DEVICE WITH A MAGNETORHEOLOGICAL BRAKE DEVICE AND METHOD

Description

[0001] The present invention relates to a device with a magnetorheological braking device for braking relative movements and a corresponding method. A device according to the invention or the magnetorheological braking device comprises at least two braking components, between which at least one receiving space with at least one braking gap is formed. The braking gap is at least partially filled with a magnetorheological medium containing polarizable particles that can be influenced by a magnetic field.

[0002] In the state of the art, various magnetorheological braking devices have become known which are used to slow down or dampen relative movements.

[0003] A primary application of magnetorheological fluids is in shock absorbers, where the magnetorheological fluid flows from one chamber to another. High pressures and flow velocities can occur here. The magnetorheological fluid contains a large number of small, round particles to facilitate the flow from one chamber to the other. Low flow resistance is important to achieve low base damping.

[0004] Furthermore, magnetorheological braking devices have become known in which the deceleration of the two braking components, which can move relative to one another, is achieved by means of a shear stress between two, for example, plate-shaped surfaces. The magnetorheological fluid is located between the plates. The magnetic field flows through the magnetorheological fluid perpendicular to the direction of movement of the plate-shaped surfaces. This type of shear stress is used particularly in clutches and brakes. When a magnetic field is applied, a change in viscosity occurs very quickly, since only the magnetically polarizable particles need to be aligned. This means that force changes can be realized within a few milliseconds. In a magnetic field-free space, the shear stress behaves like a Newtonian fluid, and in a magnetic field like a Bingham fluid. The magnetic field polarizes the particles, and they form chains in the direction of the field lines.

[0005] JP 2013 181 598 A addresses the problem that clumping can occur in magnetorheological fluids due to particle sedimentation. This can occur, for example, when a magnetorheological brake is not moved for an extended period of time. JP 2013 181 598 A also addresses the problem that the viscosity of the magnetorheological fluid can increase when it rotates at high speeds or shear rates. As a solution, it is proposed that the magnetorheological fluid contain second nano-sized particles in addition to the first particles (e.g., carbonyl iron particles). This mixture reduces the increase in viscosity of the magnetorheological fluid at high speeds and simultaneously prevents sedimentation. Furthermore, both particle types are each coated with a surface modification layer. This improves the affinity for the dispersant (e.g., silicone oil).

[0006] US 2003 / 071238A1 discloses a magnetorheological device with non-circular magnetorheological particles of varying sizes. A friction-reducing additive is added. US 2002 / 110704 A also discloses a magnetorheological fluid with non-circular magnetorheological particles.

[0007] In certain applications, magnetorheological braking devices are desired that are particularly compact and can provide a particularly high braking torque. In a rotary brake with small diameters of, for example, 60 mm or smaller and a cylindrical braking gap, it is difficult to generate a high field strength in the braking gap (effective gap) because the central core or other parts of the magnetic circuit saturate first. A high coil current of the electrical coil therefore does not lead to any improvement if parts of the magnetic circuit are saturated. The smaller the diameter, the more quickly the core saturates and the less favorable the magnetic circuit surfaces become to one another. This means that smaller actuators have even lower flux densities in the braking gap.

[0008] To increase the braking force, EP 2 616 704 B1 by the applicant discloses a structure in which rotating parts, such as rollers, are arranged in the braking gap. These rollers specifically influence the course of the magnetic field acting on the magnetically polarizable particles (e.g., carbonyl iron particles) in the magnetorheological fluid. Due to the magnetic field's effect on the magnetically polarizable particles, a (geometric) wedge consisting of accumulated particles forms in front of the rotating round surfaces of the rollers or rotating bodies. The rollers can therefore also be referred to as magnetic field concentrators. This increases the braking torque.

[0009] DE 10 2020 106 328 B3 by the applicant discloses a further structure in which the magnetically polarizable particles, such as carbonyl iron particles, form a (local) cluster in the brake gap due to a special contour of the contact surfaces of the brake gap. The resulting increased particle concentration causes higher shear forces, which can generate higher braking torques. For example, the radially inner brake component is formed by a star- or gear-like structure, so that the brake gap has a variable gap height over the circumference, for example, if the outer brake component is cylindrical on the inner circumference.

[0010] Such a design results in a strong interlinking and accumulation of particles, as the braking gap does not have a constant height all the way around, but rather tapers periodically, causing clusters of particles to accumulate adjacent to these areas. Wedge-shaped clusters of magnetically polarizable particles form adjacent to the narrow spots, resulting in increased braking torque.

[0011] In principle, the designs according to DE 10 2020 106 328 B3 or EP 2 616 704 B1 function satisfactorily, whereby with the latter design, in which rotating bodies are used in the brake gap, even higher braking torques can be achieved than with the variant where, for example, a star contour in the brake gap ensures a variable gap height. Although satisfactory results are achieved, it is desirable to significantly increase the maximum locking torque or the maximum locking force, particularly under the same starting situation and under the same general conditions (similar construction volume and similar material), and thus achieve a higher power density.

[0012] This object is achieved by a device having the features of claim 1 and by the method according to claim 14. Preferred developments of the invention are the subject of the subclaims. Further advantages and features of the present invention will become apparent from the general description and the exemplary embodiments.

[0013] A device according to the invention comprises one or at least one magnetorheological braking device for braking relative movements. The braking device comprises at least two braking components, wherein a receiving space with at least one braking gap is formed between the braking components. The receiving space (and the braking gap) contains at least one magnetorheological medium with magnetically polarizable particles (magnetorheological particles) that can be influenced by a magnetic field. Furthermore, at least one core and at least one electrical coil unit are included to generate a controllable magnetic field in the braking gap. At least some of the magnetically polarizable particles are designed to form a canting structure under the influence of the magnetic field and to clamp or wedge them together. (This essentially forms a wedge at the particle level.)) For at least 25% of the magnetically polarizable particles, the ratio of maximum diameter to maximum transverse extent perpendicular to it is greater than 1.25, which are present as non-circular particles.

[0014] The device according to the invention has many advantages. A significant advantage of the device according to the invention is that the magnetorheological particles of the magnetorheological medium are designed in such a way that they can form a canting structure with one another, which can be canted or jammed together, thereby forming a significantly stronger structure. This makes it possible to generate a considerably greater braking torque than was possible with the prior art. The magnetically acting forces are mechanically amplified by the canting structure.

[0015] Conventional magnetorheological particles, on the other hand, must be pressed together tightly enough by the magnetic field alone to transmit the desired braking torque. If the magnetic field is not strong enough, the conventional magnetorheological particles slide along each other. In contrast, the magnetorheological particles of the invention can become jammed, preventing them from sliding along each other easily, even at lower magnetic forces.

[0016] In all embodiments, it is preferred that the magnetically polarizable particles are formed in particular by carbonyl iron particles.

[0017] If a magnetorheological fluid is used, fluids with 40 percent by volume are available on the market. (In-house) blends with between 40 and 50 percent by volume carbonyl iron are possible. More is not possible, as the carrier fluid takes up the remaining volume.

[0018] If powder is used without a carrier fluid, up to about 80 volume percent carbonyl iron (iron powder) is possible, which increases the braking torque considerably if the remaining design parameters are adapted accordingly (e.g. the field strength per particle should remain roughly the same as with MR fluid, i.e. the field strength in the braking gap or effective gap should be twice as high when changing from LORD MRF 140 (40 volume percent carbonyl iron with e.g. oil as a carrier fluid) to 80% carbonyl iron powder (without carrier fluid). We are talking here about magnetic field strengths in the gap of greater than 200 kA / m up to values ​​of up to 1,000 kA / m (1,000,000 A / m) or more.

[0019] A further advantage of using powder as the medium in the active gap is that it eliminates sedimentation and clumping in the sense that "the iron particles in MR fluids are drawn in the direction of the magnetic field gradient (the force on magnetizable particles always acts in the direction of the stronger magnetic field, displacing the carrier medium)" to achieve such high particle concentrations. The maximum particle concentration is already present. This improves the reproducibility of the torques (a similar braking torque is always achieved at the same current).

[0020] In all embodiments, it is particularly preferred that the magnetically polarizable particles (to a significant extent) comprise non-circular particles (non-spherical particles) for which the ratio of the largest diameter to the largest transverse extent perpendicular thereto is greater than 1.5. This ratio can also be formed as a ratio of the largest longitudinal extent to the largest transverse extent, with the longitudinal and transverse extents, in particular, being measured perpendicular to one another.

[0021] The use of non-circular particles is particularly advantageous because they enable an effective canting structure, as different non-circular sections of the particles clamp or wedge together.

[0022] Also possible and preferred are ratios of the largest diameter to the largest transverse extent perpendicular thereto of 1.75 or 2.0 or more.

[0023] Preferably, at least some of the magnetically polarizable particles are designed to clamp or wedge together under the influence of the magnetic field. This is possible, for example, with particles that are partially angular or, for example, entirely triangular or polygonal, or the like. Two (or more) correspondingly designed particles then clamp together and can cause very effective clumping of the particles and the clamping and deceleration of the two braking components together.

[0024] Preferably, at least some of the magnetically polarizable particles are designed to clamp or wedge together at two or more spaced-apart locations under the influence of the magnetic field. Such non-circular particles allow for a very effective increase in the braking force or braking torque, since, unlike spherical particles, they do not only touch at one point or within a small angular range, but at multiple points or even across a large area.

[0025] Preferably, at least some of the magnetically polarizable particles have at least one trough section. Such an inwardly curved trough section allows for particularly effective wedging with parts of other particles.

[0026] Preferably, at least one surface of at least one brake component adjacent to the brake gap is at least partially unsmooth or (locally) uneven. It is also possible for the particles or a significant portion of the magnetically polarizable particles to have regular or irregular elevations or ridges and / or depressions on the outer surface. This can increase jamming with the particles. For example, at least one surface can have elevations and / or depressions similar to pointed or rounded dimples on golf balls. A surface with a pointed or rounded sawtooth profile is also possible. A relative height (of at least some of) the elevations or depressions is preferably at least 5% or 10% of the minimum diameter of a magnetically polarizable particle.

[0027] In advantageous embodiments, at least some of the magnetically polarizable particles have at least one angled structural section. Angled structures allow for particularly effective clamping between them, thus generating a high braking torque.

[0028] In all embodiments, it is preferred that a projection or edge of one particle is clamped with a recess or trough portion of another particle.

[0029] Surprisingly, it has been found that non-circular particles can transmit particularly high braking forces while also generating a low base torque. The idle torque (base torque) decreases due to the reduction in the effective surfaces (the surfaces moving at a small distance from each other – these primarily generate the base friction – are reduced), which is very advantageous.

[0030] The tilting of the magnetically polarizable particles can occur not only two-dimensionally, but also three-dimensionally (e.g. also in the axial direction...).

[0031] It has been found that particularly effective jamming and clamping of individual particles can be achieved using high magnetic field strengths. For this purpose, a magnetic field strength of greater than 150 kiloamperes / meter (kA / m), 250 kiloamperes / meter, or 500 kA / m or more is preferably generated in the brake gap. In particular, a magnetic field strength of greater than 500 kiloamperes / meter (kA / m), 750 kiloamperes / meter, or 1000 kA / m or more can be generated in the brake gap or is generated there.

[0032] For a particularly effective increase in the achievable braking torque or the achievable braking force, it has proven very advantageous to reduce the minimum gap height of the braking gap between the braking components compared to the dimensions in the prior art. It is preferred that the minimum gap height is less than five times the largest diameter of the magnetically polarizable particles in the braking gap. In particular, however, a minimum gap height of the braking gap between the braking components is greater than twice the maximum transverse extent perpendicular to the maximum diameter of the magnetically polarizable particles in the braking gap. It is also possible and preferred that the minimum gap height of the braking gap between the braking components is greater than three times the maximum transverse extent perpendicular to the maximum diameter of the magnetically polarizable particles in the braking gap. This results in a low basic torque ora low basic force is ensured, while at the same time a particularly high braking torque or a particularly high braking force can be generated.

[0033] Preferably, at least 10% and in particular at least 20% of the magnetically polarizable particles have a ratio of maximum diameter to maximum transverse extent of greater than 1.5 or greater than 2.0.

[0034] Particularly preferably, for at least 33% or at least 50% of the magnetically polarizable particles, a ratio of maximum diameter to maximum transverse extent perpendicular thereto is greater than 1.25 or greater than 1.5 or greater than 2.0.

[0035] In particular, at least 10%, 25%, 33%, or 50% of the magnetically polarizable particles have a maximum diameter and / or a maximum transverse extent of at least 10 µm. It has been found that a higher braking effect can be achieved with larger particles than with smaller particles. Therefore, it is preferred that at least 10%, 25%, 33%, or 50% of the magnetically polarizable particles have a maximum diameter of at least 20 µm, or at least 30 µm, or at least 50 µm. Smaller particles may be included.

[0036] Surprisingly, it has been found that with larger particles a lower base torque and a higher braking torque (or base force and braking force) can be achieved.

[0037] In all embodiments, it is preferred that at least one load sensor, such as a torque sensor or torque transducer or torque observer, and / or a force sensor, is included. It is also preferred that at least one position sensor for detecting an angular position and / or relative position is included.

[0038] The coil unit, or at least one coil unit, may comprise a (cylindrical) coil wire. The coil wire may be made of a flat material. It is also possible to use a wire with a customized contour made of copper or another suitable material.

[0039] In preferred embodiments, the two brake components are pivotable relative to one another. However, it is also possible for the two brake components to be movable linearly relative to one another. Particularly preferably, the two brake components are continuously rotatable relative to one another.

[0040] The electrical coil unit or several coil units can be wound radially and / or axially around the core.

[0041] It is preferred that the brake gap completely radially surrounds the inner component. The brake gap can, in particular, be designed as a circumferential annular gap.

[0042] It is possible and preferred for at least one brake component to be provided with a star-shaped contour or the like that extends toward the other brake component, creating or providing a gap height that is variable over the circumference or length of the brake gap. Radially projecting arms or a star-shaped contour form local magnetic field concentrators that lead to a local increase in the field strength in the brake gap. This increases the jamming and clumping of individual non-circular particles.

[0043] It is possible for at least one rotating body to be arranged in at least one gap section of the braking gap. Such a rotating body can be designed, for example, as a sphere or, in particular, as a roller and can also lead to the (geometric) wedge effect described in the prior art, which also leads to clumping or jamming of the canting structure. This significantly increases the maximum torque that can be generated, or the maximum braking force that can be generated.

[0044] In all embodiments, it is possible for the magnetorheological medium to comprise at least one liquid as a carrier medium in which the magnetically polarizable particles are accommodated. The proportion of magnetically polarizable particles is, in particular, between 25 and 50 percent by volume (in the receiving space). In particular, a volume fraction of between 25 and 40% of polarizable particles is provided.

[0045] In particularly preferred embodiments, the magnetorheological medium comprises at least one gas surrounding the magnetically polarizable particles as a carrier medium. In this case, it is possible for no liquid to be provided as a carrier medium. For (dry) magnetically polarizable particles, the proportion of particles in the receiving space is in particular between 40 and 90 percent by volume, and preferably between 50 and 80 percent by volume.

[0046] In all embodiments, it is preferred that the device comprises an operating element connected to the magnetorheological braking device. The operating element can, for example, be designed as an operating roller and / or comprise an operating button. The magnetorheological braking device is preferably at least partially accommodated within the interior of the operating element.

[0047] It is possible and preferred for the operating element to have an outer diameter of less than 75 mm, in particular less than 60 mm, and preferably less than 50 or less than 45 mm. When configured as an operating roller, the operating element can also have a diameter of less than 25 mm or less than 15 mm.

[0048] In another embodiment, which does not fall within the scope of claim 1, the device for braking relative movements has at least two braking components, wherein a receiving space with a braking gap is formed between the braking components. The braking gap contains a magnetorheological medium with magnetically polarizable particles that can be influenced by a magnetic field. At least one electrical coil unit is included to generate a controllable magnetic field in the braking gap. A minimum gap height of the braking gap between the braking components is less than ten times, eight times, or five times the average diameter of a typical magnetically polarizable particle in the braking gap.

[0049] The method according to claim 14 serves to brake relative movements of at least two brake components of a magnetorheological braking device. A receiving space with a brake gap is formed between the brake components. The brake gap contains a magnetorheological medium with magnetorheological or polarizable particles that can be influenced by a magnetic field. An electric coil unit generates a magnetic field in the brake gap in order to form a canting structure over at least some of the magnetically polarizable particles in the brake gap under the influence of the magnetic field, and to wedge the magnetically polarizable particles together therein.

[0050] For at least 25% of the magnetically polarizable particles (20) used, the ratio of maximum diameter (22) to maximum transverse extent perpendicular thereto is greater than 1.25, these particles being non-circular particles.

[0051] In the current technology, which uses the shear principle, a chain formation of carbonyl iron particles is generated in a braking gap. The strength of the chain formation depends on the strength of the magnetic field. The generated shear stress is easily adjustable and directly influenceable.

[0052] In the device according to the present invention, a braking torque is generated in the braking gap at low field strengths, similar to the prior art shearing. At higher field strengths, clumping or jamming of the particles is caused. However, the use of rotating bodies in the braking gap is not necessary for this. Due to their non-circular structure, the individual particles can mesh with one another and form a jamming structure that generates high and very high braking forces (even without rolling elements or the like). The transition to clumping is progressive and is not directly or immediately related to the shear stress. According to current knowledge, the field strength (a very high field strength) is a trigger for clumping. The clumping or jamming or wedging of the magnetically polarizable particles with one another is a mechanical process and not easily controllable.In particular, when "dry" particles are used with a gas or gas mixture without the use of oil, a particularly low base torque can be achieved, while a high static braking torque can be generated when the clumping is triggered.

[0053] If rotating bodies or rollers are also used, an even (much) higher braking torque can be generated.

[0054] Another advantage of smaller gap heights compared to the state of the art is that a noticeable acceleration in reaction speeds or a noticeable improvement in responsiveness can be perceived. This could be due to the fact that fewer particles need to be aligned, resulting in a faster effect. It has been found that the haptic sensation during operation can be improved, as the reaction speed can be increased on the one hand, and the maximum braking torque or maximum braking force can be increased on the other. This is made possible to a large extent by the particle structure. The particles are designed in such a way that they form a canting structure and can jam together.

[0055] It is particularly advantageous if very high flux densities with very high field strengths are achieved in the brake gap, the brake gap has a low height and non-circular or misshapen particles or particles that can be jammed together, and in particular carbonyl iron particles, are used in high concentrations. This then leads to the effects mentioned above and to the jamming or clumping of the individual particles. Several individual particles stick together due to the magnetic field forces (rheological chain formation), much like Velcro. They form larger structures such as clumps, which in turn lead to jamming or wedging in the brake gap with high tangential forces. With a suitable design of the magnetic field strength or flux density, the brake gap height and the number, type and shape of the particles, this effect does not require a mechanical (geometric) wedge shape as in the prior art, nor does it require a special shape of the brake gap.Even with two parallel or concentric surfaces, clumping occurs, resulting in tilting, wedging, jamming, or clogging, and high tangential forces, which in turn lead to high braking torques and damping forces. This is not caused by the shear stresses between the individual freely moving (round) particles, but rather by the interlocking of the individual non-round and misshapen (non-spherical) particles in the braking gap.

[0056] Magnetic field forces between or to the individual particles are the trigger and the resulting shear stresses multiply through clumping to high braking forces or high braking torques.

[0057] It is advantageous if the gap height of the braking gap is smaller than in the state of the art. This is because the higher the gap height (relative to the particle dimensions), the more likely it is that the interlinked particles will break up or become separated. This behavior is non-linear, meaning that the braking torque decreases disproportionately with increasing gap height.

[0058] Therefore, small brake gap heights are progressively effective. As the particles become larger, the gap height can be increased accordingly. As the particles become smaller, it makes sense to also choose a correspondingly smaller gap height.

[0059] A very high and above-average magnetic field strength (flux density) in the brake gap is very advantageous. Advantageous values ​​are far higher than those cited in the literature or those required for shearing. State-of-the-art shearing typically generates a flux density between 50 and 100 kiloamperes / meter, as shear stresses increase linearly in this range. The curve flattens sharply in the range between 150 and 250 kiloamperes / meter. Higher flux densities (generated by the electric coil) lead to only smaller increases in shear stress, rendering the system ineffective (it reaches saturation).

[0060] Therefore, in pure shear conditions, very high flux densities are pointless or lead only to a small and inefficient increase in shear stresses and thus in the braking torque. High flux densities require correspondingly large magnetic field circuits and powerful electrical coil units. In summary, this means increased weight, space requirements, and costs.

[0061] Small brake gap heights place high demands on manufacturing and, according to the current state of the art, make no sense for braking devices based on the shear principle, nor do they lead to an increase in stress and thus in the braking torque. Therefore, based on current technology, one would not combine a small brake gap height with a very high field strength or flux density and misshapen or non-circular particles, as this would likely result in an unfavorable end product. However, when properly coordinated, they surprisingly produce a disproportionately high braking effect.

[0062] With a ring-cylindrical brake gap and a given installation space, specific cross-sections result through which the magnetic field flows. Normally, the specialist designs the magnetic circuit so that there are no magnetic field constrictions or bottlenecks. The brake gap is subjected to the flux density according to the state of the art. However, this does not lead to the clumping in the brake gap described here. Higher flux densities in the brake gap cannot be achieved because the magnetic circuit reaches magnetic saturation in the core area due to the installation space requirements. Therefore, the ring-shaped brake gap has a lower flux density. To increase the braking torque, however, one would not reduce the shear area of ​​the brake gap (shear area = effective area), since according to the literature this would lead to a reduction in the braking torque. Thus, half the shear area results in half the braking torque.It would therefore be absurd to reduce the shear area (effective area) in the brake gap, as this would proportionally reduce the transferable shear stresses and thus the braking torque.

[0063] To achieve optimal results, however, this is precisely what is necessary to ensure clump formation. By reducing the shear area in the braking gap at the interface between the solid metal and the carbonyl iron powder (particles), the flux density between / in the carbonyl iron powder (particles) is increased by reducing the shear area in the remaining effective gap, which in turn leads to clump formation of the individual particles.

[0064] If one has a magnetorheological damper with a magnetorheological fluid, designed according to the above invention, and fills it only with carbonyl iron powder, i.e., instead of 40 percent by volume of particles with magnetorheological fluid, one then has up to 80 percent by volume of particles (because the space-consuming carrier fluid is missing), one would expect noticeably higher braking torques. However, the opposite is true. The transition / effective area at the transition surface to the brake gap should be reduced so that the flux density / field strength in the remaining surface area increases. This then leads to clumping in the brake gap due to the higher flux density and significantly higher braking torques.

[0065] These braking torques are, for example, a factor of 4 to 10 higher than with pure shear according to the state of the art. This means that, for example, a shear area (effective area) reduced by half still delivers braking torques a factor of 4 higher due to the resulting clump formation, even though, according to the literature, these should decrease noticeably because the shear area decreases first, and the increase in flux density / field strength should actually lead to a much smaller increase in torque due to the flattening shear stress curve (with higher kA / m). In fact, a significant increase can be achieved.

[0066] In all embodiments, it is preferred that the receiving space be filled with magnetorheological particles to less than 95 percent by volume. The magnetorheological particles can, in particular, each consist predominantly of carbonyl iron powder. The particles can have a corrosion-resistant coating. The magnetorheological medium can include a graphite additive.

[0067] In particular, the magnetically polarizable particles have a packing density of greater than 74%. For the magnetically polarizable particles, geometries and / or size distributions are preferably provided that enable an improved packing density, and particularly preferably a packing density of greater than 74%.

[0068] In particular, at least some of the magnetically polarized particles each have at least one form-fitting structure. In particular, the form-fitting structures of the individual particles interact to produce the canting structure. The form-fitting structure is provided in particular by at least one of the previously described geometric properties of the particles. In particular, the particles interlock in a form-fitting manner by means of their form-fitting structures, thereby providing the canting structure.

[0069] In all embodiments, it is possible to include a torque sensor, torque transducer, torque observer, or force sensor. Such a sensor can be implemented as a strain gauge, but is not limited to this. The use of a passive magnetoelastic strain measurement (magnetostriction), an active magnetic-inductive strain measurement (inverse magnetostriction), or a fiber-optic strain measurement is also possible.

[0070] Further advantages and features of the present invention, which is defined by the appended claims, will become apparent from the exemplary embodiments explained below with reference to the accompanying figures. In these figures: Figure 1 shows a highly schematic embodiment of a device according to the invention with a magnetorheological braking device; Figure 2 shows another embodiment of a device according to the invention; Figures 3 and 4 show schematic representations of a braking gap of a device according to the invention; Figure 5 shows a highly schematic representation of a magnetically polarizable particle; Figure 6 shows a further embodiment of a device according to the invention; Figure 7 shows two schematic cross sections of a further device according to the invention; Figure 8 shows the simulation of the magnetic field profile in a device according to Fig. 7 ; Figures 9 and 9a show a scanning electron microscope image of conventional magnetorheological particles; and Figures 10 and 10a show a scanning electron microscope image of magnetorheological particles for the braking device according to the application.

[0071] Figure 1shows a highly schematic sectional view of a device 100 according to the invention, which comprises a braking device 1 or is designed as such. The braking device 1 comprises an inner braking component 2, which is designed as an inner component 2a, and an outer braking component 3 surrounding it, which is designed as an outer component 3a. A brake disc 32 is firmly connected to the braking component 2. The braking component 3 surrounds the brake disc 32 and forms a receiving space 4 between the brake disc 32 and the braking component 3, which receiving space is provided with a magnetorheological medium 9 with magnetorheological particles 20. A braking gap 5 is formed between the brake disc 32 and the braking component 3 on each side of the disc 32 and radially outward. The braking component 3 forms a housing.

[0072] The magnetic field lines 8, which are generated by the electrical coil unit 10, pass through the lateral braking gaps 5 and cause - depending on the magnetic flux density - a linking or clumping or canting of the individual magnetorheological particles 20 with each other (compare the Figures 3 and 4 ).

[0073] A control unit 11 serves to control the electrical coil unit 10 and thus the strength of the magnetic field 8. A load sensor 12 and a position sensor 13 serve to detect the relative position of the two brake components to each other and to detect the generated braking torque.

[0074] In all embodiments, preferably ferromagnetic and / or ferrimagnetic and / or superparamagnetic particles and preferably at least particles of carbonyl iron powder are provided. A magnetorheological medium provided from carbonyl iron powder in ambient air can be used particularly advantageously. Auxiliary substances can also be added, which in particular improve lubrication. The particles can, for example, have a particle size distribution between one and, in particular, between five or ten and twenty micrometers. Also possible are smaller (< 1 micrometer) to very small (a few nanometers) or larger particles of thirty, forty, and fifty micrometers or even larger.

[0075] Between the brake components 2 and 3, a brake gap 5 is provided, which has a gap height and is filled with a medium. The medium can also be a magnetorheological fluid, which, for example, comprises an oil containing ferromagnetic (magnetorheological) particles 20 as the carrier fluid. Glycol, grease, silicone, water, wax, and viscous or thin-viscous substances can also be used as the carrier medium, but are not limited to these.

[0076] However, the carrier medium is particularly and particularly preferably also gaseous and / or can be a gas mixture (e.g., air or ambient air, nitrogen, gas or gas mixture, air mixture), or the carrier medium can be omitted (vacuum or air and, for example, ambient air). In this case, only particles that can be influenced by the magnetic field (e.g., carbonyl iron) are filled into the braking gap or active gap. Mixing with other particles—preferably with lubricating properties, but not limited to them—such as graphite, molybdenum, plastic particles, or polymeric materials is possible. A combination of the materials mentioned can also be used (e.g., carbonyl iron powder mixed with graphite and air as the carrier medium). As a carbonyl iron powder without a (liquid) carrier medium, for example, a powder can be used that contains a minimum iron content of 97%. An SiO2 coating, for example, is possible.

[0077] The ferromagnetic or ferrimagnetic particles 20 are preferably carbonyl iron powder. The particles can also have a special coating / shell (titanium coating, ceramic, carbon coating, polymer coating, etc.) to better withstand the high compressive loads that may occur depending on the application or to be stabilized. The particles can also have a coating to protect against corrosion or electrical conduction. The magnetorheological particles for this application can be made not only from carbonyl iron powder (pure iron; iron pentacarbonyl), but also from special iron (harder steel) or other special materials (magnetite, cobalt, etc.), or a combination thereof. Superparamagnetic particles with low hysteresis are also possible and advantageous.

[0078] Figure 2shows an alternative embodiment in which a ring-cylindrical brake gap 5 is formed between the two brake components 2 and 3. A core 7 is formed on the axle unit 42, which core comprises a plurality of radially outwardly projecting arms 47. The arms 47 can be finger-like or extend considerably in depth in the form of ribs, so that the length perpendicular to the plane of the sheet can also be greater than the diameter in the plane of the sheet. In principle, with (adapted modifications) the braking device 1 according to Figure 2 It is possible to slow down or dampen both linear movements perpendicular to the plane of the sheet and rotational movements.

[0079] Each individual arm 47 here has multiple windings of an electrical coil unit 10 to generate a corresponding magnetic field. The magnetic field 8 passes essentially radially through the brake gap 5 and extends in the outer brake component 3, which can be designed as a rotor unit 43, in the circumferential direction to the next arm 47, where it passes essentially radially again through the brake gap 5.

[0080] Between the individual arms 47, intermediate sections 48 are provided or formed, which are in particular filled with a material having a considerably lower magnetic permeability than the magnetic permeability of the arms 47. The ratio of the relative magnetic permeability of the arm 47 to the relative magnetic permeability of the intermediate section 48 is preferably greater than 10 and in particular greater than 100 and particularly preferably greater than 1000 and can reach or exceed values ​​of 10,000 or 100,000.

[0081] If a magnetorheological fluid with a carrier material such as an oil or the like is used, a compensation tank 41 can be provided. If "dry" particles 20 with a gas or gas mixture are used as the magnetorheological medium 9, a compensation tank (temperature compensation, leakage compensation, etc.) can be omitted.

[0082] The radially outer end of an arm 47 may be tapered to produce a greater concentration of field strength in the brake gap, cf. the constriction 49 above in the illustration of Figure 2 It is also possible for the radially outer end of one or more arms 47 to have a star contour or a wave shape, as shown in the lower right area, in order to achieve a certain amplification in certain sections above the surface of the arm. Elevations 18 and depressions 19 are shown there. Corresponding contours in the housing, which reduce the effective areas and thus increase the field strength in the transition areas, are also possible as an alternative or in addition.

[0083] Figure 3 shows a highly schematic sectional view through the brake gap of a braking device 1. Magnetic field lines 8 are schematically drawn into the braking component 2 and the braking component 3, which pass vertically through the braking gap 54.

[0084] Four magnetorheological particles 20 are schematically shown in the brake gap 5, which are non-circular in shape and can thus form an effective jamming structure 15. An edge 29 on one of the magnetorheological particles 20 is shown as an example. It can be seen that the type and structure of the magnetorheological particles 20 enable effective jamming of the individual particles among themselves and of the two brake components 2 and 3 relative to one another.

[0085] For carbonyl iron powder according to the state of the art, we speak of preferably < 1 mm brake gap height 5, particularly preferably about 0.1 mm for e.g. an actuator diameter of < 40 mm.

[0086] A smaller gap height is preferred here. If larger particles are used, the effective gap thickness / height can also be larger. If smaller particles are used, the effective gap thickness / height must also be smaller.

[0087] Figure 4shows a further schematic cross-sectional view of a braking device 1, in which a number of irregularly shaped magnetorheological particles 20 are shown. The braking gap extends between the two braking components 2 and 3. Several particles 20 are schematically shown in the effective gap or braking gap 5. The particle shown at the top right has a maximum diameter 22 that is considerably larger than the maximum transverse extent 23 perpendicular thereto. Some of the particles have trough sections 28, projections 16, or recesses 17 into which other sections of other particles can engage. This creates an effective canting structure overall when the particles engage with one another. Even smaller particles can be located between the particles shown. These can also be spherical.The jamming and wedging of the individual particles is promoted by a high magnetic field strength in the braking gap 5, which also attracts the particles to one another, which intensifies clump formation. The mean diameter 21, averaged over all particles, or the typical diameter 24 of the particles 20 can differ from the maximum diameter and the maximum transverse extent 23. A large surface area of ​​the particles per volume is advantageous. For example, flatter particles are advantageous. The surface itself can also be rough and / or wavy.

[0088] It has been found that a relatively small minimum gap height 6a is conducive to increasing the braking torque, while an excessively large distance between the two brake components 2 and 3 leads to a reduction in the achievable braking torque. If one or both brake components have an uneven surface, the minimum gap height 6a can be reduced accordingly by adding elevations or depressions.

[0089] Figure 5 shows a schematic representation of a single particle 20, which is formed as a non-circular particle 25. The ratio of maximum diameter 22 to maximum transverse extent perpendicular thereto is more than 1.25 and can reach and exceed values ​​of 1.5 or 2.

[0090] Figure 6shows a highly schematic representation of a device 100 with a braking device 1, wherein rotating bodies 44 in the form of rollers or the like are provided in the braking gap 5. As a result, the minimum gap height 6a of the braking gap 5 is considerably smaller than the gap height 6 between the braking components 2 and 3. In this exemplary embodiment, too, irregularly shaped and non-circular particles 25 are used, which lead to clumping and tilting of the individual particles 20, so that a particularly high braking torque can be achieved.

[0091] The magnetically polarizable particles from e.g. Figures 3 to 6jam, particularly three-dimensionally. The active surfaces of the brake components 2 and / or 3 in contact with the particles can also have a corresponding surface and / or surface texture that promotes jamming with the particles. These can have depressions, knurls, pyramids, indentations and protrusions, corners, dimples, and the like. The surfaces can be rough and irregular. Preferably, a height difference from the "lowest" to the "highest" point of a surface is greater than 1% or 5% of the gap height in the brake gap 5 and / or greater than 5% or 10% of the diameter of a particle.

[0092] Figure 7shows two schematic cross sections of braking devices 1, each with two braking components 2, 3, wherein a braking gap 5 is formed between the surfaces 2b, 3b. An electrical coil unit 10 is wound around a core 7, which can be formed in one piece or consists of several parts. In the right-hand illustration of Figure 7 the core is tapered in the radially outer region and thus has a radially outer constriction 49. As a result, the magnetic field lines of the magnetic field 8 are concentrated and run "narrower" than in the left illustration of Figure 7 in which the core 7 has no constriction 49 or taper at the radially outer end.

[0093] Right next to Figure 7Possible configurations of the (outer) surface 2b of the brake component 2a and the (inner) surface of the brake component 3 are schematically shown in an enlarged manner. Elevations 18 and depressions 19 can be formed regularly or irregularly on the surfaces 2b and 3b to promote and reinforce the interlocking of the particles with the brake components. This effectively reinforces the interlocking structure.

[0094] Through a Fig. 7 By changing the geometry of the effective gap as shown, the magnetic field 8 can be specifically amplified at certain points and thus weakened at others. Figure 7This is shown schematically. In rotationally symmetric dampers, the magnetic field automatically decreases radially, since the magnetic field must flow through a larger area. The effective gap, which has a larger radius than the core around which the electrical coil unit is wound, therefore has a lower field strength than in core 7, even if the axial diameters are the same as in core 7. Increasing the current in the coil unit would no longer be of any use above a certain field strength, since core 7 would enter magnetic saturation.

[0095] However, the effects described in the invention require a high magnetic field. Therefore, the effective area at the braking gap can be reduced to increase the magnetic field 8. This results in a loss of shear area, but at the same time, a larger magnetic field is obtained.

[0096] The Figure 8shows a schematic of a magnetic field simulation for two different geometries, whereby the centrally provided coil unit 10 is not shown. It can be seen that the magnetic field is stronger with a narrower effective area (denser and longer vectors = higher magnetic field, further apart and shorter vectors = lower magnetic field). At the right and left ends of the core 7, different constrictions 49 (different angles) are formed at the radially outer end of the core 7. The remaining web at the braking gap is therefore different in width on the right and left. At the right end, the remaining web is narrower, so that a locally stronger magnetic field passes through the braking gap 5. The shearing area is narrower, but the magnetic field strength is significantly higher, so that the particles can become jammed.

[0097] Figures 9 and 9ashow a scanning electron microscope image as a line drawing and as an image of a conventional magnetorheological fluid, with the round particles 20 clearly visible. The scale and a section of 10 µm are shown at the edge.

[0098] In contrast to the particles according to Figure 9 According to the invention, a significant proportion of non-circular particles 25 are Figure 10 (as a line drawing) or Figure 10a (as a recording) is used according to the invention. In the illustration according to Figures 10 (and 10a ) it is immediately apparent that a significant proportion of the particles 20, or the majority of them, are non-circular and misshapen. For the centrally depicted particle 20, the maximum diameter 22 is more than twice as large as the maximum transverse extent 23 of the same particle 20 perpendicular to it.

[0099] Figures 9 and 9ashow essentially the same section. Figures 10 and 10a show in principle the same detail.

[0100] Both projections 16 and trough sections 28 are formed on the particles 20. A corresponding number of particles 20 designed in this way enables an effective canting structure 15 in the brake gap 5. Even if the scale according to Figure 8 (compare the 1 µm distance shown) is considerably larger than the scale according to Figure 7 , it is clear that the structure of particles 20 in Figure 8 significantly different than in Figure 7 This results in a significantly better clamping of the individual particles 20 among each other and thus of the brake components 2 and 3.

[0101] Particles after Figure 9 (9a) can be treated with particles according to the Figures 3 to 6and / or 10 (10a) are mixed to form the magnetorheological medium. Preferably, the proportion of non-spherical particles is at least 30%, 40%, or 50% or more.

[0102] The magnetic attraction between particles depends on the volume and the surface area. Spheres have the smallest surface area for a given volume. Since the magnetic attraction is proportional to the (contacting) surface area, the force between two spherical particles is smaller than for differently shaped (non-spherical) particles with the same volume, e.g., cubes or the particle shapes described here. Larger particles therefore attract each other with greater force, since the flux density increases with larger volume.

[0103] Spherical or ball-shaped particles of the same diameter have a maximum packing density that cannot be exceeded. This is approximately 74%. Differently shaped (non-spherical) particles can be packed more densely. This reduces the empty space or air volume in the gap. The magnetic resistance in the gap decreases, and the magnetic circuit becomes more efficient. The magnetic flux is then increased within the same installation space, which is particularly advantageous in small installation volumes. The particles themselves then amplify the field they require to form the canting structure.

[0104] In particular, when using a magnetorheological medium in which a gas or gas mixture is used as the carrier material and no liquid components, a particularly low base torque can be achieved, while at the same time a particularly high maximum braking torque can be achieved. A particularly high braking torque is achieved with high flux densities in the braking gap and a relatively small minimum gap height 6a, and with non-circular particles 20.

[0105] For smooth, round, or spherical particles, a sufficiently strong magnetic field is necessary to ensure that the particles adhere or rub against one another strongly enough to achieve the desired braking effect. If the magnetic field is insufficient, the particles slide along one another. With the invention, the canting structure forms between the individual particles 20 even under weaker magnetic influences, so that they, for example, clamp together in a form-fitting manner and cannot slide along one another. This allows for particularly strong braking when required. Furthermore, due to the properties described here, the particles have the advantage of simultaneously enabling a particularly low base torque. This allows the braking components to rotate particularly easily relative to one another when no magnetic field is generated. List of reference symbols: 1 braking device 29 edge 2 Brake component (inner) 30 angled 2a Internal component Structural section 2b surface 32 brake disc 3 Brake component (outer) 40 winding 3a External component 41 expansion tank 3b surface 42 axle unit 4 recording room 43 Rotor unit 5 brake gap 44 Rotating body 6 Gap height 45 split section 6a minimum gap height 46 variable gap height 7 core 47 arm 8 magnetic field 48 Intermediate section 9 magnetorheological 49 narrowing medium 50 console 10 Coil unit 59 Fastening device 11 Control unit 100 device 12 Load sensor 101 Control element 13 Position sensor (distance, angle) 102 Outer diameter 103 Operating roller 14 Magnetic field sensor 103 Control knob 15 Tilting structure 16 projection 17 Rebound 18 increase 19 Deepening 20 particles 21 average diameter 22 maximum diameter 23 maximum transverse extension perpendicular to 22 24 typical diameter 25 non-circular particles 26 Position 27 Position 28 trough section

Claims

1. An apparatus (100) with a magnetorheological brake device (1) for braking relative motions, comprising at least two brake components (2, 3), wherein between the brake components (2, 3), a receiving space (4) with a braking gap (5) is formed, containing a magnetorheological medium (9) with magnetically polarizable particles (20) that can be influenced by a magnetic field, wherein at least one core and at least one electric coil unit (24) is comprised to generate a controllable magnetic field (8) in the braking gap (5), wherein at least part of the magnetically polarizable particles (20) is configured to form and to interlock an interlocking structure (15) under the influence of the magnetic field (8), characterized in that at least 25% of the magnetically polarizable particles (20), which are non-round particles (20a), have a ratio of maximum diameter (22) to maximum transverse extent (23) perpendicular thereto of greater than 1.25.

2. The apparatus (100) according to claim 1, wherein the magnetically polarizable particles (20) comprise non-round particles (20a), wherein the ratio of largest / maximum diameter (22) to largest / maximum transverse extent (23) perpendicular thereto is greater than 1.5.

3. The apparatus (100) according to any of the preceding claims, wherein at least part of the magnetically polarizable particles (20) is configured to interlock under the influence of the magnetic field (8) at two or more locations (26, 27) spaced apart from one another, and / or wherein at least part of the magnetically polarizable particles (20) have at least one trough section (28), and / or wherein at least part of the magnetically polarizable particles (20) have an angled structural section (30).

4. The apparatus (100) according to any of the preceding claims, wherein a projection or an edge of a particle interlocks with a recess or a trough section of another particle, and / or wherein at least one surface of at least one brake component (2, 3) adjoining the braking gap (5) is at least partially non-smooth and has elevations (18) and / or depressions (19) configured to reinforce interlocking with the particles (20).

5. The apparatus (100) according to any of the preceding claims, wherein a minimum gap height (6a) of the braking gap (6) between the brake components (2, 3) is larger than twice the largest transverse extent (23) perpendicular to the maximum diameter (22) of the magnetically polarizable particles (20) in the braking gap (6).

6. The apparatus (100) according to any of the preceding claims, wherein at least 50% of the magnetically polarizable particles (20) have a ratio of maximum diameter (22) to maximum transverse extent (23) perpendicular thereto of larger than 1.25, and / or wherein at least 25% of the magnetically polarizable particles (20) have a maximum diameter (22) and / or a maximum transverse extent (23) of at least 10 µm or at least 20 µm, and / or wherein at least 25% of the magnetically polarizable particles (20) have a maximum diameter (22) of at least 30 µm or 50 µm.

7. The apparatus (100) according to any of the preceding claims, wherein the two brake components (2, 3) are pivotable relative to one another and / or continuously rotatable relative to one another.

8. The apparatus (100) according to any of the preceding claims, wherein the electrical coil unit (10) is wound radially or axially around the core (7).

9. The apparatus (100) according to any of the preceding claims, wherein the braking gap (5) completely surrounds the inner component (2a), and wherein the braking gap (5) is in particular configured as a circumferential annular gap.

10. The apparatus (100) according to any of the preceding claims, wherein at least one brake component (2, 3) has a star contour (47), which projects towards the other of the brake components and which generates / provides a gap height (46) that is variable over the circumference or the length of the braking gap (5).

11. The apparatus (100) according to any of the preceding claims, wherein at least one rotary body (44) is disposed in a gap section (45) of the braking gap.

12. The apparatus (100) according to any of the preceding claims, wherein the magnetorheological medium (9) comprises for a carrier medium, at least one liquid in which the magnetically polarizable particles (20) are received, wherein the magnetically polarizable particles (20) in particular constitute between 25 and 50 percent by volume in the receiving space (4), or wherein the magnetorheological medium (9) comprises for a carrier medium, at least one gas surrounding the magnetically polarizable particles (20), wherein the magnetically polarizable particles (20) in particular constitute between 40 and 90 percent by volume in the receiving space (4).

13. The apparatus (100) according to any of the preceding claims, comprising an operating member (101) connected with the magnetorheological brake device (1), and wherein the operating member (100) comprises an operating roller (103) and / or an operating knob (104), and wherein the magnetorheological brake device (1) is at least partially received in the interior of the operating member (101).

14. A method (100) for braking relative motions of at least two brake components (2, 3) of a magnetorheological brake device (1), wherein between the brake components (2, 3), a receiving space (4) with a braking gap (5) is formed, containing a magnetorheological medium (9) with magnetically polarizable particles (20) that can be influenced by a magnetic field, wherein an electric coil unit (24) generates a magnetic field (8) in the braking gap (5), to form, under the influence of the magnetic field (8), an interlocking structure (15) over at least part of the magnetically polarizable particles (20) in the braking gap, to thereat interlock magnetically polarizable particles (20), and that at least 25% of the utilized, magnetically polarizable particles (20), which are non-round particles (20a), have a ratio of maximum diameter (22) to maximum transverse extent (23) perpendicular thereto of larger than 1.25.

15. The method according to the preceding claim, wherein the magnetic field strength between individual particles is above 500 kA / m, and wherein the concentration of particles in the braking gap is higher than 40%.