Rotary magnetorheological dampers (RMRDs) have good application prospects in semi-active suspension due to their compact structure and good sealing performance. However, the existing RMRD cannot be practically applied in the field of high-torque demand. Therefore, this paper aims to improve the mechanical performances and response-ability of a high-output torque rotary vane magnetorheological damper (RVMRD) for vehicle suspension. Firstly, the mechanical, equivalent magnetic circuit and equivalent circuit models of the RVMRD are established, and the one-at-a-time (OAAT) method is used to analyze model parameter sensitivity. Then, the multi-objective optimization design of the RVMRD is based on the non-dominated sorting genetic algorithm (NSGA-II), and the magnetic field formation time of the initial and optimal RVMRD is analyzed by transient electromagnetic field analysis. Finally, to verify the validity of the multi-objective optimization design of RVMRD, the initial and optimal RVMRD were tested for mechanical performances and response time. The mechanical performance testing results show that the output torque and dynamic range of the optimal RVMRD are significantly improved, and maintain good mechanical performance at different temperatures. The response time testing results show that the optimal RVMRD has a phased improvement in response-ability under different step currents, which can effectively suppress vibration and shock in high-frequency dynamic environments The research results in this paper provide helpful guidance for developing and optimizing an RMRD, which has excellent potential for application in the large-scale mechanical industry with space-limited and high-torque requirements.
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