Compared to clinic-based systems, rehabilitation robots designed for home use could enable increased accessibility and intensity of therapy for stroke survivors. To move upper extremity rehabilitation robots from the clinic to the home, the designs must become smaller, lighter, and less complex. One path to reducing the size of the robot’s hardware is to replace conventional actuators with smaller designs utilizing the unique properties of smart materials. As a first step towards reducing the size of upper extremity rehabilitation robots, this paper presents results from a characterization study of a prototype electrorheological fluid. The fluid’s dynamic yield stress was first measured using a modified controlled stress rheometer. A testbed was then developed to analyze the mechanical performance of a custom brake filled with the fluid. System parameters measured included braking torque at varying electric field strengths as well as the fluid’s speed of response. Maximum torque output was 4.80 N-m at an electric field strength of 3 kV/mm. Experimental results also indicate that the fluid’s activation and relaxation times will enable sufficient control bandwidth for the desired application. However, non-linear effects, such as field-dependent hysteresis, are significant and may require compensation from the controller supervising interaction between the robot and patient.

Magneto-rheological fluids (MRF) are commonly applied in MRF brakes and vibration damping. The apparent viscosity dependence with respect to the magnetic field has been addressed in detail in the state of the art. The aim of this paper is to experimentally study the vibration effects on the particle chain-like structures and, as a consequence, the shear stress variation applied to the fluid. Three vibration configurations have been applied to a ferromagnetic cylinder rotating between two magnetic poles filled with MRF a “Z-vibration” where the generated displacement is along the rotation axis of the shearing cylinder, a “θ-vibration”, tangential to the cylinder, and an “R-vibration”, normal to the cylinder surface. First we focus on the vibration mode characterisation in free air, and then when plunged in the fluid. In a second step, we measure the reactive torque generated on the clutch under different magnetic field intensities with different rotation speeds and vibration amplitudes. It appears that the “R-vibration” configuration is providing the most influence, up to 20% of torque reduction observed at moderate B field. The “Z-vibration” and the “θ-vibration” configurations respectively have less influence on the torque, nevertheless vibrations always tend to decrease the corresponding yield stress in the MRF.

In the present paper we investigated the behaviour of magnetorheological fluids (MRFs) under a hydrostatic pressure up to 40 bar. We designed, manufactured and tested a magnetorheological damper (MRD) with a novel architecture which provides the control of the internal pressure. The pressure was regulated by means of an additional apparatus connected to the damper that acts on the fluid volume. The MRD was tested under sinusoidal inputs and with several values of magnetic field and internal pressure. The results show that the new architecture is able to work without a volume compensator and bear high pressures. On the one hand, the influence of hydrostatic pressure on the yield stress of MRFs is not strong probably because the ferromagnetic particles cannot arrange themselves into thicker columns. On the other hand, the benefits of the pressure on the behaviour of the MRD are useful in terms of preventing cavitation.

This contribution deals with the theoretical and experimental investigation of the giant MR-effect. The giant MR-effect can be utilized to increase the yield stress of magnetorheological fluids (MRF). To obtain a boost of the yield stress the MRF has to be normally compressed while it is exposed to a magnetic field in order to create stronger particle structures. For the experimental investigation a MRF test actuator with an conical shear gap is designed, enabling an adjustment of the shear gap’s height by applying a compressing normal force. The experimental investigation points out that a potentially increase of the yield stress can be achieved on the one hand. On the other hand it is dependent on the magnetic field strength during the compression as well as on the shear rate and shear strain. The results are used to motivate a modeling approach which combines the rheological behavior with tribological effects. The validation of the modeling approach shows a good accordance to the behavior of the physical investigated giant MR-effect.

This research details a novel method of increasing the shear yield stress of magnetorheological (MR) fluids by combining shear and squeeze modes of operation to manipulate particle chain structures, to achieve so-called compression-assisted aggregation. The contribution of both active gap separation and particle concentration are experimentally measured using a custom-built Searle cell magnetorheometer, which is a model device emulating a rotary Magnetorheological Energy Absorber (MREA). Characterization data from large (1 mm) and small (250 μm) gap geometries are compared to investigate the effect of the gap on yield stress by compression enhancement. Two MR fluids having different particle concentrations (32 vol% and 40 vol%) are also characterized to demonstrate the effect of solids loading on compression-assisted chain aggregation. Details of the experimental setup and method are presented, and a chain microstructure model is used to explain experimental trends. The torque resisted by practical rotary MREAs is directly related to the strength of the MR fluid used, as measured by the shear yield stress. This study demonstrates that it is feasible, utilizing the compression-enhanced shear yield stress, to either (1) design a rotary MREA of a given volume to achieve higher energy absorption density (energy absorbed normalize by device volume), or (2) reduce the volume of a given rotary MREA to achieve the same energy absorption density.

In this work, we present results on mathematical modelling of polymeric yield stress fluids which have the properties of both elastic solids and fluids. Our research is based on the approach of multiphase continuum mechanics. A two-phase solid-fluid model is developed. This model is thermodynamically compatible and its governing differential equations can be written in a conservative form. Such a model is convenient for application of advanced high-accuracy numerical methods and modelling of discontinuous solutions such as shock waves and contacts.

Magnetorheological fluids consist of micron sized iron particles mixed in a carrier fluid, and are commonly used in adaptive dampers. Current simulations of MR fluids have been limited to thousands of particle and have been unable to simulate a a practical fluid volume (∼ mm 3 ) with a high solids loading (∼ 25 vol %). In this paper, we use NVIDIA’s CUDA programming environment to simulate over one million particles. Using these simulations, we can dynamically simulate chain formation and restructuring in a practical millimeter scale fluid volume with realistic solids loading. The chain structures can be characterized in terms of extent and number, as well as obtaining physical metrics such as yield stress.

The study presents an experimental investigation into the trade-offs between field-on versus field-off rheological characteristics of magnetorheological (MR) fluids. This is relevant in a particular application in prosthetic devices where field-off characteristics are of equal importance to the field-on rheological characteristics. The paper introduces a biomechanical prosthetic knee joint that uses an MR fluid to actively control its rotary stiffness while an amputee walks. The knee is a synergy of artificial intelligence, advanced sensors and MR actuator technology. The knee joint is equipped with an MR rotary brake, utilizing the fluid in direct-shear mode. The MR fluid has response time in the order of milliseconds, making it possible to vary the knee’s stiffness in real-time, depending on sensors data. The field-on characteristics of the employed MR fluid define the rigidness of the knee joint while the field-off characteristics define its flexibility in the absence of a magnetic field. Five MR fluid compositions are prepared, each with a different solid loading ranging from 0.25 to 0.35, by volume. All fluids employ a commercially available carbonyl iron powder and a base fluid. The MR fluids are experimentally evaluated in a rheometer, where both field-off and field-on characteristics are measured. An MR fluid figure of merit function is introduced which is used to rate the selected MR fluids for a potential application in the MR prosthetic knee. An MR fluid composition is sought with the highest ratio between the field-on shear yield stress and the off-state viscosity. The research shows the off-state viscosity to decrease faster than the field-on shear yield stress when reducing the solid loading from 0.35 to 0.25. This suggests that an optimum solid loading exists with regards to the defined merit function. The off-state viscosity of suspensions is known to be exponentially dependent on solid loading while the field-on shear-yield stress is known to sub-quadratically dependent on solid loading. Field-on and field-off models are presented from literature. The models compared to the experimental data and used to theoretically predict the optimum solid loading with regards to field-on shear yield stress and off-state viscosity. As a result of the experimental and the theoretical analysis, a prominent MR fluid composition is selected for a potential application in the MR prosthetic knee. This has been shown to help in the development of prosthetic devices and furthering the success of an MR prosthetic knee joint.

This study focuses on the effect of temperature on the performance of compressible magnetorheological fluid dampers (CMRDs). In addition to change of properties in the presence of a magnetic field, magnetorheological fluids (MRFs) are temperature-dependent materials that their compressibility and rheological properties change with temperature, as well. A theoretical model that incorporates the temperature-dependent properties of MRF is developed to predict the behavior of a CMRD. An experimental study is also conducted using an annular flow CMRD with varying temperatures, motion frequencies, and magnetic fields. The experimental results are used to verify the theoretical model. The effect of temperature on the MRF properties, such as, the bulk modulus, yield stress and viscosity, are explored. It is found that the shear yield stress of the MRF remains unchanged within the testing range while both the plastic viscosity, using the Bingham plastic model, and the bulk modulus of the MRF decrease as temperature increases. In addition, it is observed that both the stiffness and the energy dissipation decrease with an increase in temperature.

Magnetorheological (MR) fluids have a lot of applications in the industrial world, but sometimes their properties are not performing enough to meet system requirements. It has been found that in shear mode MR fluids exhibits a pressure dependency called squeeze strengthen effect. Since a lot of MR fluid based devices work in flow mode (i.e. dampers) this paper investigates the behaviour in flow mode under pressure. The system design is articulated in three steps: hydraulic system design, magnetic circuit design and design of experiment. The experimental apparatus is a cylinder in which a translating piston displaces the fluid without the use of standard gear pumps, incompatible with MR fluids. The experimental apparatus measures the MR fluid yield stress as a function of pressure and magnetic field allowing the yield shear stress to be calculated. A statistical analysis of the results shows that the squeeze strengthen effect is present in flow mode as well and the presence of internal pressure is able to enhance the performance of MR fluid by nearly ten times.

Aqueous magnetorheological (MR) suspensions of composite carbonyl iron particles (CCIPs) were prepared with carbonyl iron particles and an organic reagent coating (N-polyether, N, N, N,-acetyloxy) 2, 6-aminion-1, 3, 4-thiadiazole dimer (EAMTD). The properties of the CCIPs, including morphology, structure, and magnetic behaviors, were characterized using scanning electron microscopy (SEM) and a vibrating sample magnetometer (VSM). The MR properties of the aqueous MR suspensions were analyzed via a strain-controlled parallel disk rheometer equipped with a magnetic field source. The results show that the stability and redispersibility of the aqueous MR suspensions were greatly improved, and the yield stress is influenced by the EAMTD coating layer of the CCIPs.

Regaining biomechanical function, comfort and quality of life is a prime consideration when designing prosthetic limbs. Recently, microprocessor-controlled prosthetic knees, which rely on magneto-rheological (MR) technology, have become available and have the potential to meet these needs. One of these promising products is a prosthetic knee manufactured by the company Ossur Inc. The knee is a synergy of artificial intelligence, advanced sensors and MR actuator technology. A critical factor in the success of the prosthetic knee is the composition of the MR fluid. In the prosthetic actuator, the fluid is used in shear mode in a micron-sized fluid gap. The characteristics of the MR fluid, such as, the off-state viscosity, the field-induced shear yield stress, the post-yield viscosity, and the particle sedimentation rate, determine the properties of the prosthetic knee. This paper describes a novel perfluorinated polyether (PFPE)-based MR fluid with properties that are tailored for the requirements of the prosthetic knee actuator. Rheological measurements of monodisperse and bidisperse PFPE-based fluid mixtures are presented. The monodisperse fluid consists of micron-sized carbonyl iron particles and the bidisperse mixture contains micron- and nano-sized particles. A few different concentrations of nano particles are investigated; first by holding the total solid concentration constant, and then by increasing the total solid concentration, to exceed that of the MR fluid containing only micron-sized particles. An MR fluid composition is sought that has a suitable balance between field-induced strength, off-state viscosity and sedimentation rate, for the proposed application. This balance is determined by desired qualities of the prosthetic knee and relate directly to the MR fluid. The field-induced shear stress of MR fluid samples is measured as a function of the magnetic flux density along with the off-state viscosity as a function of the shear-rate. The shear stress and off-state viscosity at high-shear rates are of particular interest, since the working shear rate in the prosthetic knee is high, due to the micron-sized gap between the blades in the fluid chamber of the actuator. Mathematical models are presented that describe how the MR fluid properties relate to the behavior of the prosthetic knee. The paper shows how a tailored design of an MR fluid can further the success of the MR prosthetic knee.