Regarding Cable Cross Section Selection

Increasing the cable cross section, the resistance would only reduce and thus the voltage drop would only reduce for the same load current. You need not worry! It is a widely practised method in industry to increase the cable cross section, to overcome the problem of higher volatge drops, particularly with long cable lengths.

In your case, 2c x 2.5 sq.mm cable would very definitely cause a much lesser voltage drop than the 2 x 1.0 sq.mm cable. So, pl. go ahead & implement your new proposal.

Dear Sir,

I thank you for your guidance and help. Your timely help will help us in setting a standard for our product. many thanks for the same.

Regards

EE65, our OP indicated your response is "very useful/insightful with respect to the original Forum Thread", so I will vote accordingly. Well done.

The best way to maximize the brake performance is to have a relay at the brake controlled by the control voltage.

Then the current draw will be minimal, and a 1000 Mfd capacitor can be added across the 24 volt supply to provide the surge that the electromagnetic brake is sure to require.

A reverse bias diode across the coil of the relay and brake will minimize arcing and reverse EMF effects.

Will there be a current surge ? The current will simply be equal to V/R, and the highly inductive circuit will delay its rising to this value. The voltage, current and stroke curves vs time will be something like this...

While a freewheeling diode will completely eliminate the voltage surge, it will also delay the drop-off of the brake. Which may not be acceptable since one would want the brake to clamp on immediately on deenergisation (i assume it is a fail-safe brake). A varistor across the coil may be better.

I thank Mr. Sridhar and our other forum members for explaining in more depth. please give me a couple of days to explain about our braking system.

I thank everyone once again

Regards