Starter One-Way Clutch Inner Ring Integration
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Solution Overview
Problem
Existing starters with one-way clutches face issues of size constraints due to the need for larger ball bearings for increased mechanical strength, leading to increased costs and potential lubricant displacement causing seizing and abrasion.
Innovation Solution
The clutch-inner of the one-way clutch is utilized as the inner ring of the ball bearing, eliminating the original inner ring and forming an integral unit with the ball bearing, allowing for improved lubrication and increased mechanical strength without enlarging the outer diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the outer diameter of the clutch-inner is enlarged to increase its mechanical strength, then the mechanical strength is improved, but the size of the starter becomes large
Solution Approach 1:
The clutch-inner and the inner ring of the ball bearing are merged into a single integral structure. The clutch-inner has a bearing portion formed integrally therewith that serves as the inner ring of the ball bearing, eliminating the need for a separate inner ring component. This integration allows the clutch-inner to maintain sufficient mechanical strength while keeping the overall starter size compact.
2Device complexity
If the balls of the ball bearing directly contact the rotating shaft to eliminate the inner ring, then the component count is reduced, but lubricant retention becomes impossible causing seizing
Solution Approach 1:
The clutch-inner and the inner ring of the ball bearing are merged into a single integral structure. The clutch-inner has a bearing portion formed integrally therewith that serves as the inner ring of the ball bearing. This integration maintains the necessary component structure for lubricant retention while reducing the overall component count by eliminating the separate inner ring.
Solution Approach 2:
The ball-groove is formed in advance on the outer circumference of the bearing portion of the clutch-inner. This preliminary formation of the lubricant-retaining groove ensures that lubricant can be properly retained and distributed before the starter operates, preventing seizing between the bearing balls and the rotating shaft.
3Volume of moving object
If the inner ring of the ball bearing is eliminated to make the starter compact, then the size is reduced, but mechanical strength may be compromised
Solution Approach 1:
The clutch-inner and the inner ring of the ball bearing are merged into a single integral structure. The clutch-inner has a bearing portion formed integrally therewith that serves as the inner ring of the ball bearing. This integration allows the clutch-inner to maintain sufficient mechanical strength while keeping the overall starter size compact.
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 design results in a more compact starter with enhanced mechanical strength, reduced component count, and effective lubrication retention, preventing seizing and extending the starter's lifespan.
Implementation Method 1
the clutch-inner is rotatably supported by a ball bearing held in the starter frame
Implementation Method 2
lubricant such as grease is retained in the ball-groove
Data Source
AI summary
A starter for cranking an internal combustion engine includes an electric motor, an output shaft, and a one-way clutch for transmitting a rotational torque of the electric motor to the output shaft. The one-way clutch is composed of a clutch-outer driven by the electric motor, a clutch-inner spline-coupled to the output shaft, and rollers disposed between the clutch-outer and the clutch-inner. A portion of the clutch-inner is utilized as an inner ring of a ball bearing rotatably supporting the clutch-inner. A ball-groove rotatably supporting the bearing balls and retaining lubricant therein is formed on the outer circumference of the clutch-inner. In this manner, an original inner ring of the ball bearing can be eliminated without adversely affecting the lubricating function.