Design optimization of a novel elastomeric baffle magnetorheological fluid device

This article details the design optimization of a novel magnetorheological fluid device, which incorporates a rolling elastomeric baffle to contain the fluid and minimize cost and complexity. The application considered here is an electronic joystick for a drive-by-wire construction machine, although designs for other semi-active applications could be similarly optimized. Performance is evaluated computationally and experimentally. A computationally efficient system model is developed and validated using finite element analysis to accurately predict the device’s magnetic flux characteristics. The design methodology is based on a variant of the firefly algorithm, which identifies promising initial designs, and conjugate gradient methods, which optimize these designs. A unique graphical method for interpreting the results of population-based firefly optimization is demonstrated. An experimental prototype, based on the optimized design, is tested and its data compared to simulation results.