Investigating the Impact of Circular Sector Pole Head Structure on the Performance of a Multipole Magnetorheological Brake

Abstract

The magnetorheological brake (MRB) epitomized a revolutionary modification in the braking systems because of its extremely efficient and well-controlled performance. To increase the safety and controllability of automotive braking system, researchers have developed a different MRB structures. Although much research on magnetorheological brakes has shown positive results in terms of brake torque, braking time, thermal efficiency, etc., the ability to increase braking force by expanding the disc surface, through which the magnetic field operates in a compact structure, is restricted. To address this issue, a new multipole MRB configuration with a unique pole head design that maintains compactness. Initially, the conceptual design was achieved by leveraging the combined impact of the twin disc-type structure and multipole concept. The model was used in a dynamic simulation to show how the braking torque of a magnetorheological braking system varies with coil current. The effects of circular sector pole head shape on braking performance were investigated using COMSOL Multiphysics software (version 5.5). A three-dimensional electromagnetic model of the proposed MRB was developed to examine the magnetic flux intensity and the impact of magnetic field dispersion on the proposed pole head structure of a magnetorheological brake. Based on simulation results, the circular sector pole head configuration is capable of increasing the active chaining regions for the MR fluid on the rotor surface, allowing for a more effective use of magnetic flux throughout the whole surface of a rotating brake disc, thereby increasing the magnetic field usage rate. The acquired simulation results show an increase in braking torque while keeping a compact and practical design structure.