Design, simulation and experimental test of a novel magnetorheological brake with T-shape multilayer rotor

This paper presents the design and simulation of a novel magnetorheological (MR) brake with a T-shaped multilayer rotor. The objective is to enhance the braking performance and operational stability of MR brakes for a wide range of industrial applications. The proposed design incorporates a T-shaped rotor configuration consisting of multiple layers of magnetorheological fluid (MRF) and ferromagnetic materials. The multilayer rotor structure enables the generation of a stronger magnetic field and provides enhanced braking torque. The design process involves the optimization of the T-shape multilayer rotor geometry, considering factors such as the number of layers, thicknesses, and materials used. Finite element analysis (FEA) simulations are conducted to evaluate the magnetic field distribution and torque generation of the brake. Comparative analyses are carried out between the simulated outcomes of the proposed design and existing MR brake setups to gauge the performance enhancements conferred by the T-shaped multilayer rotor. The simulation findings elucidate the benefits of the new design, encompassing heightened braking efficacy and augmented torque production. Subsequently, leveraging the design, a prototype of the MR brake is manufactured and subjected to testing to assess its performance against the simulation projections.