Interactive design optimization of magnetorheological-brake actuators using the Taguchi method

This research explored an optimization method that would automate the process of designing a magnetorheological (MR)-brake but still keep the designer in the loop. MR-brakes apply resistive torque by increasing the viscosity of an MR fluid inside the brake. This electronically controllable brake can provide a very large torque-to-volume ratio, which is very desirable for an actuator. However, the design process is quite complex and time consuming due to many parameters. In this paper, we adapted the popular Taguchi method, widely used in manufacturing, to the problem of designing a complex MR-brake. Unlike other existing methods, this approach can automatically identify the dominant parameters of the design, which reduces the search space and the time it takes to find the best possible design. While automating the search for a solution, it also lets the designer see the dominant parameters and make choices to investigate only their interactions with the design output. The new method was applied for re-designing MR-brakes. It reduced the design time from a week or two down to a few minutes. Also, usability experiments indicated significantly better brake designs by novice users.