Effect of Pole Head Profile on Torque Performance of a Disc-Type Multipole Magnetorheological Brake

A magnetorheological brake (MRB) works on the shearing effect of MR fluid in the magnetic field to develop resistance between the stator and the rotor, which are relative moving surfaces. Researchers achieved high torque volume ratios in magnetorheological fluid braking systems by adding multiple layers and using multipole approaches. Even though several designs already exist, there is a need for innovative ideas and advanced structures of MRBs for practical engineering applications. The number of magnetic poles, pole geometry and placement have a significant effect on the performance of multipole MR brakes. This research focused on the effect of the pole head geometry in a multipole dual disc compact MR brake to understand the relationship between the geometry and its magnetic flux flow. The magnetic field generated by the electromagnetic coil's orthogonal travel through pole heads, rotor and MR fluid layers results in friction to fulfill the action of braking that achieves maximum brake torque. This flow depends on the magnetic pole head area and corresponding core dimensions. This study considered polygon, square, hexagon, trapezoid and ellipse pole head profiles in place of the conventional circular pole and the best possible core dimensions were used for each geometry. To study the brake's performance, COMSOL Multiphysics software (version 5.5) commonly used for 3D electromagnetic modeling was used to simulate and examine the magnetic flux intensity for various pole head configurations. Results indicate an improvement compared to previous works, considering the same dimensional limitations and the flux leakage between the adjacent poles being much less. The hexagonal and elliptical pole heads had better magnetic field area, magnetic intensity distribution and higher magnetic flux lines piercing through the MR fluid perpendicularly than the circular and square pole heads. An increment of 3.88% for braking torque performance was obtained, and the braking torque was significantly enhanced.