Magneto-Rheological Fluid Device as Artificial Feel Force System on Aircraft Control Stick

86 Pages·2017·4.59 MB·English

by  Vignesh Manoharan

Dissertations and Theses
5-2016
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Vignesh Manoharan
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MAGNETO-RHEOLOGICAL FLUID DEVICE AS ARTIFICIAL FEEL FORCE
SYSTEM ON AIRCRAFT CONTROL STICK

A Thesis
Submitted to the Faculty
of
Embry-Riddle Aeronautical University
by
Vignesh Manoharan

In Partial Fulfillment of the
Requirements for the Degree
of
Master of Science in Aerospace Engineering

May 2016
Embry-Riddle Aeronautical University
Daytona Beach, Florida

iii

ACKNOWLEDGMENTS

I would like to thank Embry-Riddle Aeronautical University and my thesis advisors
Dr. Daewon Kim and Dr. Dongeun Seo for providing the resources and their endless
support in sharing their expertise to conduct this research.
In addition, I want to especially acknowledge Dr. Yongho Lee for his support in
the smart fluid modeling and I thank Dr. David J. Sypeck for helping in selection of
materials. I also acknowledge Mr. Mike Potash for his endorsement in sensor selection and
Mr. Bill Russo for his help in the manufacturing of this device.
Finally, thanks to my colleague Edmund Charlton for his aid in development of the
concept presented, and my friends and family for their immense moral support.
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TABLE OF CONTENTS
LIST OF TABLES ............................................................................................................ vii
LIST OF FIGURES ......................................................................................................... viii
SYMBOLS .......................................................................................................................... x
ABBREVIATIONS ........................................................................................................... xi
ABSTRACT .................................................................................................................... xiiii
1. Introduction ................................................................................................................ 1
1.1. Artificial Feel Force System ..................................................................................... 1
1.1.1. Prior Arts ........................................................................................................... 2
1.2. Magneto-Rheological Fluid ...................................................................................... 4
1.2.1. MR Fluid Principles of Operation ..................................................................... 5
1.2.2. Magneto-Rheological Device ............................................................................ 6
2. Objective and Approaches ...................................................................................... 20
3. Mathematical Modeling .......................................................................................... 22
3.1 Kinetic Theory Model ..............................................................................................22
3.2 Bouc-Wen Hysteresis Model ...................................................................................25
3.3 Herschel-Buckley Model ..........................................................................................27
3.4. Bingham Plastic Model ...........................................................................................28
3.5. Electrical Equation and Yield Stress .......................................................................29
4. MR Damper Design ................................................................................................. 32
4.1. Fabrication of MR Device ...................................................................................... 36
4.2. Selection of Poly-Urethane Foam .......................................................................... 39
5. Magnetostatic Analysis ........................................................................................... 45
6. MR Damper Testing ............................................................................................... 48
6.1. NImyDAQ .............................................................................................................. 50
6.2. Experiment ..............................................................................................................51
6.3. Experimental Result ................................................................................................51
7. MR Device Model Simulation ................................................................................ 54
7.1. Simulation Result ....................................................................................................55
8. System Development and Testing .......................................................................... 58
8.1. Real Time Data Acquisition ....................................................................................59
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8.2. Force Feedback Control ..........................................................................................59
9. Conclusions and Future Work .................................................................................63
REFERENCES ................................................................................................................. 64
A. LabVIEW code for the MR damper experiment ..................................................... 68
B. Experimental Force VS Displacement Plot ............................................................. 71
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LIST OF TABLES

Table 4.1 Preliminary MR damper with dimensions ........................................................ 38
Table 4.2 Final MR damper with dimensions ....................................................................38
Table 4.3 Weights of PU foam at different time ............................................................... 42
Table 5.1 Area dimensions of MR damper developed in ANSYS ................................... 45
Table 5.2 BH curve data points..........................................................................................46
vii

LIST OF FIGURES

Figure 1.1 Conventional spring type feel system used in Airbus 320/340/360 .................. 2
Figure 1.2 Schematic of artificial feel system operating using servo mechanism .............. 3
Figure 1.3 MR fluid behaviour with and without magnetic field ....................................... 5
Figure 1.4 Three operational modes of MR fluid ............................................................... 6
Figure 1.5 The picture of robotic surgery using MR dampers as force feedback device ... 7
Figure 1.6 MR damper being used in cables of suspension bridges ................................... 8
Figure 1.7 MR fluid operated clutch with permanent magnet ............................................ 9
Figure 1.8 MR fluid muscle rehabilitant device ............................................................... 10
Figure 1.9 MR fluid joystick for haptic force applications ............................................... 11
Figure 1.10 MR damper for vibration isolation in rotary shafts ....................................... 12
Figure 1.11 MR damper for automobile suspension mounted in the UTM ...................... 13
Figure 1.12 Components present in a MR fluid damper ................................................... 15
Figure 1.13 The magnetic field direction in MR fluid valve ............................................ 16
Figure 1.14 Magnetic field direction of MRF orifice ....................................................... 17
Figure 1.15 MRE experimental setup ............................................................................... 17
Figure 1.16 Two modes of MR fluid device operation (a) external (b) internal .............. 18
Figure 1.17 The experimental setup for gun recoil damping ............................................ 19
Figure 2.1 The research flow chart with different forecasted stages in research .............. 21
Figure 3.1 Kinetic theory model with MR particles as dumbbell constants ..................... 24
Figure 3.2 Kinetic theory data compared with the experimental shear stress data ........... 25
Figure 3.3 Mechanical model of Bouc-Wen hysteresis model ......................................... 26
Figure 3.4 Improved Bouc-Wen model with hysteresis parameter .................................. 26
Figure 3.5 Mechanical Bingham model ............................................................................ 28
Figure 3.6 Schematic of cross section of the MR device with MR fluid gap ................... 29
Figure 4.1 Cross section view of monotube MR damper with accumulator .................... 32
Figure 4.2 Cross-sectional view of MR damper with sponge design ............................... 34
Figure 4.3 Preliminary MR damper with sponge design with coil winding gap .............. 35
Figure 4.4 Piston with MR fluid sponge and electromagnet ............................................ 36
Figure 4.5 Gauss meter with probe for magnetic field detection ...................................... 37
Figure 4.6 MR damper piston with electromagnet and sponge ........................................ 37
Figure 4.7 Front view of MR damper with piston inside the cylinder .............................. 38
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Figure 4.8 Closed cell PU foam sample............................................................................ 39
Figure 4.9 Open cell PU foam sample .............................................................................. 40
Figure 4.10 Closed cell PU foam without MR fluid ......................................................... 41
Figure 4.11 Weight of open cell PU foam with MR fluid ................................................ 41
Figure 4.12 Weight of closed cell PU foam ...................................................................... 42
Figure 5.1 Axisymmetric model of MR damper created in ANSYS ................................ 44
Figure 5.2 Mesh model created for MR damper with 4 different regions ........................ 46
Figure 5.3 BH curve generated in ANSYS APDL ........................................................... 47
Figure 5.4 Magnetic vector lines with magnetic field intensity ........................................ 47
Figure 6.1 MTS machine with MR damper mounted on the clamps ................................ 49
Figure 6.2 LabVIEW code with velocity input ................................................................. 49
Figure 6.3 LabVIEW code with displacement input ........................................................ 50
Figure 6.4 NImyDAQ with wires connected to the output terminal................................. 50
Figure 6.5 MR damper connected with external power supply and DAQ system ........... 51
Figure 6.6 Experimental force VS displacement graph of MR damper ........................... 53
Figure 6.7 Experimental force VS velocity graph of MR damper .................................... 53
Figure 7.1 Simulation loop created in LabVIEW with transfer function blocks .............. 55
Figure 7.2 Transfer function equation with function blocks in LabVIEW ........................55
Figure 7.3 Comparison of Force VS velocity plot of experiment and simulation .............57
Figure 8.1 Functional flow diagram of joystick integration with LabVIEW ....................58
Figure 8.2 PID control loop block diagram for feel system ..............................................59
Figure 8.3 PID block diagram for temperature control system .........................................61
Figure 8.4 Laboratory setup of feel system with MR device and sensors interfaced ........62
Figure 10.1 Force vs velocity plot for 1.53 V ....................................................................68
Figure 10.2 Force vs velocity plot for 1.3 V ......................................................................68
Figure 10.3 Force vs velocity plot for 1 V .........................................................................69
Figure 10.4 Force vs velocity plot for 0.7 V ......................................................................69
Figure 10.5 Force vs velocity plot for 0.5 V ......................................................................70
Figure 10.6 Force vs velocity plot for 0 V .........................................................................70
Figure 10.7 Force vs displacement plot for 1.5 V ..............................................................71
Figure 10.8 Force vs displacement plot for 1.2 V ..............................................................71
Figure 10.9 Force vs displacement plot for 1 V .................................................................72
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Figure 10.10 Force vs displacement plot for 0.7 V ............................................................72
Figure 10.11 Force vs displacement plot for 0.5 V ............................................................73