Research Papers: Flows in Complex Systems

Steady-State Heat-Flow Coupling Field of a High-Power Magnetorheological Fluid Clutch Utilizing Liquid Cooling

[+] Author and Article Information
Daoming Wang

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China;
School of Mechatronic Engineering,
China University of Mining and Technology,
Xuzhou 221116, China
e-mail: cumtcmeewdm@hotmail.com

Bin Zi

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: binzi.cumt@163.com

Sen Qian

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: qiansencumt@126.com

Jun Qian

School of Mechanical Engineering,
Hefei University of Technology,
Hefei 230009, China
e-mail: qianjun@hfut.edu.cn

1Corresponding author.

Contributed by the Fluids Engineering Division of ASME for publication in the JOURNAL OF FLUIDS ENGINEERING. Manuscript received November 12, 2016; final manuscript received June 20, 2017; published online August 11, 2017. Assoc. Editor: Bart van Esch.

J. Fluids Eng 139(11), 111105 (Aug 11, 2017) (11 pages) Paper No: FE-16-1744; doi: 10.1115/1.4037171 History: Received November 12, 2016; Revised June 20, 2017

Compared with traditional speed regulation (SR) approaches like variable frequency and hydraulic coupling, magnetorheological clutch (MRC) provides a more superior solution for high-efficiency energy saving SR. However, recent developments have demonstrated that severe heating is an outstanding challenge for MRC, especially in high-power applications. Among commonly used cooling methods, liquid cooling offers a viable alternative for the problem. Aiming at pre-evaluating the cooling efficiency of a liquid-cooled MRC in high-power situations, this study introduces a heat-flow coupling simulation method. In this paper, theoretical basis for the simulation is presented first, which is followed by an illustration of the heat-flow coupling simulation. This paper details the simulation model establishment, finite element meshing (FEM), boundary conditions, and simulation parameters. After the simulations, the results concerning the steady flow field of the internal coolant, along with the steady-state temperature fields of MRC, magnetorheological (MR) fluids and the coolant are presented and discussed. Finally, several heating tests of an MRC prototype under various operation conditions are performed and the results verify the correctness and rationality of the simulation.

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Fig. 1

Geometric model of the liquid-cooled MRC: (a) full-size model (transparent), (b) quarter of the model (transparent), and (c) sectional model

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Fig. 2

Viscosity–temperature curve of the machine oil

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Fig. 3

Sketch of boundary conditions for MRC: (a) full-size model and (b) quarter of the model

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Fig. 6

Velocity vector of the internal coolant: (a) overall velocity distribution, (b) sectional velocity vector near inlet 1, and (c) tangential velocity vector of the coolant in the cavity of the inner input rotor

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Fig. 7

Sectional velocity vector of the coolant around inlet 1 with different inlet velocities: (a) vin = 0.83 m/s, (b) vin = 1.66 m/s, and (c) vin = 2.49 m/s

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Fig. 8

Tangential velocity vector of the coolant in the cavity of the inner input rotor at various rotational speeds: (a) ns = 0, (b) ns = 500 rpm, (c) ns = 1000 rpm, and (d) ns = 1500 rpm

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Fig. 9

Overall velocity vector of the coolant under WC7

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Fig. 12

Steady-state temperature distribution of MR fluids: (a) in each axial gap at r = 61 mm, (b) MR fluids temperature in the No. 8 gap for the inner and outer layers, and (c) MR fluids temperature versus radius in the No. 8 outer layer gap

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Fig. 4

Specific matches for the comparative study

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Fig. 5

Streamline of the internal coolant in MRC

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Fig. 14

Test bed for the heating tests of the MRC prototype

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Fig. 15

Installation of the temperature sensors

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Fig. 16

Heating test results for the MRC prototype under different conditions: (a) temperature variation of MR fluids, (b) simulation and experimental results of the steady-state MR fluids temperature, and (c) a comparison of the steady-state outlet coolant temperature for simulation and experiment



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