Helical Spring Clutch for Engine Starter Wear Reduction
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Solution Overview
Problem
Conventional engine starter systems have a limited lifespan and are not suitable for frequent starting applications, such as in start-stop hybrids, due to mechanical wear and tear.
Innovation Solution
An engine starter apparatus featuring a clutch assembly with a helically wound spring wire clutch element and an actuator, which selectively engages with a drive hub to transmit rotary power from a starter motor to a flywheel or flexplate, allowing for improved power transmission and reduced mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional pinion gear and ring gear system is used, then power transmission is achieved, but mechanical wear and tear limit the lifespan
Solution Approach 1:
The patent replaces the conventional mechanical gear engagement system with a magnetic coupling system. The clutch element with magnetic particles creates a magnetic field that couples the drive hub to the plate structure, eliminating direct mechanical contact between moving parts. This substitution of magnetic fields for mechanical gear teeth significantly reduces wear and extends the operational lifespan of the starter motor.
2Productivity
If frequent starting cycles are implemented, then productivity is improved, but mechanical stress reduces system reliability
Solution Approach 1:
By replacing mechanical gear contact with magnetic coupling, the system can handle frequent engagement and disengagement cycles without accumulating mechanical wear. The magnetic particles in the clutch element can be rapidly repositioned by the magnetic field, enabling frequent starting cycles in start-stop hybrid applications without compromising system durability.
Solution Approach 2:
The magnetic coupling system dynamically responds to the activation of the starter motor. When the motor activates, the magnetic field engages the clutch element to transmit power; when deactivated, the magnetic field releases, allowing smooth disengagement. This dynamic magnetic coupling enables rapid response to frequent starting cycles without mechanical shock or wear.
3Reliability
If a clutch assembly with helically wound spring wire is used, then mechanical stress is reduced, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the clutch element: the helically wound spring wire provides both the structural framework and the magnetic particle containment. The spring wire's helical structure naturally accommodates the expansion and contraction of magnetic particles during engagement and disengagement, merging mechanical support and magnetic coupling functions into a single integrated component that reduces overall system complexity.
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
The solution extends the lifespan of engine starter systems by reducing mechanical stress and enabling efficient power transmission, making it suitable for more frequent starting cycles without the need for lubrication, thus enhancing reliability and durability.
Implementation Method 1
The clutch element comprises a helically wound spring wire having a first end and a second end. The first end of the helically wound spring wire is configured to receive rotary power from the plate structure, while the second end is coupled to the member for rotation therewith.
Implementation Method 2
The clutch element comprises a helically wound spring wire... configured to receive rotary power... and coupled to the member for rotation therewith
Implementation Method 3
The actuator comprises a member that is axially movable to selectively initiate engagement of the clutch element to a circumferentially extending surface of the drive hub.
Implementation Method 4
The actuator comprises a member that is axially movable to selectively initiate engagement of the clutch element
Implementation Method 5
The clutch element comprises a helically wound spring wire having a first end and a second end
Data Source
AI summary
An engine starter that employs a clutch between a flywheel or flex plate and a plate structure that is configured to receive rotary power from a starter motor through a transmission. The transmission may include ring and pinion gears or a belt that transmits rotary power between pulleys.