High-Voltage Pinion Starter for Hybrid Engine Starting
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Solution Overview
Problem
Hybrid vehicles require a separate 12-V additional-start onboard power supply system for starting the internal-combustion engine, which necessitates a separate accumulator and coupling element, and demands high torque from the driving machine, limiting electric driving capabilities.
Innovation Solution
A high-voltage pinion starter system integrated with a polyphase electric motor and solenoid switch, powered by a low-voltage and high-voltage onboard power supply system respectively, allowing for cold, warm, and reflex starts without additional power supplies, utilizing existing space and interfaces similar to conventional starters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a separate 12-V additional-start onboard power supply system is used for starting the internal-combustion engine in hybrid vehicles, then the engine can be started during electric drive, but it requires a separate accumulator and coupling element, increasing device complexity
Solution Approach 1:
The patent combines the starting function with the existing high-voltage power supply system by using the high-voltage accumulator and DC converter that are already present in hybrid vehicles. The high-voltage pinion starter integrates the motor, solenoid switch, and power electronics into a single unit that draws power from the high-voltage system, eliminating the need for a separate 12-V additional-start power supply system with its own accumulator and coupling elements.
Solution Approach 2:
The high-voltage pinion starter serves multiple functions: it can start the internal-combustion engine during electric drive (reflex start), after automatic stop at traffic lights (warm start), and at the beginning of a drive (cold start). By using the existing high-voltage power supply infrastructure for multiple starting scenarios, the system avoids requiring separate dedicated power supplies for different starting conditions.
2Device complexity
If a high-voltage pinion starter is used to start the internal-combustion engine, then additional power supplies are eliminated, but the solenoid switch must be powered by low-voltage system while the motor uses high-voltage
Solution Approach 1:
The power electronics unit acts as an intermediary between the high-voltage accumulator and the solenoid switch. It converts high-voltage power to low-voltage power to operate the solenoid switch, or draws low-voltage power separately for the solenoid while using high-voltage power for the motor. This intermediary approach resolves the conflict between high-voltage motor operation and low-voltage solenoid operation.
Solution Approach 2:
The system segments the power supply requirements by using high-voltage power for the motor (which requires high power) and low-voltage power for the solenoid switch (which requires low power). The power electronics unit enables this segmentation by managing the separate voltage requirements independently, allowing each component to operate at its optimal voltage level.
3Power
If the electric motor is supplied by high-voltage onboard power supply system, then starting power is sufficient, but the solenoid switch powered by low-voltage system may experience voltage drops during starting operations
Solution Approach 1:
The patent extracts the high-power starting function from the low-voltage power supply system and assigns it to the high-voltage power supply system. By using the high-voltage accumulator and DC converter for motor operation, the low-voltage system is relieved of the high current demands during starting, preventing voltage drops and maintaining stability for other 12-V consumers.
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
Enables efficient and noiseless starting operations, including reflex starts, without disrupting the low-voltage power supply and maintaining system stability, by using galvanic isolation and air-cooled power electronics, thus eliminating the need for additional power supplies and optimizing space usage.
Implementation Method 1
the power electronics unit or the control device unidirectionally exchanges control signals with the solenoid switch and controls the solenoid switch
Implementation Method 2
the solenoid switch can be electrically powered by the low-voltage onboard power supply system
Data Source
AI summary
A vehicle is provided with a pinion starter for an internal-combustion engine, which vehicle includes a low-voltage onboard power supply system and a high-voltage onboard power supply system. The pinion starter has an electric motor and a solenoid switch, wherein the electric motor is constructed as a polyphase machine. The polyphase machine can be supplied with electric power from the high-voltage onboard power supply system, and the solenoid switch can be electrically supplied by the low-voltage onboard power supply system.