Integrated Starter Clutch and Balancer Gear for Compact Engines
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Solution Overview
Problem
Internal combustion engines with separate one-way clutches and balancer drive gears tend to have increased axial dimensions and weight due to the arrangement of these components side-by-side on the crankshaft, leading to larger and heavier engine designs.
Innovation Solution
The integration of the one-way clutch and balancer drive gear, along with the arrangement of the starter idle gear coaxial with the main shaft, reduces the axial dimension and weight of the engine by eliminating the need for additional supporting shafts and allowing for a more compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the one-way clutch and balancer drive gear are arranged side-by-side in the axial direction of the crankshaft, then the engine can function properly with separate components, but the dimension of the engine in the axial direction of the crankshaft becomes large
Solution Approach 1:
The one-way clutch and balancer drive gear are integrated into a single composite component that rotates on the crankshaft, combining two previously separate functions into one unified structure. This merging eliminates the need for side-by-side arrangement and reduces the axial dimension occupied by these components.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it acts as both the one-way clutch for the starter motor and the balancer drive gear for the vibration balancing system. This multi-functionality allows a single component to replace what previously required two separate parts arranged in series axially.
2Reliability
If the one-way clutch and balancer drive gear are arranged side-by-side in the axial direction of the crankshaft, then the engine can operate with distinct components, but the weight of the engine increases
Solution Approach 1:
By combining the one-way clutch and balancer drive gear into a single integrated component, the total number of parts is reduced. This consolidation eliminates redundant materials, fasteners, and mounting structures, thereby reducing the overall weight of the engine while maintaining operational reliability.
Solution Approach 2:
The integrated component is designed with distinct functional segments - one portion engages with the starter motor as a one-way clutch, while another portion meshes with the balancer driven gear. This segmentation within a unified structure allows both functions to coexist in a single lightweight component rather than requiring two separate heavy assemblies.
3Ease of manufacture
If the one-way clutch and balancer drive gear are formed as separate parts, then each component can be optimized independently, but the number of parts increases and manufacturing complexity increases
Solution Approach 1:
The patent integrates the one-way clutch and balancer drive gear into a single molded or machined component, reducing the assembly from two separate parts to one. This simplifies the supply chain, reduces assembly steps, and lowers manufacturing complexity while maintaining the ability to optimize each functional segment during the design phase.
Data Source
AI summary
An internal combustion engine includes: a crankshaft; a starter motor including a motor shaft; a starter gear fixed to the crankshaft, for receiving a driving force from the motor shaft; a one-way clutch that is interposed between the crankshaft and the starter gear, the one-way clutch being configured to transmit a driving force from the starter gear to the crankshaft, and to block a driving force from the crankshaft to the starter gear; and a balancer including a balancer drive gear fixed to the crankshaft and a balancer driven gear that is driven by the balancer drive gear to thereby rotate. The one-way clutch and the balancer drive gear are formed integrally.