Title: Analytical modelling and experimental study on the design optimisation of an electromagnetic retarder

Authors: R. Kalyan Kumar; S. Sridhar

Addresses: Engineering, Research and Development, Brakes India Private Limited, Padi, Chennai, 600 050, India ' Engineering, Research and Development, Brakes India Private Limited, Padi, Chennai, 600 050, India

Abstract: An investigation on design optimisation of an electromagnetic retarder has been carried out as it is crucial to balance braking performance and structural mass of assembly. This paper presents a cost-effective mathematical model as an alternative to expensive and time-consuming computational methods for predicting braking performance, considering factors like eddy current power loss, skin effect, and the magnetic reluctance of excitation devices, which were not addressed in earlier studies for a complex system with higher capacity in dynamic conditions. The mass and torque-influencing factors are systematically assessed to optimise the design, which provides significant mass savings while maintaining the necessary performance levels with the analytical results in close agreement with the experimental findings. The optimised design led to a 12.3% reduction in mass compared to the initial design, with only a 2.1% decrease in performance. The study offers guidance for manufacturers to optimise the design to fit the vehicle's needs.

Keywords: electromagnetic retarder; design; optimisation; eddy current; skin effect; magnetic reluctance; braking torque; speed; deceleration; heavy vehicles.

DOI: 10.1504/IJHVS.2025.149285

International Journal of Heavy Vehicle Systems, 2025 Vol.32 No.5, pp.694 - 709

Received: 14 Oct 2024
Accepted: 13 Nov 2024
Published online: 22 Oct 2025 *

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