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For the efficient application of Terfenol-D rod, six kinds of rods were studied. Finite element software was used to simulate and calculate the hysteresis loss, eddy current loss, coil resistance, and inductance of the rods at different frequencies and currents. Three kinds of rods were manufactured, the coil resistance and inductance were measured. The results showed that the hysteresis loss, eddy current loss, and coil resistance increased, and the coil inductance decreased with the increase of frequency. As the current increased, the hysteresis and eddy current losses of the rods increased, the coil resistance and inductance remain unchanged; the hysteresis loss, eddy current loss and coil resistance of the radially slit rod were the largest, whereas that of the slit rods were larger than those of the sliced rods, the coil inductance of the slit rods was less than that of the sliced rods. The numerical calculation values of coil resistance and inductance at different frequencies and currents basically agreed with the experimental test values. [ABSTRACT FROM AUTHOR]

To improve the vibration performance of the Terfenol-D rod and make its work more efficient, six types of Terfenol-D rods were studied in this paper. The dynamic simulation analyses of the rods were carried out, and the core loss of the rods were calculated and analyzed. Three structures of rods were manufactured, and their output amplitude were tested. The results showed that an untreated rod had the highest resonance frequency, the largest mechanical quality factor, and the smallest output amplitude and outer surface stress; compared with the untreated rod, the resonant frequency and mechanical quality factor of the sliced and slit rods reduced, the output amplitude and outer surface stress of the sliced and slit rods increased; the resonant frequency and mechanical quality factor of the sliced rods were smaller than those of the slit rods; and the output amplitude and outer surface stress of the sliced rods were larger than those of the slit rods. The untreated rod had the largest core loss on the outer diameter surface; the core loss on the outer diameter surface of the sliced and slit rods reduced, and the core loss of sliced rods was less than that of slit rods. The radially slit rod had the largest overall core loss; the overall core loss of the radially cut and bonded rod and the sliced rods was less than that of the untreated rod and the radially slit rod. [ABSTRACT FROM AUTHOR]

Abstract Engine mount system affects the automobile NVH performance. Active mounts would achieve excellent vibration isolation and relative displacement control performance in a broad frequency bandwidth by outputting controlled force to the mounting system. The actuator and control method of the active mounts determine the system performance. In this paper, an active mount based on the smart material, i.e., Terfenol-D rod, is proposed, which mainly includes three parts: rubber spring, magnetostrictive actuator (MA), and hydraulic amplification mechanism (HAM). Dynamic model of the active mount is correspondingly established. A state feedback control method based on x-LMS (Least-Mean-Square) algorithm is proposed as well. Specifically, with the consideration of the unmeasurable state parameters in the active mounting system, an x-LMS state feedback controller with the system state as the reference signal is constructed by employing Sage-Husa Kalman filter to realize the state estimation of the active mounting system. Then a detailed analysis of the proposed control method is conducted, with deriving iterative formula of tap-weight vector. Sequentially, the problem of the dependence on the excitation signal in the x-LMS algorithm is addressed. The feasibility and capability of the proposed control method are verified and evaluated by simulation of a two-degree-of-freedom active mounting system.

To efficiently use Terfenol-D rods, six of its structures were studied. Finite element analysis was used to estimate and compare the hysteresis, eddy current, and coil resistance losses of the six Terfenol-D rods. The loss factors of the rods were calculated and analyzed. Furthermore, three structures of Terfenol-D rods were manufactured, and the loss factors of the rods were measured. The results showed that an untreated rod had the largest hysteresis and eddy current losses on the outer diameter surface, and the overall hysteresis loss of the rod was the smallest. Compared with the untreated rod, the eddy current and hysteresis losses on the outer diameter surface of sliced and slit rods reduced, the overall hysteresis loss of sliced and slit rods increased, and the overall eddy current loss of sliced rods reduced; the hysteresis and eddy current losses on the surface of the sliced rods were less than that of the slit rods, and the overall eddy current loss of the sliced rods was less than that of the slit rods; moreover, the eddy current loss of each rod was larger than its hysteresis loss. The numerical calculation values of the coil resistance loss basically agreed with the theoretical calculation values. The finite element simulation calculation values of the loss factors of the Terfenol-D rods agreed with the experimental test values. [ABSTRACT FROM AUTHOR]

To reduce the heating of the Terfenol-D rod and evaluate its working efficiency, six kinds of Terfenol-D rods were designed, and the temperature field of the rods was simulated and calculated using the finite element method to obtain the temperature distribution. The results showed that the untreated rod had the highest temperature; the temperature was higher in the middle and lower at both ends; higher on the outer diameter surface; and lower on the inside. When compared to the untreated rod, the temperatures of sliced rods and slit rods decreased, and the temperature of sliced rods was lower than that of slit rods; the temperature of slit rods was higher in the middle and lower at both ends; the temperature distribution of sliced rods was more uniform relatively; the slice treatment rod had the lowest temperature and the best heat suppression effect. Three structural rods were chosen and manufactured from a total of six that were tested. It shows that the temperature of all rods was higher in the middle and lower at both ends after 30 min of operation. The actual temperature of untreated rod was 34 °C, the actual temperature of radially slit rod was 32 °C, and the actual temperature of sliced rod at both ends was 28 °C. The tested temperature distributions of three rods agreed with the calculated ones. [ABSTRACT FROM AUTHOR]

Engine mount system affects the automobile NVH performance. Active mounts would achieve excellent vibration isolation and relative displacement control performance in a broad frequency bandwidth by outputting controlled force to the mounting system. The actuator and control method of the active mounts determine the system performance. In this paper, an active mount based on the smart material, i.e., Terfenol-D rod, is proposed, which mainly includes three parts: rubber spring, magnetostrictive actuator (MA), and hydraulic amplification mechanism (HAM). Dynamic model of the active mount is correspondingly established. A state feedback control method based on x-LMS (Least-Mean-Square) algorithm is proposed as well. Specifically, with the consideration of the unmeasurable state parameters in the active mounting system, an x-LMS state feedback controller with the system state as the reference signal is constructed by employing Sage-Husa Kalman filter to realize the state estimation of the active mounting system. Then a detailed analysis of the proposed control method is conducted, with deriving iterative formula of tap-weight vector. Sequentially, the problem of the dependence on the excitation signal in the x-LMS algorithm is addressed. The feasibility and capability of the proposed control method are verified and evaluated by simulation of a two-degree-of-freedom active mounting system. [ABSTRACT FROM AUTHOR]

Vibration energy harvesting is a new alternative to lithium battery power for low-power devices, attempting to recover wasted or lost vibration energy to generate electricity. Magnetostrictive-based energy harvesting exploits the coupling properties of the Villari and Faraday electromagnetic induction effects to achieve mechanical–magnetic–electric energy conversion. In order to better apply to the actual vibration environment, such as buses, and improve the ability to capture low-frequency vibration energy, a double-stage rhombus vibration energy harvesting device, based on Terfenol-D rods, was developed. By establishing an analytical model of the force amplification ratio of the harvesting device, the design is optimized using the Single-Objective Genetic Algorithm, and the safety and pre-magnetization layout methods are analyzed by Finite Element Analysis. The output characteristics of the prototype, including the output voltage frequency response under low-frequency regular excitation and random excitation, the effect of external resistance, and the vibration energy capture performance under random excitation, are investigated in detail through experiments. The results of the experiments showed that the peak output power of the fabricated prototype was 1.056 mW at 30 Hz operating frequency, the energy harvesting capability reached 41.4 μW/N, and the peak open circuit voltage and output power were 2.92 V and 266 mW, respectively, under random excitation. Practical application test results showed that the peak voltage generated was 1.06–1.51 V when the excitation level was 2.2–4.9 m/s2. The comparative study indicates that the output performance of the proposed double-stage rhombus magnetostrictive vibration energy harvesting system is a great improvement over the proposals of existing literature. [ABSTRACT FROM AUTHOR]

To reduce the heating of the Terfenol-D rod and evaluate its working efficiency, six kinds of Terfenol-D rods were designed, and the temperature field of the rods was simulated and calculated using the finite element method to obtain the temperature distribution. The results showed that the untreated rod had the highest temperature; the temperature was higher in the middle and lower at both ends; higher on the outer diameter surface; and lower on the inside. When compared to the untreated rod, the temperatures of sliced rods and slit rods decreased, and the temperature of sliced rods was lower than that of slit rods; the temperature of slit rods was higher in the middle and lower at both ends; the temperature distribution of sliced rods was more uniform relatively; the slice treatment rod had the lowest temperature and the best heat suppression effect. Three structural rods were chosen and manufactured from a total of six that were tested. It shows that the temperature of all rods was higher in the middle and lower at both ends after 30 min of operation. The actual temperature of untreated rod was 34 °C, the actual temperature of radially slit rod was 32 °C, and the actual temperature of sliced rod at both ends was 28 °C. The tested temperature distributions of three rods agreed with the calculated ones.

Vibration energy harvesting is a new alternative to lithium battery power for low-power devices, attempting to recover wasted or lost vibration energy to generate electricity. Magnetostrictive-based energy harvesting exploits the coupling properties of the Villari and Faraday electromagnetic induction effects to achieve mechanical–magnetic–electric energy conversion. In order to better apply to the actual vibration environment, such as buses, and improve the ability to capture low-frequency vibration energy, a double-stage rhombus vibration energy harvesting device, based on Terfenol-D rods, was developed. By establishing an analytical model of the force amplification ratio of the harvesting device, the design is optimized using the Single-Objective Genetic Algorithm, and the safety and pre-magnetization layout methods are analyzed by Finite Element Analysis. The output characteristics of the prototype, including the output voltage frequency response under low-frequency regular excitation and random excitation, the effect of external resistance, and the vibration energy capture performance under random excitation, are investigated in detail through experiments. The results of the experiments showed that the peak output power of the fabricated prototype was 1.056 mW at 30 Hz operating frequency, the energy harvesting capability reached 41.4 μW/N, and the peak open circuit voltage and output power were 2.92 V and 266 mW, respectively, under random excitation. Practical application test results showed that the peak voltage generated was 1.06–1.51 V when the excitation level was 2.2–4.9 m/s2. The comparative study indicates that the output performance of the proposed double-stage rhombus magnetostrictive vibration energy harvesting system is a great improvement over the proposals of existing literature.

The paper presents the numerical and experimental investigations of the axisymmetric magnetostrictive actuator with a Terfenol-D rod. The applied model consists of equations that describe the magnetic and mechanical displacement fields. The equations of both fields are coupled through a nonlinear magneto-mechanical constitutive law. The model is considered as 2D axisymmetric. The finite element method is used to solve the field equations. Special attention is paid to the proper definition of magneto-mechanical relations. These relations are formed from measurements. A unique test stand is designed for the experimental investigation. The selected results of the simulation are compared with the measurement results. The comparison shows that the applied numerical model is sufficiently accurate.

Terfenol is an ideal choice for medium to high power low frequency sonar. It can offer the transducer designer higher strain, higher power density, but the designer must be aware of the eddy current. To enhance efficiency of the barrel-stave transducer powered by a Terfenol rod, radial slots rather than laminations were used to control eddy currents in the Terfenol drive rod, and the effectiveness and the number of these slots were studied experimentally and calculated by finite element modeling. Based on the characteristic of vortex path,a new simple geometrical method to calculate the number of the radial slots of a Terfenol rod at the operating frequency is put forward in this paper. Moreover, the calculated results are in good agreement with those of using the finite element method (FEM) for the slotted Terfenol rod given by the literature. The method will save much cost to design Terfenol rod transducers. [ABSTRACT FROM AUTHOR]

The paper presents the numerical and experimental investigations of the axisymmetric magnetostrictive actuator with a Terfenol-D rod. The applied model consists of equations that describe the magnetic and mechanical displacement fields. The equations of both fields are coupled through a nonlinear magneto-mechanical constitutive law. The model is considered as 2D axisymmetric. The finite element method is used to solve the field equations. Special attention is paid to the proper definition of magneto-mechanical relations. These relations are formed from measurements. A unique test stand is designed for the experimental investigation. The selected results of the simulation are compared with the measurement results. The comparison shows that the applied numerical model is sufficiently accurate. [ABSTRACT FROM AUTHOR]