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This paper examines the effect of an electromagnetically optimized magnetorheological (MR) damper for vehicle suspension on vibration control performance. In order to achieve this goal, a cylindrical MR damper that satisfies design specifications for a middle-sized commercial passenger vehicle is designed using an optimization methodology. The optimization problem is to find the optimal geometric dimensions of the electromagnetic circuit for the MR damper in order to maximize the damping force. A first-order optimization method using commercial finite element method (FEM) software is adopted for the constrained optimization algorithm. After manufacturing the MR damper with optimally obtained design parameters, its field-dependent characteristics are experimentally evaluated. The effect of the optimal MR damper on suspension control is then investigated using a quarter-vehicle test facility. Control performances such as vertical acceleration, suspension travel, and power consumption are evaluated and compared between the initial and optimal dampers. In addition, vibration control performances of the optimal MR damper are experimentally evaluated under bump and random road conditions and presented in both time and frequency domains.

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