Daiel Tilahun (PhD)Harnet Tekle,2024-03-122024-03-122024-01https://etd.aau.edu.et/handle/123456789/2382In this study, an optimized electromagnetic brake system (EMB) is designed and simulated to replace the conventional hydraulic brake (CHB) system of a lightweight vehicle Lifan 530. The electromagnetic brake system is a pure frictionless electromechanically controlled actuator that has the potential to further reduce braking time and braking distance. The primary goal of this research is to design an electromagnetic braking system that replaces the CHB of the Lifan 530 car to stop as a standalone using a 12v battery source. A theoretical and numerical model is developed in the quarter vehicle model. Using ANSYS Workbench 2020 R2, a 3D finite element model of the EMB was created by SpaceClaim 2020 R2 to simulate and optimize the EMB domain using magnetostatic analysis to study the magnetic flux and braking torque created by the system. Steady-state thermal analysis was performed to investigate heat buildup and the thermal effect of the electromagnet on the brake system. In addition, a static structural analysis is performed to investigate the structural response to temperature changes. The finite element (FEM) has been used to optimize the magnetic circuit design for maximizing the braking torque. The optimized electromagnetic result is achieved by using a wire diameter of 3.2 x 10−4m and 70 turns. Which results in a maximum torque of 338 𝑁𝑚 The simulated result revealed that the braking torque increases with the conducting area and shows the suitability of the concept for the selected vehicle in terms of dynamics, installation space, and energy requirements without demanding extra battery. Finally to validate the numerical result MatLab and ANSYS software are utilized.en-USBrakeConventional hydraulic brakeElectromagnetic brakeEddy currentFinite element.Thesis