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Article(id=1263881629865489104, tenantId=1146029695717560320, journalId=1263187878914834467, issueId=1263881604263437054, articleNumber=null, orderNo=null, doi=10.16578/j.issn.1004.2539.2026.01.003, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1723564800000, receivedDateStr=2024-08-14, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1779262462344, onlineDateStr=2026-05-20, pubDate=1768406400000, pubDateStr=2026-01-15, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1779262462344, onlineIssueDateStr=2026-05-20, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1779262462344, creator=13041195026, updateTime=1779262462344, updator=13041195026, issue=Issue{id=1263881604263437054, tenantId=1146029695717560320, journalId=1263187878914834467, year='2026', volume='50', issue='1', pageStart='1', pageEnd='191', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=1, specialIssue=null, createTime=1779262456241, creator=13041195026, updateTime=1779263107607, updator=13041195026, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1263884336399528882, tenantId=1146029695717560320, journalId=1263187878914834467, issueId=1263881604263437054, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1263884336403723187, tenantId=1146029695717560320, journalId=1263187878914834467, issueId=1263881604263437054, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=19, endPage=26, ext={EN=ArticleExt(id=1263881632457568992, articleId=1263881629865489104, tenantId=1146029695717560320, journalId=1263187878914834467, language=EN, title=Structural design and braking performance analysis of magnetorheological brakes with internal and external fluid flow channels, columnId=1263881611804795649, journalTitle=Journal of Mechanical Transmission, columnName=Special Topic of Magnetic Transmission, runingTitle=null, highlight=null, articleAbstract=
Objective

In order to improve the torque to volume ratio of magnetorheological （MR） brakes, a MR brake with internal and external fluid flow channels was developed.

Methods

Firstly, the structure and working principle of the MR brake with internal and external fluid flow channels were introduced, and the mathematical model of the braking torque was established based on Bingham constitutive model. Secondly, in order to obtain the optimal structure size of the MR brake, structural optimization design was carried out based on the non-dominated sorting genetic algorithm (NSGA-Ⅱ). Finally, the prototype of MR brake was fabricated, the torque performance test system was built, and the braking performance test was conducted for the MR brake.

Results

There are both internal and external fluid flow channels in the MR brake. Six effective damping gaps are obtained by reasonable setting of magnetic conductive and magnetic isolating materials in the MR brake, so that it can produce excellent torque performance under the premise of the same size. The theoretical calculation results show that the braking torque and the adjustable range after optimization are increased by 30.23% and 16.58% respectively compared with those before optimization. Test results show that at the applied current of 2.0 A, the maximum braking torque is 44.28 N·m, and the dynamic adjustable range is 17.8. The relative errors of the braking torque and the dynamic adjustable range between the test values and the theoretical calculation values are 6.5% and 16.1% respectively, which verifies the rationality of the design.

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目的

为提高磁流变制动器的转矩体积比，提出一种具有内外液流通道的磁流变制动器。

方法

首先，阐述了内外液流通道式磁流变制动器的结构和工作原理，基于Bingham本构模型建立了制动转矩数学模型；其次，基于非支配排序遗传算法（Non-dominated Sorting Genetic Algorithm, NSGA-Ⅱ）对制动器进行优化设计，得到最优结构尺寸；最后，加工磁流变制动器样机并搭建转矩性能测试系统，对制动器进行了制动性能试验。

结果

该制动器具备内外两条液流通道，通过合理设置导磁和隔磁材料，获得了6条有效阻尼间隙，从而使该制动器在外形尺寸不变的前提下具备优良的转矩性能。理论计算结果显示，优化后的制动转矩和可调范围比优化前分别提升了30.23%、16.58%。试验结果表明，当外加电流为2.0 A时，制动转矩最大可达44.28 N·m，动态可调范围为17.88；试验值与理论计算值的相对误差分别为6.5%和16.1%，验证了设计的合理性。

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胡洁颖，女，2003年生，江西南昌人；主要研究方向为磁流变智能器件结构设计及优化；。

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胡洁颖，女，2003年生，江西南昌人；主要研究方向为磁流变智能器件结构设计及优化；。

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胡洁颖，女，2003年生，江西南昌人；主要研究方向为磁流变智能器件结构设计及优化；。

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Journal of Chongqing Jiaotong University （Natural Science），2024，43（1）：107-115., articleTitle=Braking performance analysis of drum MR brake with internal and external fluid flow channel, refAbstract=null), Reference(id=1263881768940221015, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, doi=null, pmid=null, pmcid=null, year=2024, volume=41, issue=3, pageStart=110, pageEnd=118, url=null, language=null, rfNumber=21, rfOrder=23, authorNames=应仕诚, 胡国良, 喻理梵, journalName=华东交通大学学报, refType=null, unstructuredReference=应仕诚，胡国良，喻理梵. 基于NSGA-Ⅱ的内外液流通道筒式磁流变制动器优化设计［J］. 华东交通大学学报，2024，41（3）：110-118., articleTitle=基于NSGA-Ⅱ的内外液流通道筒式磁流变制动器优化设计, refAbstract=null), Reference(id=1263881769460314716, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, doi=null, pmid=null, pmcid=null, year=2024, volume=41, issue=3, pageStart=110, pageEnd=118, url=null, language=null, rfNumber=21, rfOrder=24, authorNames=YING Shicheng, HU Guoliang, YU Lifan, journalName=Journal of East China Jiaotong University, refType=null, unstructuredReference=YING Shicheng，HU Guoliang，YU Lifan. Optimal design of drum MR brake with internal and external fluid flow channels based on NSGA-Ⅱ algorithm［J］. Journal of East China Jiaotong University，2024，41（3）：110-118., articleTitle=Optimal design of drum MR brake with internal and external fluid flow channels based on NSGA-Ⅱ algorithm, refAbstract=null)], funds=null, companyList=[AuthorCompany(id=1263881669027705832, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, xref=null, ext=[AuthorCompanyExt(id=1263881669090620394, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, companyId=1263881669027705832, language=EN, country=null, province=null, city=null, postcode=null, companyName=null, departmentName=null, remark=School of Mechatronics and Vehicle Engineering, East China Jiaotong University, Nanchang330013, China), AuthorCompanyExt(id=1263881669119980523, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, companyId=1263881669027705832, language=CN, country=null, province=null, city=null, postcode=null, 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（a）零件图 （b）装配图

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Material properties of the magnetorheological brake with internal and external fluid flow channels

, figureFileSmall=null, figureFileBig=null, tableContent=
零件材料导磁性
端盖304不锈钢不导磁
磁芯10号钢导磁
旋转套筒10号钢导磁
隔磁环304不锈钢不导磁
隔磁盘304不锈钢不导磁
缸体10号钢导磁
转轴304不锈钢不导磁
磁流变液MRF-J25T—
线圈铜线导磁
), ArticleFig(id=1263881743178805655, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=CN, label=表1, caption=

内外液流通道式磁流变制动器材料属性

, figureFileSmall=null, figureFileBig=null, tableContent=
零件材料导磁性
端盖304不锈钢不导磁
磁芯10号钢导磁
旋转套筒10号钢导磁
隔磁环304不锈钢不导磁
隔磁盘304不锈钢不导磁
缸体10号钢导磁
转轴304不锈钢不导磁
磁流变液MRF-J25T—
线圈铜线导磁
), ArticleFig(id=1263881744038637985, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=EN, label=Tab. 2, caption=

Key dimensional parameters of the magnetorheological brake with internal and external fluid flow channels

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参数数值/mm
绕线架厚度t025
绕线架左翼长h126
绕线架长lc56
左侧间隙宽度wg7.5
制动器半径rb51.5
制动器总长lb187
), ArticleFig(id=1263881744474845607, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=CN, label=表2, caption=

内外液流通道式磁流变制动器关键尺寸参数

, figureFileSmall=null, figureFileBig=null, tableContent=
参数数值/mm
绕线架厚度t025
绕线架左翼长h126
绕线架长lc56
左侧间隙宽度wg7.5
制动器半径rb51.5
制动器总长lb187
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Value range of the design variables

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设计变量下限上限
t0/ mm2428
h1/ mm2026
lc/ mm5258
wg/ mm710
), ArticleFig(id=1263881749109551539, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=CN, label=表3, caption=

设计变量取值范围

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设计变量下限上限
t0/ mm2428
h1/ mm2026
lc/ mm5258
wg/ mm710
), ArticleFig(id=1263881751101845948, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=EN, label=Tab. 4, caption=

Initial and optimized dimensional parameters and results of the magnetorheological brake with internal and external fluid flow channels

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参数优化前优化后
绕线架厚度t0/mm2528
绕线架左翼长h1/mm2622
绕线架长lc/mm5654
左侧间隙宽度wg/mm7.58.5
输出转矩T/（N·m）36.3847.36
动态可调范围18.2821.31
), ArticleFig(id=1263881751600968130, tenantId=1146029695717560320, journalId=1263187878914834467, articleId=1263881629865489104, language=CN, label=表4, caption=

内外液流通道式磁流变制动器优化前后尺寸参数及结果

, figureFileSmall=null, figureFileBig=null, tableContent=
参数优化前优化后
绕线架厚度t0/mm2528
绕线架左翼长h1/mm2622
绕线架长lc/mm5654
左侧间隙宽度wg/mm7.58.5
输出转矩T/（N·m）36.3847.36
动态可调范围18.2821.31
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内外液流通道式磁流变制动器结构设计及制动性能研究
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胡洁颖
机械传动 | 磁传动专题 2026,50(1): 19-26
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机械传动 | 磁传动专题 2026, 50(1): 19-26
内外液流通道式磁流变制动器结构设计及制动性能研究
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胡洁颖
作者信息
  • 华东交通大学 机电与车辆工程学院，南昌330013

    • 胡洁颖，女，2003年生，江西南昌人；主要研究方向为磁流变智能器件结构设计及优化；。

Structural design and braking performance analysis of magnetorheological brakes with internal and external fluid flow channels
Jieying HU
Affiliations
  • School of Mechatronics and Vehicle Engineering, East China Jiaotong University, Nanchang330013, China
出版时间: 2026-01-15 doi: 10.16578/j.issn.1004.2539.2026.01.003
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摘要
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目的

为提高磁流变制动器的转矩体积比，提出一种具有内外液流通道的磁流变制动器。

方法

首先，阐述了内外液流通道式磁流变制动器的结构和工作原理，基于Bingham本构模型建立了制动转矩数学模型；其次，基于非支配排序遗传算法（Non-dominated Sorting Genetic Algorithm, NSGA-Ⅱ）对制动器进行优化设计，得到最优结构尺寸；最后，加工磁流变制动器样机并搭建转矩性能测试系统，对制动器进行了制动性能试验。

结果

该制动器具备内外两条液流通道，通过合理设置导磁和隔磁材料，获得了6条有效阻尼间隙，从而使该制动器在外形尺寸不变的前提下具备优良的转矩性能。理论计算结果显示，优化后的制动转矩和可调范围比优化前分别提升了30.23%、16.58%。试验结果表明，当外加电流为2.0 A时，制动转矩最大可达44.28 N·m，动态可调范围为17.88；试验值与理论计算值的相对误差分别为6.5%和16.1%，验证了设计的合理性。

磁流变制动器  /  内外液流通道  /  优化设计  /  电磁场仿真  /  制动性能
Objective

In order to improve the torque to volume ratio of magnetorheological （MR） brakes, a MR brake with internal and external fluid flow channels was developed.

Methods

Firstly, the structure and working principle of the MR brake with internal and external fluid flow channels were introduced, and the mathematical model of the braking torque was established based on Bingham constitutive model. Secondly, in order to obtain the optimal structure size of the MR brake, structural optimization design was carried out based on the non-dominated sorting genetic algorithm (NSGA-Ⅱ). Finally, the prototype of MR brake was fabricated, the torque performance test system was built, and the braking performance test was conducted for the MR brake.

Results

There are both internal and external fluid flow channels in the MR brake. Six effective damping gaps are obtained by reasonable setting of magnetic conductive and magnetic isolating materials in the MR brake, so that it can produce excellent torque performance under the premise of the same size. The theoretical calculation results show that the braking torque and the adjustable range after optimization are increased by 30.23% and 16.58% respectively compared with those before optimization. Test results show that at the applied current of 2.0 A, the maximum braking torque is 44.28 N·m, and the dynamic adjustable range is 17.8. The relative errors of the braking torque and the dynamic adjustable range between the test values and the theoretical calculation values are 6.5% and 16.1% respectively, which verifies the rationality of the design.

MR brake  /  Internal and external fluid flow channels  /  Optimal design  /  Electromagnetic field simulation  /  Braking performance
胡洁颖. 内外液流通道式磁流变制动器结构设计及制动性能研究. 机械传动, 2026 , 50 (1) : 19 -26 . DOI: 10.16578/j.issn.1004.2539.2026.01.003
Jieying HU. Structural design and braking performance analysis of magnetorheological brakes with internal and external fluid flow channels[J]. Journal of Mechanical Transmission, 2026 , 50 (1) : 19 -26 . DOI: 10.16578/j.issn.1004.2539.2026.01.003
正文
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0　引言
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传统的制动器是通过机械或液压传动的方式，使非旋转元件与旋转元件相互摩擦来实现制动的。由于可控转矩小、响应速度慢及电子集成度低等问题，传统的制动器制动效果一般。以磁流变液为工作介质的磁流变制动器是一种新型半主动装置，制动器内部设置励磁线圈，通过调节输入电流可实现连续可控的制动力矩[1-2]。磁流变制动器可有效解决传统制动器的问题，受到国内外研究学者的广泛关注。磁流变制动器按结构可分为盘式制动器[3-4]、筒式制动器[5-6]及混合式制动器[7-8]。
为了提高转矩体积比，得到整体体积小、输出转矩大的磁流变制动器，国内外学者设计并提出多种不同结构的磁流变制动器。ZHOU等[9]对盘式磁流变制动器进行了改进，在励磁线圈的另一侧增加了1个对称的制动盘，使得磁力线垂直穿过4个盘面，形成8段有效阻尼间隙。该结构充分利用了能够产生高转矩的径向尺寸，从而有效提高了制动器的制动性能。NGUYEN等[10]研发了一种带齿形转子的新型磁流变制动器，将传统圆柱转子结构设计成齿形转子，使得有效阻尼面积增大。试验结果表明，在外加电流条件下，制动转矩可达9.8 N·m。MOUSAVI等[11]提出一种带T型转子的磁流变制动器，采用圆弧边界结构，有效增加了制动器转子与磁流变液之间的剪切面积，提高了有效阻尼间隙的利用率。仿真和试验结果表明，该制动器的最大转矩可达38.4 N·m。上述研究基于盘式磁流变制动器设计了几种新颖的结构，在一定程度上提高了制动器的转矩体积比，但是其结构都比较复杂。
筒式磁流变制动器是另一种典型结构。相比于盘式结构，筒式结构更适合应用于狭窄细长的工作场所。此外，在较高转速下，盘式磁流变制动器工作介质的铁磁颗粒会由于离心力而与载液分离，从而导致性能降低[12]。WANG等[13]在单筒式制动器的基础上提出一种多筒式磁流变制动器，将传统筒式制动器上的制动筒增加到8个，通过与外端盖交叉配合，形成16段有效阻尼间隙，提高了整体输出转矩。然而，多筒式磁流变制动器在提高输出转矩的同时，必然导致整体体积增大。因此，QIN等[14]设计了一种中空多筒式磁流变制动器，将微型电动机与比例微分积分（Proportional-Integral-Derivative, PID）控制器结合，以实现制动力矩的补偿。试验结果表明，该中空多筒式制动器最大力矩可达1.26 N·m，转矩体积比为41.25 kN/m2，动态可调范围为41.17。但是该系统需要借助力矩补偿，消耗功率较大。
除了对盘式或筒式磁流变制动器结构进行设计外，也可以在制动器内部合理设置导磁与非导磁材料，使磁力线发生扭转，垂直通过更多的液流通道，实现延长有效阻尼间隙长度的目标，从而提高输出转矩。SENKAL等[15]设计了一种紧凑性磁流变制动器，将非磁性套管穿插放入导磁碳钢中，使得磁力线能蜿蜒穿过液流通道，形成6段有效阻尼间隙。仿真和试验结果表明，该制动器可在体积不变的情况下得到更大的输出转矩。HU等[16]在磁流变制动器中安装了可转动的套管，并在套管中央设置了非导磁材料，在不增大制动器整体尺寸的情况下，增大了制动器系统的有效工作面积，使输出转矩得到进一步提高。POZNIC等[17]提出一种结合非导磁材料的磁流变制动器，可以在不增大整体尺寸的情况下实现液流通道处磁感应强度的增加。试验结果表明，改进后的磁流变制动器可获得更大的制动转矩。
虽上述研究能在一定程度上提高制动转矩，但总体提高程度相对较小，同时存在结构复杂、尺寸不最优等缺点。基于此，本文提出并设计了一种具有内外液流通道结构的新型筒式磁流变制动器。在缸筒和旋转套筒中增设非磁性器件，使得磁力线蜿蜒通过内外轴向液流通道的6段有效阻尼间隙，在不增大制动器外形结构尺寸的前提下，有效改善了其制动性能。建立制动器输出转矩数学模型，对制动器进行结构优化设计，得到了最优尺寸；加工磁流变制动器样机，对制动性能进行了测试分析。
1　内外液流通道式磁流变制动器结构设计
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1.1　结构及原理
图1为内外液流通道式磁流变制动器结构图，其主要由端盖、缸体、旋转套筒、转轴、绕线架、线圈、隔磁环以及隔磁盘等部件组成。旋转套筒外表面与缸体内表面之间的环形间隙形成外液流通道，旋转套筒内表面与绕线架外表面之间的环形间隙形成内液流通道，内外液流通道中充满磁流变液。在磁场作用下，内外液流通道中的磁流变液产生磁流变效应。基于此，为了在固定体积约束下延长有效阻尼间隙，对制动器内部的导磁与非导磁材料进行了合理布置。表1所示为磁流变制动器材料属性。缸体中间设置有隔磁盘，旋转套筒两侧设置有2个隔磁环；绕线架、旋转套筒和缸体的其他部分为导磁材料。当线圈通入电流时，在制动器内部产生感应磁场，磁力线在隔磁环和隔磁盘的作用下发生扭转，垂直通过两端内液流通道和4段外液流通道，形成S1~S6共6条有效阻尼间隙。这种结构设计可使制动器在不增大整体外形尺寸的条件下延长有效阻尼间隙长度，从而产生更大的制动转矩，有效提高制动器的转矩体积比。
内外液流通道式磁流变制动器的工作区域可以分为转子和定子两部分。旋转套筒与转轴通过螺栓固定连接，在外部激励驱动下可随转轴一起旋转，这两个零件构成制动器的转子部分；绕线架与右侧端盖通过螺栓固定连接，而右侧端盖又与缸体固定连接，该部分在工作过程中保持静止，构成制动器的定子部分。当线圈无外部加载电流时，制动器内部不产生感应磁场，转子和定子部分可自由相互转动；当线圈通入加载电流时，制动器内部产生感应磁场，磁力线垂直通过6条有效阻尼间隙，有效阻尼间隙处的磁流变液在磁场作用下产生黏度变化，由液态转变为类固态，从而使转子与定子间产生剪应力，形成制动转矩，实现制动效果。此外，在不同的制动工况下，调节加载电流的大小可以得到可控制动转矩。
1.2　制动转矩数学模型
为了准确描述磁流变制动器的制动转矩与各参数之间的关系，基于Bingham本构模型建立了内外液流通道式磁流变制动器的制动转矩数学模型[18-19]。图2为Bingham本构模型简化图。
MRF-J25T型磁流变液的剪应力可表示为
τ=τ(B)sgn(γ˙)+ηγ˙
式中，τ为剪应力；τ（B）为磁致应力；γ˙为剪切应变率；η为零场黏度。
为了更好地建立磁流变制动器的制动转矩模型，做出以下假设：
1）磁流变液的体积不可压缩。
2）磁感应强度在制动器工作平面上均匀分布。
3）磁流变液的流速与制动盘半径成线性关系。
图3为磁流变制动器的液流通道示意图。图3中，r1为绕线架外圆半径；r2为旋转套筒外圆半径；gi为内液流通道宽度；go为外液流通道宽度；w为制动器转子与定子的相对角速度。磁流变液在半径r处的剪切应变率可定义为
γ˙=wrl
式中，l为磁流变液所在的有效阻尼间隙的长度。
采用微元法，将半径r分为多个微小单元，得到在半径r处的制动力矩表达式，即
T=2πr2lτ
分析式（1）可知，磁流变液的剪应力由磁致应力和黏滞应力两部分构成。因此，制动器的总制动转矩计算式为
T=TB+Tη
式中，TB为磁致转矩，与感应磁场强度有关；Tη为黏滞转矩，与相对转速有关。
结合式（1）和式（3），制动器磁致转矩TB计算式为
TB=4πLτ(B)r2(r+g)2ln[(r+g)/r](r+g)2-r2
黏滞转矩Tη计算式为
Tη=4πηLr2(r+g)2ω(r+g)2-r2
式中，L为有效阻尼间隙长度；g为液流通道宽度；ω为转轴转速。
由于磁流变制动器是一种半主动控制器，其制动力矩可通过输入电流控制，因此，制动转矩的最大可调范围是衡量制动器性能的又一指标。制动转矩的最大可调范围为输入电流从0增加至最大值时制动转矩的变化范围。本文选取最大制动转矩与电流为0时制动转矩的比值作为衡量标准。由于当无电流输入时，磁流变制动器只有黏滞转矩，所以，最大可调范围的计算式为
β=TTη
2　内外液流通道式磁流变制动器优化设计
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2.1　初始结构确定
通过磁路分析、仿真及模型计算，初步确定了内外液流通道式磁流变制动器的尺寸参数[20-21]。图4为该制动器尺寸示意图，表2所示为优化前该制动器的关键尺寸参数。
通过计算得到制动转矩和动态可调范围随电流变化的关系，分别如图5和图6所示。观察图5可知，该磁流变制动器的制动转矩随电流增加而增加，且当电流为2 A时达到最大值36.38 N·m。这说明该结构可实现可控制动转矩，且能输出较大转矩。由图6可知，最大可调范围为18.28。这说明该制动器能够提供较大范围的制动转矩变化。
2.2　结构优化设计
通过理论分析和计算确定的初始尺寸虽能在一定程度上满足设计要求，但并不是最优结构。为进一步提高磁流变制动器的转矩体积比，本文采用非支配排序遗传算法（Non-dominated Sorting Genetic Algorithm, NSGA-Ⅱ）对该制动器进行结构优化设计。考虑到磁流变制动器包含制动转矩和最大可调范围两个性能指标，本次优化目标设定如下：在保持外形尺寸不变的情况下得到更大的制动力矩和最大可调范围。另外，考虑到有效阻尼间隙处的磁感应强度对制动器的影响至关重要，因此，本文主要对线圈及绕线架进行优化，分别选取绕线架厚度t0、绕线架左翼长h1、线圈长lc以及左侧间隙宽度wg作为设计变量。由于外形尺寸固定，所以，各设计变量均设定有上限值和下限值，如表3所示。
为了简化计算，基于试验设计的方法建立试验正交表，找到目标函数与设计变量之间的关系，再利用NSGA-Ⅱ进行求解，得到最优尺寸参数。图7为NSGA-Ⅱ求解流程图。确定初始化种群的规模为50组，交叉比例和变异概率分别设置为0.8和0.05，设置最大迭代次数为200。
采用Matlab软件进行计算，经过185次运算后，得到图8所示的Pareto最优解集。图8中，横坐标为最大制动转矩M，纵坐标为最大可调范围β。由图8可知，最大制动转矩与最大可调范围成反比例。基于此，为了综合得到较优的制动转矩和最大可调范围，选取Pareto解集中间部分的尺寸作为优化后的尺寸参数，如表4所示。
2.3　优化结果分析
为了分析尺寸参数对磁感应强度的影响，选择有效阻尼间隙处的磁感应强度作为研究对象，利用COMSOL软件进行磁场仿真计算。由图1可知，内液流通道处的有效阻尼间隙S1和S2具有对称关系，外液流通道处的有效阻尼间隙S4和S5具有对称关系。因此，本次主要选择S1、S3、S5和S6这4条有效阻尼间隙进行分析。图9所示为优化前后磁流变制动器有效阻尼间隙处磁感应强度对比曲线。观察图9可知，有效阻尼间隙处的磁感应强度随电流的增加而增加，优化后的4条有效阻尼间隙处的磁感应强度在全局上均大于优化前的值。当输入电流为2 A时，优化后的S1、S3、S5和S6处的磁感应强度分别为0.734、0.668、0.459、0.401 T。与优化前的磁感应强度值相比，4条有效阻尼间隙处的磁感应强度分别提高了28.39%、30.43%、9.4%、20.19%，优化有效提高了磁场利用率。
图10所示为优化前后磁流变制动器的制动转矩随电流变化的对比。由图10可知，优化前后磁流变制动器的制动转矩均随电流的增加而增加；在输入电流小于0.4 A时，优化前后制动器的制动转矩曲线基本重合；而当输入电流大于0.4 A时，优化后制动器的制动转矩得到显著提升，且随电流的增加提升越明显。主要原因如下：电流较小时，黏滞转矩在总制动转矩中占比较大，优化前后变化不明显；当电流较大时，磁致转矩占比较大，优化前后的差别开始显现。当输入电流为2.0 A时，磁流变制动器的制动转矩由36.38 N·m提高到47.35 N·m，提升了30.23%。
图11所示为优化前后的磁流变制动器可调范围。当输入电流为2.0 A时，优化前后制动器的可调范围均达到最大值，分别为18.28和21.31。与优化前数值相比，优化后的数值提升了16.58%。优化后的磁流变制动器结构在制动转矩和动态范围上均有较大提升，验证了优化设计方法的有效性。
3　内外液流通道式磁流变制动器制动性能测试分析
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3.1　制动性能测试系统搭建
根据优化后的尺寸参数，加工了内外液流通道式磁流变制动器，如图12所示。需要注意的是，考虑到连接稳定性，零件图中的隔磁环和旋转套筒采用了焊接工艺，隔磁盘和缸筒亦是如此。
搭建了磁流变制动器制动性能测试平台，如图13所示。该试验台可以测量磁流变制动器转矩输出特性、响应特性等性能参数，包含电动机驱动系统、性能采集系统和控制系统3部分。电动机驱动系统由三相异步电动机、飞轮组、磁流变制动器等组成，采用三相异步电动机提供动力，采用飞轮组高速旋转模拟车辆行驶过程。性能采集系统包括角位移传感器、转矩传感器、温度传感器、数据采集卡和计算机；测试数据由传感器和数据采集卡采集，存储在计算机中。控制系统由直流电源、变频器和离合器组成，电源用于为磁流变制动器的励磁线圈提供电流，变频器用来调节电动机转速，离合器用来控制电动机电源的开关。
3.2　转矩性能测试
调节变频器的频率，给系统一个初始恒定转速，并以0.2 A为间隔调节外加电流，对制动系统进行试验。得到的不同转速条件下制动转矩随电流变化的曲线如图14所示。由图14可知，在不同初始转速条件下，转矩随电流变化的趋势基本一致；且当电流恒定时，初始转速由200 r/min增长到800 r/min的过程中，磁流变制动器的制动转矩也随之增大。
对比转速为200 r/min时的理论计算值与试验值，得到图15所示的制动性能对比曲线。由图15（a）可知，磁流变制动器制动转矩试验值与理论计算值随电流变化的趋势基本一致；当激励电流由0逐渐增加到2.0 A时，系统的制动转矩试验值由2.47 N∙m上升到44.28 N∙m。此外，试验值测量出的黏滞转矩略大于理论计算值。这是因为制动平台各部分连接处存在机械摩擦，制动器内部油封与端盖之间也存在部分摩擦。由图15（b）可知，转矩动态可调范围试验值整体上小于理论计算值；当激励电流由0逐渐增加到2.0 A时，动态可调范围试验值由1上升到17.88。当外加电流为2.0 A时，试验值的制动转矩与动态可调范围分别为44.28 N∙m和17.88，相比于理论计算值47.35 N∙m和21.31，二者之间的相对误差分别为6.5%和16.1%。总体来说，所设计的内外液流通道式磁流变制动器可输出较大制动转矩和可调范围，制动性能良好。
3.3　响应性能测试
图16所示为不同激励电流下磁流变制动器响应结果。由图16可知，随着初始激励电流的增大，电流的响应时间有着细微的增加；但整体上看，激励电流的大小对电流响应时间的影响较小。分别对0.5、1.0、1.5、2.0 A等4种外加电流进行试验，测得其稳态值的95%的响应时间分别为45、47、48、49 ms。
制动系统响应测试结果如图17所示。试验平台测量得到的响应时间是一个总的响应时间，该响应时间主要包括电流的输入时间、磁场形成的时间、磁流变液的响应时间和机械系统传动的时间。由图17可知，施加激励电流后，系统输出转矩随时间变化；同时，当外加电流由0.5 A增加到1.0 A时，系统输出转矩的响应时间由120 ms增加到135 ms。由此可知，当改变外界激励电流时，制动系统的响应时间会存在些许差异。该内外液流通道式磁流变制动器的响应时间在毫秒级，能够快速地反应并完成制动功能。
4　结论
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1）设计了一种具有内外两条液流通道的筒式磁流变制动器，通过合理设置导磁和隔磁材料，可获得6条有效阻尼间隙。
2）基于Bingham本构模型建立了制动转矩数学模型。采用非支配排序遗传算法对磁流变制动器进行结构优化，得到最优尺寸参数。理论计算结果显示，优化后的制动转矩和可调范围分别提升了30.23%、16.58%。
3）加工出优化后的磁流变制动器并搭建了转矩性能测试系统，测试得到了磁流变制动器的转矩输出特性和响应特性。电流由0增加到2 A，系统输出转矩由2.57 N∙m上升到44.28 N∙m，动态可调范围由1上升到17.88，验证了所设计制动器的优异性能；此外，与理论计算结果进行对比分析，二者之间的相对误差分别为6.5%和16.1%，初步验证了设计的有效性。
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2026年第50卷第1期
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doi: 10.16578/j.issn.1004.2539.2026.01.003
  • 接收时间：2024-08-14
  • 首发时间：2026-05-20
  • 出版时间：2026-01-15
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  • 收稿日期：2024-08-14
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    华东交通大学 机电与车辆工程学院，南昌330013
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2种不同金属材料的力学参数
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Family		 属数
Number of
genus		 种数
Number of
species		 占总种数比例
Percentage of
total species (%)		 属
Genus		 种数
Number of
species		 占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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