Develop Real Time Techniques for Instantly Detecting Viscosity Changes to Facilitate Timely Maintenance and Defect Detection in MR Suspension Systems

Magnetorheological (MR) fluids are essential in modern semi-active suspension systems due to their field-responsive viscosity properties. However, extended usage leads to viscosity degradation, adversely affecting damper efficiency and vehicle safety. This study develops and validates a real-time condition monitoring system capable of detecting refined changes in MR fluid viscosity, pressure and flow rate. By integrating sensors with MATLAB-based analysis and heatmap visualization, the system identifies localized faults and degradation patterns. Experimental results from a monotube MR damper setup confirm a liberal decline in fluid performance. The study contributes a practical tool for predictive maintenance and early defect detection, improving the reliability and durability of MR-based suspension systems.