Optimal design of disc-type magneto-rheological brake for mid-sized motorcycle: experimental evaluation

In this paper, a disc-type magneto-rheological (MR) brake is designed for a mid-sized motorcycle and its performance is experimentally evaluated. The proposed MR brake consists of an outer housing, a rotating disc immersed in MR fluid, and a copper wire coiled around a bobbin to generate a magnetic field. The structural configuration of the MR brake is first presented with consideration of the installation space for the conventional hydraulic brake of a mid-sized motorcycle. The design parameters of the proposed MR brake are optimized to satisfy design requirements such as the braking torque, total mass of the MR brake, and cruising temperature caused by the magnetic-field friction of the MR fluid. In the optimization procedure, the braking torque is calculated based on the Herschel–Bulkley rheological model, which predicts MR fluid behavior well at high shear rate. An optimization tool based on finite element analysis is used to obtain the optimized dimensions of the MR brake. After manufacturing the MR brake, mechanical performances regarding the response time, braking torque and cruising temperature are experimentally evaluated.