Optimal Design and Analyses of T-shaped rotor Magnetorheological Brake

Magnetorheological brake (MRB) provide a potential alternative to traditional mechanical friction brakes in automobile applications owing to their technical advantages in terms of being compact yet powerful, having superior control performance, and wire-control features. However, the temperature effect has been an important issue that should be considered in the design and precise control of MRB. This paper presents the multi-objective optimal design and stability control of an automotive MRB considering the temperature effect. First, a description of the configuration design, magnetostatic field simulation, and mathematical modelling of the automotive MRB is presented in detail. Subsequently, design optimization of the MRB is carried out. The design of experiment method was adopted to screen out the major design variables, and the optimal solution was obtained using a multi-objective genetic algorithm (GA) NSGA-II. Thereafter, the torque output and response performance, as well as the temperature characteristics of the optimal MRB prototype are experimentally evaluated. The results indicate that the optimal design of the MRB was reasonable and effective. Finally, a GA-based back propagation neural network proportion integration differentiation controller is proposed for the stability control of the MRB during automobile braking. Its performance was verified to be satisfactory through both simulations and experiments.

Section: Introductionmentioning

confidence: 99%

Optimal design and stability control of an automotive magnetorheological brake considering the temperature effect

Wang¹,

Yang²,

Luo³

et al. 2023

“…Over the years, a large number of magneto-rheological brake (MRB) configurations have been proposed to improve their braking torque, compact size or mass and power consumption [17][18][19][20][21][22][23][24][25][26][27][28][29]. The original and well-known configuration of MRB is the disc-type [17][18][19].…”

Section: Introductionmentioning

confidence: 99%

“…Compared to the disc type MRB, at the same value of maximum achievable braking torque, the mass of drum-type MRB is significantly greater than that of the disc-type [23]. The MRB with T-shaped rotor configuration, a combination of drum-type and disc type, was proposed taking advantages from both the disc-type and the drum type [24,25]. It was shown that, at the same constrained space, the braking torque of the T-shaped rotor MRB was considerably higher than that of the drum-type.…”

Section: Introductionmentioning

confidence: 99%

Development of a novel magnetorheological brake with zigzag magnetic flux path

Nguyen¹,

Biên²,

Hiep³

et al. 2021

In this research work, a novel disc-type configuration of magneto-rheological brake (MRB) with zigzag magnetic flux path is proposed. In this design, a rotor component consisting of several magnetic plates integrated in a disc made of non-magnetic material is implemented. A magnetic plate is separated with the others by nonmagnetic separators of the disc. Corresponding magnetic plates and separators are also implemented on the housing of the MRB. With this configuration, the magnetic flux line is forced to cross the MR fluid (MRF) duct from the disc to the housing at this separator and then from the housing to the disc at the next separator. This results in a zigzag magnetic flux path between the disc and the housing. The separators on each side of the housing are integrated on a bobbin, on which the magnetic coil is installed. When counter currents are applied to the coils on each side of the housing, a mutual magnetic field with zigzag flux lines across the MRF duct is generated. Based on the electromagnetic finite element and torque analysis, optimization problem considering the maximum achievable braking torque and the minimum mass of the MRB is performed. After that, optimal results of the MRB are obtained and compared with those of MRBs in previous works. Based on optimal results of the MRB with a maximum achievable braking torque of 20 Nm, an MRB prototype is fabricated and experimentally investigated to validate the simulation results.

“…By optimal design, performance of the hybrid type MRB can be significantly improved, especially in case the available working space is a long, large cylinder [12,13]. To increase the torqueto-mass ratio of the hybrid-type MRB, MRBs with T-shaped rotor (T-shaped rotor MRB) were developed [14,15]. In the T-shaped rotor MRB, two mutual magnetic coils are placed on the side housings at two ends of the T-shaped rotor flange.…”

Section: Introductionmentioning

confidence: 99%

Design and experimental evaluation a novel magneto-rheological brake with tooth shaped rotor

Biên¹,

Hiep²,

Nguyen³

et al. 2021

In this study, a novel magnetorheological brake (MRB) with tooth-shape rotor is developed. In this new MRB, traditional cylindrical rotor is replaced by a new one with tooth-shaped rotor. The teeth on the rotor act as multiple magnetic poles of the brake. Two magnetic coils are placed on side-housings of the brake to generate a mutual magnetic field of the MRB. The inner face of each side-housing has tooth shaped features as well. These tooth shaped features interact with the rotor teeth via magnetorheological fluid (MRF) medium. By using the tooth shaped rotor, more interface area between the rotor and the working MRF can be archived, which can improve performance characteristics of the proposed MRB such as compact size, low power consumption and high braking torque. After an introduction of state of the art of MRB development, the schematics and working principle of the MRB with tooth-shaped rotor is proposed. The modeling of the MRB is then derived based on magnetic finite element analysis and Bingham rheological model of MRF. Optimal design of the MRB considering mass and braking torque of the MRB is then conducted. From the optimal design result, it is shown that the mass and power consumption of the proposed MRB are significantly smaller than those of previously developed ones. In details, at high value of the maximum braking torque (100 Nm), the proposed MRB mass is only around 31.3% of the mass of the thin-wall single-coil and 42.6% of the mass of the thin-wall double coil MRB. In addition, at small values of the maximum braking torque (5 Nm), power consumption of the proposed MRB is only around 33% of that of the thin-wall single-coil and 45.5% of that of the thin-wall double coil MRB. Experimental works on prototypes of the proposed MRB are then performed for validation.