Geometric optimal design of a magneto-rheological brake considering different shapes for the brake envelope

When designing a magneto-rheological brake (MRB), it is well known that the shape of the brake envelope significantly affects the performance characteristics of the brake. In this study, different shapes for the MR brake envelope, such as rectangular, polygonal or spline shape, are considered and the most suitable shape identified. MRBs with different envelope shapes are introduced followed by the derivation of the braking torque based on Bingham-plastic behavior of the magneto-rheological fluid (MRF). Optimization of the design of the MRB with different envelope shapes is then done. The optimization problem is to find the optimal value for the significant geometric dimensions of the MRB that can produce a certain required braking torque while the brake mass is minimized. A finite element analysis integrated with an optimization tool is employed to obtain optimal solutions for the MRBs. From the results, the most suitable shape for the brake envelope is identified and discussed with the reduction of mass. In addition, the results of the analysis are compared with the experimental results to verify the proposed optimal design characteristics.