Design and Control of Multi-Plate MR Clutch Featuring Friction and Magnetic Field Control Modes

A magnetorheological (MR) multi-plate clutch was proposed with both mechanical friction mode and magnetic field control modes. The magnetic field control mode was based on an MR fluid coupler that changed its viscous properties according to the density of an applied magnetic field. This mode was used in the early stage of clutch operation to reduce the impact of friction between the disc and plate, and eliminate to the extent possible the difference in their relative speeds when contacting each other in later stages. Once the rotational speed difference between the disc and plate was reduced, the clutch was operated in mechanical friction mode by compressing the friction surfaces together. A torque modeling equation was then derived for each mode based on the Bingham model of the MR fluid, and the transmission torque of the proposed multi-plate clutch was derived using these equations as well as magnetic field analysis results obtained using ANSYS Maxwell. A multi-plate MR clutch was then fabricated, and its torque transmission characteristics were evaluated in the magnetic field control and mechanical friction modes. The results confirmed that the model-based torque calculations were consistent with the observed transmission torque. Finally, control algorithms for mechanical friction only and mixed mechanical friction/magnetic field control torque tracking of the proposed MR multi-plate clutch were designed, and their performances were evaluated when applying unit step command, half-sine-wave command, and rotational speed changes. The results indicated that the torque tracking control was performed smoothly, demonstrating the advantages of the proposed clutch.