Design and Analysis of Electromagnetic Brake Retarder for HOWO 336 Dump Truck

Abstract

Now And Then Braking Is Utilized By Heavy Duty Vehicles When They Are Driven At High Speed On Downhill, Or During Uphill Driving With Carrying Goods. These Frequent Braking Leads To Brake Fading In Heavy Duty Vehicles Which Also Causes A Serious Fatal And Material Accident.Therefore, Adding Auxiliary Braking System Is Essential For Heavy Duty Vehicles. Since Howo 336 Dump Truck Is One Of Heavy-Duty Vehicle Type And Widely Used In Ethiopia, It Is Necessary To Add Electromagnetic Brake Retarder Feature By Systematically Studying The Required Braking Torque Of The Vehicle. Therefore, This Study Focuses On Designing And Analysing Of Electromagnetic Brake Retarder For The Howo 336 Dump Truck. Electromagnetic Brake Retarders, Also Known As Electric Retarders, Utilize Opposing Electromagnetic Fields To Generate Retarding Force, Providing Effective Braking Without The Need For Friction. Initially, The Required Torque For Retarding Is Calculated Using The Road Load Equation, Assuming The Vehicle Is Driven Downhill While Carrying Goods. A Braking Force Of 38.2 Kn Is Determined, And The Corresponding Torque On The Propeller Shaft Is 1700nm. The Design Of The Retarding Brake Involves Determining The Necessary Current For Excitation, Considering The Number Of Turns, Air Gap, And Other Parameters. The Amount Of Current Helps To Determine The Wire Gauge, So That, The Total Wire Length For Coil Winding Was Determined. The Power Dissipation, Retarding Force And Torque Were Calculated. Optimal Torque Generation Is Achieved By Adjusting The Air Gap (0.009-0.0015m), Number Of Turns (800-1000), And Current (10-15a). Design Expert Software Generates 19 Iterations Or Combinations. Using The Generated Iterations, Maximum Retarding Torque Was Determined By Taking Aluminium Alloy 6061 And Copper Properties For Comparison. Considering The Maximum Torque Generation, The Necessary Aspects Are Redesigned. Solidworks Cad Modelling Software, Ansys Simulation Software Are Used For Modelling And Simulation Of Components Of Electromagnetic Brake Retarder. The Design Process Finds An Optimal Excitation Current Of 19a And Magnetic Flux Density Of 0.1 Tesla. Calculations Determined The Vehicle's Required Braking Force And Torque To Be 10 Kn And 1700 Nm, Respectively. The Designed System Generated 5 Kn Of Force And 850 Nm Of Torque, Achieving 50% Of The Required Braking Capacity And Effectively Contributing To Vehicle Braking With Reduced Power Consumption And Excitation Current.