A direct drive starting motor structure with replaceable carbon brush for engine

Abstract

The application relates to the technical field of engines and discloses a direct-drive starting motor structure with replaceable carbon brushes for an engine, which comprises a top cover provided with a box body at the bottom; and an integrated mechanism installed in the inside of the box body, wherein a first-stage spring with a different line diameter is coaxially and parallelly sleeved between a carbon brush and a support plate together with a second-stage spring, a hierarchical progressive jacking mechanism is constructed by using the stiffness difference and the stroke difference of the two-stage springs, the second-stage spring independently absorbs energy in a flexible mode only when small-amplitude high-frequency vibration occurs, the first-stage spring is synchronously intervened to provide high-pressure jacking when the second-stage spring is compressed to the bottom in a violent impact, the jacking mode is automatically switched according to the vibration amplitude, the contact between the carbon brush and a magneto rotor is maintained in a sticking mode throughout the whole process, layered attenuation of vibration in the whole frequency band is realized, the micro-motion disengagement between the carbon brush and the magneto rotor is effectively inhibited, the power generation stability is ensured, and the elastic resistance of a rubber ring to the excessive displacement of the carbon brush is matched, so that double-limiting protection is formed, and the contact failure under the impact is avoided.

Description

Technical Field

[0001] This invention relates to the field of engine technology, specifically to a direct-drive starter motor structure with replaceable carbon brushes for engines. Background Technology

[0002] In existing starter generators, to ensure stable current transmission by the carbon brushes when the magneto rotor rotates at high speed, the conventional design involves installing a clamping spring on the back of the carbon brush. The pre-compression of the spring provides a constant clamping force, keeping the arc surface of the carbon brush in contact with the rotor commutator or slip ring surface. Simultaneously, to suppress radial runout of the carbon brush under vibration conditions, some designs add guide supports to constrain the brush's degrees of freedom, allowing it to slide only slightly in a preset direction, thereby maintaining a basic conductive path.

[0003] However, under actual off-road and other high-vibration conditions, the high-frequency alternating vibration of the magneto rotor, generated by the crankshaft, fluctuates in real time in amplitude and frequency. The fixing clamping force cannot be dynamically adjusted according to the vibration intensity. When the vibration impact exceeds the spring preload threshold, the carbon brush is prone to momentary fretting and disengagement, leading to a sharp increase in contact resistance and even arcing that erodes the rotor surface. Conversely, if an excessive clamping force is preset to cope with extreme impacts, the carbon brush will excessively press against the rotor under stable operating conditions, accelerating abnormal wear of the carbon brush and scratching the rotor surface, which in turn exacerbates the subsequent generation of electrical sparks. At the same time, as a vulnerable component in sliding contact, the carbon brush wears significantly faster under strong vibration and high-current conditions, requiring frequent replacement. However, in existing structures, the carbon brush is usually rigidly connected to the clamping spring and guide bracket, which cannot be quickly separated. Replacement requires disassembly of the entire machine, which is cumbersome and easily damages the concentricity of the magneto stator and rotor assembly, further aggravating vibration and electrical spark problems. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a direct-drive starter motor structure with replaceable carbon brushes for engines. It has the advantage of adaptive carbon brush contact clamping, and solves the problems of existing rigid clamping structures being unable to dynamically adjust with vibration intensity and single-stage springs being unable to provide full-frequency vibration damping.

[0005] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: A direct-drive starter motor structure with replaceable carbon brushes for an engine includes: The top cover has a box-like structure at its bottom; An integrated mechanism is installed inside a housing. The integrated mechanism has at least a drive component for high-speed operation, a carbon brush for close contact, and an elastic component for graded pre-compression of the carbon brush. The drive component is installed inside the housing, with one end of the drive component abutting against the side wall of the carbon brush, and the other side of the carbon brush being disposed at the end of the elastic component. An oil storage mechanism is installed on the side wall of a carbon brush. The oil storage mechanism has at least an oil reservoir for storing conductive grease and a round rod for assisting in pressing against the carbon brush. One side of the oil reservoir is installed on the side of the carbon brush near the elastic element, and the other side of the oil reservoir is located at the end of the round rod. When the drive unit is running at high speed, the working end face of the carbon brush is always pressed against the surface of the drive unit under the pre-pressure of the elastic element, establishing a stable sliding electrical contact. It is subjected to graded compression by the elastic element, which adjusts the two pressing states respectively for the slight vibration generated by the high-speed operation of the drive unit and the excessive vibration generated during off-road driving. The carbon brush and the drive unit are in close contact throughout the process, and are also subjected to the reverse pressing of the round rod to prevent the carbon brush from moving too far, ensuring that the working end face of the carbon brush is always limited to the effective contact stroke under vibration conditions.

[0006] The oil storage component includes two oil storage shells. One side of each oil storage shell is fixedly connected to one side of the carbon brush. The side wall of the carbon brush has a shaped groove that communicates with the oil storage shell. One end of the round rod is fixedly connected to a square plate. The outer wall of the square plate is slidably connected to the inner wall of the oil storage shell to control the conductive grease inside the oil storage shell to enter the shaped groove.

[0007] The bottom of the housing is equipped with an exhaust mechanism, which includes a first arc shell and a second arc shell. The front end of the second arc shell is provided with an air inlet, and the rear end is provided with a jet nozzle. The inner wall of the first arc shell and the outer wall of the second arc shell form an ejection cavity. The ejection cavity is connected to the inside of the housing through a connecting port opened at the top of the first arc shell. An arc-shaped inclined plate is fixedly connected inside the second arc shell. Several conical holes are opened on the arc-shaped inclined plate to accelerate the oncoming airflow and eject it at high speed through the jet nozzle. The high-speed jet generates negative pressure in the ejection cavity, and draws the hot air inside the housing out through the connecting port and discharges it outward through the air hole opened at the bottom of the first arc shell.

[0008] The driving component includes a starter motor, the outer wall of which is fixedly connected to the inner wall of the housing. A magneto stator is fitted on the inner wall of the housing near the starter motor. A magneto rotor is fixedly connected to the output end of the starter motor. One end of the magneto rotor is fixedly connected to an engine crankshaft for starting the equipment with the shortest possible transmission chain.

[0009] The elastic element further includes a rubber ring, the inner wall of which is fixedly connected to the outer wall of the magneto stator. Two crossbars are fixedly connected to both ends of one side of the carbon brush. A bracket plate is slidably connected to one end of each crossbar. The side wall of the bracket plate is fixedly connected to the inner wall of the magneto stator for positioning the carbon brush.

[0010] One end of the primary spring is fixedly connected to the side wall of the support plate, and the other end of the primary spring is fixedly connected to the side wall of the carbon brush. A secondary spring is installed inside the primary spring. One end of the secondary spring is fixedly connected to the side wall of the carbon brush, and the other end of the secondary spring is fixedly connected to the side wall of the support plate, which is used for graded and progressive tightening.

[0011] The oil storage component further includes a first filter plate and a magnet. The side wall of the first filter plate is fixedly connected to the inner wall of the irregular groove, and the top of the magnet is fixedly connected to the bottom of the carbon brush for separating metal shavings inside the irregular groove.

[0012] The oil reservoir has a square structure, with one end being a conical cylindrical structure. The end near the carbon brush has a large opening, while the end away from the oil reservoir has a small opening. This is used to guide the conductive grease into the irregular groove and prevent the conductive grease inside the irregular groove from flowing back into the oil reservoir.

[0013] The exhaust mechanism also includes a second filter plate, the sidewall of which is fixedly connected to the inner wall of the second arc shell to filter impurities in the airflow entering the second arc shell. The upper end of the conical hole is large and the lower end is small to prevent dust from entering the box through the conical hole during off-road driving.

[0014] (III) Beneficial Effects Compared with the prior art, the present invention provides a direct-drive starter motor structure with replaceable carbon brushes for engines, which has the following advantages: 1. This engine adopts a direct-drive starter motor structure with replaceable carbon brushes. By coaxially connecting and paralleling primary and secondary springs of different wire diameters between the carbon brush and the support plate, a graded and progressive clamping mechanism is constructed by utilizing the difference in stiffness and stroke between the two springs. During small-amplitude high-frequency vibrations, only the secondary spring independently absorbs energy flexibly. During severe impact vibrations, the secondary spring is compressed to the bottom, and the primary spring intervenes simultaneously to provide high-pressure clamping. The clamping mode is automatically switched according to the vibration amplitude, maintaining close contact between the carbon brush and the magneto rotor throughout the process. This achieves layered attenuation of vibrations across the entire frequency band, effectively suppressing the micro-motion disengagement between the carbon brush and the magneto rotor, ensuring the stability of power generation. At the same time, the rubber ring provides elastic resistance to excessive displacement of the carbon brush, forming a double limit protection to avoid contact failure under impact.

[0015] 2. This engine adopts a direct-drive starter motor structure with replaceable carbon brushes. Through the linkage of the oil reservoir, square plate, round rod, and irregular grooves on the side wall of the carbon brush, the lateral movement of the carbon brush due to vibration drives the round rod to push against the square plate. The mechanical displacement of the carbon brush is directly converted into a squeezing action on the conductive grease inside the oil reservoir. The conductive grease is then coated onto the outer wall of the magneto rotor through the irregular grooves, achieving an adaptive match between the oil supply and the vibration intensity—more oil is supplied when the vibration is stronger, and less oil is supplied when the vibration is weaker. This satisfies the increased demand for lubrication and conductive film repair at the friction interface under severe operating conditions to suppress arc wear, while avoiding grease leakage and contamination of the motor coil under stable operating conditions. It forms a synergistic effect of "shock reduction and vibration reduction—lubrication and friction reduction" with the elastic components. At the same time, the first filter plate and magnet installed in the irregular grooves filter and magnetically adsorb impurities, respectively, trapping metal shavings at the bottom of the irregular grooves. This prevents hard particles from returning to the friction interface with the grease circulation and scratching the rotor surface, thus achieving the desired lubrication supply.

[0016] 3. The engine adopts a direct-drive starter motor structure with replaceable carbon brushes. Through the exhaust mechanism formed by the first and second arc shells at the bottom of the housing, the oncoming airflow generated by the vehicle's movement enters through the air inlet at the front of the second arc shell, accelerates along the conical hole on the arc-shaped inclined plate, and is then discharged downstream at high speed. The airflow generates a negative pressure effect at the outlet of the conical hole, resulting in a local increase in flow velocity and a decrease in pressure. This negative pressure is transferred to the inside of the housing through the suction port opened on the side wall of the first arc shell, forming a forced suction effect, continuously expelling the high-temperature gas inside the housing, and achieving passive forced convection cooling without external power. At the same time, the upper-larger and lower-smaller structure of the conical hole, combined with the inclined arrangement of the arc-shaped inclined plate, effectively blocks external mud and sand when it enters with the reverse airflow and sinks into the lower sand storage chamber. It has the dual functions of efficient heat dissipation and dust prevention and anti-clogging, providing the equipment with a stable low-temperature and low-impurity working environment, ensuring the long-term reliable operation of the whole machine in off-road mud and sand conditions. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall side structure of the present invention.

[0018] Figure 2 This is a schematic diagram of the overall cross-sectional structure in this invention.

[0019] Figure 3 This is a bottom view of the rotor structure of the magneto in this invention.

[0020] Figure 4 In this invention Figure 3 A magnified view of A in the middle.

[0021] Figure 5 This is a schematic diagram of the exploded structure of the starter motor in this invention.

[0022] Figure 6This is a schematic diagram of the magnet structure viewed from below in this invention.

[0023] Figure 7 This is a schematic cross-sectional view of the carbon brush in this invention.

[0024] Figure 8 This is a schematic cross-sectional view of the support plate in this invention.

[0025] Figure 9 In this invention Figure 8 A magnified view of B in the middle.

[0026] Figure 10 This is a top view schematic diagram of the arc-shaped inclined plate structure in this invention.

[0027] Figure 11 This is a schematic diagram of the first arc shell structure in this invention from a bottom view.

[0028] In the diagram: 100, top cover; 101, housing; 200, integrated mechanism; 300, oil storage mechanism; 400, exhaust mechanism; 201, starter motor; 202, magneto rotor; 203, magneto stator; 204, engine crankshaft; 205, rubber ring; 206, carbon brush; 207, crossbar; 208, bracket plate; 209, primary spring; 210, secondary spring; 301, oil reservoir; 302, square plate; 303, round rod; 304, irregular groove; 305, first filter plate; 306, magnet; 401, first arc shell; 402, second arc shell; 403, arc-shaped inclined plate; 404, second filter plate; 405, vent. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] In the description of this invention, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0031] In addition, a fixed connection refers to a connection in which parts or components are fixed and there is no relative movement; a transmission connection refers to a connection in which mechanical motion or torque is transmitted to other working parts through a transmission component; a sliding connection refers to a connection in which two objects are in contact but not fixed and can slide relative to each other; and a rotational connection refers to a connection in which two objects are in contact but not fixed and can rotate relative to each other.

[0032] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0033] Please see Figure 1-10 This embodiment provides a direct-drive starter motor structure with replaceable carbon brushes for engines, including: The top cover 100 has a box 101 fixedly connected to its bottom by bolts. The box 101 is a rectangular hollow shell structure, and its interior forms an installation chamber for accommodating various components.

[0034] An integrated mechanism 200, installed inside the housing 101, is used to realize the starting drive and power generation functions of the equipment. It includes a drive component, a carbon brush 206, and an elastic component.

[0035] The drive components include a starter motor 201, a magneto rotor 202, a magneto stator 203, and an engine crankshaft 204. The outer wall of the starter motor 201 is fixedly connected to the bottom of the inner wall of the housing 101 by bolts. The output shaft of the starter motor 201 extends horizontally. The magneto stator 203 is an annular structure and is fitted inside the housing 101. The magneto stator is located inside the housing. The center hole of the magneto rotor 202 is fixedly connected to the output end of the starter motor 201 by a flat key. A uniform annular air gap is formed between the outer wall of the magneto rotor 202 and the inner wall of the magneto stator 203. One end of the engine crankshaft 204 is fixedly connected to the end face of the magneto rotor 202 by a coupling, which is used to transmit the rotational power of the starter motor 201 to the engine crankshaft with the shortest transmission chain to realize the equipment start-up.

[0036] The carbon brush 206 is a rectangular block conductive component. The side of the carbon brush facing the outer wall of the magneto rotor 202 has an arc-shaped working surface. This arc-shaped working surface is adapted to the arc surface of the outer wall of the magneto rotor 202 to establish sliding electrical contact. The side wall of the carbon brush 206 has a shaped groove 304. The shaped groove 304 is a stepped groove extending along the length of the carbon brush 206. Its opening faces the magneto rotor 202 and is used to contain conductive grease and guide it to flow to the friction interface.

[0037] The elastic components include a primary spring 209, a secondary spring 210, and a rubber ring. Both the primary spring 209 and the secondary spring 210 are helical compression springs, coaxially sleeved together. One end of the secondary spring 210 is welded and fixed to the side wall of the carbon brush 206, and the other end is hooked and fixed to the side wall of the support plate 208. The secondary spring 210 has a thinner wire diameter and is used to provide basic preload, mainly to cope with the small-amplitude, high-frequency vibrations generated when the starter motor 201 operates at high speed. The primary spring 209 is sleeved outside the secondary spring 210, with one end welded and fixed to the side wall of the carbon brush 206 and the other end welded and fixed to the side wall of the support plate 208. The wire diameter of spring 9 is relatively thick, and it is used to intervene after the secondary spring 210 is fully compressed to provide high-pressure clamping force. It is mainly used to deal with the severe impact and vibration under off-road conditions. The primary spring 209 and the secondary spring 210 are arranged in parallel. One end of both is fixed to the carbon brush 206, and the other end is fixed to the bracket plate 208, forming a graded and progressive clamping mechanism. The rubber ring 205 is an annular elastic body. Its inner wall is fixed to the outer wall of the magneto stator 203 by snap-fit. An annular gap is formed between the outer wall of the rubber ring 205 and the inner wall of the housing 101 to absorb the high-frequency micro-vibration generated when the magneto stator 203 is running.

[0038] Furthermore, the existing carbon brush 206 elastic clamping structure mostly uses a single stiffness spring, and its design can only match the vibration of a single frequency band. If a soft spring is selected, it cannot suppress the instantaneous disengagement of the carbon brush during severe off-road impact vibration. If a hard spring is selected, the high-frequency micro-vibration generated by high-speed operation cannot be effectively absorbed, but instead aggravates the frictional loss between the carbon brush 206 and the magneto rotor 202.

[0039] Furthermore, the secondary spring 210 mentioned above is a low-stiffness soft spring with a free length greater than that of the primary spring 209. In the initial assembly state, the two ends of the secondary spring 210 abut against the side walls of the carbon brush 206 and the support plate 208, respectively, and have a large pre-compression amount to reserve sufficient compression stroke and ensure that it has independent flexible expansion space under small vibration conditions. The primary spring 209 is a high-stiffness hard spring with a free length less than that of the secondary spring 210. In the initial assembly state, the two ends of the primary spring 209 have a preset assembly gap with the carbon brush 206 and the side wall of the bracket plate 208, respectively, and the primary spring 209 only maintains a slight preload or does not bear a preload. When the magneto rotor 202 generates a small-amplitude high-frequency vibration, the displacement of the carbon brush 206 relative to the support plate 208 does not exceed the stroke threshold corresponding to the assembly gap. At this time, only the secondary spring 210 independently undergoes elastic extension and contraction deformation, using its soft elasticity and ample compression margin to absorb all minor impacts and maintain a smooth fit between the carbon brush 206 and the magneto rotor 202. When the vehicle encounters severe conditions such as off-road ramps or engine knocking, the vibration amplitude increases sharply. The displacement of the carbon brush 206 relative to the bracket plate 208 reaches and exceeds the stroke threshold. The secondary spring 210 is compressed to its limit, and its own compression margin is exhausted, so it can no longer buffer. At this time, the assembly gap at both ends of the primary spring 209 is completely eliminated. The two ends of the primary spring 209 abut against the carbon brush 206 and the side wall of the bracket plate 208, respectively. The impact force is transmitted to the outer high-rigidity primary spring 209. The high elasticity of the primary spring 209 continuously presses the carbon brush 206 to prevent the carbon brush 206 from being lifted off due to severe impact, thus ensuring the continuity of electrical contact.

[0040] like Figure 4-8 As shown, two crossbars 207 are welded and fixed to both ends of one side of the carbon brush 206. The crossbars 207 are cylindrical metal rods with their axes parallel to the sliding direction of the carbon brush 206. One end of the crossbar 207 passes through and is slidably connected to the inner wall of the support plate 208. The support plate 208 is a rectangular plate structure, and its sidewalls are bolted to the inner wall of the magneto stator 203, ensuring quick replacement of the carbon brush 206. The crossbars 207 and the support plate 208 slide... The dynamic fit is used to constrain the carbon brush 206 to move only in the radial direction, preventing the carbon brush 206 from wobbling in the circumferential or axial direction, and ensuring that the arc-shaped working surface of the carbon brush 206 is always facing the outer wall of the magneto rotor 202. The bracket plate 208 is detachably fixed to the inner wall of the magneto stator 203 by bolts. Loosening the bolts allows the bracket plate 208, along with the carbon brush 206, crossbar 207, primary spring 209, and secondary spring 210, to be removed from the magneto stator 203 as a whole.

[0041] An oil reservoir 300, which is installed on the side wall of the carbon brush 206, is used to store and supply conductive grease to the friction interface between the carbon brush 206 and the magneto rotor 202. It includes an oil reservoir and a round rod 303.

[0042] The oil reservoir includes an oil reservoir shell 301, which is a hollow rectangular shell. One side wall of the oil reservoir shell 301 is fixedly connected to the side of the carbon brush 206 away from the magneto rotor 202 by bolts. The interior of the oil reservoir shell 301 forms a sealed chamber for storing conductive grease. The oil reservoir shell 301 is generally square in shape, and one end of it, which is the end closest to the carbon brush 206, is a conical cylindrical structure. The large end of the conical cylindrical structure is connected to the side wall of the carbon brush 206, and the small end is connected to the main chamber of the oil reservoir shell 301. The conical structure is used to guide the conductive grease to smoothly enter the irregular groove 304, while preventing the conductive grease inside the irregular groove 304 from flowing back into the oil reservoir shell 301 under the action of gravity or pressure.

[0043] like Figure 7-9As shown, a square plate 302 is slidably disposed inside the oil reservoir 301. The square plate 302 is a rectangular plate structure. Its outer wall and the inner wall of the oil reservoir 301 are slidably sealed by a sealing ring. A round rod 303 is welded and fixed at the center of the side of the square plate 302 away from the carbon brush 206. The round rod 303 is made of high elasticity oil-resistant rubber and has elastic deformation. One end of the round rod 303 penetrates through and extends to the outside of the oil reservoir 301. The extended end of the round rod 303 is disposed opposite to the side wall of the support plate 208. When the carbon brush 206 moves toward the support plate 208, it is pushed in the opposite direction by the support plate 208, thereby pushing the square plate 302 to slide inside the oil reservoir 301.

[0044] Furthermore, there are two main lubrication methods for existing carbon brush 206: one is to manually apply conductive grease periodically, but under the severe vibration of off-road conditions, the grease is quickly thrown off or consumed, and cannot provide continuous lubrication; the other is to passively drip oil by centrifugal force or gravity, with a constant oil supply rate that cannot be adaptively adjusted according to changes in operating conditions. Under stable operating conditions, the grease escapes and contaminates the coil, while under severe operating conditions, insufficient oil supply leads to arc erosion.

[0045] The irregular groove 304 is connected to the large end of the conical cylindrical structure of the oil reservoir 301. A first filter plate 305 is also embedded and fixed inside the irregular groove 304. The first filter plate 305 is a microporous ceramic plate, located in the middle to rear section of the irregular groove 304, between the oil reservoir 301 and the settling groove. Its pore size is smaller than the diameter of wear particles that may be mixed into the conductive grease. This position ensures that the grease flowing from the oil reservoir 301 to the friction interface is filtered by the first filter plate 305 before reaching the friction interface, guaranteeing that the grease supplied to the friction interface is clean and free of impurities. Simultaneously, metal wear particles carried in the grease flowing back from the friction interface to the irregular groove 304 naturally settle into the settling groove under gravity and are attracted and retained by the magnet 306, preventing hard metal particles from moving to the friction interface with the grease.

[0046] Furthermore, in the existing technology, a filter screen is installed in the oil storage chamber to intercept wear debris. However, the filter screen is easily clogged by fine metal particles and cannot intercept micro-fine ferromagnetic particles smaller than the filter screen pore size. After clogging, it needs to be frequently disassembled and replaced, resulting in high maintenance costs.

[0047] like Figure 2 , Figure 10-11 As shown, the bottom of the housing 101 is also provided with an exhaust mechanism 400, which is used to exhaust the high-temperature gas inside the housing 101 to the outside and prevent external mud and sand from entering the housing 101. The exhaust mechanism 400 includes a first arc shell 401, a second arc shell 402, an arc-shaped inclined plate 403, and a second filter plate 404.

[0048] Both the first arc shell 401 and the second arc shell 402 are semi-circular hollow shells. The tops of both are fixed to the bottom of the box 101 by bolts, and they are arranged opposite each other to form a complete annular cavity. The front end of the second arc shell 402 is provided with an air inlet, and the rear end is provided with a jet nozzle. The bottom of the box 101 is provided with a connecting hole, which is connected to the internal cavity of the first arc shell 401 to allow hot air inside the box 101 to enter the first arc shell 401. The bottom of the first arc shell 401 is provided with multiple air holes 405, which are circular holes penetrating the bottom wall of the first arc shell 401 to allow the gas inside the first arc shell 401 to be discharged to the outside.

[0049] like Figure 11 As shown, an arc-shaped inclined plate 403 is welded and fixed to the inner wall of the second arc shell 402. The arc-shaped inclined plate 403 is an arc-shaped thin plate that extends circumferentially along the second arc shell 402. The arc-shaped inclined plate 403 is inclined from the top to the bottom of the second arc shell 402, and several conical holes are opened at the top of the arc-shaped inclined plate 403. The upper end of the conical hole is large and the lower end is small. This is used to generate an acceleration effect when airflow passes through, and to utilize the unidirectional conduction characteristic of the conical structure to prevent cross-country movement. External dust enters the housing 101 through the conical hole and is blocked by the arc-shaped inclined plate 403. The upper half of the area between the first arc shell 401 and the second arc shell 402 is the exhaust area, and the lower half is the sand storage area. The second filter plate 404 is an arc-shaped mesh plate, and its sidewall is fixedly connected to the inner wall of the second arc shell 402 by welding. The second filter plate 404 is located above the arc-shaped inclined plate 403 and is used to filter large particulate impurities in the airflow entering the second arc shell 402 from the outside.

[0050] Working principle: Drive phase: The starter motor 201 drives the magneto rotor 202 and the engine crankshaft 204 to rotate. Since the starter motor 201 is directly connected to the magneto rotor 202 and the engine crankshaft 204, the transmission chain is shortened, thereby greatly improving the transmission efficiency of the speed.

[0051] Supplementary Stage: When the magneto rotor 202 rotates, its outer wall slides and adheres to the arc surface of the carbon brush 206, establishing a stable electrical contact and ensuring power generation stability. During this process, the small-amplitude high-frequency vibrations generated by the high-speed rotation of the magneto rotor 202 are flexibly absorbed independently by the large preload of the secondary spring 210. When the vibration intensity increases to the point where the secondary spring 210 is compressed to the bottom, the outer primary spring 209 intervenes simultaneously, providing high-pressure clamping force, mainly to cope with the severe impact vibration under off-road conditions. The two-stage springs automatically switch clamping modes based on the vibration amplitude, maintaining the contact between the carbon brush 206 and the magneto rotor 202 throughout the process, achieving full-frequency vibration layered attenuation, thereby effectively suppressing the micro-motion separation between the carbon brush 206 and the magneto rotor 202, ensuring the stability of power generation. At the same time, when the carbon brush 206 shakes violently, the carbon brush 206 drives the crossbar 207 to move towards the rubber ring 205, which is resisted by the elasticity of the rubber ring 205, thus preventing excessive displacement during impact.

[0052] Dual-function stage: Since the starter motor 201 can drive the engine crankshaft 204 to achieve electric start, and can also switch to generator mode after the equipment is driven, it can use the rotation of the engine crankshaft 204 to generate electrical energy to replenish the vehicle battery, thus realizing the dual-function application of the starter motor 201, improving the system integration and energy utilization efficiency.

[0053] Lubrication Stage: When the slight vibration generated by the high-speed rotation of the magneto rotor 202 causes the carbon brush 206 to move laterally, the carbon brush 206 drives the crossbar 207 to slide along the inner wall of the support plate 208. Simultaneously, the carbon brush 206 drives the oil reservoir 301 to move closer to the support plate 208, where it is resisted by the round rod 303. The round rod 303 then drives the square plate 302 to slide along the inner wall of the oil reservoir 301, allowing the conductive grease inside the oil reservoir 301 to gradually enter the irregular groove 304 at the carbon brush 206. Because the curved surface of the carbon brush 206 can fully conform to the magneto rotor 202, the conductive grease entering the irregular groove 304 will coat the outer wall of the magneto rotor 202, thereby inhibiting... When the carbon brush 206 rubs against the magneto rotor 202, an electric spark is generated. At the same time, the equipment can automatically adjust the oil supply based on the intensity of vibration. When the vibration intensity increases, the oil reservoir 301 injects more conductive grease into the irregular groove 304 to meet the increased demand for lubrication and conductive film repair at the friction interface under severe vibration, and to suppress arc wear. When the vibration intensity decreases, the oil supply automatically drops back to a low level to avoid grease overflow and contamination of the motor coil and surrounding components under stable operating conditions. This achieves adaptive matching between the oil supply and real-time operating conditions, further reducing the friction loss between the carbon brush 206 and the magneto rotor 202 from a lubrication perspective. Together with the pre-stage graded vibration reduction system, it forms a synergistic effect of vibration reduction and shock reduction, lubrication and friction reduction.

[0054] Supplementary stage: When the conductive grease lubricates the outer wall of the magneto rotor 202 inside the shaped groove 304, the friction between the magneto rotor 202 and the carbon brush 206 will generate a small amount of impurities. Due to the setting of the first filter plate 305 and the conical cylinder at the oil reservoir 301, the impurities can be prevented from mixing with the conductive grease and flowing back into the oil reservoir 301. Furthermore, due to the adsorption of the magnet 306, the metal shavings in the impurities can be adsorbed and trapped at the bottom of the inner wall of the shaped groove 304, preventing hard metal particles from returning to the friction interface between the magneto rotor 202 and the carbon brush 206 with the grease circulation, thereby preventing the surface of the magneto rotor 202 from being scratched by metal shavings.

[0055] Exhaust Phase: When the vehicle is traveling at high speed, the oncoming airflow enters through the air intake at the front end of the second arc shell 402, accelerates along the conical hole of the arc-shaped inclined plate 403, and is then ejected at high speed from the jet nozzle at the rear end of the second arc shell 402, forming a high-speed jet zone in the ejector chamber. Based on the principle of a jet pump, the high-speed jet entrains the surrounding gas to generate negative pressure. This negative pressure is transmitted to the inside of the housing 101 through the connecting port at the top of the first arc shell 401, continuously entraining the high-temperature gas inside the housing 101 and expelling it outward along with the jet through the air hole 405, achieving forced convection cooling without external power. At the same time, the upper-larger and lower-smaller structure of the conical hole, combined with the inclination of the arc-shaped inclined plate 403, further enhances the cooling effect. The oblique arrangement effectively blocks external mud and sand from entering in the opposite direction with the airflow, causing them to settle into the lower sand storage chamber. This design combines efficient heat dissipation with dust and blockage prevention. The sediment in the lower sand storage chamber can be cleaned by disassembling the first arc shell 401 without disassembling the entire machine. This design continuously removes heat from the inside of the housing 101, reducing the thermal decay of the conductive grease, rubber ring 205, and elastic components caused by high temperatures. It also effectively prevents external mud and sand from intruding into the lubrication circulation system, reducing the load of impurities. This provides a stable, low-temperature, and low-impurity working environment for the pre-stage shock absorption and self-cleaning lubrication mechanism, ensuring long-term reliable operation of the entire machine under off-road conditions with abundant mud and sand.

[0056] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0057] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A direct-drive starter motor structure with replaceable carbon brushes for an engine, characterized in that, include: A top cover (100) has a box (101) at its bottom; An integrated mechanism (200) is installed inside a housing (101). The integrated mechanism (200) has at least a drive member for high-speed operation, a carbon brush (206) for close contact, and an elastic member for graded pre-compression of the carbon brush (206). The drive member is installed inside the housing (101). One end of the drive member abuts against the side wall of the carbon brush (206), and the other side of the carbon brush (206) is disposed at the end of the elastic member. An oil storage mechanism (300) is installed on the side wall of a carbon brush (206). The oil storage mechanism (300) has at least an oil storage element for storing conductive grease and a round rod (303) for assisting in pressing against the carbon brush (206). One side of the oil storage element is installed on the side of the carbon brush (206) near the elastic element, and the other side of the oil storage element is disposed at the end of the round rod (303). When the drive unit is running at high speed, the working end face of the carbon brush (206) is always pressed against the surface of the drive unit under the pre-pressure of the elastic element, establishing a stable sliding electrical contact. It is subjected to graded compression by the elastic element, which adjusts the slight vibration generated by the high-speed operation of the drive unit and the excessive vibration generated during off-road driving in two different pressing states. The carbon brush (206) and the drive unit are in close contact throughout the process, and are also subjected to the reverse pressing of the round rod (303) to prevent the carbon brush (206) from moving too far due to severe vibration during off-road driving, thus ensuring that the working end face of the carbon brush (206) is always limited to the effective contact stroke under vibration conditions.

2. The direct-drive starter motor structure with replaceable carbon brushes for engines according to claim 1, characterized in that, The oil storage component includes an oil storage shell (301), one side of which is fixedly connected to one side of a carbon brush (206). The side wall of the carbon brush (206) is provided with a shaped groove (304), which is connected to the oil storage shell (301). One end of the round rod (303) is fixedly connected to a square plate (302), and the outer wall of the square plate (302) is slidably connected to the inner wall of the oil storage shell (301) to control the conductive grease inside the oil storage shell (301) to enter the interior of the shaped groove (304).

3. The direct-drive starter motor structure with replaceable carbon brushes for engines according to claim 1, characterized in that, The bottom of the housing (101) is provided with an exhaust mechanism (400). The exhaust mechanism (400) includes a first arc shell (401) and a second arc shell (402). The front end of the second arc shell (402) is provided with an air inlet, and the rear end is provided with a jet nozzle. The first arc shell (401) and the second arc shell (402) are connected to form an ejection cavity. The ejection cavity is connected to the inside of the housing (101) through a connecting port opened at the top of the first arc shell (401). An arc-shaped inclined plate (403) is fixedly connected inside the second arc shell (402). Several conical holes are opened on the arc-shaped inclined plate (403) for accelerating the oncoming airflow and ejecting it at high speed through the jet nozzle. The high-speed jet generates negative pressure in the ejection cavity and draws out the hot air inside the housing (101) through the connecting port and discharges it outward through the air hole (405) opened at the bottom of the first arc shell (401).

4. The direct-drive starter motor structure with replaceable carbon brushes for engines according to claim 1, characterized in that, The driving component includes a starter motor (201), the outer wall of which is fixedly connected to the inner wall of the housing (101). A magneto stator (203) is sleeved on the inner wall of the housing (101) near the starter motor (201). A magneto rotor (202) is fixedly connected to the output end of the starter motor (201). One end of the magneto rotor (202) is fixedly connected to an engine crankshaft (204) for starting the equipment with the shortest transmission chain.

5. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 4, characterized in that, The elastic element also includes a rubber ring (205), the inner wall of which is fixedly connected to the outer wall of the magneto stator (203). Two crossbars (207) are fixedly connected to one end of the carbon brush (206). A bracket plate (208) is slidably connected to one end of the crossbar (207). The side wall of the bracket plate (208) is fixedly connected to the inner wall of the magneto stator (203) for positioning the carbon brush (206).

6. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 5, characterized in that, One end of the primary spring (209) is fixedly connected to the side wall of the support plate (208), and the other end of the primary spring (209) is fixedly connected to the side wall of the carbon brush (206). A secondary spring (210) is sleeved inside the primary spring (209). One end of the secondary spring (210) is fixedly connected to the side wall of the carbon brush (206), and the other end of the secondary spring (210) is fixedly connected to the side wall of the support plate (208), for graded progressive tightening.

7. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 2, characterized in that, The oil storage component also includes a first filter plate (305) and a magnet (306). The side wall of the first filter plate (305) is fixedly connected to the inner wall of the shaped groove (304), and the top of the magnet (306) is fixedly connected to the bottom of the carbon brush (206) for separating metal shavings inside the shaped groove (304).

8. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 7, characterized in that, The oil reservoir (301) has a square structure, with one end having a conical cylindrical structure. The end near the carbon brush (206) has a large opening, and the end away from the oil reservoir (301) has a small opening. This is used to guide the conductive grease into the irregular groove (304) and prevent the conductive grease inside the irregular groove (304) from flowing back into the oil reservoir (301).

9. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 3, characterized in that, The exhaust mechanism (400) also includes a second filter plate (404), the side wall of which is fixedly connected to the inner wall of the second arc shell (402) to filter impurities in the airflow entering the second arc shell (402). The top of the arc-shaped inclined plate (403) is provided with several conical holes, the upper end of which is large and the lower end of which is small, to prevent dust from entering the box (101) through the conical holes during off-road driving.

10. The direct-drive starter motor structure with replaceable carbon brushes for an engine according to claim 5, characterized in that, The bracket plate (208) has a guide hole for the crossbar (207) to pass through. The crossbar (207) slides through the guide hole. The bracket plate (208) is detachably connected to the inner wall of the magneto stator (203) by bolts. When replacing the carbon brush (206), loosen the bolts to remove the bracket plate (208) as a whole, slide the crossbar (207) out of the guide hole to separate the carbon brush (206) from the bracket plate (208), and after replacing the new carbon brush (206), reverse the operation to complete the assembly.

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