Development of Tiny Vane-type Magnetorheological Brake Considering Quality Function Deployment

Many studies focus on the torque-to-dimension ratio when designing magnetorheological brakes (MRB), especially for ankle foot orthosis (AFO) devices. Vane MRB is one type of MRB with a limited angle of motion that is naturally suitable to be applied to AFO. However, very few implement quality function deployment (QFD) when making MRB, whereas QFD is an essential factor in making product designs. In this study, a tiny vane-type MR brake (TVMRB) was successfully made using the QFD method. Torque characteristics are determined by analysis of magnetic flux density, theoretically, by 3D simulation, and by using Ansys Maxwell experimentally. For consideration, the analysis was carried out with fluid gap variations (0.5 mm, 0.75 mm, and 1 mm) and current variations (0.5–2 A with 0.5 A increments). As a result, ignoring the leakage of MR fluid (MRF), at a constant rotation of 10 rpm, the smallest torque of 6.14 Nm was obtained at the fluid gap variation of 1 mm and input current of 0.5 A, whereas the largest torque was 46.71 Nm at the fluid gap variation of 0.5 mm and input current of 2 A. Apart from torque, this article will also discuss other brake performances in the form of operational range and power consumption. Finally, the structure of the TVMRB design is compared with other designs presented in the House of Quality (HOQ).