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Design and Analysis of Eddy Current Multi Caliper Disc Brake

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Design and Analysis of Eddy Current Multi Caliper Disc Brake 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://iaeme.com/Home/issue/IJMET?Volume=8&Issue=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://iaeme.com/Home/issue/IJMET?Volume=8&Issue=7 http://iaeme.com/Home/journal/IJMET 267 [email protected] 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. http://iaeme.com/Home/journal/IJMET 268 [email protected] 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.” http://iaeme.com/Home/journal/IJMET 269 [email protected] 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).
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