Optimal design of an automotive magnetorheological brake considering geometric dimensions and zero-field friction heat

Abstract

This paper presents an optimal design of a magnetorheological (MR) brake for a middle-sized passenger car which can replace a conventional hydraulic disc-type brake. In the optimization, the required braking torque, the temperature due to zero-field friction of MR fluid, the mass of the brake system and all significant geometric dimensions are considered. After describing the configuration, the braking torque of the proposed MR brake is derived on the basis of the field-dependent Bingham and Herschel-Bulkley rheological model of the MR fluid. The optimal design of the MR brake is then analyzed taking into account available space, mass, braking torque and steady heat generated by zero-field friction torque of the MR brake. The optimization procedure based on the finite element analysis integrated with an optimization tool is proposed to obtain optimal geometric dimensions of the MR brake. Based on the proposed procedure, optimal solutions of single and multiple disc-type MR brakes featuring different types of MR fluid are achieved. From the results, the most effective MR brake for the middle-sized passenger car is identified and some discussions on the performance improvement of the optimized MR brake are described.

Optimal Design Methodology of Magnetorheological Fluid Based Mechanisms

“…Zubieta et al [44] have proposed field-dependent plastic models for MRF based on the original Bingham plastic and Herschel-Bulkley plastic models. The models were then applied in several researches [45,46] with experimental agreement. In the field dependent Bingham and Herschel-Bulkley model, the rheological properties of MRF depend applied magnetic field and can be estimated by the following equation …”

“…Park et al [82] have performed multidisciplinary design optimization of an automotive MR brake, in which a multi-objective function considering both braking torque and mass of the brake was considered. Nguyen et al [45] have performed a thorough research on optimal design of MR brake for middle-sized vehicle considering the available space, mass, braking torque and steady heat generated by a zero-field friction torque of the MR brake on cruising at a speed of 100km/h. Furthermore, different configurations of MR brake and different types of MRF are taken into account in that research.…”

Experimental Studies on Magnetorheological Brake for Automotive Application

“…They investigated effect of MR gap and speed on torque output of MR brake. Nguyen and Choi [6,7,8] contributed to the research on MR brakes in the form of design and optimization studies. They developed an optimized MR brake for a motorcycle application [8].…”

Synthesis and Characterization of Antifriction Magnetorheological Fluids for Brake

“…They considered the effect of MR gap on the performance of MR brake. Nguyen and Choi 16 considered minimization of zero-field friction heat in theoretical design of automotive magnetorheological brake to optimize the brake performance. In the present work, flywheel based MR brake experimental set up has been designed and developed.…”