Design of a Full-Length Effective Automotive Magnetorheological Damper with magnetically Conductive Ring of Trapezoidal Cross Section

doi:10.12382/bgxb.2021.0731

Abstract

Abstract:

Magnetorheological dampers (MRD) used in automobiles are usually of small size, and the traditional MRD damping channel features short effective working length and small output damping force, which results in its limited engineering application. To solve this problem, a novel full-length effective MRD with magnetically conductive ring of trapezoidal cross section was proposed to increase the effective working length of the damping channel and slow down magnetic saturation. Based on the rheological properties of magnetorheological fluid and fluid dynamics theory, the design and calculation method of specific structure and magnetic circuit were given. Five MRDs with different structures were compared by finite element simulation. The results showed that: the proposed novel full-channel effective MRD can significantly increase the effective working length of the damping channel, reaching over 99% of the full length; it can also improve the magnetic saturation problem for a small-size MRD; in addition, under the same current excitation and size constraint, the magnetic field intensity distribution of the damping channel is more uniform, the average magnetic field intensity is larger, and the output damping force is larger; the damping characteristics of the new MRD were analyzed and compared with those of the common MRD and the full-length effective MRD with bending magnetic circuit, indicating that the new full-length effective MRD has a larger output damping force while the structure size is smaller. Finally, the LQG controller was used to analyze the vibration reduction performance, showing that the new full-length effective MRD has better vibration reduction performance than the common MRD, and can further reduce the sprung mass acceleration and tire dynamic deformation by 21.51% and 1.43%. This study can effectively expand the practical application range of small-size MRDs and has certain engineering application significance.

Key words: Magnetorheological damper, Wheeled military vehicle, Full-length effective, Structural design, Magnetic circuit design, Magnetically conductive ring of trapezoidal cross section

CLC Number:

TB535⁺.1

WU Huan, LI Yinong, ZHANG Zhida, ZHANG Ziwei, PU Huayan, LUO Jun. Design of a Full-Length Effective Automotive Magnetorheological Damper with magnetically Conductive Ring of Trapezoidal Cross Section[J]. Acta Armamentarii, 2023, 44(1): 61-73.

Figures/Tables 24

Fig.1 Diagram of Full-length effective MRD structure with magnetically conductive ring of trapezoidal cross section

Fig.2 Sectional view of the piston structure of the new full-length effective MRD

Fig.3 Sketch of piston section

Table 1 Dimensions of the new full-length effective MRD’s pistonmm

参数	l_a	l_b	r	R_c	R_i	R_h	R	l_c	l_d	l_m
数值	6	22	6	10	13	14	17	2.5	0.2	2

Fig.4 Diagram of conventional MRD’s piston section

Fig.5 Diagram of magnetic field line distribution

Fig.6 Diagram of magnetic induction intensity distribution

Fig.7 Diagram of magnetic field intensity distribution

Fig.8 Comparison of magnetic induction intensity at magnetically conductive ring of the full-length effective MRD

Fig.9 Comparison of magnetic field intensity at the damping channel of the five types of MRD

Table 2 Mean magnetic field intensity at the damping channel of the five types of MRD

MRD类型	A型	B型	C型	D型	E型
阻尼通道平均磁场强度/(kA·m^-1)	18.52	24.62	24.50	18.69	30.65

Fig.10 Machining and assembly drawings

Fig.11 Test equipment of damping characteristics

Fig.12 Damping characteristic curve at peak speed 0.1m/s

Fig.13 Damping characteristic curve at peak speed 0.3m/s

Fig.14 Damping characteristic curve at peak speed 0.6m/s

Table 3 Comparison of damping characteristics

参数	新型全通道有效MRD	普通MRD	带弯曲磁路的MRD
缸筒外径/mm	42	45.8	66
电源激励/安匝	150	150	150
最大输出阻尼力/N	1395	743	1351

Fig.15 Two-degree-of-freedom 1/4 vehicle model

Table 4 Parameters of vehicle model

参数	m_b/kg	m_w/kg	k_s/(N·m^-1)	k_t/(N·m^-1)	c_s/(N·s·m)
数值	245	40	15680	180000	1760

Fig.16 Time domain response of sprung mass acceleration

Fig.17 Time domain response of tire dynamic deformation

Table 5 Root mean square value of vibration damping performance indicator

减振性能指标	普通 MRD	新型全通道有效MRD	衰减率/ %
簧上质量加速度/(m·s^-2)	0.3083	0.2420	21.51
轮胎动变形/m	0.0070	0.0069	1.43

Fig.18 Frequency domain response of sprung mass acceleration

Fig.19 Frequency domain response of tire dynamic deformation

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