Design considerations for an automotive magnetorheological brake

In this paper, design considerations for building an automotive magnetorheological (MR) brake are discussed. The proposed brake consists of multiple rotating disks immersed in a MR fluid and an enclosed electromagnet. When current is applied to the electromagnet, the MR fluid solidifies as its yield stress varies as a function of the magnetic field applied. This controllable yield stress produces shear friction on the rotating disks, generating the braking torque. In this work, practical design criteria such as material selection, sealing, working surface area, viscous torque generation, applied current density, and MR fluid selection are considered to select a basic automotive MR brake configuration. Then, a finite element analysis is performed to analyze the resulting magnetic circuit and heat distribution within the MR brake configuration. This is followed by a multidisciplinary design optimization (MDO) procedure to obtain optimal design parameters that can generate the maximum braking torque in the brake. A prototype MR brake is then built and tested and the experimental results show a good correlation with the finite element simulation predictions. However, the braking torque generated is still far less than that of a conventional hydraulic brake, which indicates that a radical change in the basic brake configuration is required to build a feasible automotive MR brake.