A direct current motor driven air-cooled diesel engine free cranking starter

Abstract

The utility model discloses a kind of air-cooled diesel engine free shaking starter of DC motor drive, belong to diesel engine starting device technical field.The starter includes shell, DC motor, clutch assembly and detachable installation energy storage battery device;The output shaft of the DC motor is connected with clutch assembly, for driving its rotation, drive driving tongue and diesel engine flywheel gear ring engagement, realize starting;The motor can be directly driven, or through setting speed reduction mechanism to reduce speed and increase torque;Energy storage battery device is equipped with slide rail buckle structure, mechanical self-locking button switch and integrated control circuit board, with relay control and under-voltage protection function.The utility model is high in starting efficiency, convenient to operate, strong in adaptability, can effectively replace traditional human energy storage structure, significantly improve the reliability and automation level of air-cooled diesel engine.

Description

Technical Field

[0001] This utility model relates to the technical field of diesel engine starting devices, and in particular to a DC motor driven air-cooled diesel engine starter that does not require cranking. Background Technology

[0002] Currently, air-cooled diesel engines generally use a no-crank starter to replace the traditional hand-crank starting method. Its core structure mainly consists of the following parts:

[0003] Energy storage mechanism: Mechanical energy is stored through a planar spiral spring. Typical parameters are a diameter of 120mm and an energy storage torque of 80N·m. The energy storage is completed by manually turning the handle 90°.

[0004] Transmission system: It adopts a multi-stage gear set (transmission ratio 1:5 to 1:8) to transmit torque, and is equipped with an overrunning clutch to prevent reverse rotation.

[0005] Control device: Equipped with safety components such as a safety lock plate and a pressure reduction linkage mechanism to ensure that the start-up process is controllable.

[0006] Its working principle is as follows: when the handle is manually turned to compress the spiral spring, the spring drives the gear set when released, the one-way wheel engages with the flywheel ring gear, and the crankshaft rotates to achieve ignition.

[0007] Existing shakeless starters still have the following shortcomings:

[0008] Reliability bottleneck: The fatigue life of the planar spiral spring is only 5,000 cycles, and it is prone to fatigue failure after long-term use; the spring stiffness increases in low temperature environment, requiring an additional operating force of more than 30%.

[0009] Insufficient operational efficiency: The energy storage process requires 5 to 8 seconds of manual operation, and the success rate of starting is affected by the operator's physical strength; there is a 15% to 20% energy loss in the gear transmission chain, resulting in the actual output torque being lower than the theoretical value.

[0010] High maintenance costs: Lubricating grease and spring components need to be replaced regularly; the meshing clearance between the one-way wheel and the flywheel ring gear needs to be adjusted with professional tools, otherwise tooth breakage is likely to occur.

[0011] Poor environmental adaptability: In explosion-proof environments such as coal mines and chemical plants, traditional mechanical structures pose a risk of sparking; gears are prone to corrosion in high humidity environments, leading to transmission jamming. Utility Model Content

[0012] The purpose of this invention is to propose a DC motor-driven, air-cooled diesel engine starter that eliminates the need for cranking, aiming to overcome the inherent defects of existing technologies in terms of reliability, operational efficiency, and environmental adaptability.

[0013] The technical solution adopted by this utility model to solve its technical problem is:

[0014] A DC motor-driven, air-cooled diesel engine starter that requires no cranking, comprising a housing, characterized in that:

[0015] The housing contains a clutch assembly, and a DC motor and an energy storage battery device are fixed on the outside of the housing.

[0016] The output shaft of the DC motor passes through the housing and is connected to the input end of the clutch assembly to drive its rotation;

[0017] The outer periphery of the clutch assembly is provided with a movable drive tongue for engaging with the diesel engine flywheel ring gear;

[0018] The energy storage battery device is electrically connected to the DC motor to provide it with power, and is detachably fixed to the housing.

[0019] The energy storage battery device is equipped with a control circuit board, which includes a control input module, a relay control module, and an undervoltage protection module. The control input module, the relay control module, and the undervoltage protection module are coordinated and transmit signals through a control chip.

[0020] The control input module consists of a self-locking push-button switch, the output of which is connected to the input of the control chip to receive the user's start signal.

[0021] The relay control module includes a normally open DC relay, whose control terminal is connected to the output terminal of the control chip, and whose main contacts are connected in series in the power supply circuit of the DC motor to control the power supply on and off.

[0022] The undervoltage protection module includes a voltage detection circuit and a comparator chip, which are used to detect the output voltage of the energy storage battery. When the battery voltage is lower than a set threshold, a shutdown signal is output to the control chip, which then cuts off the relay and disconnects the motor power supply.

[0023] More preferably, the clutch assembly includes a first annular disc seat and a second annular disc seat, which are coaxially arranged and clamp an isolation washer, and are fixed by disc seat bolts.

[0024] The outer edge of the isolation gasket has multiple notches distributed at equal angles. A driving tongue is pivotally connected to each notch. The driving tongue is installed by a tongue bolt and is provided with return elasticity by a tongue torsion spring.

[0025] The two ends of the tongue torsion spring respectively abut against the first annular disc seat and the outer side of the driving tongue;

[0026] The annular disc base and the inner ring of the isolation washer are provided with an internal spline structure, and the output shaft end of the DC motor is provided with a matching external spline.

[0027] In a further preferred embodiment, the rock-free starter also includes a reduction mechanism disposed between the DC motor and the clutch assembly, wherein the input end of the reduction mechanism is connected to the output shaft of the DC motor and the output end is connected to the clutch assembly.

[0028] More preferably, the reduction mechanism is a planetary gear reducer, an eccentric shaft gear reducer, or an equivalent structure thereof, and the reduction ratio is 1:8 to 1:15.

[0029] Further preferably, the rated output torque of the DC motor is 1.5 N·m to 3 N·m, and the rated speed is 3000 to 5000 rpm.

[0030] More preferably, the output torque of the reduction mechanism is 15 N·m to 20 N·m.

[0031] In a further preferred embodiment, the energy storage battery device is equipped with a mechanical self-locking push-button switch, which is connected in series in the power supply path. When pressed for the first time, the circuit is closed to drive the DC motor, and when pressed again, the circuit is opened to stop the DC motor.

[0032] More preferably, the energy storage battery device is installed on the top of the housing via a slide rail buckle structure, the slide rail buckle structure including a guide slide rail, a slider and a buckle mechanism;

[0033] The guide rails are disposed on both sides of the top of the housing, forming two parallel guide grooves along the front-back direction;

[0034] The sliders are located on both sides of the bottom of the energy storage battery device and are adapted to the guide groove, enabling the energy storage battery device to slide within the guide rail and be fixed in the correct position.

[0035] The latching mechanism is located at the rear end of the energy storage battery device and consists of a latching piece and a locking groove. One end of the latching piece is fixed to the outer shell of the energy storage battery device, and the other end is latched in and out by spring force or plastic deformation structure. The locking groove is located at the top of the shell. When the energy storage battery device is fully installed, the elastic part of the latching piece automatically springs into the locking groove, ensuring that the energy storage battery device is firmly installed on the top of the shell and preventing the battery device from falling off or loosening due to vibration or external force.

[0036] The beneficial effects of this utility model are:

[0037] 1. Overcoming the reliability bottleneck of traditional energy storage mechanisms:

[0038] This invention completely abandons the traditional spiral spring structure, adopting a DC motor to directly drive or drive the clutch assembly through a reduction mechanism, greatly extending its service life. The DC motor drive system can achieve a cycle life of 100,000 cycles, far exceeding the 5,000 cycles of the traditional spring structure. Furthermore, the lithium-ion battery can still stably output 80% of the rated current at -30℃, greatly improving the system's reliability and low-temperature start-up performance.

[0039] 2. Significantly improves operational efficiency and energy utilization:

[0040] After the energy storage battery device is triggered, the DC motor can achieve full power output within 0.2 seconds and start the diesel engine within 3 seconds, improving starting efficiency by 10 times compared to the traditional hand-crank starting method. The highly efficient transmission system of the planetary gear reducer and eccentric shaft gear reducer significantly improves the system's energy utilization rate. Actual measurements show that the planetary gear reducer achieves a transmission efficiency of 94%, while the eccentric shaft gear reducer not only has a 40% reduction in size but also increases its efficiency to 92%. The overall system's energy utilization rate is improved by 20%-25%.

[0041] 3. Reduce maintenance costs and failure rate:

[0042] Compared to traditional starters, this invention features a fully enclosed housing design, preventing external environmental contamination of internal mechanical components, reducing the need for lubricating grease, and lowering the frequency of regular maintenance. The drive tongue automatically compensates for flywheel gear clearance under the action of the return spring, completely eliminating the risk of gear breakage and significantly reducing the system's failure rate by up to 90%.

[0043] 4. Overcoming environmental adaptability limitations:

[0044] This system is designed to produce no metal-to-metal friction sparks, making it suitable for explosion-proof environments (such as coal mines and chemical plants). The push-button switches on the control circuit board are made of copper-nickel alloy, meeting ATEX IIB explosion-proof requirements and ensuring the system's safety in special environments. Furthermore, the housing and gear assembly surfaces undergo micro-arc oxidation treatment, enabling the system to operate stably for extended periods even in environments with humidity levels as high as 95%. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of the structure of the first embodiment of the present invention (excluding the deceleration mechanism).

[0046] Figure 2 This is a schematic diagram of the structure of the second embodiment of the present invention (including a speed reduction mechanism);

[0047] Figure 3 An exploded view of the clutch assembly disc seat and isolation gasket;

[0048] Figure 4This is a top view of the clutch assembly.

[0049] Figure 5 yes Figure 4 A schematic diagram of the internal structure of the first annular disk seat removed.

[0050] Figure 6 This is a schematic diagram of the installation method of the energy storage battery device.

[0051] Figure 7 This is a block diagram of the control circuit board in an energy storage battery device.

[0052] In the diagram: 100-Housing, 200-DC motor, 300-Reduction mechanism, 400-Clutch assembly, 410-First annular disc base, 411-Second annular disc base, 412-Isolation washer, 413-Notch, 414-Drive tongue, 415-Disc base bolt, 416-Tongue torsion spring, 417-Inner ring, 500-Energy storage battery device, 501-Self-locking push-button switch, 502-Guide rail, 503-Slider, 504-Snap-on mechanism, 510-Energy storage battery pack Detailed Implementation

[0053] The specific embodiments of this utility model will be further described below with reference to the accompanying drawings. It should be understood that the following embodiments are only used to illustrate this utility model and are not intended to limit the scope of protection of this utility model.

[0054] Example 1 (excluding reduction gear, direct drive clutch for motor)

[0055] This embodiment provides a crankless starter for an air-cooled diesel engine with a DC motor directly driving clutch assembly, such as... Figure 1 As shown, it includes a housing 100, with a clutch assembly 400 inside, and a DC motor 200 and an energy storage battery device 500 fixed on the outside of the housing.

[0056] A DC motor 200 is fixedly mounted on the side of the housing 100, transmitting power to the clutch assembly 400 via its output shaft. The DC motor 200 is a permanent magnet DC motor with a rated voltage of 24V, a rated output torque of 15 N·m, and a rated speed of 600 rpm. Its output shaft passes through the housing 100 and is coaxially connected to the input end of the clutch assembly 400 via a spline connection. During startup, the DC motor 200 is energized and rotates, driving the clutch assembly 400. This, in turn, engages with the diesel engine flywheel ring gear via the drive tongue 414 of the clutch assembly 400, thus starting the diesel engine.

[0057] Clutch assembly 400, etc. Figure 3-5As shown, the device consists of a first annular disc base 410, a second annular disc base 411, an isolation washer 412 clamping between them, and three evenly distributed drive tongues 414. The first annular disc base 410 and the second annular disc base 411 are coaxially arranged and clamp the isolation washer 412, and are fixed by disc base bolts 415. Each drive tongue 414 is pivotally connected to a notch 413 in the isolation washer 412, installed by a tongue bolt 418, and is equipped with a tongue torsion spring 416 to provide a return force, ensuring that the drive tongue 414 quickly disengages after startup. The inner ring opening 417 of the disc base has an internal spline structure, which mates with the external spline on the output shaft of the DC motor 200.

[0058] like Figure 6 As shown, the energy storage battery device 500 is installed on the top of the housing 100 via a slide rail snap-fit ​​structure. The slide rail snap-fit ​​structure includes a guide slide rail 502, a slider 503, and a snap-fit ​​mechanism 504. The guide slide rail 502 is located on both sides of the top of the housing 100, forming two parallel guide grooves along the front-back direction. The slider 502 is located on both sides of the bottom of the energy storage battery device 500, and is adapted to the guide grooves, enabling the energy storage battery device 500 to slide within the guide slide rail 502 and be fixed in the correct position.

[0059] The latching mechanism 504 is located at the rear end of the energy storage battery device 500 and consists of a latching piece 504a and a locking groove 504b. One end of the latching piece 504a is fixed to the outer shell of the energy storage battery device 500, and the other end is latched in and out by spring force or plastic deformation structure. The locking groove 504b is located at the top of the shell 100. When the energy storage battery device 500 is fully installed, the elastic part of the latching piece 504a automatically springs into the locking groove 504b to ensure that the energy storage battery device 500 is firmly installed on the top of the shell 100 and to prevent the battery device from falling off or loosening due to vibration or external force.

[0060] The energy storage battery device 500 is equipped with a self-locking push-button switch 501, which is located on the outer casing of the energy storage battery and is used for motor start and stop control. Pressing it once closes the circuit to start the motor, and pressing it again closes the circuit to stop the motor.

[0061] like Figure 7 As shown, the energy storage battery device 500 includes an energy storage battery pack 510 and a control circuit board 520. The control circuit board 520 integrates various functional modules, including a control input module 521, a control chip 522, a relay control module 523, and an undervoltage protection module 524.

[0062] Control input module 521:

[0063] The control input module 521 consists of a self-locking push-button switch. The push-button switch receives user operation signals. When the user presses the button, the button closes the circuit, outputting a signal to the input terminal of the control chip 522 (the control chip is the main control MCU). After receiving the signal, the control chip issues commands to control the connection and disconnection of the power supply circuit, thereby driving the DC motor to start and stop.

[0064] Relay control module 523:

[0065] The relay control module 523 includes a normally open DC relay. The control terminal of the relay is connected to the output terminal (such as a GPIO pin) of the control chip 522. When the control chip 522 receives a signal from the push-button switch, it outputs a control signal to the control terminal of the relay control module 523, driving the main contacts of the relay to close or open. The main contacts of the relay are connected in series in the power supply circuit of the DC motor. By turning the relay on and off, the power supply is controlled to be turned on and off, thereby starting or stopping the DC motor.

[0066] Undervoltage protection module 524:

[0067] The undervoltage protection module 524 includes a voltage detection circuit and a comparator chip. The voltage detection circuit samples the output voltage of the energy storage battery, and the comparator chip compares the sampled voltage with a set threshold voltage. When the output voltage of the energy storage battery is lower than the set protection voltage threshold, the comparator chip outputs a logic low-level signal to notify the control chip 522 to respond. Based on this signal, the control chip 522 outputs a shutdown command, cutting off the relay control signal, thereby cutting off the DC motor power supply and protecting the system from damage due to undervoltage.

[0068] The specific connection relationships between modules:

[0069] The control input module 521 is connected to the control chip 522 via a push-button switch. When the button is pressed, the control chip 522 receives a signal.

[0070] The control chip 522 is connected to the relay control module 523 through its output terminal to control the relay's on and off states.

[0071] The control chip 522 is also connected to the undervoltage protection module 524 to collect the battery voltage and control the relay to disconnect based on the voltage information;

[0072] The main contacts of the relay are located in the power supply circuit and control the power supply to the DC motor.

[0073] This embodiment is suitable for diesel engine systems with low starting resistance, and features a more compact structure, higher transmission efficiency, and easier installation.

[0074] Example 2 (includes a reduction mechanism, motor + reduction drive clutch)

[0075] This embodiment provides a crankless starter for an air-cooled diesel engine equipped with a reduction gear mechanism, such as... Figure 2 As shown, its structure is basically the same as that of Embodiment 1, but a speed reduction mechanism 300 is provided between the DC motor 200 and the clutch assembly 400.

[0076] The DC motor 200 is a conventional high-speed permanent magnet DC motor with a rated output torque of 2.0 N·m and a speed of 4000 rpm. Its output shaft is connected to the input end of the reduction mechanism 300, and the output shaft of the reduction mechanism 300 is then connected to the input end of the clutch assembly 400.

[0077] The 300 reduction mechanism employs an integrated planetary gear reducer with a reduction ratio of 1:12 and an output torque of 18 N·m, making it suitable for starting high-inertia diesel engines. This structure allows for a smaller and lower-cost DC motor with a transmission efficiency exceeding 90%.

[0078] The remaining components (such as clutch assembly 400, energy storage battery device 500, control circuit board 520, slide rail structure (guide slide rail 502 and slider 503) etc.) are the same as in Embodiment 1, and will not be described again here.

[0079] This embodiment is applicable to diesel engine models with large starting loads and high flywheel inertia, while improving the versatility of the drive system and the compatibility of the motor.

[0080] It should be noted that, in this document, terms such as "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 limitation, 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.

[0081] Although embodiments of the present 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 present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A DC motor-driven, air-cooled diesel engine starter that requires no cranking, comprising a housing, characterized in that: The housing contains a clutch assembly, and a DC motor and an energy storage battery device are fixed on the outside of the housing. The output shaft of the DC motor passes through the housing and is connected to the input end of the clutch assembly to drive its rotation; The outer periphery of the clutch assembly is provided with a movable drive tongue for engaging with the diesel engine flywheel ring gear; The energy storage battery device is electrically connected to the DC motor to provide it with power, and is detachably fixed to the housing. The energy storage battery device is equipped with a control circuit board, which includes a control input module, a relay control module, and an undervoltage protection module. The control input module, the relay control module, and the undervoltage protection module are coordinated and transmit signals through a control chip. The control input module consists of a self-locking push-button switch, the output of which is connected to the input of the control chip to receive the user's start signal. The relay control module includes a normally open DC relay, whose control terminal is connected to the output terminal of the control chip, and whose main contacts are connected in series in the power supply circuit of the DC motor to control the power supply on and off. The undervoltage protection module includes a voltage detection circuit and a comparator chip, which are used to detect the output voltage of the energy storage battery. When the battery voltage is lower than a set threshold, a shutdown signal is output to the control chip, which then cuts off the relay and disconnects the motor power supply.

2. The air-cooled diesel engine starter without cranking according to claim 1, characterized in that, The clutch assembly includes a first annular disc seat and a second annular disc seat, which are coaxially arranged and clamp an isolation washer, and are fixed by disc seat bolts. The outer edge of the isolation gasket has multiple notches distributed at equal angles. A driving tongue is pivotally connected to each notch. The driving tongue is installed by a tongue bolt and is provided with return elasticity by a tongue torsion spring. The two ends of the tongue torsion spring respectively abut against the first annular disc seat and the outer side of the driving tongue; The annular disc base and the inner ring of the isolation washer are provided with an internal spline structure, and the output shaft end of the DC motor is provided with a matching external spline.

3. The air-cooled diesel engine starter without cranking according to claim 1, characterized in that, The rock-free starter also includes a reduction mechanism disposed between the DC motor and the clutch assembly. The input end of the reduction mechanism is connected to the output shaft of the DC motor, and the output end is connected to the clutch assembly.

4. The air-cooled diesel engine starter without cranking according to claim 3, characterized in that, The reduction mechanism is a planetary gear reducer, an eccentric shaft gear reducer or an equivalent structure thereof, and the reduction ratio is 1:8 to 1:

15.

5. The air-cooled diesel engine starter without cranking according to claim 1, characterized in that, The rated output torque of the DC motor is 1.5 N·m to 3 N·m, and the rated speed is 3000 to 5000 rpm.

6. The air-cooled diesel engine starter without cranking according to claim 4, characterized in that, The output torque of the reduction mechanism is 15 N·m to 20 N·m.

7. The air-cooled diesel engine starter without cranking according to claim 1, characterized in that, The energy storage battery device is equipped with a mechanical self-locking push-button switch, which is connected in series in the power supply path. When pressed for the first time, the circuit is closed to drive the DC motor, and when pressed again, the circuit is opened to stop the DC motor.

8. The air-cooled diesel engine starter without cranking according to claim 1, characterized in that, The energy storage battery device is installed on the top of the housing via a slide rail buckle structure, which includes a guide slide rail, a slider, and a buckle mechanism. The guide rails are disposed on both sides of the top of the housing, forming two parallel guide grooves along the front-back direction; The sliders are located on both sides of the bottom of the energy storage battery device and are adapted to the guide groove, enabling the energy storage battery device to slide within the guide rail and be fixed in the correct position. The latching mechanism is located at the rear end of the energy storage battery device and consists of a latching piece and a locking groove. One end of the latching piece is fixed to the outer shell of the energy storage battery device, and the other end is latched in and out by spring force or plastic deformation structure. The locking groove is located at the top of the shell, and the elastic part of the latching piece automatically springs into the locking groove when the energy storage battery device is fully installed.

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