Development of a peristaltic rotary magnetorheological brake for force-feedback systems

User safety problems arise due to the use of active actuators in force feedback systems of haptic devices. In addition, smart solutions are needed to prevent unwanted vibrations due to impedance in systems using active actuators. Electrorheological (ER) and Magnetorheological (MR) fluids, whose rheological properties can be controlled, are used both in the prevention of vibrations and in obtaining response force. Magnetorheological Fluids (MRF) are smart materials whose viscosities can be controlled much more easily than Electrorheological Fluids (ERF). For this reason, it is preferred to use MRF instead of ERF in various brakes, clutches and dampers. Existing MRF devices have problems such as fluid leakage and high friction torques. On the other hand, the forces obtained from these rather heavy devices are too high for people to use. Furthermore, when patents and academic publications are examined, it has been found that there is very little work on a compact MRF device that can be used with haptic devices. In this study, a peristaltic rotary MRF device which can be used in haptic devices was developed. The aim of reducing the difficulties mentioned above in the developed device is based on the working principle of peristaltic pumps. Two types of MRF reservoirs are designed and manufactured using elastic materials with the aim of achieving peristaltic movement and sealing. The rapid assembly process has been utilized to produce elastic bulkheads. As the moving parts increase the inertia, the developed product must also be in reduced dimensions. For this purpose, optimization study was done by using the dimensions of working prototypes. The optimization study was performed using the Particle Swarm Optimization (PSO) method. The design that achieved the lightest, least power consumption and highest reaction torque reached after the PSO process is completed. The theoretical calculations are compared with the experimental results of both the working prototypes and the design obtained with PSO. In addition, numerical thermal analyzes were carried out to obtain temperatures that can occur in the device. The viscosity of the MR fluid in a closed loop fluidized system can be controlled with the developed design and device. Thus, haptic devices or systems that use this device will be able to perform vibration-free power transmission. The device, which can also be used as a semi-active actuator, can be used in place of the existing adjustable brakes. Other applications for adjustable brakes and dampers include seat suspension, exercise instrument dampers, and leg prostheses.