Optimal design of a magnetorheological damper used in smart prosthetic knees

In this paper, a magnetorheological (MR) damper is optimally designed for use in smart prosthetic knees. The objective of optimization is to minimize the total energy consumption during one gait cycle and weight of the MR damper. Firstly, a smart prosthetic knee employing a DC motor, MR damper and springs is developed based on the kinetics characteristics of human knee during walking. Then the function of the MR damper is analyzed. In the initial stance phase and swing phase, the MR damper is powered off (off-state). While during the late stance phase, the MR damper is powered on to work as a clutch (on-state). Based on the MR damper model as well as the prosthetic knee model, the instantaneous energy consumption of the MR damper is derived in the two working states. Then by integrating in one gait cycle, the total energy consumption is obtained. Particle swarm optimization algorithm is used to optimize the geometric dimensions of MR damper. Finally, a prototype of the optimized MR damper is fabricated and tested with comparison to simulation.