A new design approach based on differential evolution algorithm for geometric optimization of magnetorheological brakes

In recent years, various types of magnetorheological brakes (MRBs) have been proposed and optimized by different optimization algorithms that are integrated in commercial software such as ANSYS and Comsol Multiphysics. However, many of these optimization algorithms often possess some noteworthy shortcomings such as the trap of solutions at local extremes, or the limited number of design variables or the difficulty of dealing with discrete design variables. Thus, to overcome these limitations and develop an efficient computation tool for optimal design of the MRBs, an optimization procedure that combines differential evolution (DE), a gradient-free global optimization method with finite element analysis (FEA) is proposed in this paper. The proposed approach is then applied to the optimal design of MRBs with different configurations including conventional MRBs and MRBs with coils placed on the side housings. Moreover, to approach a real-life design, some necessary design variables of MRBs are considered as discrete variables in the optimization process. The obtained optimal design results are compared with those of available optimal designs in the literature. The results reveal that the proposed method outperforms some traditional approaches.