臺灣博碩士論文加值系統

磁流變液(magneto-rheological fluid, MRF)為一智慧型材料，目前許多設備利用磁流變液技術達到力量或扭力之轉換。磁流變液剎車器(magneto-rheological brake, MRB)為其中之一，其可產生剎車所需之扭力。MRB目前已廣泛應用於車輛工程、訓練設備和機器人上。一般MRB於輸出扭力上，受限於體積、重量及消耗功率之限制。此外，有關最佳化設計、成本降低、大範圍之可控性及長久操作之穩定性皆需於設計時加以考量。
本研究設計一新型多極多層之高扭矩磁流變液阻力器，本阻力器採用多個電磁極和多層之磁流變液層，其目的在比一般單極或多極單層之MRB具有更高的扭力及更高的扭力體積比(toque-to-volume ratio, TVR)，同時利用創新之圓柱形隔板圍繞定子以解決磁流變液滲透之問題。
為達上述所提之目標，本研究首先說明新型MRB之結構，並分析MRB之磁流變液層數對磁場強度之影響，以及不同參數下之磁通密度和相對應之扭矩；經過最佳化計算得知此阻力器之最佳內部結構尺寸，並根據其最佳尺寸進行實體製造及測試，測試其扭力和動態特性。實驗結果顯示本研究之阻力器具有高扭力及高扭力體積比。
最後，本研究提出一新式多層式MRB之設計，分別將三層MRF層放置定子內側及磁極外側，並進行磁場模擬分析，經最佳化計算後於有限的體積內達到最大扭力，由結果可發現將MRF層放置在外側可得到最大的扭力及最大的扭力體積比。
透過本研究可得知，增加磁流變液層之層數可提升阻力器之扭力，但增加之層數與增加之扭力並非線性關係，其層數增加同時亦影響到內部結構設計與裝配之難度。相較於多極式MRB的發展，此研究之新型多極多層式MRB在扭力轉換的表現上，更能有效的呈現多極式MRB之高扭力體積比的特點。

Magneto-rheological fluid (MRF), a smart material fluid, is used by many MR devices to achieve a transitional force or torque. Magneto-rheological brake (MRB) is one of those devices that creates the braking torque and has been applied widely including vehicle engineering, training equipment, and robot. The conventional MRB has the limits of output brake torque within constrains of size, weight as well as power consumption. Moreover, the demands of optimal design, low-cost, wide-range controllable and long-term stability operation are needed to be concerned.
Therefore, this dissertation presents the development and optimization of a new high-torque multipole bilayer MRB. The proposed MR brake has unique structure design of multiple electromagnetic poles and multiple media layers of magneto-rheological fluid. The objective of this dissertation is to obtain higher torque and larger torque-volume ratio than conventional single-pole or multi-pole single-layer MR brakes. Moreover, the problem of potential leakage of MRF is solved by using cylindrical separator rings around MRB’s stator in this research.
In order to achieve those goals, in this study, structure of the proposed MR brake was introduced first. And an analog magnetic circuit for the MR brake had been built to investigate the effects of parameters of MR brake to the magnetic field intensity of MRF layers. In addition, the 3D magnetic model of the MR brake had been built for magnetic simulation to examine the magnetic flux intensity and corresponding braking torque. Thereafter, this research applied an approximated optimization method to achieve the optimal geometric dimensions for major dimensional parameters of MR brake. This MR brake was also manufactured and tested to validate the torque and dynamic characteristics of the MR brake. The result showed that the MR brake has great enhancement of brake torque and toque-to-volume ratio (TVR).
Lastly, a case study was presented with the initial study of new design of multipole multilayer MRB. With two sample models of three MRF layers placed inside and outside the stator cores and poles, magnetic simulation was conducted and analyzed. The optimization design has also been completed to achieve the highest braking torque within limited size. The results show that the outside-layer model get the highest not only the braking torque but also TVR.
Briefly, the more MRF layers were employed in an MRB the higher braking torque generated. However, the torque rising is not linear and the structure design as well as the parts assembly are more complicated. With the rapidly development of the multipole MR brake, this work of new multilayer MR brake shows a great promise especially in the actual applications in term of torque transition devices.

摘　要 i
ABSTRACT iii
ACKNOWLEDGMENTS v
CONTENTS vi
LIST OF TABLES ix
LIST OF FIGURES x
Chapter 1. INTRODUCTION 1
1.1 Overview 1
1.2 Research Motivation 3
1.3 Research Purpose 4
1.4 Outline of Dissertation 4
Chapter 2. LITERATURE REVIEW 6
2.1 Non-Newtonian Fluids 6
2.2 Controllable Fluids 8
2.2.1 Controllable Fluids 8
2.2.2 Comparison of MR and ER Fluids 9
2.3 Magnetorheological Fluids 10
2.3.1 Composition of MR Fluids 10
2.3.2 Mathematical Models for MR Fluid Behavior 12
2.3.3 Properties of MR Fluids 14
2.3.4 Operational Modes 16
2.4 Application Devices Based on MR Fluid 18
2.4.1 MR Clutches 18
2.4.2 MR Dampers 20
2.4.3 MR Brakes 22
2.4.4 MR Mounts 23
2.4.5 MR Haptic Devices 24
2.5 Summary 26
Chapter 3. INNOVATIVE DESIGN OF NEW MULTIPOLE MR BRAKE 27
3.1 Torque Enhancing Methodology of MR Brake 27
3.1.1 Disk Type 28
3.1.2 Drum Type 30
3.1.3 Hybrid Type 30
3.1.4 T-shape 31
3.1.5 Multiple Poles 33
3.1.6 Comparison of Different Type of MRBs 34
3.2 Characteristics of Multipole MR Brake 36
3.2.1 Magnetic Saturation Phenomenon 36
3.2.2 Effect of Cylindrical Separator on Magnetic Field 40
3.2.3 Yield Stress Effect 44
3.3 Design of a New Multipole Bilayer MRB 48
Chapter 4. MAGNETIC ANALYSES OF MULTI-POLE MR BRAKE 53
4.1 Fundamentals of Electromagnetism 53
4.1.1 Electromagnetic Laws 53
4.1.2 Magnetic Circuit with MRF Gap 56
4.2 Magnetic Circuit Analysis of MPBL MR Brake 57
4.3 Magnetic Field Intensity of MRF Layers 61
Chapter 5. OPTIMIZATION DESIGN AND STRUCTURE ANALYSIS 64
5.1 Optimal Design of the Multipole Bilayer MRB 64
5.2 Structure Analysis 66
5.3 Finite Element Model Construction 69
Chapter 6. DYNAMIC TESTING OF PROPOSED MR BRAKE 72
6.1 Manufacturing and Assembling 72
6.1.1 Prototype of MPBL MRB 72
6.1.2 Manufactured MPBL MRB 73
6.2 Test Platform 76
6.2.1 Servo Motor 76
6.2.2 Torque Sensor 77
6.2.3 Test Platform of Proposed MR Brake 77
Chapter 7. RESULTS AND DISCUSSIONS 79
7.1 Simulation and Optimization Results 79
7.2 Structure Analysis 84
7.3 Dynamic Experimental Result 88
7.3.1 Transmission Torque 88
7.3.2 Hysteresis Phenomenon 89
7.4 Evaluation of the MPBL MRB 90
7.5 Case Study: New Design of Multipole Multilayer MR Brakes 92
7.5.1 Simulation Models 93
7.5.2 Magnetic Simulation and Optimal Design 94
7.5.3 Simulation Results 96
7.5.4 Summary 101
Chapter 8. CONCLUSIONS 102
REFERENCES 104
APPENDIX A 111
A1. JOURNAL PAPER(S) 111
A2. INTERNATIONAL CONFERENCE PAPER(S) 111
APPENDIX B 113
B1. GLOSSARY OF SYMBOLS 113
B2. SUBSCRIPTS 114
B3. ABBREVIATIONS 115

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