Experimental investigation of rotor wound multi disc magneto-rheological fluid brake

Abstract

Magneto-Rheological fluid (MRF), known for changing properties under a magnetic field, is ideal for brakes and dampers in magnetically controlled devices. This research presents a novel design for a 10-disc MR brake using in-house Magneto-Rheological Fluid (MRF), distinguished by its integration of electromagnet windings directly onto the brake shaft. Magneto-static analysis, performed using Finite Element Method Magnetics (FEMM) software, optimized the material selection and dimensions, enhancing the magnetic field distribution across the MRF gap and maximizing braking torque. The design, with rotor windings and a consistent MRF gap, generates a uniform magnetic field, significantly boosting performance. Theoretical braking torque was estimated using Bingham plastic model for MRF characterization, aligning well with experimental results. The compact 10-disc MR brake design, weighing 1.19 kg, shows robust torque performance across varying current levels. Remarkably, prior research had not integrated electromagnet windings directly on the rotor of MR brake, marking this study as pioneering in advancing MR brake performance. © The Author(s) 2025.