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The present work reports an integrated (experimental and numerical) methodology that combines the development of a finite element multiphysics model with an experimental strategy to optimally design an eddy current damper for automotive suspensions. The multiphysics model couples the whole set of time-dependent electromagnetic, thermal, mechanical, and fluid–wall interaction (CFD) partial differential equations. The developed FE model was validated against both literature model predictions and in-house experimental data. The electromagnetic model takes into account the magnetic material characteristics of the ferromagnetic material and iron poles. Loss separation and the Jiles–Atherton hysteresis models were invoked to determine the heat generated in the soft iron parts. The computation of the fluid–wall interaction phenomena in the air gap allowed for the prediction of the temperature field across the solid materials, including the magnets. The design of the EC damper addresses the effects of the geometries of the stator and rotor, as they are the most critical geometries for maximizing the functions of an eddy current damper. The magneto-thermal simulations suggested that the heating of the permanent magnets remains within a safe region over the investigated operational frequency range of the eddy current damper.

Integral Methodology for the Multiphysics Design of an Automotive Eddy Current Damper