DESIGN, MODELING AND CONTROL OF MAGNETORHEOLOGICAL FLUID-BASED FORCE FEEDBACK DAMPERS FOR TELEROBOTIC SYSTEMS DISSERTATION Presented in Partial Fulfillment of the Requirements for the Degree Doctor of Philosophy in the Graduate School of The Ohio State University By Farzad Ahmadkhanlou, M.S. * * * * * The Ohio State University 2008 Dissertation Committee: Professor Gregory N. Washington, Adviser Approved by Professor Stephen Bechtel Professor Vadim Utkin ______________________________ Professor Giorgio Rizzoni Adviser Mechanical Engineering Graduate Program ABSTRACT The overall goal of the research done in this dissertation is to develop next generation force feedback systems by combining novel Magnetorheological (MR) fluid based electromechanical systems with microstructural analysis and advanced control system design. Four MR fluid based systems are designed, prototyped and tested with medical applications: A two degree of freedom (2-DOF) force feedback joystick and a 5-DOF force feedback manipulator for telerobotic surgery application, a passive and a semi- active orthopedic knee brace for rehabilitation application. Furthermore, a force feedback steering wheel is modified using MR damper with application to steer-by-wire automobiles. The test results show the appropriate performance of MR fluid based systems used in haptic and force feedback applications. ii Dedicated to my dear parents and my beloved wife, Bahareh iii ACKNOWLEDGMENTS I would like to thank the Almighty God for his blessings and all the things He has given me. Everything I have is due to His compassion, mercy and beneficence. I would like to extend my sincere appreciation to my adviser, Professor Gregory Washington, for his intellectual support, technical guidance and encouragement throughout the course of this research. As a result of his excellent ability in teaching, I became so interested in control and smart materials that I changed my major and transferred to Mechanical Engineering. I am so glad I worked under his supervision and I am 100% sure I made the right decision. This research and dissertation could not have been completed without his continuous support and encouragement. I would also like to thank my co-advisor, Professor Stephen Bechtel, for all of his support and technical guidance. I never forget the weekly group meetings I had with Professor Washington and Professor Bechtel. The meetings were not only informative but also full of fun! I would like to thank Professor Vadim Utkin and Professor Giorgio Rizzoni for being on my doctoral committee and giving invaluable inputs on my dissertation. It is my great honor to have them on my doctoral committee member. I am thankful to the National Science Foundation for supporting this research. iv I would like to thank my colleagues at the Intelligent Structures and Systems Laboratory (ISSL) for their help. Special thanks to Leon Headings for his help, time, and support. I would also like to thank Dr. Vijay Neelakantan, Dr. LeAnn Faidley, Dr. Hwan- Sik Yoon, Anthony Roy, Matt Detrick, Yingru Wang, Monon Mahboob, Mohsen Kolivand, Mohammad Shakiba, Amitesh Punhani, Byeongil Kim, Prashanth Ramesh, and Jamaal Zite. I thank Professor Menq and his student Yanan in the Mechanical Engineering Department for the Scanning Electron Microscope (SEM) images, Professor Kurt Koelling and his student Christopher Kagarisein in the Chemical Engineering Department for the rheological tests, and Professor Fengyuan Yang and his student Adam Hauser in the Physics Department for the magnetization tests on MR fluid samples. I would like to thank the Mechanical Engineering Department staff specially Mr. Joe West (electronics shop), Mr. Gary Gardner (machine shop), and Mr. Jerry Kingzett for their help. And finally, I wish to thank my mother and my late father for all of their support during my undergraduate and graduate studies. I would like to thank my wife, Bahareh, for her continuous support throughout my graduate studies. And I would like to thank my brother, Dr. Fariborz Ahmadkhanlou for all of his support. v VITA September 14, 1973………………………Born - Tehran, Iran 1996………………………………………B.S., Civil Engineering University of Tehran, Tehran, Iran 1994 - 1999……………………………….Engineer and Software Analyst/Programmer Rah-Shahr International Engineering Group Tehran, Iran 1999………………………………………M.S., Civil/Structural Engineering University of Tehran, Tehran, Iran 1998 - 2001……………………………….Software Analyst/Programmer Rayan-Sazeh Company, Tehran, Iran 1996 - 2000……………………………….Teaching Assistant and Instructor Department of Civil Engineering University of Tehran, Tehran, Iran 2001 - 2002……………………………….Graduate Research Associate Department of Civil Engineering The Ohio State University 2003 - 2008……………………………….Graduate Research Associate Department of Mechanical Engineering The Ohio State University 2005 ………………………………………M.S., Mechanical Engineering The Ohio State University March 2008 - Present……………………..Scientist/System Engineer US Hybrid, CA vi PUBLICATIONS Refereed Journal 1. Christopher Kagarise, Monon Mahboob, Farzad Ahmadkhanlou, Stephen Bechtel, Gregory N. Washington, and Kurt W. Koelling “The Measurement and Modeling of the Viscoelastic Response of Magnetorheological Fluids to Steady and Dynamic Shear”, to be submitted, 2008 2. Farzad Ahmadkhanlou, Gregory N. Washington, and Stephen Bechtel “Modeling and Control of Single and Two Degree of Freedom Magnetorheological Fluid-Based Haptic Systems for Telerobotic Surgery”, Journal of Intelligent Material Systems and Structures, November 2007 (Accepted) 3. Farzad Ahmadkhanlou, Monon Mahboob, Stephen Bechtel, and Gregory Washington, "Experiments and Models of the Magneto Rheological Behavior of High Weight Percent Suspensions of Carbonyl Iron Particles in Silicone Oil", Journal of Fluids Engineering, September 2007 (in Review) 4. Farzad Ahmadkhanlou, Yingru Wang, Stephen Bechtel, Gregory Washington, "An improved model for magnetorheological fluid-based actuators and sensors", International Journal of Engineering Science, December 2006 (in Review) Refereed Conference 1. Christopher Kagarise, Farzad Ahmadkhanlou, Monon Mahboob, Stephen Bechtel, and Gregory N. Washington “Experiments and Models of the Magneto Rheological Behavior of High Weight Percent Suspensions of Carbonyl Iron Particles in Silicone Oil”, ASME International Mechanical Engineering Congress and Exposition, 11-15 November 2007 Seattle, Washington (presentation only) 2. Farzad Ahmadkhanlou, Gregory Washington, and Stephen Bechtel, "Analysis and Development of Magnetorheological Fluid Based Transparent Haptic Systems", Proceedings of the 10th Electrorheological Fluids and Magnetorheological Suspensions Conference, Lake Tahoe, June 2006 3. Stephen Bechtel, Gregory Washington, Farzad Ahmadkhanlou, and Yingru Wang, "Microstructural Analysis and Control of Magneto- Rheological Fluid", Proceedings of ASME International Mechanical Engineering Congress, November 15-17, 2004, Anaheim, CA. vii Non-Refereed Conference 1. Farzad Ahmadkhanlou, Gregory Washington, and Stephen Bechtel, "The Development of a Five DOF Magnetorheological Fluid-Based Telerobotic Haptic System", 15th SPIE International Symposium, 9-13 March 2008, San Diego, CA 2. Farzad Ahmadkhanlou, Gregory Washington, and Stephen Bechtel, "Design, Modeling, and Control of Magnetorheological Fluid-Based Force Feedback Systems", NSF Civil, Mechanical, and Manufacturing Innovations, 7-10 January 2008, Knoxville, TN 3. Farzad Ahmadkhanlou, Jamaal L. Zite, and Gregory N. Washington, “A Magnetorheological Fluid Based Controllable Active Knee Brace”, 14th SPIE International Symposium, 18-22-March 2007, San Diego, CA 4. Farzad Ahmadkhanlou, Gregory Washington, Yingru Wang, Stephen Bechtel, "Magnetorheological Fluid Based Automotive Steer-By-Wire Systems", 13th SPIE International Symposium, Feb 22-March 3 2006, San Diego, CA 5. Jamaal L. Zite, Farzad Ahmadkhanlou, Vijay A. Neelakantan, and Gregory N. Washington, “A Magnetorheological Fluid Based Orthopaedic Active Knee Brace”, 13th SPIE International Symposium, Feb 22-March 3 2006, San Diego, CA 6. Farzad Ahmadkhanlou, Gregory Washington, Yingru Wang, Stephen Bechtel, "The Development of Variably Compliant Haptic Systems using Magnetorheological Fluids", 12th SPIE International Symposium, March 6- 10 2005, San Diego, CA Posters 1. Farzad Ahmadkhanlou, Gregory Washington, and Stephen Bechtel, "Design, Modeling, and Control of Magnetorheological Fluid-Based Force Feedback Systems", NSF Civil, Mechanical, and Manufacturing Innovations, 7-10 January 2008, Knoxville, TN 2. Jamaal L. Zite, Farzad Ahmadkhanlou, Vijay A. Neelakantan, and Gregory N. Washington, “A Magnetorheological Fluid Based Active Knee Brace”, Denman Undergraduate Research Forum, The Ohio State University, May 17, 2006, Columbus, OH 3. Jamaal L. Zite, Farzad Ahmadkhanlou, Vijay A. Neelakantan, and Gregory N. Washington, “A Magnetorheological Fluid Based Knee Brace”, OSEA Forum, The Ohio State University, August 18, 2006, Columbus, OH 4. Tamika Rentas, Farzad Ahmadkhanlou, and Gregory N. Washington, “A Door Locking Mechanism Using A Magnetorheological Fluid Based Hinge”, OSEA Forum, The Ohio State University, August 18, 2006, Columbus, OH viii FIELDS OF STUDY Major Field: Mechanical Engineering Major Areas of Specialization: Dynamics Systems, Smart Materials, Vibration and Control, Characterization & Modeling, Robotics, Mechatronics. Minor Fields: Civil/Structural Engineering, Computer Science Minor Areas of Specialization: Structural Analysis/Design, Software Analysis/Development.