Magnetic fluid control for viscous loss reduction of high-speed MRF brakes and clutches with well-defined fail-safe behavior

No-load losses within brakes and clutches based on magnetorheological fluids are unavoidable and represent a major barrier towards their wide-spread commercial adoption. Completely torque free rotation is not yet possible due to persistent fluid contact within the shear gap. In this paper, a novel concept is presented that facilitates the controlled movement of the magnetorheological fluid from an active, torque-transmitting region into an inactive region of the shear gap. This concept enables complete decoupling of the fluid engaging surfaces such that viscous drag torque can be eliminated. In order to achieve the desired effect, motion in the magnetorheological fluid is induced by magnetic forces acting on the fluid, which requires an appropriate magnetic circuit design. In this investigation, we propose a methodology to determine suitable magnetic circuit designs with well-defined fail-safe behavior. The magnetically induced motion of magnetorheological fluids is modeled by the use of the Kelvin body force, and a multi-physics domain simulation is performed to elucidate various transitions between an engaged and disengaged operating mode. The modeling approach is validated by captured high-speed video frames which show the induced motion of the magnetorheological fluid due to the magnetic field. Finally, measurements performed with a prototype actuator prove that the induced viscous drag torque can be reduced significantly by the proposed magnetic fluid control methodology.