Electromagnetic Brake Research Articles

Numerical Simulation of Flow Field, Distribution of Bubbles, and Inclusions in Slab Continuous Casting Mold under Electromagnetic Braking Assisted with High‐Temperature Quantitative Velocity Measurement

Numerical Simulation of Flow Field, Distribution of Bubbles, and Inclusions in Slab Continuous Casting Mold under Electromagnetic Braking Assisted with High‐Temperature Quantitative Velocity Measurement

Large eddy simulation of various EMBr effects on the fluid flow, heat transfer and solidification process in an ultra-high speed thin slab casting mould with multi-port SEN

Effective control of intense turbulence is a crucial challenge for achieving steady production with ultra-high casting speed in thin slab continuous casting. In thin slab casting process, specially designed multi-port submerged entry nozzle (SEN) with four outlets is utilised to ensure an ample supply of molten steel, necessitating the selection and optimisation of suitable Electromagnetic Braking (EMBr) equipment for steel jet control. This study established a comprehensive three-dimensional model of a funnel-type mould, employing a combined experimental-numerical approach to validate and investigate the flow, heat transfer, solidification and electromagnetic behaviour in the mould. The steel grade studied in the simulation is Q235B, and its physical properties were calculated based on its composition with a temperature range of 1450–1826 K. To analyse the influence of high casting speed on the flow and solidification behaviour in the mould, three casting speeds were selected for the study, which were 6, 7 and 8 m/min. The results indicate that the novel Bowl EMBr significantly suppressed the penetration of steel jet and thus enhanced the thickness and uniformity of the solidified shell. As the casting speed increases from 6 to 8 m/min, the solidified shell thickness at the mould exit decreases from 7.91 to 5.94 mm, with the stagnant growth region approaching the mould exit. This highlights the requirement to correspondingly increase EMBr strength under ultra-high casting speed condition to avoid remelting of the shell and the risk of molten steel leakage. The coupled mathematical model established in this study provides guidance for optimising EMBr structures and casting speed under special multi-port SEN conditions, offering recommendations for the rational control of flow, heat transfer and solidification process in the mould.

Study on electromagnetic stirring–braking structure layout design and its synergistic mechanism in electromagnetic metallurgy

During the continuous casting process, electromagnetic stirring (EMS) can control the flow pattern of the molten steel on the meniscus in the slab mould, while it is difficult to effectively control the entire molten steel. To this end, a novel composite magnetic field structure of EMS and electromagnetic braking (EMBr) is proposed, and the EMS–EMBr synergistic mechanism is analysed. The flow field of molten steel without a magnetic field is analysed. The magnetic field regulation strategy required to control the molten steel is clarified. The coil core structure layout of existing EMS is analysed. The action mechanism of EMS is studied through simulation, revealing the poor control effect of EMS on the molten steel under high casting speeds. Thus, a novel EMS–EMBr structure layout is proposed to enable the braking magnetic field to cover the key areas within the slab mould, ensuring that the main flow is effectively suppressed. On this basis, the effects of EMS–EMBr synergy and different process parameters on the flow pattern of molten steel are studied. The results indicate that the EMS–EMBr composite magnetic field structure proposed can more effectively control the molten steel, providing technical support for the development of electromagnetic metallurgical equipment.

Modeling and Simulation of Multi-phase and Multi-physical Fields for Slab Continuous Casting Mold Under Ruler Electromagnetic Braking

Modeling and Simulation of Multi-phase and Multi-physical Fields for Slab Continuous Casting Mold Under Ruler Electromagnetic Braking

Effects of the asymmetric and oscillating turbulent melt flow on the heat transfer and solidification inside the thin slab continuous casting (TSC) mold under the applied electromagnetic brake (EMBr)

The thin slab casting (TSC) is a breakthrough near-net-shape technique for flat products accompanied by rapid casting and solidification rates. The TSC quality hinges on the turbulence, super-heat flow and growth of the solidified shell. The electromagnetic brake (EMBr) is commonly applied to control the fresh melt flow after feeding through a submerged entry nozzle (SEN). Numerical modelling is a perfect tool to investigate the multiphase phenomena in the continuous casting (CC). The presented study considers the heat transfer through the solid shell and water-cooled copper mold including the averaged thermal resistance of the slag skin and the air gap coupled with the turbulent flow and magnetohydrodynamics (MHD) model using an in-house code developed inside the open-source computational fluid dynamics (CFD) package OpenFOAM®. The model is applied to investigate different undesired asymmetric melt flow issues: (i) with the misaligned or (ii) partially blocked SEN; (iii) caused by the mean flow fluctuations with the natural frequencies; (iv) related to the oscillations of the fresh melt jets for the specific SEN designs and casting regimes. The variation of the flow pattern and superheat distribution is studied and presented for different scenarios both with and without applied EMBr.

ELECTROMAGNETIC BRAKING SYSTEM

In this paper, we delve into the intricacies of Electromagnetic Braking systems and their influence on traditional braking methods. Ensuring driver safety and comfort on the road is paramount for any braking system. Conventional braking systems, including Drum Brakes, Disc Brakes, Hydraulic Brakes, and Pneumatic Brakes, rely on friction to decelerate vehicles, leading to heat generation and wear on braking components, thereby diminishing efficiency over time. Electromagnetic Braking emerges as a viable alternative, boasting superior efficiency characterized by a high power-to-torque ratio and reduced friction. This paper examines the transition to electromagnetic braking and its implications for conventional braking methodologies. Keywords: Electromagnetic Braking; Traditional Braking; Friction; Heat Generation; Efficiency.

Research and Characteristic Analysis of A New Type of Dual Winding Electromagnetic Brake

Taking the electromagnetic brake as the research object, a new structure of double-winding electromagnetic brake is proposed in view of the serious temperature rise phenomenon of traditional single-winding electromagnetic brake, the high requirement of insulation level and the obvious decrease of electromagnetic force. The equivalent magnetic circuit method is used to analyze and calculate the magnetic field, and the simulation model of the new brake is constructed, and the influence of different parameters on the braking characteristics of the double-winding electromagnetic brake is analyzed by the single-variable method, and the influence curves of each parameter on the electromagnetic force and response time are obtained. At the same time, the magnetic-thermal coupling analysis of the double-winding electromagnetic brake is carried out, and the results show that the total ampere-turns and power of the double-winding electromagnetic brake decreases by 15.3% in the same proportion, the rated electromagnetic force decreases by 22.9%, the release time grows by 23.7%, and the closure time is shortened by 14.6%.

Energy Simulation of Marine Currents through Wind Tunnel with use of Electromagnetic Brake

A demand clean and renewable energy through the use of submerged turbines. Using this new source of energy that we can grow the production of electrical energy from sustainable way. This paper presents the simulation of maritime currents using a wind tunnel which allows the comparison of speed variations of water compared to air. It also features a brake system that uses a magnetic sensor in real time using the wavelets. As an example, it can be the ones mentioned concerning the feedback control system applied in a brand WEG motor of 100 hp with 2 poles 3500rpm rotation. Using software tools, the Acquired data are post-processed.

Influence of operating parameters on metal flow and thermal characteristics in an EMBr-single-ruler controlled CSP funnel-shaped mould

Electro-magnetic brake (EMBr), as a necessary technique to adjust the metal flow within the mould, has been extensively applied in the continuous casting (CC) production. The EMBr technique, if appropriately applied, can take the benefit of braking effect to weaken jet impingement effect, suppress fluid disturbance and stabilize surface fluctuation. As a result, to obtain a reasonable flow pattern within the CC mould, the braking performance of EMBr technique needs to be flexibly adjusted according to the variation of operational parameters. In this article, to obtain a braking performance of a commonly used EMBr-single-ruler technique within an optimal range, the effect of operating parameters on the metal liquid flow and thermal characteristics in a compact strip production (CSP) thin slab mould is described through a 3-D mathematical modeling of multi-physical field coupling. The results illustrate that the braking performance of the EMBr-single-ruler device is weakened with the increase of the casting speed or the mould width. For the effect of the casting speed and mould width on the metal flow with the application of an EMBr device, an optimum braking performance of the EMBr-single-ruler device can be obtained under the matching parameters of a magnetic induction intensity of 0.30 T and a casting speed of 4.5 m ∙ min‒1 together with a mould width of 1500 mm. Relative to the absence of the EMBr-single-ruler device, the maximum surface fluctuation height is controlled at 6.2 mm, and the mean surface temperature is raised to 1803.6 K. Based on these findings, we conclude that the proper utilization of the EMBr-single-ruler device can avoid the entrainment of flux powder and improve the melting performance of flux powder.

Research on the Failure Mechanism and Solution Strategy for Friction Braking of Electric Hoists

The electromagnetic braking motor, which combines cylindrical motors with electromagnetic brakes, has gradually been widely used in the lifting mechanism of electric hoists. This configuration of electric hoists usually has a large difference in lifting speed between fast and slow, and the highest speed can reach the lowest speed Liu Bei. During the process of rapid sudden braking and sudden switching between fast and slow speeds, it is easy to generate a large amount of braking slip, posing a huge challenge to friction braking. In response to the issue of excessive brake slip of a wire rope electric hoist, the mechanism causing the excessive brake slip was analysed, and a solution was provided. This paper analyses the methods of shortening braking time and reducing braking slip from mechanical, electrical, and control aspects, with a focus on the impact of rectifier and brake response delay on braking deceleration time and braking slip amount.

Experimental Analysis on Effective Electro Magnetic Braking System

A traditional breaking system involves conversion of mechanical energy in to the heat energy leads to reduction in effectiveness of breaking due to thermal effects. This results improper functioning and may fail ultimately. It has been found in the literature that the development of magnetic breaking system which is an improved version of traditional braking system to enhance its effectiveness and durability. Even though this magnetic braking system is better than traditional braking system, it has drawbacks in generating required amount of magnetic field, inducing directional torque, adjustment of air gap, selection of motor for driving and stopping the system. Hence present work Electromagnetic braking assembly has been designed, fabricated and partially validated for improvement of performance of braking system by analyzing similar parameters such as braking torque, speed, current, arrangement of number of magnets, magnetic field, air gap. A small scale prototype has been fabricated for testing and verification. Therefore more effective braking system is suggested than magnetic braking system. Implementation of this braking system is environment friendly in a sense pollution free, easy to operate and simple to fabricate. Hence this kind of system sustains for long life.

Effect of static magnetic field on the molten pool dynamics during laser powder bed fusion of Inconel 718 superalloy

Recent researches show that a static magnetic field (SMF) has an impact on the molten pool dynamics and microstructure of laser powder bed fusion (L-PBF). This work is intended to the multiple effect of SMF on the molten pool dynamics during L-PBF of Inconel 718 superalloy. A three-dimensional (3D) multiphase computational fluid dynamics (CFD) model at the powder-bed scale was established by coupling the electromagnetic braking and Seebeck effect in a static vertically-distributed magnetic field. Results show that the magnetic damping force (MDF) of the order of 104 N/m3∼105 N/m3 within the whole molten pool suppresses the Marangoni convection. The thermoelectric magnetic force (TEMF) of the order of 106 N/m3∼107 N/m3 rotates in the mushy zone and further enhances the melt flow of the whole molten pool. The SMF will not transform the flow pattern and temperature distribution in the molten pool. SMFs of 0.1 T and 0.3 T will suppress the melt flow, while that of 0.5 T will enhance the melt flow. The width of molten pool first decreases and then increases when the magnetic flux density (MFD) increases from 0 T to 0.5 T. In addition, applying a SMF of 0.3 T can effectively inhibit pore defect and spatters. This work can provide insight into the control of molten pool by introducing a SMF during L-PBF.

Revolutionizing Aviation: Pressure Assisted Electromagnetic Braking System (PAEBS) for Sustainable Air Travel

Air transportation is integral to modern society, facilitating global connectivity and access to remote regions. Nevertheless, challenges such as runway length requirements, landing/take-off accidents, airport congestion, and fuel inefficiencies necessitate innovative solutions. This research paper introduces the Pressure Assisted Electromagnetic Braking System (PAEBS), a self-sustained braking and accelerating system designed to address these challenges and enhance air travel safety, accessibility, and sustainability. The integration of the PAEBS is a seamless process, necessitating no significant alterations to the existing hardware of commercial aircraft, as its operation occurs beneath the runway surface. This innovation has the remarkable capacity to reduce the required runway length for aircraft landing and take-off by up to half. Traditionally, a runway extends to approximately 3000 meters, but with the implementation of PAEBS, this length can be halved to a mere 1500 meters. Preliminary calculations indicate the potential for substantial fuel consumption reductions, ranging from 3% to 4.5% (Rowland, n.d.) [1], contingent upon the size of the airliner. The adoption of this system holds the promise of reducing worldwide commercial jet fuel consumption by a significant 9 billion litres annually (stat, n.d.) [2], which would result in substantial cost savings for airliners, estimated at approximately $4.2 billion per year.

Effect of the Intensity of Single-Ruler Electromagnetic Braking on the Flow Pattern in a Thin-Slab Funnel Mold

Effect of the Intensity of Single-Ruler Electromagnetic Braking on the Flow Pattern in a Thin-Slab Funnel Mold

Melt flow, heat transfer and solidification in a flexible thin slab continuous casting mold with vertical-combined electromagnetic braking

Melt flow, heat transfer and solidification in a flexible thin slab continuous casting mold with vertical-combined electromagnetic braking

Optimization of structural parameters and numerical simulation of stress field of composite crucible based on the indirect coupling method

Abstract The research starts with the treatment of the multiscale transmission problem and establishes the electromagnetic solidification transmission coupling mathematical model based on the indirect coupling method. It uses the three-dimensional magnetic field finite element theory to establish a three-dimensional crucible structure continuous casting model built on the electromagnetic solidification transmission coupling mathematical model. This model is used to optimize the parameters of the composite crucible structure and to simulate electromagnetic transmission and braking phenomena. The results show that the L-shaped static magnetic field has a more potent inhibition and a guidance effect on melt circulation. The braking effect of the actual magnetic field on the downward impact is worse. Under the influence of an L-shaped magnetic field, the flow velocity of the melt is better, and the flow state distribution is more smooth and uniform. The computational efficiency test results show that the conversion calculation time of the method designed in this study is 18.03 min. The total calculation time is 680.48 min, which is superior to traditional methods. It proves that this model can accurately analyze the magnetic field coupling problem and at the same time ensure the superiority of its computing efficiency.

Design and Realization of a Controlled Electromagnetic Breaking System

Industrial machines with sharp moving blades are extremely dangerous to workers. These machines often rotate for some time (called the run-down time) before completely stopping due to little or no brakes. In the case where brakes are used, they are mechanical in nature and are associated with problems of wear out and frequent maintenance among others. In this paper, we proposed a mathematical model and implementation of an electromagnet and design and construction of a mechanical support frame and a controller for the electromagnetic braking system. The electromagnetic braking system works on the principle of electromagnetism. To realize the semicircular electromagnets, we coil the gauge wires several times around a ferromagnetic core material. The electromagnet was connected to a 12 V 7 Ah battery and was used to lift a load whose mass and corresponding weight were predetermined using a scale balance. The magnetic force generated was equal to the amount of maximum load it could lift. The mechanical frame, on which the electromagnets, motor, battery, switches, and chain drive system were mounted, was designed using SolidWorks and constructed by measuring, cutting, and joining of iron materials. A microcontroller and a power MOSFET were used in the control circuit to drive the electromagnet. Major results such as the realized electromagnets and the magnitude of the electromagnetic force (1.43 N) produced by the electromagnets are presented. The mechanical frame and the control circuit are also presented. The braking force was greater than the rotation torque of the disc, and hence braking was achieved.

Eddy Current Braking Force Analysis of a Water-Cooled Ironless Linear Permanent Magnet Synchronous Motor

The ironless linear permanent magnet synchronous motor (ILPMSM) is highly compact, easy to control, and exhibits minimal thrust fluctuations, making it an ideal choice for direct loading applications requiring precise positioning accuracy in linear motor test rigs. To address the issue of temperature rise resulting from increased primary winding current and to simultaneously enhance thrust density while minimizing thrust fluctuations, this paper introduces a bilateral-type ILPMSM with a cooling water jacket integrated between the dual-layer windings of the primary movers. The primary winding of the motor adopts a dual-layer coreless structure where the upper and lower windings are closely spaced and cooled by a non-conductive metal cooling water jacket, while the dual-sided secondary employs a Halbach permanent magnet array. The motor’s overall braking force is a combination of the electromagnetic braking force generated by the energized windings and the eddy current braking force induced on the cooling water jacket. This paper specifically focuses on the analysis of the eddy current braking force. Initially, the motor’s geometry and working principle are presented. Subsequently, the equivalent magnetization intensity method is employed to determine the no-load air gap magnetic density resulting from the Halbach array. An analytical model is then developed to derive expressions for the eddy current density and braking force induced in the water-cooling jacket. The accuracy of the analytical method is validated through finite element analysis. Then, a comparative analysis of the braking forces in two primary cooling structures, namely the inter-cooled type and the two-side cooled type ILPMSM, is conducted. Moreover, the characteristics of the eddy current braking force are thoroughly examined concerning motor size parameters and operating conditions. This paper provides a solid theoretical foundation for the subsequent optimization design of the proposed motor.

Modelling Study of EMBr Effect on Interface Fluctuation and Melt Flow in a Thin Slab Mould

Electromagnetic brakes (EMBrs) are regularly used in continuous casting to control interface fluctuations in a mould. In the research, to appraise the damping effect of EMBr technique, namely EMBr-ruler technique, the influence of magnetic field intensity on behaviours of melt flow and interface fluctuation in a Compact Strip Production (CSP) thin slab funnel mould are numerically simulated. The numerical results illustrate that the existence of the EMBr-ruler technique is conducive to inhibiting the impact of the ascending circulation on the interface in the CSP funnel mould. With the gradual enhancement of magnetic intensity, the service efficiency of the EMBr-ruler on the fluctuation of two-phase steel/slag interface is enhanced. For instance, by applying a magnetic induction intensity of 0.5 T, the maximum fluctuation height of two-phase steel/slag interface is decreased to 6.4 mm. This can well prevent surface defects, such as slag entrapment.

Invention of Electro Magnetic Eddy Braking System

Electromagnetic braking systems use electronic and magnetic power to apply wheel brakes. Our system utilizes the concept of electromagnetism in order to achieve braking without friction. Eddy braking improves the reliability &life of brakes since they do not wear out over time due to friction. This needs comparatively very less maintenance and no oiling. Electromagnetic brakingis an upcoming technological replacement for traditional braking systems. The main objective behind the proposed use of these eddy braking system in automobiles is that it is frictionless. This leads to a very low maintenance cost due to no friction and no oiling. Also traditional braking systems are prone to slipping while this one is guaranteed to apply brakes to the vehicle.