MAGNETORHEOLOGICAL FLUID TECHNOLOGY APPLICATIONS IN VEHICLE SYSTEMS S E U N G-B O K C H O I • YO U N G-M I N HAN MAGNETORHEOLOGICAL FLUID TECHNOLOGY APPLICATIONS IN VEHICLE SYSTEMS MAGNETORHEOLOGICAL FLUID TECHNOLOGY APPLICATIONS IN VEHICLE SYSTEMS S E U N G-B O K C H O I • YO U N G-M I N HAN Boca Raton London New York CRC Press is an imprint of the Taylor & Francis Group, an informa business CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2013 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group, an Informa business No claim to original U. Government works Version Date: 20120530 International Standard Book Number-13: 978-1-4398-5674-1 (eBook - PDF) This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been made to publish reliable data and information, but the author and publisher cannot assume responsibility for the validity of all materials or the consequences of their use. The authors and publishers have attempted to trace the copyright holders of all material reproduced in this publication and apologize to copyright holders if permission to publish in this form has not been obtained.
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Visit the Taylor & Francis Web site at http://www.com and the CRC Press Web site at http://www.com Contents Preface.ix The Authors.xi 1 Magnetorheological Fluid.2 Semi-Active Control.5 Sliding Mode Control.30 3 Hysteretic Behaviors of Magnetorheological (MR) Fluid.2 Preisach Hysteresis Model Identification.3 Hysteresis Identification and Compensation.3 Polynomial Hysteresis Model Identification.3 Hysteresis Identification and Compensation.4 Some Final Thoughts. 61 4 Magnetorheological (MR) Suspension System for Passenger Vehicles.1 Configuration and Modeling.3 Damping Force Control.2 Inverse Bingham model.3 Preisach hysteresis compensator.4 Full-Vehicle Test.2 Full-Vehicle Suspension.5 Some Final Thoughts. 122 5 Magnetorheological (MR) Suspension System for Tracked and Railway Vehicles.2 Optimal Design of the MR Valve.3 Vibration Control Results.2 Vibration Control Results.4 Some Final Thoughts. 149 6 MR Applications for Vibration and Impact Control.2 MR Engine Mount.1 Configuration and Modeling.2 Full-Vehicle Model.3 MR Impact Damper.4 Some Final Thoughts.
175 7 Magnetorheological (MR) Brake System.2 Bi-directional MR Brake.1 Configuration and Torque Modeling.4 Results and Discussions.3 Torsional MR Brake.1 Control System of Torsional Vibration.3 Results and Discussions.4 Some Final Thoughts. 220 8 Magnetorheological (MR) Applications for Heavy Vehicles.2 MR Fan Clutch.3 MR Seat Damper.3 Vibration Control Results.4 Some Final Thoughts. 253 9 Haptic Applications for Vehicles.2 Multi-Functional MR Control Knob.3 MR Haptic Cue Accelerator.1 Configuration and Optimization.2 Automotive Engine-Transmission Model.4 Some Final Thoughts. 297 Preface In recent years, smart materials technologies have been spreading rapidly and various engineering devices employing such technologies have been developed.
The inherent characteristics of smart materials are actuator capa- bility, sensor capability, and control capability. There are many smart mate- rial candidates that exhibit one or multifunctional capabilities. Among these, magnetorheological (MR) fluids, piezoelectric materials, and shape memory alloys have been effectively exploited in various engineering applications. This book is a compilation of the authors’ recent work on the application of MR fluids and other smart materials to use in vehicles.
In particular, this book attempts to thread together the concepts that have been separately introduced through papers published by the authors in international, peer- reviewed journals. This book consists of nine chapters. In Chapter 1, we introduce the physical phenomenon and properties of MR fluids, and their potential applications. In Chapter 2, we discuss control methodologies that can be used to effectively control vehicle devices or systems featuring MR fluids.
In Chapter 3, we introduce the hysteresis identification of MR fluid and its application through the adoption of the Preisach and polynomial models. In Chapter 4, we discuss an optimal design method and damping force control of MR shock absorber, which has practical applications in pas- senger cars. In addition, we introduce full-vehicle test results of a suspen- sion system equipped with MR fluids. Chapter 5 discusses the application of MR-equipped suspension systems to tracked and railway vehicles.
We eval- uate their performance metrics (vibration controllability, position controlla- bility, and stability) by using a controllable MR damper. Chapter 6 discusses potential application of MR technology to passenger vehicles. This chapter first introduces dynamic modeling and vibration control of an MR engine mount system associated with a full-car model, followed by a discussion of a novel MR impact damper positioned inside car bumpers to mitigate collision force. Chapter 7 discusses MR brake systems applicable to various classes of vehicles including passenger vehicles, motorcycles, and bicycles.
This chapter deals with two types of brake mechanisms—bi-directional brakes for braking vehicles and torsional brakes for absorbing torsional vibrations. In Chapter 8, we discuss potential applications of MR technology for heavy vehicles. In this chapter, a drum-type MR fan clutch is introduced to actively control the temperature in engine rooms of commercial vehicles. Another application, a controllable MR seat damper, is introduced by presenting modeling and control strategies.
In Chapter 9, we present two cases where haptic technologies are applied to vehicles. The first application is a multi- functional MR control knob for the easy operation of vehicle instruments such as the radio and air conditioning. The second application is a haptic cue ix x Preface system associated with accelerator pedals, which has been devised using MR fluids to achieve optimal gear shifting; we demonstrate experimentally its effectiveness and utility. This book can be used as a reference text by graduate students who are interested in dynamic modeling and control methodology of vehicle devices, or systems associated with MR fluid technology.
The students, of course, should have some technical and mathematical background in vibra- tion, dynamics, and control in order to effectively master the contents. This book can also be used as a professional reference by scientists and engineers who wish to create new devices or systems for vehicles featuring control- lable MR fluids. The authors owe a debt of gratitude to many individuals; foremost is Professor N. Wereley at the University of Maryland who has collaborated with the authors in recent years in the field of smart materials.
We acknowl- edge the contributions of many talented graduate and doctoral students at the Smart Structures and Systems Laboratory, Department of Mechanical Engineering, Inha University. Many of the experimental results presented in this book are the consequence of research endeavors funded by various agencies. In particular, the authors wish to acknowledge the financial sup- port provided by the Korea Agency for Defense Development (Program Monitor Dr. Suh), the National Research Foundation of Korea (NRF), and Inha University’s Research Fund.
Seung-Bok Choi and Young-Min Han The Authors Seung-Bok Choi received his PhD in mechanical engineering from Michigan State University, East Lansing in 1990. Since 1991, he has been a professor at Inha University, Incheon, South Korea. Currently, he is an Inha Fellow Professor, and his current research interests include the design and control of functional struc- tures and systems utilizing smart mate- rials such as electrorheological fluids, magnetorheological fluids, piezoelectric materials, and shape memory alloys. He is the author of over 310 archival interna- tional journals, 5 book contributions, and 220 international conference publications.
He is currently serving as the associate editor of the Journal of Intelligent Material Systems and Structures, Smart Materials and Structures, and is a mem- ber of the editorial board of the International Journal of Vehicle Autonomous Systems and the International Journal of Intelligent Systems Technologies and Applications. Young-Min Han received his PhD in mechanical engineering from Inha Uni versity, Incheon, South Korea in 2005. Since 2011, he has been a professor at Ajou Motor College, Boryeong, South Korea. His current research interest includes the design and control of functional mechanisms utiliz- ing smart materials such as active mounts, semi-active shock absorbers, hydraulic valve systems, robotic manipulators, and hap- tic interfaces.
Professor Han is the author of over 50 archival international journal articles and 25 international conference publications. xi 1 Magnetorheological Fluid 1.1 Physical Properties The initial discovery and development of magnetorheological (MR) fluids is attributed to Jacob Rabinow at the U. National Bureau of Standards in the late 1940s [1–3]. Interestingly, even though MR fluids were introduced almost at the same time as electrorheological (ER) fluids, more patents and publications were reported in the late 1940s and early 1950s for MR fluids than for ER fluids [4].
Until recently, the non-availability of MR fluids of an acceptable quality has resulted in a dearth of relevant published literature, except for the brief flurry of publications in the period following their initial discovery. Encouragingly, there has been a resurgence of interest in MR flu- ids in recent years. MR fluids belong to a family of rheological materials that undergo rheo- logical phase-change under the application of magnetic fields. Typically, MR fluids are composed of soft ferromagnetic or paramagnetic particles (0.03~10 μm) dispersed in a carrier fluid.
As long as the magnetizable par- ticles exhibit low levels of magnetic coercivity, many different ceramic metal and alloys can be used in the composition of MR fluids. Usually, the MR particles are pure iron, carbonyl iron, or cobalt powder and the carrier fluid is a non-magnetic, organic, or aqueous liquid, usually a silicone or mineral oil. In the absence of a magnetic field, the MR particles are ran- domly distributed in the fluid. However, under the influence of an applied magnetic field, the MR particles acquire a dipole moment aligned with the external field and form chains, as shown in Figure 1.
This chain formation induces a reversible yield stress in the fluid. In addition, the yield stress of the MR fluid is continuously and rapidly adjustable because it responds to the intensity of the applied magnetic field. As a result, MR fluid-based devices have inherent advantages such as continuously variable dynamic range and fast response. From the fluid mechanics point of view, the behavior of MR fluid in the absence of a magnetic field can be described as Newtonian, while it exhibits distinct Bingham behavior in the presence of the field [5].
Therefore, MR 1 2 Magnetorheological Fluid Technology: Applications in Vehicle Systems No Current Applied Current Applied N N S S N N N N N S S S S S Base Oil N S N S N S S N N N N N S N S S S S Ferro-Magnetic N N N S N Particle S S N N S N S S S N N S Magnetic Pole S A A FIGURE 1.1 Microstructure of MR fluids. fluid has been modeled in general as a Bingham fluid whose constitutive equation is given by the following: τ = τ y ( ⋅ ) + ηγ (1.1) where η is the dynamic viscosity, γ is the shear rate, and τ y ( ⋅ ) is the dynamic yield stress of the MR fluid. It should be noted that the applied magnetic field could be expressed by either magnetic flux density (B) or magnetic field strength (H).2 presents the nature of the change from Newtonian to Bingham behavior.