Axial Starting Device with Shared Magnetic Plate
Solution Overview
Problem
Conventional starting devices for engines face challenges in minimizing size restrictions, reducing collision noise from electromagnetic switches, and minimizing gear noise during pinion gear engagement, while also improving durability and wear resistance.
Innovation Solution
The starting device integrates a solenoid device and electromagnetic switch in series along the axial direction, sharing a magnetic plate to reduce size and parts, and incorporates a laminated iron core with a laminated part to absorb collision shocks and a pinion gear with laminated steel sheets that can bend at tooth portions for noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the solenoid device and electromagnetic switch are arranged separately in the circumferential direction, then each component can be optimized independently, but the overall device size increases and installing ability decreases
Solution Approach 1:
The patent combines the solenoid device and electromagnetic switch into a single integrated unit, arranging them in the axial direction rather than separately in the circumferential direction. This merging reduces the overall device diameter and improves installing ability while maintaining independent optimization of each component through modular design within the integrated structure.
Solution Approach 2:
The patent transitions from arranging components in the circumferential direction (horizontal arrangement) to arranging them in the axial direction (vertical arrangement). This dimensional change allows the device to have a smaller diameter while accommodating both components, effectively resolving the space conflict.
2Device complexity
If the fixed iron core is made of soft steel to enable collision with the movable iron core, then the electromagnetic switch can be simplified, but loud collision noise is generated
Solution Approach 1:
The patent uses a composite structure for the fixed iron core, combining soft steel (for magnetic properties and collision capability) with a laminated plate structure (for vibration suppression). This composite approach maintains the simplified electromagnetic switch design while reducing collision noise through the damping effect of the laminated structure.
Solution Approach 2:
The patent converts the harmful collision noise into a beneficial damping effect by using the laminated plate structure. The laminated construction absorbs and dissipates the collision energy, transforming the noisy impact into controlled vibration damping while maintaining the necessary mechanical collision function.
3Strength
If the pinion gear is made of rigid material to ensure strength, then durability is improved, but gear engagement noise increases
Solution Approach 1:
The patent applies a laminated composite structure to the pinion gear, combining rigid material (for strength and durability) with laminated layers (for noise reduction). The laminated structure allows controlled flexibility at the tooth portions while maintaining overall gear strength, effectively reducing gear engagement noise without sacrificing durability.
4Use of energy by moving object
If the number of starting operations is increased due to idle stop system adoption, then fuel consumption is improved, but durability of the starter decreases
Solution Approach 1:
The patent incorporates damping structures (laminated plates in the fixed iron core and pinion gear) that provide beforehand cushioning for the inevitable collision operations. These damping structures are designed to absorb and dissipate collision energy from the start, protecting the electromagnetic switch and other components from damage during frequent starting operations required by idle stop systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for a more compact design, reduced noise during operation, and enhanced durability by minimizing collision noise and gear engagement noise, while improving wear resistance and reducing the overall noise pollution associated with engine starting.
Implementation Method 1
an electromagnetic coil that forms an electromagnet by energization
Implementation Method 2
a movable iron core that moves in an axial direction in an inner circumference of the electromagnetic coil
Implementation Method 3
a laminated part formed by laminating a plurality of steel sheets... to reduce a collision noise generated when the movable iron core collides with the fixed iron core
Data Source
AI summary
An electromagnetic switch unit comprises a solenoid device that pushes out a pinion gear to a ring gear side of an engine, and an electromagnetic switch that opens and closes a main point of contact of a motor circuit. The solenoid device and the electromagnetic switch are arranged in series in an axial direction, while a magnetic plate that forms a part of magnetic circuit between a first coil used for the solenoid device and a second coil used for the electromagnetic switch is shared by the solenoid device and the electromagnetic switch.