This research focuses on a new design to facilitate the manufacturing and improve performance of magneto-rheological brake (MRB). In this proposed MRB, the coils are directly placed on inner part of the side housing of the MRB and separated with the working MR fluid by a thin wall. The coils are then covered by the outer part of side housing to form a closed magnetic circuit. With this configuration, the coils do not directly contact with the MRF therefore a very small MRF gap size can be archived. In addition, the coils can be assembled and disassembled in the housing without separating the inner parts of the housing out of the disc. This makes a lot of convenience in fabrication, testing and maintenance of the MRB. After a review of MRB development, configuration of the proposed MRB is presented. Braking torque of the proposed MRB is then derived based on Bingham-plastic rheological model of MRF. Based on finite element analysis, optimal design of the proposed MRB is then conducted. The results are then compared with other types of MRB to figure out the advanced performance characteristics of the proposed one. In order to validate simulated results, prototypes of the proposed MRBs are manufactured and experimental works are then conducted.

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In this research, a new configuration of magnetorheological fluid–based brake with multiple coils placed on each side of the brake housing (multiple side-coil magnetorheological fluid–based brake) is proposed, optimally designed, and evaluated. With this configuration, the multiple side-coil magnetorheological fluid–based brake is expected to provide higher braking torque and more compact size than the traditional magnetorheological fluid–based brake. After a brief introduction about the development of magnetorheological fluid–based brake, the configuration of multiple side-coil magnetorheological fluid–based brake is proposed. Braking torque of the proposed magnetorheological fluid–based brake is then analyzed based on the Bingham plastic rheological model of magnetorheological fluid. The optimization of the proposed multiple side-coil magnetorheological fluid–based brake, the magnetorheological fluid–based brake with one coil placed on each side of the brake housing (single side-coil magnetorheological fluid–based brake), and the conventional magnetorheological fluid–based brake is then performed considering maximum braking torque and mass of the brakes. Based on the optimal results, advanced performance characteristics of the proposed magnetorheological fluid–based brake are figured out. In addition, experimental works are conducted to validate the performance of the proposed multiple side-coil magnetorheological fluid–based brake.

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This study focuses on material characterizations of Magneto-rheological fluid (MRF) on performance characteristics of magneto-rheological brake (MRB). In this study, three different types of MRF (low viscosity, medium viscosity, and high viscosity) are considered for several types of MRB. Firstly, the optimization solution of the MRB design is proposed based on the Bingham plastic model of the MRFs and finite element analysis of MRB magnetic circuit. From optimal design of the MRBs with different MRFs, performance characteristics of the MRBs such as braking torque, off-state torque, and power consumption are evaluated. In addition, the compact size of MRB using different MRFs is also studied. Finally, some observations and guidance on selection of MRFs in MRB design are summarized.