CONTROL DESIGN

UNIT 3

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 MAGNETORHEOLOGICAL
FLUIDS
 Magneto rheological (MR) fluids react to an external stimulus i.e.

magnetic field.

 They too undergo a dramatic change in their rheological properties

when subjected to a magnetic field.

 When subjected to a magnetic field, MR fluids undergo a

change in their viscosity and can change from a liquid state

with a relatively low viscosity, like motor oils, to an almost solid
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state.
 The time span in which this change occurs lies within a few

milliseconds and the effect is completely reversible.

 Upon removal of the applied field, the fluid returns to its original

configuration.

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 Working principle
 Magneto rheological (MR) fluids are typically colloidal suspensions
consisting of highly polarizable magnetic particles, with sizes in the order of a few
microns, in a low permeability, non-magnetic base fluid.
 In the absence of a magnetic field the MR fluid is in the ‘off’ state. It is then not yet

magnetized and in this state the particles exhibit a random pattern.

 In this ‘off’-state, MR fluids appear to have a consistency similar to liquid paint and

also exhibit comparable levels of apparent viscosity. In the absence of an applied

field, the controllable fluids exhibit Newtonian-like behavior.
 When the MR fluid is subjected to a magnetic field, the particles become
magnetized (induced dipoles) and they start to behave like tiny magnets. This is the
‘on’ or magnetized state of the MR fluid.

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 The magnetic interaction, and with that the total potential energy, between these

particles can be minimized if the particles line-up along the direction of the magnetic

field lines. With the potential energy minimized the particles are in a stable position.

 The interaction between the resulting induced dipoles causes the particles to aggregate

and form fibrous structures within the carrier liquid (chains or column-like structures),

changing the rheology of the MR fluid to a near solid state.

  These chain-like structuresrestrict the flow of the fluid, thereby increasing the

viscous characteristics of the suspension.

 Magnetic fields intensities up to 160 tesla are required, which are easy to obtain using a

standard 12 V or 24 V power supply.

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The response time of a complete system using MR device(s) is
estimated to be around between 15-25 ms , strongly depending
on the nature of the device. The density of the whole suspension
ranges from 3 to 4 gr / cm3.

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Magneto-rheological (MR) fluids

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 Material Composition
 Magnetorheological (MR) fluids are built up of 3 components: the dispersed phase (the

magnetizable particles), the continuous phase (the carrier liquid), and small amounts of additives and
stabilizers.

 1. Dispersed Phase

 The requirements set on the choice of particle material are that the particles have to be magnetically

multi-domain and that they exhibit low levels of magnetic coercivity. coercivity measures the
resistance of a ferromagnetic material to becoming demagnetized

 In addition, maximizing the inter-particle forces and thus maximizing the MR effect can be achieved

by choosing the particle material on basis the saturation magnetization s J [Tesla].

 The material most used today is high purity carbonyl iron ( Fe ) powder, made by chemical vapor

deposition (CVD) of iron penta- carbonyl ( Fe(CO)5 ).

 The particles usually have a diameter ranging from 1-10 μm and a density of approximately 7 gr /

cm3.

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 2. Continuous Phase
 The primary function of the carrier liquid is to provide a low permeability, nonmagnetic

base liquid in which the magnetically active phase particles can remain suspended.

 The liquid has to be low permeable to allow the particles to polarize with the utmost

effectiveness, thus enhancing the MR effect.

 The carrier liquid has to be largely non-reactive towards the magnetic particles

and to the materials used in the device construction.

 The off-state viscosity of the MR fluid depends largely on the selection of the base

fluid. To avoid large friction losses the ‘off’-state viscosity should be as low as
possible.

 Typical materials used as carrier liquid are water or other polar organic liquids (such as

glycol), silicone oils, (semi-)synthetic oils, mineral oils, petroleum based oils and
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combinations of several types of oil
 3. Additives
 Additives form the third part of a MR fluid. Because the magnetic

polarization mechanism, the working principle of MR fluids, is not

affected by the surface chemistry of surfactants, it is relatively straightforward
to use additives in MR fluids for all kinds of purposes, such as:
 Prevention or minimization of sedimentation

 Prevention or minimization of coagulating of the particles

  Provide additional lubricating properties to improve anti-wear

  To enhance anti-oxidation

  In water-based carrier liquids additives are used to control the pH- value

 Sedimentation is typically controlled by the use of thixotropic agents and

surfactants such as xantham gum, silica gel, stearates and carboxylic acids.
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 Advantages

 MR fluids show a reversible and controllable change in their

rheological properties upon subjection to a magnetic field

 MR fluids are current driven. For the control of the field coil

voltages below 10 V and currents below 2 A can be sufficient to

operate the device properly.
 These can be obtained using a standard 12 V or 24 V power

supplier, such as the battery in a car.

 The response time of MR based devices is estimated to be around 15-

25 ms , which is still very fast, but slower than their electrically

activated cousins, the Electrorheological (ER) fluids.
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 MR fluids are able to attain high shear stresses in the order of

magnitude of 50-100 kPa , which results in the fact that only a small
amount of active fluid is required to achieve a certain performance
level. This can positively affect the size and weight of a MR based
device.
 MR fluids are not very sensitive to contaminants and impurities, which

can be commonly encountered during manufacture and also during

usage.
 Fail-safe operation of MR based devices can be achieved through the

use of permanent magnets MR fluids. In this way MR fluids can be

energized without the need for any steady-state power.
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 MR fluids are able to operate over a wide range of temperatures.
 Disadvantages
 Magnetic fields are not easy to supply and use.

 The density mismatch between that of the particles and the carrier

liquid is typically fairly high, which can lead to a higher risk of

sedimentation
 This high density of the particles also leads to a relatively high density

of the entire MR fluid, ranging from 3 to 4 gm / cm3.

 The typical ‘off’-state viscosity of MR fluids is relatively high. This

can lead to relatively high friction or flow losses .

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 Applications

 Clutches

 Brakes

 Valves

 Dampers

 Robotics

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 MR Damper: (Linear MR Device)

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The single ended damper has only one reservoir for the MR
fluid which is transferred through an orifice from on chamber to
another.
Since the rod volume is just on one side the system accounts for
the change in volume that results from piston rod movement.
In order to accommodate this change in reservoir volume, an
accumulator is usually used.
The accumulator provides a barrier between the MR fluid and a
compressed gas (usually nitrogen) that is used to accommodate
the necessary volume changes.
Moreover the accumulator pressure can be used to enhance the
performance of the MR system.
The applications of the MR damper are mainly in the vibration
suppression of mechanical components like seat suspension, car
suspensions, and industrial vibration suppression.
MR Clutch: (Rotary MR Device)
The MR based clutch is ideally described by Figure,
the fluid is between the input disk and the output disk
and the amount of transmitted torque is proportional to
the yield stress of the fluid.
No moving parts are used to change the transmitted
torque and the torque value can be smoothly controlled
through the coil current.
Even though multidisc applications can be used to
increase the output torque, the typical application of
rotary MR fluid devices is in the high precision and
low power range.
MR Brake: (Rotary MR Device)
The typical architecture for a MR based brake is depicted
in the above figure.
 The aim is to obtain a precise control of the braking
torque with no moving parts by simply varying the
current in the coils.
The magnetic flux path passes through the chassis and the
rotating disk and the fluid is sheared between these
elements.
 The braking force depends on the yield stress of the fluid
making the system controllable.
Micro-robot actuated by a shape memory
alloy
The Japanese have recently focused their efforts on
employing SMAs in the field of robotics.
Two main types of SMA actuators for robots have been
developed, namely, biased and differential.
Biasing uses a coil spring to generate the bias force that
opposes the unidirectional force of SMA.
 In the differential type, the spring is replaced with
another SMA and the opposing forces control the
actuation.
The assembly of a micro-robot actuated by SMAs is
schematically shown in Figure.
This micro-robot features five degrees of freedom
corresponding to the capabilities of the human fingers,
wrist, elbow, and shoulder.
The variety of robotic maneuvers and operations are
coordinated by activating the TiNi coils on the fingers
and the wrist in addition to contraction and expansion
of straight TiNi wires in the elbow and shoulders.
Digital control techniques exploiting a pulse current, in
which the current is modulated with pulse width
modulation, are employed in all of the components in
order to control their spatial positions and speeds of
operations.
microsensors
Sensors are one of the essential ingredients of a smart
structure since they provide the ability to monitor and
measure external stimuli in addition to the subsequent
behavior throughout the structural medium.
Conventional sensors, such as thermocouples,
accelerometers, and strain gauges are generally unable
to serve in this capacity because of their significant
size and weight characteristics, which are typically
measured in inches and ounces { a unit of weight of
one sixteenth of a pound (approximately 28 grams)}.
These relatively large conventional sensors can also adversely
affect the behavior of the structure being monitored. For
example it is inappropriate to utilize a heavy accelerometer in
measuring the dynamic behavior of a light flexible structure
subjected to a time-dependent fluid loading.
The protrusion of the accelerometer from the surface of the
structure will modify the now field, and hence the dynamical
loading, and the additional weight of the accelerometer will
change the dynamical properties of the structure being excited.
It is evident, therefore, that the large conventional sensors are
inappropriate under these conditions and these constraints of
large mechanical, thermal and electrical inertias have been
responsible for the development of a new generation of
smaller sensors exploiting semiconductor technology.
Microsensor technology exploits the maturity of the
semiconductor industry to manufacture precise three-
dimensional structures on the surface of a silicon chip,
measuring only a few microns.
These sensors involve the fabrication of chips and
integrated circuits which enable a sensor of dimensions
one mm2 to typically respond to changes in pressure,
radiation, temperature and acceleration.
Advantages of microsensors
First a micron-sized sensor will not adversely affect
the behavior of the environment in which it is located.
Second, by integrating the sensing function and the
processing function on a single silicon wafer then a
'smart' sensor can be developed which offers the
designer great versatility.
Third, the current generation of microsensors is
extremely robust and durable relative to conventional.
Finally, microsensors are cheaper than conventional
sensors.
ELECTRORHEOLOGICAL FLUID
Fluids that under go significant instantaneous
reversible change in their mechanical properties
such as mass distribution, energy dissipation when
subjected to electric field.
An ER fluid is typically a suspension consisting
polarizable nano/micro-meter particles well
dispersed in a non-conducting, low-viscosity
medium.
ELECTRO-RHEOLOGICAL FLUID.
(ER FLUID)
Viscous properties are modified by applying electric fields

Obtained by mixing SILICONE OIL AND CORN STARCH.

In the neutral state particles are uniformly distributed. Under

electric field the large dielectric constants redistributes the

particles changing the viscous properties.

E R fluid are non Newtonian fluids.

Useful in transforming shear stresses

ER FLUID

ELECTRIC ER CHANGES LIQUID

FIELD FLUID TO SOLID
APPLIED

 ELECTRIC CHANGES FROM

FIELD ER FLUID SOLID TO LIQUID
REMOVED
ER EFFECT
• Viscosity increase ~10,000 times
• Instantaneous response ~ 1mS
• Reversible liquid ⇔ solid change

ER APPLICATIONS
• Vibration control of structures
• Shock absorbers and dampers
• Torque transfer devices
• ER BRAKES
ER clutch
The normal application of ER fluids is clutches.
with the separation between plates being in the order
of 1 mm and the applied potential being in the order of
1 kV.
In simple terms, when the electric field is applied, the
plates of an ER clutch are locked together.
 When the electric field is removed the clutch plates
are disengaged
ER shock absorber