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Design and analysis of eddy current multi caliper disc brake

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 8, Issue 7, July 2017, pp. 267–274, Article ID: IJMET_08_07_031
Available online at http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7
ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication Scopus Indexed

DESIGN AND ANALYSIS OF EDDY CURRENT

MULTI CALIPER DISC BRAKE
G.V.R. Seshagiri Rao
Associate professors, Mechanical Engineering Department,
Institute of Aeronautical Engineering, Dundigal, Hyderabad-500043, India

G. Naveen Kumar
Associate professors, Mechanical Engineering Department,
Institute of Aeronautical Engineering, Dundigal, Hyderabad-500043, India

B. Prashanth
Assistant professor, Mechanical Engineering Department,
MLR Institute of Technology, Dundigal, Hyderabad-500043, India

D.V.Ramana Reddy
Associate Professor, Mechanical Engineering Department,
Vardhaman college of Engineering, Shamshabad, Hyderabad, India

ABSTRACT
In this paper “Eddy current Multi Caliper Disc Brake” uses the eddy currents
generated by the magnets influence on the disc rotor to retard the rotating disc. The
trends of the braking torque are observed by varying various parameters like angular
velocity, disc rotor thickness, magnetic field strength etc. that could affect the eddy
current braking. This is further studied using experimentation and is further optimized.
The brake, includes Conventional friction braking also, improving the chances of eddy
current braking. Several other improvements are included of the Split brake master
cylinder, usage of Floating calipers etc. With the help of permanent magnets and the
disc rotor being aluminium this can be used to generated currents with low power. But
in large scale uses this has large scope. This paper deals with Design and fabrication
of the eddy current multi caliper brake exclusively for the two wheeler vehicles. This
Brake is a combination of Foucault brake and a Conventional disc brake. This has both
the advantages of an Eddy current brake and a disc brake.
Key words: Disc Brake, Thermal Analysis, Eddy Current
Cite this Article: G.V.R. Seshagiri Rao, G. Naveen Kumar, B. Prashanth and
D.V.Ramana Reddy, Design and Analysis of Eddy Current Multi Caliper Disc Brake.
International Journal of Mechanical Engineering and Technology, 8(7), 2017, pp. 267–
274.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=8&IType=7

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 Design and Analysis of Eddy Current Multi Caliper Disc Brake

1. INTRODUCTION
The Disc brake is a wheel brake which moderates the revolution of the wheel by the erosion
caused by pushing brake cushions against a brake plate with an arrangement of calipers as
appeared in Fig.1.0 A brake is a mechanical device that hinders the movement by retaining
energy from a moving framework. It is utilized for reduction or ceasing a moving vehicle,
wheel, hub, or to keep its movement, frequently achieved by methods for friction.
Most brakes generally utilize friction between two surfaces squeezed together to change
over the dynamic energy of the moving article into heat, however different strategies for energy
transformation might be utilized. For instance, regenerative braking changes over a significant
part of the energy to electrical energy, which might be put away for later utilize. Different
techniques change over dynamic energy into potential energy put away in such structures as
pressurized air or pressurized oil. Vortex current brakes utilize attractive fields to change over
dynamic vitality into electric current in the brake plate, blade, or rail, which is changed over
into heat. Still other braking methods, even change motor vitality into various structures, for
instance by exchanging the vitality to a turning flywheel. Brakes are for the most part connected
to pivoting axles or wheels, however may likewise take different structures, for example, the
surface of a moving liquid (folds sent into water or air). A few vehicles utilize a mix of braking
components, for example, racing autos with both wheel brakes and a parachute, or planes with
both wheel brakes and drag folds raised into the air amid landing. At the point when the brake
pedal of an advanced vehicle with water driven brakes is pushed against the ace barrel, at last
a cylinder pushes the brake cushion against the brake circle which backs the wheel off. On the
brake drum it is comparable as the chamber pushes the brake shoes against the drum which
additionally moderates the wheel down. Fig 2.0 demonstrates the design of disc brake.
Electromagnetic brakes are in like manner regularly utilized where an electric engine is as
of now part of the hardware. For instance, numerous half breed fuel/electric vehicles utilize the
electric engine as a generator to charge electric batteries and furthermore as a regenerative
brake. Electromagnetic brakes moderate a protest through electromagnetic enlistment, which
makes resistance and thusly either warmth or power.

Figure 1.0 Disc brake Figure 2.0 Disc brake layout

Brake Caliper
The brake caliper is the gathering which houses the brake cushions and cylinders. The cylinders
are typically made of aluminum or chromed steel. Calipers are of two sorts, drifting or settled
as appeared in figure 3.0. A settled caliper does not move in respect to the plate and is in this
way less tolerant of circle flaws. It utilizes at least one sets of restricting cylinders to brace from
each side of the plate, and is more mind boggling and costly than a skimming caliper.

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 G.V.R. Seshagiri Rao, G. Naveen Kumar, B. Prashanth and D.V.Ramana Reddy

A skimming caliper (likewise called a "sliding caliper") moves regarding the circle, along
a line parallel to the hub of revolution of the plate; a cylinder on one side of the circle pushes
the internal brake cushion until it reaches the braking surface, at that point pulls the caliper body
with the external brake cushion so weight is connected to both sides of the circle.
In 2001, An eddy current reduction apparatus was designed by Tohru Kuwahara “An eddy
current reduction braking system in which with high speed rotation of a brake drum, magnetic
flux produced by magnets is concentrated to increase magnetic flux density and thereby
enhance braking force. According to the invention, there is provided a guide tube formed of a
non-magnetic material and having a hollow portion in the shape of a rectangle in section
disposed interiorly of a brake drum. A number of ferromagnetic pole pieces are disposed at
annularly equal intervals on an outer surface of the guide tube and at least one magnet support
tube is movably mounted in the hollow portion of the guide tube. Magnets are mounted on the
magnet support tube such that their polarities with respect to the ferromagnetic pole pieces are
alternately different.”
In 2002, Jeremie Lagarrigue invented and published systeme de freinage a disque
multipistons and explained it as “The invention concerns a multiple-piston disc brake system,
consisting of a double calliper equipped with two sets of six pistons diametrically opposite
relative to the axis of rotation, and a disc comprising two concentric tracks, the pistons of each
set, opposite in sets of three on either side of the disc, being arranged such that two pistons act
on the inner track and twice two pistons act on the outer track, a metering valve enabling to
delay the action of the two tracks. The invention generally concerns the industrial and
commercial field of the manufacture and distribution of braking equipment adaptable on all
rotating systems, but particularly designed for motorcycles and in particular powerful and fast
motorcycles such as racing motorcycles.”
In 2014, Christopher James Allington described his Braking mechanism as “An eddy-
current braking mechanism including a rotor, rotatable about a rotor axis; at least one
electrically conductive member coupled to the rotor for rotation therewith; at least one magnet
configured to apply a magnetic field extending at least partially orthogonal to the plane of
rotation of the conductive member, and characterized in that upon rotation of the rotor, the
conductive member is configured to move at least partially radially from the rotor axis into the
applied magnetic field.”

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 Design and Analysis of Eddy Current Multi Caliper Disc Brake

2. EDDY CURRENT MULTI CALIPER BRAKE

These brakes use the principles of both Eddy current brakes and Disc Brake i.e., this is a simple
yet elegant combination of the eddy current brake and a conventional Friction Disc brake. This
is a simple construction of an eddy current brake embedded in a disc brake for a functional
piece of braking tech in the Modern day automobiles. The construction is similar to that of a
disc brake, this contains a disc rotor, brake caliper and hydraulic mechanism but with a slight
change in materials and their actuation with a few additional parts. The disc rotor material is
considered to be an aluminium alloy and additionally two more Calipers are arranged over the
disc that accommodate the permanent magnets. The two Calipers are actuated initially which
function as an eddy current brakes and the third caliper is equipped with a general brake pad
which functions as a conventional disc brake caliper. Thus this is named as “Eddy Current Multi
Caliper Brake”.

3. DESIGN AND CALCULATION OF DISC BRAKE

Designed Eddy current Disc brake model using creo software and carry out the finite element
analysis (FEA) using ANSYS 14.5. Thus we obtained the values of shear stress, total
deformation, and convective heat transfer coefficient and temperature distribution on disc
brake.
Figure 4 shows the meshed model of disc brake for Thermal analysis .For analysis disc
brake was meshed using triangular surface meshes. The model is mashed and analyzed to get
the result of contact zone (disc-pad). This is very important because in this zone the temperature
rises considerably.

Figure 4 Meshed model of Disc Brake

Table 1 shows the Dimensions of Disc brake

Disc outer Diameter 190 mm

Disc inner Diameter 127mm
Disc Thickness 5 mm
Calliper piston diameter 29.21mm
Area of master cylinder 314.15mm2
Coefficient of friction 0.3
Weight distribution 60% to rear 40% to front
Static rolling radius front tyre 842.6mm
Static rolling radius rear tyre 766.04mm
Coefficient of friction of road and tyre 0.7
Brake torque 79.2 N-m
Braking effort 100 N
Deceleration 6.86 ms-2

Vehicle speed 60km/hr

Stopping distance 9.247m
Stopping time 2.32 sec

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 G.V.R. Seshagiri Rao, G. Naveen Kumar, B. Prashanth and D.V.Ramana Reddy

4. CALCULATIONS
Mass of vehicle = 225 kg
Velocity of vehicle = 16.66 m/s
Kinetic Energy = ½ *M*V2
=31225.005 Joules
Kinetic energy = Thermal Energy absorbed by brakes
Heat flux = Thermal Energy/ 2 * Area of rubbing surface
= 998241.84 W/m2
Braking Efficiency is 60:40 for front and rear so heat flux=998241.84*.6
=598945.108 W/m2

5. SELECTION OF MATERIAL
Using the analysis done on various materials with varying parameters theoretically, we can
determine that the best materials suitable for disc material are Tungsten, Titanium and
Aluminium. This result is also predicted initially using the density to specific conductivity ratio.
Keeping in mind the cost of the materials and availability we short listed the materials from
those to Aluminium, because aluminium is cheap of cost and is abundance. The added
advantages of easy machinability improve over choosing of material.
Even though Titanium and Tungsten are very good materials to conduct the project with but
The graphical data does not prove then to be a better material for conducting the
experimentation, their availability is limited to tool bits and casted shapes. These materials can
be applied for further applications. They give advantages over Aluminium in several aspects
like strength, stress concentration, thermal and electrical conductivity etc. even though bearing
various disadvantages as machining, material cost and others.

6. BRAKING TORQUE OF DISC BRAKE

When brake is applied using the brake pedal the brake pad engages and results in a stopping
force tangentially the total force excreted and the braking torque generated is proportional to
the rotor disc area and the brake pad area because this f=gives the frictional area for brakes to
be applied. This braking effort results in converting the mechanical energy into heat energy
resulting in reading or stopping the vehicle. The disc rotor material in our project needs to
sustain a very low speeds and low forces as most of the braking at high speeds is carried away
by the eddy current braking segment of the brake. Assumed values and parameters are as
follows.
Rotor Disc diameter (2R) = 280mm
Rotor disc material = Aluminium
Pad brake area (Ad) = 700mm2
Pad material = Asbestos
Coefficient of friction (Wet) = 0.07-0.13
Coefficient of friction (Dry) = 0.3-0.6
Maximum Temperature (Tmax) = 350˚C
Maximum Pressure (Pmax) = 1Mpa
Normal Force at inner face (Ni)
Ni= µi FRI Eq. 6.1

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 Design and Analysis of Eddy Current Multi Caliper Disc Brake

Where µi =Coefficient of friction=0.5

FRI= Pa X Pmax /2
Ni = (0.5)(0.5)(700 x 106)
Ni = 175 N = No (Normal Force at inner face)
Braking Torque (TB) TB= FR Eq. 6.2
F = Total Force = Ni + No = 350 N
R = Radius of rotor = 140 x 10-3 mm
TB= (350)(140 x 10-3) = 49 Nm

7. HEAT GENERATED BY DISC BRAKE

When brake is applied using the brake pedal the brake pad engages and results in a stopping
force tangentially the total force excreted and the braking torque generated is proportional to
the rotor disc area and the brake pad area because this f=gives the frictional area for brakes to
be applied. The engagement of the disc rotor and the brake pad results in generation of heat
which can be given by the equation as follows
Heat Generated Q = mCpΔT
m = mass of disc = 0.7 kg
Cp = Specific heat capacity = 800 J/Kg˚C
ΔT = Temperature difference = 15˚C Eq. 6.3
Q = mCpΔT = (0.7)(800)(15) =8400J
Disc area (Ad)= (R2-r2) =((0.14)2-(0.06)2) = 0.0503m2
Heat Flux (q) = Q/A = 8400/0.0503 = 33.42 KW/m2
Thermal Conductivity (k) of disc material (Iron) = 205 W/mk
Thermal gradient = Heat Flux(q)/ Thermal Conductivity (k) Eq.6.4
= 33422/205 = 163 m/k

8. HEAT GENERATED BY EDDY CURRENTS

Eddy currents generate resistive losses that alter a few types of electricity, consisting of kinetic
power, into heat. In transformer, we deliver alternating present day in the number one, this
alternating current produces alternating magnetizing flux inside the center and as this flux
hyperlinks with secondary winding, there will be brought about voltage in secondary, ensuing
present day to float thru the burden connected with it. a number of the alternating fluxes of
transformer; may additionally hyperlink with other undertaking components like metallic center
or iron frame of transformer and many others. As alternating flux hyperlinks with those
elements of transformer, there would be a locally brought about εmf. due to those εmf, there
would be currents so that you can flow into locally at that parts of the transformer. These
circulating current will not contribute in output of the transformer and dissipated as heat. This
type of energy loss is called eddy current loss of transformer. But in this brake we use these
eddy currents as braking parameters so the heat generated by these eddy currents are also to be
considered experimentally.

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 G.V.R. Seshagiri Rao, G. Naveen Kumar, B. Prashanth and D.V.Ramana Reddy

9. RESULTS & CONCLUSIONS

9.1. RESULTS
By comparing the results of both the experimental and analytical analysis, it was sure that the
pattern of graphs and values predict up to some extent. There is a limitation to this eddy current
brake, this cannot work under low speeds. According to analytical analysis the eddy current
brake functions at low speeds but ineffectively. Reviewing at the value from the experimental
analysis this is completely wrong, the eddy current brake doesn’t work at all at lower speed.
The use of conventional friction caliper helps to eradicate this problem completely. Even
though the observations are almost similar to others, there is an error experimental analysis
shows that the eddy current brake is effected by several other conditions like Local weather,
Temperature, Surrounding Magnetic or electromagnetic equipment, Vibrations in the body,
Magnets losing their Magnetic properties at high temperatures.
The Air being a bad conductor of electricity reduced the induction of eddy currents and
generation of opposing magnetic field. So the air gap is optimised to maximum extent possible
to the attained equipment.
The area of the magnet is further increased by adding more magnets on to the brake pads
which in turn increased the surface area effected by the magnetic field generating more and
more eddy currents. But there is a problem of heat dissipation when a disc is completely
enclosed by set of calipers.
Several other modifications of minute terms are made for the prototype to actually function
which are listed in this report. The Eddy current multi caliper brake will function as predicted
for other materials but the factors effecting the braking are also to be minimized.
This eddy Current multi caliper brake is designed for a motor bike, because a completely
functioning eddy current brake for cars is already developed which is sealed type eddy current
brake. This concealing of the brake cannot be done in two wheelers due to their less body and
space in the bike chassis.
The error is calculated as follows based on Angular velocity
%error= (Analtyical- Actual)/ Analytical x 100
=1.58-1.27/1.58 x 100
=19.6%

9.2. CONCLUSION
The Eddy Current Multi Caliper Brake consists of both the advantages and frictional disc brake
and Eddy Current brake. The Brake is further modified with optimised materials like
Aluminium alloys and Tungsten Alloys. The Tungsten alloys show the required properties of
an eddy current brake and satisfy the forces seen in a disc brake. These materials can be
implemented to commercial use.
Several other factors affecting the braking can also be minimised by using electromagnets
than permanent magnets. These can help the actuation of brake with ease when compared to
that of a complicated hydraulic actuated disc brake.

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 Design and Analysis of Eddy Current Multi Caliper Disc Brake

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