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Design, modelling and testing of a novel high-torque magnetorheological

damper
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 Smart Materials and Structures

Smart Mater. Struct. 29 (2020) 025024 (13pp) https://doi.org/10.1088/1361-665X/ab6436

Design, modelling and testing of a novel

high-torque magnetorheological damper
Min Wei, Xiaoting Rui , Wei Zhu , Fufeng Yang, Lilin Gu and
Hongtao Zhu
Institute of Launch Dynamics, Nanjing University of Science and Technology, Nanjing, People’s Republic
of China

E-mail: ruixt@163.net

Received 31 July 2019, revised 13 November 2019

Accepted for publication 19 December 2019
Published 17 January 2020

Abstract
To provide sufficient damping torque performance for heavy tracked vehicle’s suspensions, the
design of a novel high-torque rotary magnetorheological (MR) damper with a parallel plate
channel, referred to as PPCRMRD, is presented and the prototype of the PPCRMRD is
manufactured. The theoretical model of the PPCRMRD considering the Hybrid magnetic fields
effect and leakage effects is proposed. The max damping torque and controllable damping torque
of the PPCRMRD are tested on the established experimental setup based on MTS rotary test
system and compared with the theoretical results based on the proposed theoretical model, the
theoretical model ignoring leakage effect and Bingham plastic model respectively. Under the
sinusoidal excitation of 0.05 Hz and amplitude of 35°, compared with the theroetical model
without considering the leakage gap and the Bingham plastic model, the maximum error of the
proposed model is reduced by 11.08% and 40.66%. The tested max damping torque and
controllable damping torque of the PPCRMRD under sinusoidal excitation with an amplitude of
35° and frequencies of 0.1 Hz are as high as 2677 and 1711 N m. The research results show that
the principle of the PPCRMRD can provide sufficient damping torque as well as a wide range of
controllable damping torque and the proposed theoretical model of the PPCRMRD can describe
and predict its damping torque performance precisely.
Keywords: high-torque, rotary magnetorheological damper, parallel plate channel, theoretical
model

(Some figures may appear in colour only in the online journal)

1. Introduction MR damper is adjustable by changing the magnetic field

Owing to the advantages of the wide range of controllable
force [1], negligible energy consumption [2], a few Milli-
seconds response time [3] and continuously adjustable per-
formance [4], MR devices have been widespreadly
investigated and applied in numerous fields including vehicles
[5–10], civil engineering [11, 12], medical device and other
fields [13].
In general, MR dampers can be divided into two cate-
gories: linear MR dampers and rotary MR dampers [14].
Linear MR dampers, as the ideal choose of semi-active
automotive suspension systems, are most popular among
researchers. Unlike the conventional linear hydraulic damper
of passive suspensions, the damping characteristic of linear
strength of damping path inside the damper, which can
effectively enhance the comprehensive performance of sus-
pension systems and improve the comfort of the occupants.
Bai et al designed a kind of MR damper utilizing an inner
bypass for ground vehicle suspensions [6]. Fitrian Imaduddin
et al designed a novel MR valve using the meandering flow
path to increase the effectiive area so that the MR fluid can be
regulated within a small-sized valve. The simulation and
experiment results show that the proposed MR valve design
could yield substantial pressure drop improvement [15].
Subsequently, B Ichwan et al designed a novel modular MR
valve with a meandering flow path [16]. Abdul Yasser Abd
Fatah et al studied on magnetorheological valve using ser-
pentine flux path method. The results show that MR effective

0964-1726/20/025024+13$33.00 1 © 2020 IOP Publishing Ltd Printed in the UK

Smart Mater. Struct. 29 (2020) 025024 M Wei et al

region can be increased with the serpentine flux path method,

and the additional steps and thicknesses of non-magnetic
materials help to further increase the pressure drops within the
valve [17]. WG Ata & AM Salem investigated the semi-active
suspension with the linear MR damper for the M113 tracked
vehicle, which can significantly attenuate the pitching vibra-
tion of the tracked vehicle on the bumpy road profile [18].
Jianfeng Li et al presented a new coordinated control strategy
which can simultaneously improve vertical acceleration and
pitch acceleration for the hull [19]. Sun et al developed a new
generation of variable stiffness and variable damping (VSVD)
MR vehicle suspension system which consists of two MR
dampers and two coil springs. Comparing with the variable
damping suspensions, experimental results demonstrate that
the quarter car system with the VSVD suspension performs
much better in terms of reducing the sprung mass accelera-
tions [20].
Notwithstanding its great achievement in the automotive
applications, the linear MR dampers have inevitable limita-
tions, such as a large installation space requirement, restricted
Figure 1. The structure of the PPCRMRD.
stoke because of the risk of the buckle of the damper rod,
substantial sums of demands of expensive MR fluids and so
devices with small displacement. Compared to the damper
on. In consequence, the design of rotary MR dampers have
based on the first two modes, the rotary MR dampers based
been welcomed by researchers and rotary MR dampers for
on flow mode are most suitable for semiactive suspension
many different applications have been developed. Huang et al
design which combines damping characteristics and working
first published a paper on rotary MR Brake in 2002 [21].
stroke. The current research on the rotary MR dampers based
Later, Kikuchi T designed a rotary MR damper with a multi-
on the flow mode is not able to provide sufficient damping
coil structure to improve the magnetic field performance [22].
torque and cannot be used as dampers for vehicle suspen-
Zhu [23] and Naito [24] designed a kind of low-torque disc
sions, especially for heavy-duty tracked vehicle suspensions.
MR damper respectively. In the past decade, research on the
advanced semi-active suspensions research for heavy-duty
design and application of rotary MR dampers has become
tracked vehicles is critical to improving both comfort and
more extensive. Ha et al designed and optimized a double-rod
driveability on the bumpy road. Accordingly developing a
type magnetorheological suspension system for tracked
high-torque rotary MR damper is a prerequisite for achieving
vehicle [25]. Sun et al developed a seat suspension with a
this goal. For the above purpose, A novel high-torque rotary
rotary MR damper for the heavy-duty vehicles, which is
magnetorheological (MR) damper with a parallel plate flow
effective in reducing the vibrations under fuzzy logic control
channel, referred to as PPCRMRD, is designed, fabricated,
[26]. A novel rotary MR damper based on helical flow for
modeled and tested in this paper. The organization of this
increasing damping torque performance has been designed
paper is as follows. Section 2 introduces the design of the
and tested by Yu [27]. Zhang Jinqiu [28–30] and Peng
PPCRMRD. The theoretical model of this novel damper is
Zhizhao [31] optimized the rotary MR damper based on the
provided in section 3. In section 4, a prototype is tested on the
conventional hydraulic damper and designed magnetorheo-
established experimental setup and the comparison and ana-
logical damper control system for vehicle suspension. The
lysis of different theoretical models and experimental data are
results show that the method is feasible, and the experiment
given. The conclusion is drawn in section 5.
results confirmed the good performance of the rotary MR
damper. Yang et al developed a rotary MR damper for semi-
active suspension. The harmonic loading test results show
that the damping characteristics of the MR damper are 2. The structure and design of the PPCRMRD
determined by the amplitude and the magnetic fields inside
the damper [32]. As shown in figure 1, the PPCRMRD mainly consists of five
To sum up, the rotary MR dampers can be divided into parts which respectively correspond to the end shield, the
three basic categories by operational modes of MR fluid: shift, the blade, the MR valves, and the housing. Figure 2(a)
shear mode, squeeze mode and flow mode. In general, the shows the structure of the MR valve which comprises the
rotary MR dampers based on shear mode which have the inner core, the coil, the gap bars, and the outer core. The
capability with infinite rotational angle and low torque per- PPCRMRD, which are filled fully with MR fluid, is divided
formance are commonly used in brakes and clutches appli- into four chambers by the blade and two MR valves. The
cation [8]. The rotary MR dampers based on squeeze mode adjacent chambers are connected through a parallel plate
which has good damping performance but can only work in damping channel in each valve. When the vehicles travel on
the very small travel are usually used in vibration suppression bumpy road profiles, the relative motion occurs between the

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Smart Mater. Struct. 29 (2020) 025024 M Wei et al

Figure 2. The schematic diagram of the MR valve: (a) MR valve structure; (b) magnetic circuit.

sprung mass and the unsprung mass. The shaft driven by the Table 1. Material selection for the PPCRMRD components.
link arm makes the blade rotate to force MR fluid to flow
Components Materials
through between chambers on both sides of the valves. In the
absence of magnetic field, the magnetic particles in the non- End shield Aluminum
magnetic carrier fluid are distributed randomly and Shift Aluminum
PPCRMRD provides a viscous torque nearly Newtonian Blade Aluminum
behavior. When the current applied to the coil, the Housing Aluminum
Inner core 20# steel
PPCRMRD can produce the magnetic circuit as shown in
Gap bar 304# stainless steel
figure 2(b), it is possible to make the magnetic flux to pass Outer core 20# steel
through the flow channel. Thus, the MR fluid in the region Coil Copper
with magnetic field can be activated and the damping torque
of the PPCRMRD consists of viscous damping torque, fric-
tional damping torque, and controllable damping torque
related to the yield stress of the MR fluid. Before the flux magnetic field in the damping channel. Therefore, the design
density reaches saturation, the yield stress increases con- and analysis of the magnetic circuit is an important role in
tinuously with the increase of input current. In this way, the designing the rotary MR damper. As shown in table 1, in the
damping torque can be continuously controlled by changing design of the PPFCRMRD, all the parts except the MR valves
the current input. are non-magnetic materials. As for MR valves, the inner core
Unlike the conventional MR valve design, the direction and the outer core are made of 20# steel, the gap bar is made
of the cores is perpendicular to the direction of the flow of 304# stainless steel, the coil is copper wire, and the
channel. Because of its unique magnetic circuit design, the damping channel is fully filled with MR fluid. Its magnetic
PPCRMRD designed in this paper has three advantages circuit can be analyzed by Kirchhoff’s law of magnetic field:
compared with the disk MR damper and other rotary MR SHk lk = Nc I, (1 )
dampers: (1) flow mode design enhances the damping torque F = Bk Sk , (2 )
performance, the PPCRMRD is expected to achieve the max
where Hk represents the magnetic field strength of the kth link
damping torque of more than 2 kN m. (2) By placing the core
in the magnetic circuit, lk is the effective length of the kth link,
perpendicular to the flow direction of the flow channel, the
Nc is the number of turns of the coil, I is the current applied
volume of the MR valve is saved and the working range of
on the coil,Φ represents the magnitude of magnetic flux, Bk is
the rotary MR damper is increased. The working angular
the magnetic flux density of the kth link, and Sk is the area of
displacement of the PPCRMRD can reach as high as 104°. (3)
the kth link.
Due to the novel design, the non-magnetic field region can be
Generally, the magnetic flux density Bk increases as the
adjusted by changing the groove depth of the coil. Thus, the
magnetic field strength Hk increases, and its characteristic is
controllable torque performance will be enhanced. In the MR
related to the kind of materials, and is commonly described by
valve designed in this paper, the region of the magnetic field
a nonlinear B–H curve. In the low strength of magnetic field,
accounts for more than 60% of the total channel.
the relationship can be derived from:
As mentioned above, the damping characteristics of the
rotary MR damper are determined by the intensity of the Bk = m 0 mk Hk , (3 )

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Smart Mater. Struct. 29 (2020) 025024 M Wei et al

Figure 3. FEA magnetic flux density verification for the MR valve design: (a) the magnetic simulation model; (b) contours of the magnetic
flux density in the damping channel at 0.5 A current input; (c) contours of the magnetic flux density in the damping channel at 1.5 A current
input; (d) contours of the magnetic flux density in the damping channel at 2.5 A current input.

where μ0 0 is the constant magnetic permeability of free space
(m0 = 4p ´ 10-7 (TmA-1)), and μk represents the relative
permeability of of the kth link material.
From the theoretical analysis, it can be known that when
the maximum current is 2.5 A, the required number of turns of
the coil should exceed 180 to produce the maximum yield
stress of the MR fluid in the magnetic region of the damping
channel.
The 3D model of the MR valve is established to verify
the magnetic field distribution via a finite element analysis
(FEA) software ANSYS. The simulation results of MR fluid
in the damping channel are shown in figure 3. It can be seen
from the simulation analysis that the magnetic flux density in
the magnetic field area of the channel is uniform. The strength
of the magnetic field increases with the increase of current
input. And the strength of the magnetic field of all-region
except for the region of the coil exceeds 800 mT at 2.5 A
current input.,which reaches the demand strength of the
maximum yield stress of the MR fluid.
3. The theoretical model of the PPCRMRD with
consideration of leakage and channels with mixed
magnetic field
Under ideal conditions, as shown in figure 1, driven by the
blade, the MR fluid all flows through the channel on the MR
valve to produce a damping torque. However, the space
among the housing, the end shield, and the blade is required
to make the blade rotate. When the blade rotates, due to the
pressure drop between the two adjacent chambers, a part of
MR fluid flows through the MR valves, and the other flows
the space, namely the leakage gap or the inner leakage.
Compared to the linear MR dampers, the inner leakage has a
more significant impact on the performance of the rotary MR

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Figure 4. Schematic diagram of multiple channels: (a) channels in series; (b) channels in parallel.

dampers. The effects of the two channels must be considered the volume flow rate Q are given by:
simultaneously to establish an accurate theoretical model. Q = Q1 = Q2==Q k==Qn , (9 )
Based on the Bingham plastic model, the formula is as n
follows: DPseries (1,2, ¼ , n) = å DPk. (10)
k= 1
DP = DPpa + DPac · sgn (Q) , (4 )
Substituting equations (8)–(10), the total pressure drop of MR
where: fluid flows through the n channels in series ΔPseries(1,2,K,n)
12hlQ can be obtained by the following equation:
DPpa = , (5 )
bh3 ⎛ n ⎞ ⎛ n ⎞
DPseries (1,2, ¼ , n) = ⎜ å a k ⎟ Q + ⎜ å bk ⎟ sgn (Q). (11)
3ty l ⎝k = 1 ⎠ ⎝k = 1 ⎠
DPac = , (6 )
h
where ΔP is the total pressure drop of MR fluid flows through
the channel, ΔPpa represents the pressure drop of the MR 3.1.2. Theoretical analysis of channels in parallel.
As shown
fluid viscosity, ΔPac is the pressure drop due to MR effect, in figure 4(b), the total pressure drop of MR fluid flows
MR fluid viscosity when no magnetic field applied η is through the n channels in parallel defined as ΔPparallel(1,2,K,n)
0.33 Pa s, l is the length of the damping channel, Q is the and the volume flow rate Q are given by:
volume flow rate due to pressure drop, b is the width of the DPparallel (1,2,  , n) = DP1 = DP2==DPk==DPn (12)
plates, h is the gap between the plates, and τy represents n
the controllable yield stress of a MR fluid which is related to
magnetic flux density B. The relationship between τy and B
Q= å Qk (13)
k= 1
can be expressed as follow
Substituting equations (8) and (12) into (13), the total
ty = - 2.7e 5 ´ B6 + 8.9e 5 ´ B5 - 1e 6 ´ B4 pressure drop of MR fluid flows through the n channels in
series ΔPparallel(1,2,K,n) can be obtained by the following
+ 4.8e 5 ´ B3 - 6.3e 4 ´ B2 + 2.3e 4 ´ B + 93. (7)
equation:
⎛ n bk ⎞
⎛ n 1⎞ ⎜ å k= 1 ⎟
ak
3.1. Pressure drop analysis of channels with mixed magnetic DPparallel (1,2,  , n) = ⎜ å ⎟ Q + ⎜ ⎟ sgn (Q). (14)
⎝k = 1 a k ⎠ ⎜⎜ n 1 ⎟⎟
field å
⎝ k= 1 a k ⎠
Firstly, it is assumed that there are n channels as shown in
figure 4 and the expression of the pressure drop of the kth
channel DPk is as follows:
3.2. Theoretical model of the PPCRMRD
DPk = a k Q k + bk sgn (Q k ) , (8 )
In the design of the PPCRMRD, the volume flow rate Q is
where ak is the passive damping coefficient, Qk is the volume determined as
flow rate of the kth channel due to pressure drop, bk represents
1
controllable pressure drop. Q= w (R2 2 - R1 2) H , (15)
2
3.1.1. Theoretical analysis of channels in series. As shown where ω represents the angular velocity of the blade, R2 is the
in figure 4(a), the total pressure drop of MR fluid flows outer radius of the blade, R1 is the inner radius of the blade,
through the n channels in series defined as ΔPseries(1,2,K,n) and and H is the height of the blade.

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Figure 6. Experimental setup for the PPCRMRD.

Table 2. Primary structural parameters of the PPCRMRD.

Description Value
Figure 5. Schematic of MR fluid profile in parallel channels.
Height of the blade(H) 77 mm
Outer radius of the blade(R2) 125 mm
As shown in figure 5, MR fluid mainly flows through two Inner radius of the blade(R1) 56 mm
Thickness of the MR valve gap(hp) 0.9 mm
kinds of channels, namely the damping path and leakage gap.
Width of region 1 and 6(lb) 10.25 mm
Damping path is the rectangular channel of uniform thickness Width of region 2 and 5(wc) 9 mm
gap and nonuniform magnetic field intensity in the MR valve. Width of region 7(lc) 30 mm
Leakage gap is the gap among the end shield, the blade and Height of region 7(hc) 55 mm
the housing without a magnetic field. Thus, the width of the Height of region 8(hb) 2.5 mm
gap bl is given by 2 (R2 - R1) + H . As the current of the coils Thickness of the leakage gap(hl) 0.013 mm
is applied, a magnetic field is exerted on the MR fluid in the Length of the leakage region(ll) 5 mm
red regions (called active regions) and no magnetic field is
exerted on the MR fluid in the blue regions (called passive
regions). The primary structural parameters of the PPCRMRD where
are listed in table 2. The pressure drop of the MR valve is
expressed as ΔPdp, the pressure drop of the kth region is 12hll
A1 = .
defined as ΔPk, and the drop pressure of the leakage region bl hl 3
is expressed as ΔPl. The values of ΔPk and ΔPl can be
Substituting equation (17) into inequation (18), the maximum
calculated by equation (4). Thus, the total pressure drop
volume flow rate in case 1 K1 is obtained by the following
between the adjacent chambers ΔP are given by
equation
DP = DPparallel (dp, l ). (16)
6lb ty
Based on Bingham plastic model, the flow of MR fluid in the K1 = .
hp A1
channel will not occur until the pressure drop exceeds the
yield stress of the MR fluid. The pressure drop in each region
is different because of the volume flow rate Q. Therefore,
According to the volume flow rate, it can be divided into five Case 2. As the increase of the volume flow rate, the pressure
cases for discussion. drop exceeds the yield stress of region 1 and 6. The MR fluid
flows through region 1, 2, 3, 4, 5, 6, and leakage gap. In this
Case 1. When the volume flow rate is small, the pressure drop case, the pressure drop of the damping path in the MR valve
is less than the yield stress of region 1 and 6. All MR fluid ΔPdp2 can be expressed as follows
flows through the leakage gap. According to equation (4), the
pressure drop ΔP can be expressed as follows DPdp2 = DPseries (1,2,5,6) + DPparallel (3,4). (19)

DP = A1 Q, (17) Substituting equation (19) into equation (16), the total pres-
sure drop ΔP can be expressed as follows
6ty lb
DP < , (18)
hp DP = A2 Q + B2 sgn (Q) , (20)

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Figure 7. Damping torque of the PPCRMRD under sinusoidal angular displacement excitation: (a) damping torque versus angular
displacement at 0.05 Hz; (b) damping torque versus angular velocity at 0.05 Hz; (c) damping torque versus angular displacement at 0.1 Hz;
(d) damping torque versus angular velocity at 0.1 Hz.

where Case 3. When the volume flow rate is greater than K2. The
⎛ 4 (l + wc) MR fluid flows through region 1, 2, 3, 4, 5, 6, 7, and leakage
l ⎞
12h ⎜ b + c ⎟ ll gap. In this case, the pressure drop of the damping path in the
⎝ hc + 2wc wc ⎠ MR valve ΔPdp3 can be expressed as follows
A2 = ,
⎛ 4 (l + wc) l ⎞
2ll hp 3 + ⎜ b + c ⎟ [2 (R2 - R1) + H ] hl 3
⎝ hc + 2wc wc ⎠ DPdp3 = DPseries(1,2,5,6) + DPparallel (3,4,7). (22)
12hp 2lb ll ty Combining the equations (16) and (22), the total pressure
B2 = .
⎛ 4 (lb + wc) lc ⎞ drop ΔP can be expressed as follows.
2ll hp + ⎜
3 + ⎟ [2 (R2 - R1) + H ] hl 3
⎝ hc + 2wc wc ⎠ DP = A3 Q + B3 sgn (Q) , (23)
In this case, the pressure drop of region 3 and 4 is less than where
the yield stress of the region 7 12h (lc + 2lb + 2wc) ll
A3 = ,
3ty lc ll (h c + 2wc) h p 3 + (lc + 2lb + 2wc)[2 (R2 - R1) + H ] hl 3
DPparrallel (3,4) < . (21)
hp 3h p 2ll [lc h c + 2lb (2wc + h c)] ty
B3 = .
Combining the equations (19), (20) and the inequation (21) ll (h c + 2wc) h p 3 + (lc + 2wc + 2lb)[2 (R2 - R1) + H ] hl 3
the maximum volume flow rate in case 2 K2 is obtained by as In case 3, the total pressure drop is less than the yield stress of
follows the region 8 or 9
hp 3ty [12 (lb + wc) wc + 3 (hc + 2wc) lc] ty 3ty (lc + 2lb + wc )
K2 = + + K1. DPdp3 < , (24)
4h 2wc (hc + 2wc) A1 hp

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Figure 8. Comparison of the theoretical results and the experimental data: (a) damping torque versus angular displacement at 0.05 Hz;
(b) damping torque versus angular velocity at 0.05 Hz; (c) damping torque versus angular displacement at 0.1 Hz; (d) damping torque versus
angular velocity at 0.1 Hz.

Substituting equations (22) and (23) into inequation (24). The 3 [2 (l c + 2wc + 2l b) h b + l c h c + 2l b (2wc + h c)] l l h p 2ty
B4 = .
maximum volume flow rate in case 3 K3 is obtained by the l l (h c + 2wc + 2h b) h p 3 + (l c + 2l b + 2wc)[2 (R2 - R1) + H ] h l 3
equations as follows
In conclusion, the model of the total pressure drop can be
3 (2lb + 2wc + lc ) ty - B3 hp
K3 = . (25) describes as follows:
A3 hp
⎧ A1Q 0  ∣ Q ∣ < K1
⎪
⎪ A2Q + B2 sgn (Q) K1  ∣ Q ∣ < K2
Case 4. When the volume flow rate is greater than K3. The DP = ⎨ . (28)
MR fluid flows through all regions. The pressure drop of the ⎪ A3Q + B3 sgn (Q) K2  ∣ Q ∣ < K3
⎪
⎩ A 4Q + B4 sgn (Q)∣ Q ∣  K3
damping path in the MR valve ΔPdp4 can be expressed as
follows
Since the PPCRMRD is a symmetrical structure with two MR
DPdp4 = DPparallel (dp3,8,,9). (26) valves. The damping torque m can be calculated as follows:
Combining the equations (16) and (26), the total pressure
drop ΔP can be expressed as follows R2
m=2 òR DPHxdx. (29)
DP = A4 Q + B4 sgn (Q) , (27) 1

where
Combining the equations (15), (28) and (29), the relationship
12h (l c + 2l b + 2wc) l l between the damping torque m and the angular velocity of the
A4 = ,
l l (h c + 2wc + 2h b) h p 3 + (l c + 2l b + 2wc)[2 (R2 - R1) + H ] h l 3 blade ω can be described.

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Smart Mater. Struct. 29 (2020) 025024
Figure 9. Comparison of the theoretical results without consideration of leakage gap and the experimental data: (a) damping torque versus
angular displacement at 0.05 Hz; (b) damping torque versus angular velocity at 0.05 Hz; (c) damping torque versus angular displacement at
0.1 Hz; (d) damping torque versus angular velocity at 0.1 Hz.
4. Testing results and analysis
4.1. Experimental testing system
To validate the PPCRMRD, the experimental testing system
for the PPCRMRD performance measurement is prepared. As
shown in figure 6, it consists of a rotary damper test system
(MTS), a controller (not shown in the figure), the PPCRMRD,
the fixture, and a power supply. The MTS machine has two
heads with fixtures that can hold the PPCRMRD in place. The
actuator which is excited by the hydraulic rotor can provide
the rotary oscillatory movement. An angular displacement
sensor and a torque sensor are applied to record the angular
displacement and damping torque respectively. The power
supply is used to supply the current to the PPCRMRD.
4.2. Test results and analysis
The excited conditions consist of the frequencies of 0.05 and
0.1 Hz and the amplitude of 35° (0.61rad) [29]. The input
currents include 0, 0.5, 1.0, 1.5, 2.0 and 2.5 A.
The relationship between torque and angular displace-
ment under different input current is provided in figure 7. The
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M Wei et al
relationship between torque and angular velocity under dif-
ferent input current is provided in figure 8. According to the
figures, it can be found that the damping torque increases with
the increase of current under the same excitied condition.
The peak damping torque under the constant current 0 A and
2.5 A at 0.05 Hz are 615 N m and 2125 N m respectively;
the dynamic range is 2.56. The peak damping torque under
the constant current 0A and 2.5A at 0.1 Hz are 966 N m and
2677 N m respectively; the dynamic range is 2.77. Figure 8
presents the comparison of the damping torque between
theoretical and experimental results. Figure 9 presents the
comparison of the damping torque between the theoretical
model without consideration of the leakage gap (the thickness
of the leakage gap hl=0) and experimental results. Figure 10
presents the comparison of the damping torque between the
Bingham plastic model and experimental results. The Bing-
ham plastic model is expressed as follows:
m = aw + sgn (w ) b , (30)
where the parameters of the Bingham plastic model α and β
are determined by the minimum error between the theoretical
Smart Mater. Struct. 29 (2020) 025024
Figure 10. Comparison of the Bingham plastic model and the experimental data: (a) damping torque versus angular displacement at 0.05 Hz;
(b) damping torque versus angular velocity at 0.05 Hz; (c) damping torque versus angular displacement at 0.1 Hz; (d) damping torque versus
angular velocity at 0.1 Hz.
model and experimental data using the GSO optimization
algorithm.
Compared with the theoretical model without con-
sideration of leakage gap and Bingham plastic model. The
theoretical model proposed in this paper can accurately pre-
dict the relationship of angular displacement and damping
torque and the relationship of angular velocity and damping
torque in non-hysteresis regions. It is to be noted that the dead
zone in the figure is caused by the clearance between the rotor
of the PPCRMRD and the fixture. Compared to the proposed
model, as shown in figure 9, no consideration of leakage gap
will lead to a large theoretical damping torque, especially in
the low-velocity zone. It indicates that the inner leakage is the
reason of the mismatch why the practical damping torque is
lower than the ideal one. As illustrated in figure 10, the
Bingham plastic model can describe the damping torque
performance well at a frequency of 0.05 Hz with 0 A (off-
state), However, when there is a magnetic field, the error of
the Bingham plastic model is extremely large. It indicates that
the magnetic field distribution of the MR damping channel
designed in this paper is complicated. It is impossible to
10
M Wei et al
accurately predict the mechanical properties of the magne-
torheological damper under the magnetic field condition by
adopting the Bingham plastic model. Figure 11 presents the
error of three models under 0.05 Hz sinusoidal angular dis-
placement excitation. Figure 12 presents the error of three
models under 0.1 Hz sinusoidal angular displacement exci-
tation.Under the condition of a certain velocity, the error is
expressed as:
mT - mE
error = ´ 100%, (31)
mE
where mT is the theoretical damping torque; mE is the mea-
sured damping torque. It can be found that the error of the
proposed model is significantly less than the other two
models, especially in the low-velocity zone. Compared to the
theoretical model without consideration of leakage gap and
the Bingham plastic model, the maximum error is reduced by
11.08% and 40.66% respectively. It can be seen from
figure 12 that the prediction errors of the three models are
larger when the current is 0 A, and the error is smaller when
the current is applied. The reason is that the damper converts
Smart Mater. Struct. 29 (2020) 025024 M Wei et al

Figure 11. The predicted error under 0.05 Hz sinusoidal angular Figure 12. The Predicted error under 0.1 Hz sinusoidal angular
displacement excitation: (a) proposed theoretical model; (b) theor- displacement excitation: (a) proposed theoretical model; (b) theor-
etical model (no leakage gap); and (c) Bingham plastic model. etical model (no leakage gap); and (c) Bingham plastic model.

11
Smart Mater. Struct. 29 (2020) 025024
the mechanical energy into internal energy so that the internal
temperature of the damper increases and the viscosity of the
MR fluid decreases accordingly. In the theoretical calculation,
the apparent viscosity is a constant, and the temperature effect
is not considered. The temperature has a great influence on
the viscosity of MR fluid, the controllable damping torque
generated by the magnetic field has less effect. The problem
will be investigated in the future. The experimental and
simulation results show that the theoretical model proposed in
this paper can predict the mechanical properties of the
PPCRMRD more accurately than the Bingham plastic model.
Considering the model of the leakage gap makes the predic-
tion in the low-speed zone more accurate.
5. Conclusion
A high-torque rotary MR damper with a parallel plate channel
was presented and the damping torque performance of the
PPCRMRD has been experimentally studied in this paper.
The main conclusions can be drawn as follows.
1. A novel structure of high-torque rotary MR damper
with parallel plate channels was designed and manu-
factured. A new compact parallel plate channel MR
valve was analyzed and applied to provide high torque
performance and sufficient travel.
2. A theoretical model of the PPCRMRD based on the
Bingham plastic model was established. The model
considers leakage gap and complicated magnetic field
distribution in channels and made a good agreement
with the experimental data. Compared to the theoretical
model without consideration of leakage gap and the
Bingham plastic model, the maximum error is reduced
by 11.08% and 40.66% respectively.
3. The damping performance of the PPCRMRD was tested
using a rotary test system under sinusoidal angular
displacement excitation. Under the same excitation
conditions, the damping torque increases with the
increase of current. The torque-angular displacement
and torque-angular velocity curves show and the
dynamic range is wide.
4. It can be concluded from the simulation and experiment
results that the inner leakage will lead to the decrease of
damping torque of the PPCRMRD. And the reduction
of inner leakage is an effective way to improve the
performance of the rotary MR dampers.
5. Due to high torque performance, the working temperature
of the PPCRMRD will increase in a short time. The effect
of temperature will be investigated in the near future.
Acknowledgments
This work has been supported by Postgraduate Research
& Practice Innovation Program of Jiangsu Province
12
M Wei et al
(No. KYCX19_0257) and Natural Science Foundation of
Jiangsu Province (Grant No. BK20181301).
ORCID iDs
Xiaoting Rui https://orcid.org/0000-0002-6114-7685
Wei Zhu https://orcid.org/0000-0003-4786-348X
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