Structural design and experimental study of composite disc magnetorheological brake

To make up for the lack of braking torque (BT) and stability of the magnetorheological brake (MRB), an innovative composite disk magnetorheological brake design is proposed in this paper. This design combines a multi-disk and T-shaped disk layout and uses a dual-coil excitation mode to boost the magnetic field strength in the working area. Based on the Bingham model, a torque model dominated by magnetic force torque is derived. Via electromagnetic field simulation analysis, the influence patterns of current, coil turns, working gap, brake disk radius, and magnetic shielding ring thickness on BT are clarified, verifying the rationality of the magnetic circuit design. Experimental findings indicate that at an initial braking speed of 100 km/h with a 2.8 A current applied, the measured maximum BT reaches 270 N·m, and the output torque increases with current and rotational speed. This structure provides an effective solution for the design of high-torque-density MRB.