Simulation and experimental investigation of a multi-pole multi-layer magnetorheological brake with superimposed magnetic fields

Abstract

This paper presents comprehensive investigations on a new multi-pole multi-layer magnetorheological (MR) brake. This unique design features MR working gaps set between two-layer individual coils. Independent current supply was proposed to generate more flexible braking torque and lower power consumption. In this article, an exploded-view drawing of the proposed MR brake was presented, and theoretical analyses of the braking torque and temperature characteristic were conducted. Then, finite element analysis was performed to verify the effect of the magnetic field superposition. A prototype MR brake was fabricated and tested to evaluate the magnetic field superposition, preliminary dynamic behavior, temperature and the performance of individual input current. The results show that the magnetic field superposition has much influence on the braking torque, and individual current supply results in different power consumption and torque ranges. Moreover, the dynamic response performance of this brake is less affected by the slip speed. Furthermore, the maximum steady-state slip power of the proposed brake is about 160 W, and the greater the slip power is, the faster the temperature increases. The results also have verified the correctness of the structure and magnetic circuit design.