Optimal Design and Control Performance Evaluation of a Magnetorheological Fluid Brake Featuring a T-Shape Grooved Disc

Abstract

Magnetorheological fluid brakes are a promising technology for developing high-performance drive-by-wire braking systems due to their controllability and adaptability. This research aims to design an optimal magnetorheological fluid brake for motorcycles and their performance. The proposed model utilizes mathematical modeling and finite element analysis using commercial software. Furthermore, the optimization of this MR brake is determined through multi-objective optimization with a genetic algorithm that maximizes braking torque while simultaneously minimizing weight and the cruising temperature. The novelty lies in the geometric shape of the disc, bobbin, and MR fluid channels, which results in a light MR brake weighing 6.1 kg, an operating temperature of 89.5 °C, and a power consumption of 51 W with an output braking torque of 303.9 Nm. Additionally, the control performance is evaluated using an extended Kalman filter controller. This controller effectively regulates braking torque, speed, and slip rate of both the rear and front wheels based on road characteristics and motorcycle dynamics. This study’s findings show that the front wheel necessitates higher braking torque compared to the rear wheel. Moreover, the slip rate is higher on the rear wheel than on the front wheel, but the front wheel stops earlier than the rear wheel.

Experimental Validation of a Permanent Magnets Magnetorheological Device under a Standardized Worldwide Harmonized Light-Duty Test Cycle

“…The integration of magnetorheological fluids and actuators is also exploited in [31], where Xu et al discussed the design and optimization of an axial flux PM device able to act as an actuator or brake. Moreover, the use of MRF-based brakes allows an increase in the device compactness, for example, exploiting the braking effects of the MRF produced with both shear and compression modes [32], but also in the performances of the vehicle they brake: the authors of [33] presented an MRF-based brake with a T-shaped disk excited by coils to improve motorcycle performance while braking. Another interesting MRF-based device is presented in [34], where the authors discuss the design and control of a clutch in which the fluid is excited both by PMs and coils.…”