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Ecole Polytechnique’s Solid Mechanics Laboratory

Joint with control stiffness

Electro-magnetic particles brake

Goal

Research, design, produce and test a new design of electro-magnetic joint with controlled stiffness (brake with controlled braking torque) based on a magnetorheological fluid technology.

This technology could advantageously replace other brake/clutch technologies in many applications thanks to:

> high braking torque/weight and braking torque/volume ratios,

> high controllability: torque accurately controlled by tension control, fast response and wide range of linear behavior

It can moreover be used to build rotary buttons with haptic feedback: force feedback patterns can be programmed and adjusted instantaneously.

Rather than focusing on building a specific application, the goal of the project was to maximize the torque over volume ratio of the joint for a given volume.

The product consists of a stack of disks, alternatively fixed to the rotor and stator of the joint, with magnetorheological fluid filling the gaps between them. When subjected to a magnetic field created by a coil, the fluid greatly increases its apparent viscosity, to the point of becoming a viscoelastic solid, completely linking the rotor and stator together.

Electro-magnetic brake

Electro-magnetic brake

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Role & contribution

  • Electromechanical design and dimensioning of the brake, including magnetic circuit and sealed rotary joint design - CAD modeling

  • Magnetic flux, heat and stress simulation; optimization of the system performance (braking torque/volume)

  • GD&T, fabrication, assembly

  • Custom test bench design and fabrication, characterization of the system performance

Outcome

Successfully designed, produced and characterized the brake.

  • Braking torque achieved ranges from a torque as low as 0.01Nm when the device is not powered, to 3Nm when powered by a current of 3A.

  • Improved braking-torque/weight ratio by more than 60% compared to a benchmark one-disk design.

Learnings

  • Electromechanical device design (including magnetic circuit design, coil design, heat dissipation considerations, magnetorheological fluid use)

  • Rotary joint design (ball bearing assembly, rotary sealing solutions)

  • Multiphysics simulation and optimization

  • Small batch metal manufacturing and prototyping

  • Test bench design and device performance characterization

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