A Systematic Design Methodology for Electromagnetic Brakes Applied to Low-Power Wind Turbines Using Analytical Modeling, Numerical Validation, and Experimental Verification

Abstract. Low-power wind turbines require reliable braking systems to ensure safe operation during emergency conditions, maintenance procedures, and high wind speeds. Among the available alternatives, eddy-current electromagnetic brakes offer an attractive solution because they operate without mechanical contact, thereby reducing component wear and maintenance requirements compared with conventional braking systems. However, existing studies have primarily focused on the analysis of electromagnetic behavior, the optimization of specific configurations, or industrial applications, while relatively few have addressed a comprehensive methodology for the design and experimental validation of electromagnetic braking systems for low-power wind turbines. This study proposes a reproducible design methodology for an eddy-current electromagnetic brake intended for a 1 kW wind turbine. The proposed methodology integrates the definition of design requirements, the development of an analytical model for electromagnetic sizing, three-dimensional finite element analysis (FEA), and the experimental validation of a prototype manufactured according to the obtained design parameters. The proposed methodology was assessed through three complementary validation stages: analytical modeling, finite element simulation, and experimental testing using a dedicated test bench. The comparison of the obtained results demonstrated good agreement among the analytical predictions, numerical simulations, and experimental measurements, with a relative difference of 1.18 % between the magnetic flux density predicted by the analytical model and that obtained from the finite element analysis. Furthermore, the developed prototype successfully achieved complete rotor stoppage under the prescribed design conditions, confirming the effectiveness of the proposed braking system. The main contribution of this work lies not only in the development of an electromagnetic braking device but also in the formulation and validation of a systematic design methodology that integrates analytical modeling, numerical validation, and experimental verification into a unified design framework. The proposed methodology provides a reproducible approach for the development of electromagnetic brakes for low-power wind turbines and establishes a foundation for future protection strategies, speed regulation systems, and scaling to higher-power wind energy applications.