Innovative magnetorheological devices for shock and vibration mitigation

Vibration and impact protection have been a popular topic in research fields, which could directly affect the passengers’ and drivers’ comfort and safety, even cause spines fracture. Therefore, an increasing number of vehicle suspensions and aircraft landing gears are proposed and manufactured. Magnetorheological fluids (MRFs), as a smart material, are growly applied into the above device owing to its unique properties such as fast response, reversible properties, and broad controllable range, which could improve the vibration/impact mitigation performance. MRF was utilized to achieve adaptive parameters of the vehicle suspensions by controlling the magnetic field strength of the MRF working areas. Generally, the magnetic field is provided by a given current, subsequently, it would consume massive energy from a long-term perspective. Thus, a self-powered concept was applied as well. This thesis reports a compact stiffness controllable MR damper with a self-powered capacity. After the prototype of the MR damper, its property tests were conducted to verify the stiffness controllability and the energy generating ability using a hydraulic Instron test system. Then, a quarter-car test rig was built, and the semi-active MR suspension integrated with the self-powered MR damper was installed on a test rig. Two controllers, one based on short-time Fourier transform (STFT) and a classical skyhook controller was developed to control the stiffness. The evaluation results demonstrate that the proposed MR damper incorporated with STFT controller or skyhook controller could suppress the response displacements and accelerations obviously comparing with the conventional passive systems

A Study on Integration of Energy Harvesting System and Semi-Active Control for a Hydraulic Suspension System

Suspension systems are used to diminish the vibration of vehicles. The hydraulic dampers in conventional suspension systems are mainly designed with the orifices of the piston; however, the vibration energy will be transferred into waste heat. In recent years, conventional vehicles with internal combustion engines and hybrid vehicles are used commonly. However, with the gradual depletion of fossil fuels, electric vehicles are developing. For this reason, the research focuses on recycling energy from the suspension of vehicles to improve the vehicle’s endurance. The purpose of this study is to develop a semi-active suspension control system with an energy harvesting system. Instead of the fixed orifices in conventional vehicles, an adjusting damping force method with variable resistance circuits system is studied for the semi-active suspension control system. Thus, we are able to develop semi-active control to improve the riding comfort. The energy harvesting system contains a hydraulic gear motor and a DC generator. When vehicles vibrate, the hydraulic damper serves as a hydraulic pump to compress the oil and drive the hydraulic motor. At the same time, the hydraulic motor drives the generator to generate electricity which will be stored in a battery. In this study, the test rig is the quarter-car system. We first design the novel hydraulic suspension system combining with the energy harvesting system. The simulation of dynamic mathematical model will be performed and analyzed by MATLAB/Simulink. Besides that, the semiactive control by the fuzzy sliding mode controller will be realized in the hydraulic suspension system with energy harvesting system. Finally, a test rig is set up for practical experimental implementation and verification

Advanced suspension system using magnetorheological technology for vehicle vibration control

In the past forty years, the concept of controllable vehicle suspension has attracted extensive attention. Since high price of an active suspension system and deficiencies on a passive suspension, researchers pay a lot attention to semi-active suspension. Magneto-rheological fluid (MRF) is always an ideal material of semi-active structure. Thanks to its outstanding features like large yield stress, fast response time, low energy consumption and significant rheological effect. MR damper gradually becomes a preferred component of semi-active suspension for improving the riding performance of vehicle. However, because of the inherent nonlinear nature of MR damper, one of the challenging aspects of utilizing MR dampers to achieve high levels of performance is the development of an appropriate control strategy that can take advantage of the unique characteristics of MR dampers. This is why this project has studied semi-active MR control technology of vehicle suspensions to improve their performance. Focusing on MR semi-active suspension, the aim of this thesis sought to develop system structure and semi-active control strategy to give a vehicle opportunity to have a better performance on riding comfort. The issues of vibration control of the vehicle suspension were systematically analysed in this project. As a part of this research, a quarter-car test rig was built; the models of suspension and MR damper were established; the optimization work of mechanical structure and controller parameters was conducted to further improve the system performance; an optimized MR damper (OMRD) for a vehicle suspension was designed, fabricated, and tested. To utilize OMRD to achieve higher level of performance, an appropriate semi-active control algorithm, state observer-based Takagi-Sugeno fuzzy controller (SOTSFC), was designed for the semi-active suspension system, and its feasibility was verified through an experiment. Several tests were conducted on the quarter-car suspension to investigate the real effect of this semiactive control by changing suspension damping. In order to further enhance the vibration reduction performance of the vehicle, a fullsize variable stiffness and variable damping (VSVD) suspension was further designed, fabricated, and tested in this project. The suspension can be easily installed into a vehicle suspension system without any change to the original configuration. A new 3- degree of freedom (DOF) phenomenological model to further accurately describe the dynamic characteristic of the VSVD suspension was also presented. Based on a simple on-off controller, the performance of the variable stiffness and damping suspension was verified numerically. In addition, an innovative TS fuzzy modelling based VSVD controller was designed. The TS fuzzy modelling controller includes a skyhook damping control module and a state observer based stiffness control module which considering road dominant frequency in real-time. The performance evaluation of the VSVD control algorithm was based on the quarter-car test rig which equipping the VSVD suspension. The experiment results showed that this strategy increases riding comfort effectively, especially under off-road working condition. The semi-active control system developed in this thesis can be adapted and used on a vehicle suspension in order to better control vibration

Active suspension control of electric vehicle with in-wheel motors

In-wheel motor (IWM) technology has attracted increasing research interests in recent years due to the numerous advantages it offers. However, the direct attachment of IWMs to the wheels can result in an increase in the vehicle unsprung mass and a significant drop in the suspension ride comfort performance and road holding stability. Other issues such as motor bearing wear motor vibration, air-gap eccentricity and residual unbalanced radial force can adversely influence the motor vibration, passenger comfort and vehicle rollover stability. Active suspension and optimized passive suspension are possible methods deployed to improve the ride comfort and safety of electric vehicles equipped with inwheel motor. The trade-off between ride comfort and handling stability is a major challenge in active suspension design. This thesis investigates the development of novel active suspension systems for successful implementation of IWM technology in electric cars. Towards such aim, several active suspension methods based on robust H∞ control methods are developed to achieve enhanced suspension performance by overcoming the conflicting requirement between ride comfort, suspension deflection and road holding. A novel fault-tolerant H∞ controller based on friction compensation is in the presence of system parameter uncertainties, actuator faults, as well as actuator time delay and system friction is proposed. A friction observer-based Takagi-Sugeno (T-S) fuzzy H∞ controller is developed for active suspension with sprung mass variation and system friction. This method is validated experimentally on a quarter car test rig. The experimental results demonstrate the effectiveness of proposed control methods in improving vehicle ride performance and road holding capability under different road profiles. Quarter car suspension model with suspended shaft-less direct-drive motors has the potential to improve the road holding capability and ride performance. Based on the quarter car suspension with dynamic vibration absorber (DVA) model, a multi-objective parameter optimization for active suspension of IWM mounted electric vehicle based on genetic algorithm (GA) is proposed to suppress the sprung mass vibration, motor vibration, motor bearing wear as well as improving ride comfort, suspension deflection and road holding stability. Then a fault-tolerant fuzzy H∞ control design approach for active suspension of IWM driven electric vehicles in the presence of sprung mass variation, actuator faults and control input constraints is proposed. The T-S fuzzy suspension model is used to cope with the possible sprung mass variation. The output feedback control problem for active suspension system of IWM driven electric vehicles with actuator faults and time delay is further investigated. The suspended motor parameters and vehicle suspension parameters are optimized based on the particle swarm optimization. A robust output feedback H∞ controller is designed to guarantee the system’s asymptotic stability and simultaneously satisfying the performance constraints. The proposed output feedback controller reveals much better performance than previous work when different actuator thrust losses and time delay occurs. The road surface roughness is coupled with in-wheel switched reluctance motor air-gap eccentricity and the unbalanced residual vertical force. Coupling effects between road excitation and in wheel switched reluctance motor (SRM) on electric vehicle ride comfort are also analysed in this thesis. A hybrid control method including output feedback controller and SRM controller are designed to suppress SRM vibration and to prolong the SRM lifespan, while at the same time improving vehicle ride comfort. Then a state feedback H∞ controller combined with SRM controller is designed for in-wheel SRM driven electric vehicle with DVA structure to enhance vehicle and SRM performance. Simulation results demonstrate the effectiveness of DVA structure based active suspension system with proposed control method its ability to significantly improve the road holding capability and ride performance, as well as motor performance

A study of a piezoelectric energy harvesting system using magnetorheological fluids

This thesis reports the study of a piezoelectric energy harvesting system using a thin layer of magnetorheological fluid as a soft impact mechanism to enhance the frequency of the energy generator. Currently, the major bottleneck of vibration energy harvesting is the dynamic nature of vibrations in the environment which necessitates that vibration energy harvesters change their frequency to match that of the source. This work used the variable rheological properties of magnetorheological fluids to tune the frequency of a piezoelectric energy harvester. The study employed both numerical and experimental studies to investigate the effect of using the fluid in vibration energy harvesting. The results obtained show an increase in the output voltage and frequency of the device by 9.7% and 36%, respectively. For the first time, a soft impact frequency-increased piezoelectric energy harvesting system using magnetorheological fluid is studied in this thesis

Proceeding Of Mechanical Engineering Research Day 2016 (MERD’16)

This Open Access e-Proceeding contains a compilation of 105 selected papers from the Mechanical Engineering Research Day 2016 (MERD’16) event, which is held in Kampus Teknologi, Universiti Teknikal Malaysia Melaka (UTeM) - Melaka, Malaysia, on 31 March 2016. The theme chosen for this event is ‘IDEA. INSPIRE. INNOVATE’. It was gratifying to all of us when the response for MERD’16 is overwhelming as the technical committees received more than 200 submissions from various areas of mechanical engineering. After a peer-review process, the editors have accepted 105 papers for the e-proceeding that cover 7 main themes. This open access e-Proceeding can be viewed or downloaded at www3.utem.edu.my/care/proceedings. We hope that these proceeding will serve as a valuable reference for researchers. With the large number of submissions from the researchers in other faculties, the event has achieved its main objective which is to bring together educators, researchers and practitioners to share their findings and perhaps sustaining the research culture in the university. The topics of MERD’16 are based on a combination of fundamental researches, advanced research methodologies and application technologies. As the editor-in-chief, we would like to express our gratitude to the editorial board and fellow review members for their tireless effort in compiling and reviewing the selected papers for this proceeding. We would also like to extend our great appreciation to the members of the Publication Committee and Secretariat for their excellent cooperation in preparing the proceeding of MERD’16

Proceeding Of Mechanical Engineering Research Day 2015 (MERD’15)

This Open Access e-Proceeding contains 74 selected papers from the Mechanical Engineering Research Day 2015 (MERD’15) event, which is held in Kampus Teknologi, Universiti Teknikal Malaysia Melaka (UTeM) - Melaka, Malaysia, on 31 March 2015. The theme chosen for this event is ‘Pioneering Future Discovery’. The response for MERD’15 is overwhelming as the technical committees have received more than 90 papers from various areas of mechanical engineering. From the total number of submissions, the technical committees have selected 74 papers to be included in this proceeding. The selected papers are grouped into 12 categories: Advanced Materials Processing; Automotive Engineering; Computational Modeling and Analysis & CAD/CAE; Energy Management & Fuels and Lubricants; Hydraulics and Pneumatics & Mechanical Control; Mechanical Design and Optimization; Noise, Vibration and Harshness; Non-Destructive Testing & Structural Mechanics; Surface Engineering and Coatings; Others Related Topic. With the large number of submissions from the researchers in other faculties, the event has achieved its main objective which is to bring together educators, researchers and practitioners to share their findings and perhaps sustaining the research culture in the university. The topics of MERD’15 are based on a combination of advanced research methodologies, application technologies and review approaches. As the editor-in-chief, we would like to express our gratitude to the editorial board members for their tireless effort in compiling and reviewing the selected papers for this proceeding. We would also like to extend our great appreciation to the members of the Publication Committee and Secretariat for their excellent cooperation in preparing the proceedings of MERD’15