Optimal design and vibration characteristics of an electromagnetic brake for high‐load logistics robots

This study develops a high‐reliability, power‐off electromagnetic brake for heavy‐duty automated guided vehicle and autonomous mobile robot systems, driven by increasing logistics automation and carbon neutrality goals. We designed the brake, optimizing geometric parameters via finite element method‐based electromagnetic analysis (Ansys Maxwell 2D) to minimize magnetic saturation. For structural vibration stability, we conducted component‐level modal tests and finite element method‐based complex eigenvalue analysis (ABAQUS/Standard 2024) to analyze unstable modes under varying friction coefficients. Our analysis identified mode coupling between the armature's out‐of‐plane modes as the main cause of vibration instability. Notably, the optimized design (a = 12 mm, b = 13 mm) successfully eliminated unstable modes at the reference friction coefficient (μ = 0.3). This research proposes a design direction and reliability methodology for high‐performance brakes suited for heavy‐load logistics robots.