Analysis of the Behaviour of an Optimized Magnetorheological Brake

This paper presents the optimization process of MR – magnetorheological brake in order to define its configuration, and to reach the requested vehicle braking torque. FEM analysis previously carried out, concerning structural sizing of such a brake, showed that both braking torque and brake mass did not satisfy the requirements. Due to the necessity of limitation on the suspended mass of a motor vehicle, the optimization of the form of MR brake stator has been executed, including determination of its contribution to the total mass of the brake. Thus a percentage reduction of approximately 40% was obtained. In order to estimate the brake temperature which results from the transformation into heat of a vehicle kinetic energy during brake application, a thermal Finite Element Analysis is carried out. In particular a fade braking test composed of snub braking, i.e. repeated cycles of acceleration and consecutive braking applications is performed.