This research focuses on development a speed control system of a rotary load shaft with different loading torque by using a clutch featuring magneto-rheological fluid (MRC). Firstly, a new configuration of a speed control system using MRC is proposed. Modeling of the MRC based speed control system is then derived based on Bingham plastic model of magneto-rheological fluid (MRF). Based on the derived model, an optimal design problem for the system is built and the optimal solution is obtained based on finite element analysis. Performance characteristics of the MRC based speed control system are then experimentally investigated. After that, the MRC based speed control system to control a varying rotary load shaft driven by an AC motor is proposed and a PID controller to control the speed is designed and implemented. Experiments on steady speed control of the rotary load shaft is then obtained and presented with remark discussions.
In industry, the AC motor is widely used because of low price, power availability, low cost maintenance. The main disadvantages of AC motors compared to DC motors are difficulty in speed and torque control, requiring expensive controllers with complex control algorithms. This is the basic limitations in the widespread adoption of AC motor systems for industrial automation. One feasible solution for AC motor control is using MRF (magneto-rheological fluid) based clutches (shortly called MR clutches) Although there have been many studies on MR clutches, most of these clutches used traditional configuration with coils wound on the middle cylindrical part and a compotator is used to supply power to the coils. Therefore, this type of MR clutches possesses many disadvantages such as high friction and unstable applied current due to commutator, complex structure which causes difficulty in manufacture, assembly, and maintenance. In addition, the bottleneck problem of magnetic field is also a challenging issue. In this research, we will develop a new type of MR clutches that overcomes the abovementioned disadvantages of traditional MR clutches and more suitable for application in controlling of AC motor. Besides, in this study, speed and torque control system for AC motors using developed MR clutches is designed and experimental validated.
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