Design and optimization of multipole disc-type magnetorheological brake

doi:10.3785/j.issn.1006-754X.2023.00.039

Chin J Eng Design

2023, Vol. 30

Issue (3): 297-305 DOI: 10.3785/j.issn.1006-754X.2023.00.039

Theory and Method of Mechanical Design

Design and optimization of multipole disc-type magnetorheological brake

Hao HUANG(

),Jie WU(

),Bingbing DENG,Hongyang XIE

School of Mechanical Engineering, Xihua University, Chengdu 610000, China

Download:

HTML

PDF(3573KB)
Export: BibTeX | EndNote (RIS)

Abstract

Aiming at the problem that the working gap magnetic field intensity distributes unevenly along the radial direction of the brake disc and the working gap magnetic field intensity far from the coil area is small, a multipole disc-type magnetorheological (MR) brake is proposed and designed. Firstly, the basic structure and working principle of the multipole disc-type MR brake were elaborated and the magnetic circuit modeling of the MR brake was completed, and then a mathematical model of its braking torque was established. Then, based on finite element simulation software, the magnetic field simulation analysis for the multipole disc-type MR brake was carried out. Finally, taking the torque density as an optimization objective, the structural optimization design of the multipole disc-type MR brake was completed by BOBYQA (bound optimization by quadratic approximation) algorithm within the gradient free optimization algorithm. The results showed that the external gap magnetic induction intensity of the designed MR brake was 0.681?0.760 T; the magnetic induction intensity at the internal gap of 0?<5 mm was 0.114?0.349 T, and the magnetic induction intensity at the internal gap of 5?65 mm was 0.362?0.498 T; the two magnetic fields generated by the inner and outer coils could be superimposed in the MR fluid gap, which improved the braking torque. Compared to before optimization, when the current of all inner and outer coils was 1 A, the braking torque increased by 15.2% and the torque density increased by 14.3% of the optimized MR brake. The multipole disc-type MR brake can provide a reference for the development of high torque density MR transmission technology.

Key words： magnetorheological (MR) brake multipole disc-type braking torque torque density

Received: 24 October 2022 Published: 06 July 2023

CLC:

TH 132

Corresponding Authors: Jie WU E-mail: hh18990363654@163.com;jiewu323@163.com

	Service
	E-mail this article
	Add to my bookshelf
	Add to citation manager
	E-mail Alert
	RSS
	Articles by authors
	Hao HUANG
	Jie WU
	Bingbing DENG
	Hongyang XIE

Cite this article:

Hao HUANG,Jie WU,Bingbing DENG,Hongyang XIE. Design and optimization of multipole disc-type magnetorheological brake. Chin J Eng Design, 2023, 30(3): 297-305.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.00.039 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I3/297

多极圆盘式磁流变制动器的设计与优化

针对传统圆盘式磁流变制动器中工作间隙磁场强度沿制动盘径向分布不均匀、远离线圈区域的工作间隙磁场强度较小的问题，提出并设计了一种多极圆盘式磁流变制动器。首先，阐述了多极圆盘式磁流变制动器的基本结构及工作原理，完成了磁流变制动器的磁路建模，并建立了其制动转矩的数学模型。然后，基于有限元仿真软件，开展了多极圆盘式磁流变制动器的磁场仿真分析。最后，以转矩密度为优化目标，采用梯度自由优化算法中的BOBYQA（bound optimization by quadratic approximation，二次逼近边界优化）算法，完成了多极圆盘式磁流变制动器的结构优化设计。结果表明，所设计的磁流变制动器的外间隙磁感应强度为0.681~0.760 T；内间隙0~<5 mm处的磁感应强度为0.114~0.349 T，5~65 mm处的磁感应强度为0.362~0.498 T；内、外线圈产生的2种磁场可以在磁流变液间隙中实现叠加，从而提高制动转矩。相较于优化前，当所有内、外线圈的电流为1 A时，优化后磁流变制动器的制动转矩增大了15.2%，转矩密度增大了14.3%。多极圆盘式磁流变制动器可为高转矩密度磁流变传动技术的发展提供参考。

关键词： 磁流变制动器, 多极, 圆盘式, 制动转矩, 转矩密度

Fig.1 Schematic diagram of coil arrangement for multipole disc-type magnetorheological (MR) brake

Fig.2 Structure diagram of multipole disc-type MR brake

Fig.3 Schematic diagram of magnetic circuit for multi-pole disc-type MR brake

Fig.4 Equivalent magnetic circuit of multipole disc-type MR brake

Fig.5 Axial schematic diagram of brake disc

Fig.6 Main structural parameters of multipole disc-type MR brake

Table 1 Optimization range of main structural parameters of multipole disc-type MR brake

Fig.7 Optimization iteration process of main structural parameters of multipole disk-type MR brake

Fig.8 Optimization iteration process of torque density of multipole disc-type MR brake

Table 2 Optimization results of main structural parameters of multipole disc-type MR brake

Table 3 Comparison of braking performance of multipole disc-type MR brake before and after optimization

Fig.9 Simulation model of multipole disc-type MR brake

Fig.10 B-H curve of MRF-305 MR fluid

Fig.11 Magnetic field distribution at each gap of multipole disc-type MR brake

Fig.12 Magnetic induction intensity variation curve at each gap of multipole disc-type MR brake

Table 4 Comparison of braking performance of multipole disc-type MR brake under different powering methods

Table 5 Comparison of braking performance of multipole disc-type MR brake with different number of magnetic poles


[1]	胡国良，钟芳，张海云，等.两级径向流蜿蜒式磁流变阀结构设计与动态性能分析［J］.农业机械学报，2016，47（10）： 376-382，389. doi：10.6041/j.issn.1000-1298.2016.10.049 HU G L， ZHONG F， ZHANG H Y， et al. Structure design and dynamic performance analysis of two-stage radial type magnetorheological valve with meandering fluid flow paths［J］. Transactions of the Chinese Society for Agricultural Machinery， 2016， 47（10）： 376-382， 389. doi: 10.6041/j.issn.1000-1298.2016.10.049

[2]	HU G L， WU L F， LI L S. Torque characteristics analysis of a magnetorheological brake with double brake disc［J］. Actuators， 2021，10（2）： 23. doi：10.3390/act10020023 doi: 10.3390/act10020023

[3]	THAKUR M K， SARKAR C. Experimental and numerical study of magnetorheological clutch with sealing at larger radius disc［J］. Defence Science Journal， 2020， 70（6）： 575-582.

[4]	SUN H， FANG C N， ZHANG L， et al. Design and research of a novel magnetorheological fluid coupling with cycloid corrugated surface［J］. International Journal of Applied Electromagnetics and Mechanics， 2019， 60（3）： 355-377.

[5]	ZHANG J R， ZHU Y Y， TU J W， et al. Development and vibration control of frequency adjustable tuned mass damper based on magnetorheological elastomer［J］. Materials， 2022， 15（5）： 1829. doi：10.3390/ma15051829 doi: 10.3390/ma15051829

[6]	KORDONSKI W， GOLINI D. Multiple application of magnetorheological effect in high precision finishing［J］. Journal of Intelligent Material Systems and Structures， 2002， 13（7/8）： 401-404. doi：10.1106/104538902026104 doi: 10.1106/104538902026104

[7]	STRECKER Z， JENIŠ F， KUBÍK M， et al. Novel approaches to the design of an ultra-fast magnetor-heological valve for semi-active control［J］. Materials， 2021， 14（10）： 2500. doi：10.3390/ma14102500 doi: 10.3390/ma14102500

[8]	胡国良，李林森.多液流通道旋转式磁流变制动器结构设计及优化［J］.现代制造工程，2019（12）：145-153. doi：10.16731/j.cnki.1671-3133.2019.12.023 HU G L， LI L S. Structure design and optimization of rotary magnetorheological brake with multi-fluid flow channels［J］. Modern Manufacturing Engineering， 2019（12）： 145-153. doi: 10.16731/j.cnki.1671-3133.2019.12.023

[9]	张玉鲁，李兆松，梁彬.圆盘式磁流变液制动器的设计与磁场仿真［J］.汽车工程学报，2018，8（1）：54-60. doi：10.3969/j.issn.2095-1469.2018.01.09 ZHANG Y L， LI Z S， LIANG B. Design and magnetic field simulation of disc type MRF brake［J］. Chinese Journal of Automotive Engineering， 2018， 8（1）： 54-60. doi: 10.3969/j.issn.2095-1469.2018.01.09

[10]	IQBAL H， YI B. Design of a new bilayer multipole electromagnetic brake system for a haptic interface［J］. Applied Sciences， 2019， 9（24）： 5394. doi：10.3390/app9245394 doi: 10.3390/app9245394

[11]	吴杰，蒋学争，姚进，等.新型双层多线圈磁流变制动器研究［J］.工程科学与技术，2016，48（5）：201-209. doi：10.15961/j.jsuese.2016.05.028 WU J， JIANG X Z， YAO J， et al. Research on a novel double-layer multi-coil magnetorheological brake［J］. Advanced Engineering Sciences， 2016， 48（5）： 201-209. doi: 10.15961/j.jsuese.2016.05.028

[12]	吴彦达，胡姗姗，殷煜翔，等.基于COMSOL的磁流变液盘式制动器仿真优化与研究［J］.大学物理实验，2019，32（6）：26-31. doi：10.14139/j.cnki.cn22-1228.2019.06.007 WU Y D， HU S S， YIN Y X， et al. Simulation optimization and research of magnetorheological fluid disc brake based on COMSOL［J］. Physical Experiment of College， 2019， 32（6）： 26-31. doi: 10.14139/j.cnki.cn22-1228.2019.06.007

[13]	吴礼繁，胡国良，易锋，等.内置永磁体的盘式磁流变制动器结构优化设计及仿真分析［J］.现代制造工程，2021（8）：138-146. doi：10.16731/j.cnki.1671-3133.2021.08.021 WU L F， HU G L， YI F， et al. Structure optimal design and simulation analysis of disc-type magnetorheological brake with inner permanent magnet［J］. Modern Manufacturing Engineering， 2021（8）： 138-146. doi: 10.16731/j.cnki.1671-3133.2021.08.021

[14]	李志华，喻军，曾宁，等.圆盘式磁流变制动器仿真优化设计［J］.农业机械学报，2015，46（10）：364-369. doi：10.6041/j.issn.1000-1298.2015.10.049 LI Z H， YU J， ZENG N， et al. Simulation and optimization design of disc-type magnetorheological brake［J］. Transactions of the Chinese Society for Agricultural Machinery， 2015， 46（10）： 364-369. doi: 10.6041/j.issn.1000-1298.2015.10.049

[15]	WU J， HU H， LI Q T， et al. Simulation and experimental investigation of a multi-pole multi-layer magnetorheological brake with superimposed magnetic fields［J］. Mechatronics， 2020， 65： 102314. doi：10.1016/j.mechatronics.2019.102314 doi: 10.1016/j.mechatronics.2019.102314

[16]	UBAIDILLAH， PERMATA A N S， MAZLAN S A， et al. Three-dimensional finite element magnetic simulation of an innovative multi-coiled magnetorheological brake［J］. IOP Conference Series： Materials Science and Engineering， 2017， 257： 012052. doi：10.1088/1757-899X/257/1/012052 doi: 10.1088/1757-899X/257/1/012052

[17]	POZNIĆ A， STOJIĆ B. A contribution to the analysis of magnetorheological brake［J］. IOP Conference Series： Materials Science and Engineering， 2018， 393： 012012. doi：10.1088/1757-899X/393/1/012012 doi: 10.1088/1757-899X/393/1/012012

[18]	NAM T H， AHN K K. New approach to designing an MR brake using a small steel roller and MR fluid［J］. Journal of Mechanical Science and Technology， 2009， 23（7）： 1911-1923.

[19]	IMADUDDIN F， MAZLAN S A， ZAMZURI H， et al. Bypass rotary magnetorheological damper for automotive applications［J］. Applied Mechanics and Materials， 2014， 663： 685-689.

[1]	WU Si-min, MENG Wen-jun, LI Shu-jun, WANG Yao, XU Cheng-gong. Design and optimization of a novel magnetorheological brake with double coils placed on the side housing[J]. Chin J Eng Design, 2016, 23(5): 453-460.

Viewed

Full text

Abstract

Cited

Shared

Discussed