Eddy Current Brake

Mechanism
December 4, 2007
Introduction
Team members and positions
Rodney Kremer (Team Lead)
Aaron Noel (Systems Lead)
Mike Martinez (Technical lead)
James Witt (Finance Manager)
Sponsor
Honeywell
Simon Waddell and Balwinder Birdi
Faculty Advisor
Dr. Hao Xin (EE/Physics department)

Outline
Background of current Honeywell application
Customer needs
Functional requirements
Constraints and Design effects
Ideal Final Result
Final Design
Analysis
FMEA-Disc Component
Ideality
Bill of Materials
Plans For Next Semester
Background
Honeywells current disconnect
system
Shear neck
Not effective with variable speeds
Irreversible
Cannot be activated at will
Honeywells new disconnect
Needs activation system

Schematic of Shear Neck
Customer Needs
Decelerates ball screw nut to activate
disconnect system
Produce required differential torque
within given constraints and
parameters
Recommended use of eddy current
brake system
Mission Statement
Our mission is to develop, design, and test
an innovative braking mechanism that will
activate a mechanical disconnect system,
applicable in a broad range of aerospace
generators.
Functional Requirements
Activate Disconnect
Unscrew the ball-screw nut



Be Resettable
Maintenance free
Constraints
Environmental Conditions Functional Constraints
Temperature -50F to 300F Infinite Life
Humidity 10 80 percent Cannot Deteriorate over time
Imbalance 0.005 oz.-inch Design Envelop
Pressure Range 0.75-1 atmosphere Diameter 5 inches
Altitude 3,000 below-
70,000 feet above
sea level
Width 1.25 inches
Operate in an oil mist Environment No Hazardous Materials
Operation Conditions Budget
Speed Range 7,200-28,800 RPM $2,000
Power Source 28 Volt DC
99% Operational Readiness
Eddy Current Brake
Produce magnetic field
Changing of Magnetic flux induces eddy currents
Eddy Currents produce another magnetic field opposing
first
Opposing magnetic fields create force that reduces
velocity.
Eddy Current Brake Rationale
Frictionless

Resetable

Light Weight

Few moving parts

Honeywell Recommendation
Components
Electromagnets
Cast Iron Core
Conducting (Copper) Wire
Mounting bolts
Disc
7075 Aluminum
Machined from plates

FMEA - Disc component
Driving Factors for Disc Design
Stress in Disc
Due to Imbalance
Due to Eddy Current Force
Due to Rotating Disc
Temperature of Disc
Electrical Conductivity
Density



Modeling Stress Due to Imbalance
Stress Due to Eddy Current Force
Red Arrows Indicate Direction of Disc Rotation
E vectors Indicate Direction of Eddy Current Force
Force on Disc from Eddy currents
Imbalance Analysis (accounts for stress from imbalance of disc, acts radially) tensil_r (lbf/in^2)
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
1 1.2 1.4 1.6 1.8 2 2.2 2.4
radius (in)
F
o
r
c
e

f
r
o
m

m
a
g
n
e
t
i
c

f
i
e
l
d

(
l
b
)
Stress Due to Rotating Disc
Where a = inner radius
b = outer radius
v = Poissons ratio
= material density
= angular velocity [rad/s]
r = radius of interest
Heat Transfer (assumptions)
Disc is approximated as flat plate with
average velocity, V
Radiation Heat Transfer Rate is Negligible
Disc Rotation Rate 7,200 RPM
Thermo-physical of oil mist can be
approximated with that of engine oil
Neglect Heat Transfer out of outer edge of
the disc
Neglect Conduction through Disc/shaft
mating surface
Eddy Current Force Analysis
Preliminary MATLAB
analysis

Faraday Software
Verification
Optimization
Single vs. Paired
Electromagnets
Constant vs.
Alternating Polarity
Relative Proximity
Coil Shape
Radius
Number of
electromagnets/pairs
Visualization
(Images from current MATLAB simulation)
Test Rig
Test Rig Supports
Design Matrix

Ideal Final Result
Predictable and Scalable Torque
No weight
Perfectly balanced
No parts
No frictional contact
Lasts Forever
Takes up no space
Operates at any angular velocity
Needs no power supply
Maintenance Free
Ideality
Importance Score Max
10 8 10
8 4 10
7 8 10
1 2 10
10 10 10
5 5 10
5 4 10
9 7 10
2 1 10
9 9 10
Function
1. Predictable and Scalable Torque
2. No weight
3. Perfectly balanced
4. No parts
5. No frictional contact
6. Lasts Forever
7. Takes up no space
8. Operates at any angular velocity
9. Needs no power supply
10. Maintenance Free
Ideality = 57.7%
577 .
660
381
*
*
9
1
= =

= i
i i
i i
MAXSCORE IMPORTANCE
SCORE IMPORTANCE
Bill of Materials
Item Source Specs Qty Price Total
Disc Speedy Metals 7075-T651 1/4x1x1 $49.42 +
EM Core Speedy Metals Cast Iron 5/8 Diameter
Extruded 24
$3.84 $71.71
Dewalt Motor Sears 24 VDC, 21000 RPM
nom T=94.5 in-lb
1 $43.05 57.31
Faraday Integrated Engineering
Software
Calc. time dependant,
3D Eddy Currents
6 month license $1,000 $1,000
DAQ Devices AME Dept.
EM Bolts McMaster-Carr 316 Stainless steel 8 $2.38 $27.03
Wire WesBell Electronics 20 AWG 500 $17.50 $26.45
Wire WesBell Electronics 22 AWG 500 $11.75 $20.70
Optical Sensor Reliability Direct Monarch remote
optical sensor
1 $140.00 $151.00
Test Rig Metal Hi-Temp Metals 6061 Aluminum (+cut) 433 cubic Inch $217.00 $230.24
Test Rig
Hardware
Hardware Metal
Specialties
Various Hardware
Components
$14.56 $14.56
DMM Multi-meter
warehouse
DMM with Computer
Output
1 $79.95 $84.90
Total $1,579.45 $1,683.90
Plans for Next Semester
Continue Remaining Analysis
Build the Test Rig
Build ECBS
Testing and Optimization
Develop Final Product
Questions???



Faradays Law
Equations used with Faradays Law:
Lenzs Law, ,
Induced Current by changing magnetic Flux



}
=
u
= - V
dt
d
ds E

r E V - =

IR V =
Faradays Law & Eddy Current
Brake Theory
Our understanding of Eddy Current
Relation of Faradays Law and Eddy
Current brake




B
F
Retardant Force:
Ampere and Faradays Equations:
&
}
= I s d B
I 0

V ds E =

IR V =
I r B
I 0
2 t =

0
2

tr B
I
I

=

}

= = = = R
r B
IR V r B
dt
d
ds E
I
0
2
2

t
t


I
B
r
R
B
dt
d

0
2

=
Use Amperes Law to approximate eddy current
with a circular wire loop of radius r:
}
u
=
dt
d
ds E
B

Design Concepts
A single electro-magnet
Two electro-magnets of opposite
Polarity
Two electro-magnets on each side of
disc
Rotating arms of electro-magnets

Problem Statement
Activate an existing disconnect
system for high-speed Aerospace
generator
Non mechanical
Resettable
Activated at will (variable speeds)