EDDY CURRENT BREAKING

CHAPTER 1

INTRODUCTION

Many of the ordinary brakes, which are being used now days, stop the vehicle by means
of mechanical blocking. This causes skidding and wear and tear of the vehicle. And if the speed
of the vehicle is very high, the brake cannot provide that much high braking force and it will
cause problems. These drawbacks of ordinary brakes can be overcome by a simple and
effective mechanism of braking system The eddy current brake. It is an abrasion-free method
for braking of vehicles including trains. It makes use of the opposing tendency of eddy current

Eddy current is the swirling current produced in a conductor, which is subjected to a

change in magnetic field. Because of the tendency of eddy currents to oppose, eddy currents
cause energy to be lost. More accurately, eddy currents transform more useful forms of energy
such as kinetic energy into heat, which is much less useful. In many applications, the loss of
useful energy is not particularly desirable. But there are some practical applications. Such an
application is the eddy current brake.

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CHAPTER 2

EDDY CURRENT

2.1 PRINCIPLE OF OPERATIONS

Eddy current brake works according to Faradays law of electromagnetic induction.

According to this law, whenever a conductor cuts magnetic lines of forces, an emf is induced in
the conductor, the magnitude of which is proportional to the strength of magnetic field and the
speed of the conductor. If the conductor is a disc, there will be circulatory currents i.e. eddy
currents in the disc. According to Lenzs law, the direction of the current is in such a way as to
oppose the cause, i.e. movement of the disc.

Essentially the eddy current brake consists of two parts, a stationary magnetic field
system and a solid rotating part, which include a metal disc. During braking, the metal disc is
exposed to a magnetic field from an electromagnet, generating eddy currents in the disc. The
magnetic interaction between the applied field and the eddy currents slow down the rotating
disc. Thus the wheels of the vehicle also slow down since the wheels are directly coupled to the
disc of the eddy current brake, thus producing smooth stopping motion.

Fig No: 2.1 Eddy Current Induced in a Conductor

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2.2 CONSTRUCTION

Essentially an eddy current brake consists of two members, a stationary magnetic field
system and a solid rotary member, generally of mild steel, which is sometimes referred to as the
secondary because the eddy currents are induced in it. Two members are separated by a short
air gap; theyre being no contact between the two for the purpose of torque transmission.
Consequently there is no wear as in friction brake.

Stator consists of pole core, pole shoe, and field winding. The field winding is wounded
on the pole core. Pole core and pole shoes are made of east steel laminations and fixed to the
state of frames by means of screw or bolts. Copper and aluminum is used for winding material
the arrangement is shown in fig. 1. This system consists of two parts.

1. Stator
2. Rotor

Stator:-
It is supported frame members of the vehicle chassis. It has introduced magnetic poles
energized by windings. Current is supplied to the winding from the battery.
Rotor:-

It is a rotating disc, which is fitted on the line of crankshaft with small air gap to stator.
When disc rotates a flux change occur in the section of the disc passing the poles of stator. Due
to the flux change there is a circulatory or eddy current in the disc around the magnetic lines of
force. The effect of this eddy current induces N and S poles at the surface of the disc. Then
there will be a drag or braking effect in between eddy current induced poles and magnetic
poles in the stator. By changing current from the battery we can change the braking force. In
this breaking system kinetic energy of the vehicle is converted to heat and this heat is dissipated
through the rotating disc.

Total resistance of field winding

R = L/A

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Where,
L = total length of field winding in meter.
= Resistivity of the wire in ohm meter
A = the area of cross section of field winding in m2
Total no: of terms = total length /mean length of one term
The rotor is a rotating disc on shaft, which is placed very near to the stator with small
air gap (1 mm to 2 mm). Rotating disc may be one or both side of stator.

The two units have common ring member, poles cores on which winding are provided
being fixed to ring number. If a malleable casting is employed, then the pole core could be cast
integrally with the right. After fitting the windings on the cores, poles shoes are fitted to
provide pole faces of appropriate shape and area. The rotor disc should be provided with
properly designed fins for faster heat removal. The magnetic circuits of the two units are
substantially the same, non-undue and thrust would be imposed on the motor bearings. Slight
axial displacement of rotor could however, cause quite appreciable discrepancy, the air gap of
two units. The effect would be to increase the magnetic pull in one air gap and diminish it on
other which could give to rise to excessive and thrust on rotor bearing to overcome the inherent
defect, the air gaps of both units could be put in series by making the central number non
magnetic and providing a continues pole core for each pair axially opposite poles. This
modification could possibly reduce the length of the combined pole course or permits a larger
winding length.

The maximum diameter of the eddy current brake is decided by

1. The spacing of vehicle chassis frame.

2. Vehicle floor clearance

2.3 WORKING

When the vehicle is moving, the rotor disc of eddy current brake which is coupled to
the wheels of the vehicle rotate, in close proximity to stationary magnetic poles. When we want
to brake the vehicle, a control switch is put on which is placed on the steering column in a

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position for easy operation. When the control switch is operated, current flows from a battery to
the field winding, thus energizing the magnet. Then the rotating disc will cut the magnetic field.
When the disc cuts the magnetic field, flux changes occur in the disc which is
proportional to the strength of the magnetic field. The current will flow back to the zero field
areas of the metal plate and thus create a closed current loop like a whirl or eddy. A flow of
current always means there is a magnetic field as well. Due to Lenzs law, the magnetic field
produced by the eddy currents works against the movement direction. Thus instead of
mechanical friction, a magnetic friction is created. In consequence, the disc will experience a
drag or the braking effect, and thus the disc stops rotation. The wheels of the vehicle, which
is directly coupled to the disc, also stop rotation. Faster the wheels are spinning, stronger the
effect, meaning that as the vehicle slows, the braking force is reduced producing a smooth
stopping action.

The control switch can be set at different positions for controlling the excitation current
to several set values in order to regulate the magnetic flux and consequently the magnitude of
braking force. I.e. if the speed of the vehicle is low, a low braking force is required to stop the
vehicle. So the control switch is set at the lowest position so that a low current will be supplied
to the field winding. Then the magnetic field produced will be of low strength, so that a
required low braking force is produced.
When the control switch is operated during the standby position of the vehicle, the magnet will
be energized and magnetic field is created. But since the wheels are not moving, magnetic lines
of force are not cut by it, and the brake will not work. However, a warning lamp is provided on
the instrument panel to indicate whether the brake is energized. This provides a safe guard for
the driver against leaving the unit energized.
When control switch is put in any one of the operating positions, the corresponding
conductor in the contractor box is energized and current flows from the battery to the field
winding to the contractor box. This current magnetizes the poles in stator, which placed very
near to the rotor. When rotor rotates it will cut magnetic lines and eddy current will set up in
the rotor. The magnetic field of this eddy current produces a breaking force or torque in the
opposite direction of rotation disc. This kinetic energy of rotor is converted as heat energy
and dissipated from rotating disc to surrounding atmosphere. Current in the field can change
by changing the position of the controls switch. Thus we can change the strength of the braking
force.

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2.4 EDDY CURRENT BRAKE IN TRAINS

In the case of trains, the part in which the eddy current is induced is rail. The brake shoe
is enclosed in a coil, forming an electromagnet. When the magnet is energized, eddy currents
are induced in the rail by means of electromagnetic induction, thereby producing braking
action.

Fig No: 2.2 Eddy Current Brake in Trains

Fig No: 2.3 Distribution of Magnetic Flux Density

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2.5TYPES OF EDDY CURRENT BRAKES

There are two types of eddy current brakes according to the method of excitation.
1. Electrically excited eddy current brake
2. Permanent magnet eddy current brake

2.5.1 ELECTRICALLY EXCITED EDDY CURRENT BRAKE

Electrically excited eddy current brakes are abruption-free method for braking. In
high-speed trains they offer a good alternative to the mechanical rail brakes which are being
used now a day. During braking, the brake comes in contact with the rail, and the magnetic
poles of brakes are energized by a winding supplied. Magnetic poles of brakes are energized by
a winding supplied with current from the battery. Then the magnetic flux is distributed over the
rail. The eddy currents are generated in the rail, producing an electromagnetic braking force.
These types of braking need an additional safety power supply when there are breakdowns in
the electrical power supply.

Fig No: 2.4 Electrically Excited Eddy Current Brake

2.5.2 PERMANENT MAGNET EDDY CURRENT BRAKE

Recently, permanent magnet eddy current brakes have been developed for subways,
trams and local trains. These brakes need a mechanical actuator to turn the magnets jn an on

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and off position. The main advantage of this type of brake is safety. i.e. it does not need
electrical power supply to energize the magnet.

Fig No: 2.5 Braking Power Calculations

Sophisticated calculation methods for the determination of braking forces of eddy

current brakes are important for the design of the brakes.
For a simple eddy current brake employing a thin non-magnetic disc as copper the drag
or braking force on the disc

Where
H = Magnetic field strength in Webbers.
A = Pole force area in cm2.
V = Velocity in cm/sec of mean radius of disc under the poles.
T = disc thickness in cm.
= specific resistance of disc material at its operating temperature in micro ohms/cm3.

Torque = F * R Nm
Where R = mean pole radius in meter.
Power P = 2 NT/60 watts.

2.6 EDDY CURRENT BRAKE REQUIREMENTS

An eddy current brake is an energy converter functions is to convert the kinetic energy
of a vehicle into heat and dissipate it such a rate to maintain the temperature of unit within

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reasonable limits under maximum and prolonged braking conditions. The energy absorbed by
the brake is transformed into heat by the currents induced in the motor, and this is heat manly
dissipated in surrounding air through the medium of suitable designed fins the rotating member.
In mountains area, continues braking force is needed for a long time (say about half an
hour), at this condition, eddy current braking is more suitable to function without overheating.
The use of these retarders is by no means limited to mountain on country. They can be
advantageously employed on public service vehicles on city routes without frequent stops. But
in this braking system there without be any braking force in the vehicle is rest. So the eddy
current brake is used as an auxiliary heavy-duty retarder. By using auxiliary retarder very
smooth retardation is assumed and likely hood of skidding on slippery roads surfaces is
minimized. Smooth braking action cuts down tier were and since brake is used as an auxiliary
heavy-duty retarder. By using auxiliary retarder very smooth retardation is assumed and likely
hood of skidding on slippery roads surfaces is minimized. Smooth braking action cuts down
tier were and since the conventional brakes are relieved of heavy duty being required only to
bring vehicles to rest.

2.7 MOUNTING AND INSTALLATION

A typical mounting of an eddy current brake consists of two discs in which pole salient
type, supported between the frame numbers of a vehicle chassis. Rotor is coupled to road
wheels being often mounted on a shaft that is interposed between the gearbox and propeller
shaft and stator is mounted on the frame of the vehicle.
The driver who can select one or four excitation settings according to the breaking
effect required mounts a control switch on a steering column in a position for easy operation.
In the operative positions of this switch 1, 2, 3, 4 contractors are energized to supply current to
the excitation windings of the retarder. Warning lamp is also provided on the instrument panel
to indicate when the retarder is energized. This provides a safe guard for the driver against
leaving the unit energized when the vehicle is stationary.

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2.8 ADVANTAGES

Less maintenance
Wide range of braking force available within the temperature limit
Prolonged braking is possible
Long life
Less strain to the operation
Smooth retardation, which cuts down, the tire wears

Eddy current brakes offer smooth retardation of vehicles without skidding. It is totally
free of wear and tear. So it has long life compared to ordinary brakes. These need less
maintenance.
In mountain areas continuous braking is needed for a long time. At this condition, eddy
current braking is more suitable to function without overheating.
By changing the excitation current to the field winding, i.e. by adjusting the position of
the control switch, we can vary the braking force to required range. The operation of eddy
current brake is very simple. i.e. the control switch is a soft switch which can be operated
without any strain.
Eddy current brakes works even under the toughest environmental conditions. For
example, in larger water slides and water coasters where the humidity would immediately
result in reduction of friction and thus impair the effectiveness of ordinary brakes. It works
even in highly corrosive environments and heavily contaminated areas.

2.9 DISADVANTAGES

No breaking force at rest

Need of electric power

The main disadvantage of the eddy current brake is that it needs electric power to work.
Researchers are going on to overcome this disadvantage by making the brake regenerative i.e.

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by converting the kinetic energy of the vehicle into electric energy and storing it back into the
battery.

2.10 APPLICATIONS

For additional safety on long decants in mountain area

For high speed passenger and goods vehicle

Eddy current brakes are best substitutes for ordinary brakes, which are being used
nowadays in road vehicles even in trains, because of their jerk-free operation. In mountain
areas where continuous braking force is needed, for a long time, the eddy current braking is
very much useful for working without overheating. Eddy current brakes are very much useful
for high-speed passengers and good vehicles. It can also be used to slow down the trolleys of
faster roller coasters.

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CHAPTER 3

CONCLUSION

Eddy current brakes are the best choice when demands for reliability and safety are the
highest. They work even in the toughest environmental conditions. Even the strike of lightning
will not result in the loss of the braking force.
Eddy current braking system is not popular now a day. But we hope that the eddy
current braking system which is simpler and more effective will take the place of the ordinary
braking system and we can do expect it to be the norm one in few years of time.

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CHAPTER 4

REFERENCES

1. Manual 1 Gonzalez, Volume 25,Issue 4,July 2004

2. IEEE Transactions on magnetic, Volume 34, Issue 4, July 1998
3. Analysis of eddy current brake for high-speed railway by Wang.P.J. & Chiuch.S.J.
4. Automobile electrical equipments by Young &Griffith.
5. Automatic engineering by Kripal Sing.
6. Clutches and brakes by William.C.Orthwin.
7. www.reelectromagneticbrakes.com
8. www.lineareddycurrentbrakes.com

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