Torque generation in lightweight four rotor magnetorheological brake

Non-Newtonian behaviour of the Magnetorheological (MR) fluid under the influence of external magnetic field can be commissioned to design various applications such as MR brake, damper, and clutches, etc. Better design strategies, material selection and characterization led to realize the potential of MR brakes to replace conventional brakes. The present study emphasises on developing lightweight (1.8 kg) multi-rotor MR brake (MMRB). Finite element method magnetics (FEMM) software is utilized to determine the material required for a single-rotor MRB. FEMM material selection analysis is incorporated into the modeled MMRB, and the nature of magnetic flux density throughout the MR gap was obtained. Magnetic circuit analysis of the proposed brake is carried out to find torque estimation using analytical equations and Bingham plastic model. The proposed brake is fabricated and characterized using commercial MRF (132 DG, Lord Corporation). The study compares the torque outputs obtained experimentally with finite element analysis (FEA) and analytical approach. The average maximum magnetic flux density through FE analysis is found to be 0.45 T @ 3 A current. The average error between FE obtained and experimentally obtained torque output of the brake is around 5%. Further, an alternate design is proposed by utilizing same rotor diameter and number of electromagnetic coils. The new design is lighter in weight (0.8 kg) and exhibits enhancement in the torque output and torque to weight ratio by around 31% and 55%, respectively than the present design.