetic braking system, if the battery gets failed due to overload,the complete brake system fails and it will not work. Another disadvantage of present brakes is their relative complexity. As a result of this increased complexity, maintenance of this braking systems are generally more time-consuming

PROPOSALS OF OUR PROJECT: To overcome some of the limitations of present braking system, we use supermagnet to reduce the friction. Since there is no metal to metal contact, the friction doesnt occurs. Instead of friction, we use magnetic attraction created by supermagnet which is used to slow down or stop the rotating shaft. Supermagnet braking system requires only supermagnet and the rotating iron plate, so designing this system is simple.

We are using supermagnet instead of brake shoes in friction brakes and electromagnet in electromagnet braking system.

A magnet is a material or object that produces a magnetic field. This magnetic field is invisible but is responsible for the most notable property of a magnet: a force that pulls on other ferromagnetic materials like iron and attracts or repels other magnets. A permanent magnet is an object made from a material that is magnetized and creates its own persistent magnetic field. An everyday example is a refrigerator magnet used to hold notes on a refrigerator door. Materials that can be magnetized, which are also the ones that are strongly attracted to a magnet, are called ferromagnetic (or ferrimagnetic). These include iron, nickel, cobalt, some alloys of rare earth metals, and some naturally occurring minerals such as lodestone. Although ferromagnetic (and ferrimagnetic) materials are the only ones attracted to a magnet strongly enough to be commonly considered magnetic, all other substances respond weakly to a magnetic field, by one of several other types of magnetism.

Ferromagnetic materials can be divided into magnetically "soft" materials like annealed iron which can be magnetized but don't tend to stay magnetized, and magnetically "hard" materials, which do. Permanent magnets are made from "hard" ferromagnetic materials which are subjected to special processing in a powerful magnetic field during manufacture, to align their internal microcrystalline structure, making them very hard to demagnetize. To demagnetize a saturated magnet, a certain magnetic field must be applied and this threshold depends on coercivity of the respective material. "Hard" materials have high coercivity whereas "soft" materials have low coercivity. An electromagnet is made from a coil of wire which acts as a magnet when an electric current passes through it, but stops being a magnet when the current stops. Often an electromagnet is wrapped around a core of ferromagnetic material like steel, which enhances the magnetic field produced by the coil. The overall strength of a magnet is measured by its magnetic moment, or alternately the total magnetic flux it produces. The local strength of the magnetism in a material is measured by its magnetization.

CHAPTER -II LITERATURE SURVEY

The history of the automobile begins as early as 1769, with the creation of steam-powered automobiles capable of human transport [1] In 1806, the first cars powered by internal combustion engines running on fuel gas appeared, which led to the introduction in 1885 of the ubiquitous modern gasoline- or petrol-fueled internal combustion engine. Cars powered by electricity briefly appeared at the turn of the 20th century but largely disappeared from commonality until the turn of the 21st century, when interest in low- and zero-emissions transportation was reignited. Olden days invention in braking system Limitation and proposed system Advantage
The drum brake, as it is now known, became all-dominant in the United States. In Europe, particularly in Great Britain, it had to share the stage with disc brakes. Disc brakes became more or less standard on European cars during the '50s, about 20 years before they were adopted by American manufacturers in 1973. This is ironic, because the spot-type disc brake is an American invention. In 1898, Elmer Ambrose Sperry of Cleveland designed an electric car having front-wheel disc brakes. He made a large disc integral with the hub on each wheel. Electromagnets were used to press smaller discs, lined with a friction material, against spots on the rotating disc to bring the wheel to a stop. Springs retracted the spot discs when current was interrupted.

Meanwhile in Great Britain, a patent was issued in 1902 to F. W. Lanchester for a nonelectric spot disc braking system that's similar in principle to what we have today. The biggest problem that Lanchester encountered was noise. Metal-to-metal contact between his copper linings and the metal disc caused an intense screech that sent chills through anyone within earshot. As roads improved and cars began to be driven at high speeds, manufacturers recognized the need for even greater braking power. One solution to the problem became apparent during the Elgin road Race of 1915. A Duesenberg took the flats at 80 mph, then screeched to a virtual crawl to negotiate the hairpin curves. Duesenberg's secret for such magnificent braking power was to simply use an internal brake on each front wheel as well as each rear wheel. In 1918, a young inventor named Malcolm Lougheed (who later changed the spelling of his name to Lockheed) applied hydraulics to braking. He used cylinders and tubes to transmit fluid pressure against brake shoes, pushing the shoes against the drums. In 1921, the first passenger car to be equipped with four-wheel hydraulic brakes appeared -- the Model A Duesenberg. As for the antilock (antiskid) units now available in the U.S., they are hardly new. The first practical antiskid braking system, named Maxaret, was developed in 1958 by the Road Research Laboratories in Great Britain and was first applied to the Jensen FF sports sedan in 1966. Good driving in traffic is shown by making the minimum use of brakes. The strain on passengers amounts to intense nervousness when the car is constantly driven so that the least alteration of direction or of pace on the part of any vehicle ahead results in the violent application of the brake."

CHAPTER-III DESIGN OF EQUIPMENT AND DRAWING

3.1 BRAKE SYSTEM Every car has a service brake system, operated by foot pressure on a pedal while the car is in motion, and a hand-operated emergency brake system employed for parking and as a backup to the service brake system. The service brake system uses fluid forced by pistons through small flexible pipes (brake lines) to transmit the pressure of the driver's foot to the brake mechanisms

3.3 MACHINE COMPONENTS The super magnet braking system is consists of the following components to full fill the requirements of complete operation of the machine. Motor Magnet Round disc plate

Iron Plate with guiding system

Battery MOTOR
In any electric motor, operation is based on simple electromagnetism.

A current-carrying conductor generates a magnetic field; when this is then placed in an external magnetic field, it will experience a force proportional to the current in the conductor, and to the strength of the external magnetic field.

MAGNET:

A magnet is a material or object that produces a magnetic field. This magnetic field is invisible but is responsible for the most notable property of a magnet: a force that pulls on other ferromagnetic materials, such as iron, and attracts or repels other magnets. A permanent magnet is an object made from a material that is magnetized and creates its own persistent magnetic field. An everyday example is a refrigerator magnet used to hold notes on a refrigerator door. Materials that can be magnetized, which are also the ones that are strongly attracted to a magnet, are called ferromagnetic (or ferrimagnetic). These include iron, nickel, cobalt, some alloys of rare earth metals, and some naturally occurring minerals such as lodestone. Although ferromagnetic (and ferrimagnetic) materials are the only ones attracted to a magnet strongly enough to be commonly considered magnetic, all other substances respond weakly to a magnetic field, by one of several other types of magnetism.

ROUND DISC PLATE

A round disc plate in which small, small magnets are encrypted on it. It is made to rotate by means of a motor coupled to it. The motor centre shaft is connected to the shaft from the round disc plate.

IRONPLATE WITH GUIDING SYSTEM: Two iron plates separated by some distance which is to be larger than that of the thickness of the disc plate provided.Ironplate is guided by the guiding system. It will slide up to the circular disc. BATTERY:

Battery is the input device which is used to store the electricity .The stored electricity is used to run the motor.The capacity of battery is 6 volts.

Fig No. : 01 Super magnet Braking System

CHAPTER-IV WORKING PRINCIPLE


The super magnet brake consists of a round disc plate in which small, small magnets are encrypted on it. It is made to rotate by means of a motor coupled to it. The motor centre shaft is connected to the shaft from the round disc plate. Two iron plates separated by some distance which distance to be larger than that of the thickness of the disc plate provided the metal iron plates will slide up to the circular disc. When, the motor starts running, the disc plate will also rotate tin the same direction to the direction of the motor. While it reached the certain speed, the iron plates is made to slide on the rail such that the round disc will be right in between the two iron plates. The moment when the iron plates moved towards the disc, the rotating disc will slower down and finally it stops.

CHAPTER -V MERITS AND APPLICATIONS


MERITS

The super magnet brake does not have any mechanical contact with

the rail, and thus no wear, and creates no noise or odor.


Super magnet brake can be used at high speeds both for emergency

braking and for regular braking. The weight of this system is less when compared to other braking systems. There is no need of any external power supply .So, the system will continue to work even the power supply is cutoff. Since there is no brake shoe or brake drums are used, the maintenance is easy.

CHAPTER-VI APPLICATIONS
APPLICATION

Supermagnet braking system can be used in trains and in trailer cars

It is also used to stop the electric motors. This is used in roller coasters.

It can be used as a speed control unit in turbine.

CHAPTER-VII

LIST OF MATERIALS
FACTORS DETERMINING THE CHOICE OF MATERIALS
The various factors which determine the choice of material are discussed below. 1. Properties: The material selected must posses the necessary properties for the proposed application. The various requirements to be satisfied Can be weight, surface finish, rigidity, ability to withstand environmental attack from chemicals, service life, reliability etc. The following four types of principle properties of materials decisively affect their selection a. Physical b. Mechanical c. From manufacturing point of view d. Chemical The various physical properties concerned are melting point, thermal Conductivity, specific heat, coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile, Compressive shear, bending, torsional and buckling load, fatigue resistance, impact resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance and sliding properties. The various properties concerned from the manufacturing point of view are, Cast ability Weld ability Bribability Surface properties Shrinkage Deep drawing etc. 2. Manufacturing case: Sometimes the demand for lowest possible manufacturing cost or surface qualities obtainable by the application of suitable coating substances may demand the use of special materials. 3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For example, it would never be desirable to go casting of a less number of components which can be fabricated much more economically by welding or hand forging the steel. 4. Availability of Material: Some materials may be scarce or in short supply.it then becomes obligatory for the designer to use some other material which though may not be a perfect substitute for the material designed.the delivery of materials and the delivery date of product should also be kept in mind. 5. Space consideration: Sometimes high strength materials have to be selected because the forces involved are high and space limitations are there. 6. Cost: As in any other problem, in selection of material the cost of material plays an important part and should not be ignored. Sometimes factors like scrap utilization, appearance, and nonmaintenance of the designed part are involved in the selection of proper materials.

CHAPTER-VIII CONCLUSION

The project carried out by us will make an impressing mark in the field of automobile. This project has also reduced the cost involved in the concern. The project has been designed to perform the required task taking minimum time.

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