Senior Capstone Project in Green Technologies:  Study of Electromagnetic Braking as Prospective Enhancement of  Friction-based Automotive Braking System

Irina Nicoleta Ciobanescu Husanu; M. Eric Carr

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Conference: 2019 ASEE Annual Conference & Exposition
Location: Tampa, Florida
Publication Date: June 15, 2019
Start Date: June 15, 2019
End Date: June 19, 2019
Conference Session: Manufacturing Division Technical Session 7
Tagged Division: Manufacturing
Page Count: 15
DOI: 10.18260/1-2--33257
Permanent URL: https://peer.asee.org/33257
Download Count: 1054

Paper Authors

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Irina Nicoleta Ciobanescu Husanu Drexel University

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Irina Ciobanescu Husanu, Ph. D. is Assistant Clinical Professor with Drexel University, Engineering Technology program. Her area of expertise is in thermo-fluid sciences with applications in micro-combustion, fuel cells, green fuels and plasma assisted combustion. She has prior industrial experience in aerospace engineering that encompasses both theoretical analysis and experimental investigations such as designing and testing of propulsion systems including design and development of pilot testing facility, mechanical instrumentation, and industrial applications of aircraft engines. Also, in the past 10 years she gained experience in teaching ME and ET courses in both quality control and quality assurance areas as well as in thermal-fluid, energy conversion and mechanical areas from various levels of instruction and addressed to a broad spectrum of students, from freshmen to seniors, from high school graduates to adult learners. She also has extended experience in curriculum development. Dr Husanu developed laboratory activities for Measurement and Instrumentation course as well as for quality control undergraduate and graduate courses in ET Masters program. Also, she introduced the first experiential activity for Applied Mechanics courses. She is coordinator and advisor for capstone projects for Engineering Technology.

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M. Eric Carr Drexel University orcid.org/0000-0003-3444-0883

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Mr. Eric Carr is an Instructor with Drexel University’s Department of Engineering Technology. A graduate of Old Dominion University’s Computer Engineering Technology program and Drexel's College of Engineering, Eric enjoys finding innovative ways to use microcontrollers and other technologies to enhance Drexel’s Engineering Technology course offerings. Eric is currently pursuing a Ph.D in Computer Engineering at Drexel, and is an author of several technical papers in the field of Engineering Technology Education.

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Abstract

Senior engineering projects are the capstone of students’ educational careers, being a proof of the skills and competencies acquired as well as an important tool to assess students’ knowledge in their field of study. Capstone design courses enable students to integrate theoretical knowledge with the practical skills gained during their academic experience. Senior design projects developed by students in our department are interdisciplinary in nature and mainly address emerging or current engineering topics in areas such as manufacturing, green and renewable energies, sustainability and healthcare. The project presented in this paper addresses the need for reducing pollution by developing environmentally-friendly automotive braking systems. Conventional frictional brakes inhibit the motion of a vehicle by converting the vehicle’s kinetic energy into heat. The friction between the brake element and the brake surface not only reduces the lifetime of components, requiring them to be replaced throughout the lifetime of the vehicle, but also generates pollutants [1]. Removing the friction between the braking elements and braking surface means the lifetime of these components would be significantly improved, which would reduce the recurring costs to the consumer over the lifetime of their vehicle. This project investigated the feasibility of total or partial replacement of the frictional braking system in an automobile with a contactless electromagnetic braking system. The investigative efforts are “proof-of-concept” type. The student-led team designed and built a prototype for a frictionless electromagnetic braking system by installing computer-controlled electromagnets inside a typical drum brake assembly. When the drum rotates and passes through the magnetic field generated by the electromagnets, a Lorentz force is induced that opposes the rotation of the drum. The electromagnetic brake was compared against standards for modern vehicle braking performance to determine the feasibility of the frictionless brake’s performance. In conjunction with the electromagnetic prototype, a control system and display panel was integrated into the test bench, allowing for automated control over the motor and electromagnet and automated data logging. The display panel shows the coil current, voltage, temperature along with the velocity, stopping distance, and stopping time. To ensure the coils stayed within a safe temperature, a simulation was used to determine the maximum current that could be applied before the wire would breakdown. Finally, a cost–benefit analysis was conducted to determine the economic advantages of an electromagnetic brake over a traditional friction brake. The proposed system and testing bed proved that the electromagnetic braking using eddy currents is possible and may be used to improve the existing braking systems. However, this system, as built, cannot achieve the performance required by the current braking standards. Besides the major milestones and project design, we will describe the lessons learned and assessment of this project throughout the academic year. The educational impact of such project is assessed as well, focusing on the interdisciplinary nature of the approach.

Citation
Format

Ciobanescu Husanu, I. N., & Carr, M. E. (2019, June), Senior Capstone Project in Green Technologies: Study of Electromagnetic Braking as Prospective Enhancement of Friction-based Automotive Braking System Paper presented at 2019 ASEE Annual Conference & Exposition , Tampa, Florida. 10.18260/1-2--33257

TY - CPAPER
AB - Senior engineering projects are the capstone of students’ educational careers, being a proof of the skills and competencies acquired as well as an important tool to assess students’ knowledge in their field of study. Capstone design courses enable students to integrate theoretical knowledge with the practical skills gained during their academic experience. Senior design projects developed by students in our department are interdisciplinary in nature and mainly address emerging or current engineering topics in areas such as manufacturing, green and renewable energies, sustainability and healthcare. The project presented in this paper addresses the need for reducing pollution by developing environmentally-friendly automotive braking systems.
Conventional frictional brakes inhibit the motion of a vehicle by converting the vehicle’s kinetic energy into heat. The friction between the brake element and the brake surface not only reduces the lifetime of components, requiring them to be replaced throughout the lifetime of the vehicle, but also generates pollutants [1]. Removing the friction between the braking elements and braking surface means the lifetime of these components would be significantly improved, which would reduce the recurring costs to the consumer over the lifetime of their vehicle.
This project investigated the feasibility of total or partial replacement of the frictional braking system in an automobile with a contactless electromagnetic braking system. The investigative efforts are “proof-of-concept” type. The student-led team designed and built a prototype for a frictionless electromagnetic braking system by installing computer-controlled electromagnets inside a typical drum brake assembly. When the drum rotates and passes through the magnetic field generated by the electromagnets, a Lorentz force is induced that opposes the rotation of the drum. The electromagnetic brake was compared against standards for modern vehicle braking performance to determine the feasibility of the frictionless brake’s performance.
In conjunction with the electromagnetic prototype, a control system and display panel was integrated into the test bench, allowing for automated control over the motor and electromagnet and automated data logging. The display panel shows the coil current, voltage, temperature along with the velocity, stopping distance, and stopping time. To ensure the coils stayed within a safe temperature, a simulation was used to determine the maximum current that could be applied before the wire would breakdown. Finally, a cost–benefit analysis was conducted to determine the economic advantages of an electromagnetic brake over a traditional friction brake.
The proposed system and testing bed proved that the electromagnetic braking using eddy currents is possible and may be used to improve the existing braking systems. However, this system, as built, cannot achieve the performance required by the current braking standards.
Besides the major milestones and project design, we will describe the lessons learned and assessment of this project throughout the academic year. The educational impact of such project is assessed as well, focusing on the interdisciplinary nature of the approach.
AU - Irina Nicoleta Ciobanescu Husanu
AU - M. Eric Carr
CY - Tampa, Florida
DA - 2019/06/15
PB - ASEE Conferences
TI - Senior Capstone Project in Green Technologies: Study of Electromagnetic Braking as Prospective Enhancement of Friction-based Automotive Braking System
UR - https://peer.asee.org/33257
DO - 10.18260/1-2--33257
ER -