Design Optimization of a Hydrodynamic Brake with an Electrorheological Fluid

This article describes the design optimization of a hydrodynamic brake with an electrorheological fluid. The design optimization is performed on the basis of mathematical model of the brake geometry and the brake’s electrical circuit. The parameters of the mathematical models are selected based on experimental tests of the prototype brake. Six different objective functions are minimized during the design optimization. The functions are created taking into consideration the following factors: the braking torque, brake weight, electric power absorbed by the brake, and the torque rise time. The assumed design variables are: the number of blades and the radii (inner and outer) of the brake’s working space. The optimization calculations are performed for two design variables intervals. The first interval is defined taking into consideration the accuracy of the mathematical model. The second, narrower interval is assumed for the tested prototypical brake. On the basis of the optimization calculation results, general guidelines are presented for the optimization of the hydrodynamic brakes with an ER fluid. In addition, the possibilities of optimizing the prototype brake are determined.