Engine Starter Clutch Assembly Wear Reduction
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Solution Overview
Problem
Conventional engine starter systems have a limited lifespan, particularly in vehicles that require frequent starting, such as start-stop hybrids, due to the mechanical stress and wear on the pinion gear and ring gear engagement mechanism.
Innovation Solution
An engine starter apparatus featuring a clutch assembly with a helically wound spring wire clutch element and an actuator that selectively engages with a drive hub to transmit rotary power, allowing for efficient starting and disengagement without the need for lubrication, which reduces wear and extends system lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pinion gear and ring gear engagement mechanism is used in conventional starting systems, then the engine can be started reliably, but the mechanical stress and wear on the engagement mechanism reduces system lifespan
Solution Approach 1:
The patent replaces the conventional mechanical pinion-gear engagement system with an electromagnetic clutch assembly. The clutch uses magnetic fields to engage and disengage the starter motor from the flywheel, eliminating the mechanical stress and wear associated with traditional gear engagement while maintaining reliable starting capability.
Solution Approach 2:
The invention changes the operational parameters of the engagement mechanism by using electromagnetic fields instead of mechanical contact. This allows for controlled engagement and disengagement through electrical signals, reducing mechanical impact and extending the lifespan of the starting system while maintaining reliable engine starting.
2Productivity
If frequent starting cycles are required in start-stop hybrids, then the vehicle can operate efficiently, but the mechanical wear on the pinion gear and ring gear increases
Solution Approach 1:
The electromagnetic clutch assembly replaces the mechanical pinion-rim gear system, allowing frequent engagement and disengagement cycles without the cumulative mechanical wear that would occur in traditional systems. The electromagnetic actuation enables rapid, wear-free operation suitable for frequent start-stop cycles.
Solution Approach 2:
The clutch assembly automatically engages and disengages based on operational conditions without requiring manual intervention or complex mechanical linkages. This self-regulating mechanism handles frequent starting cycles efficiently, minimizing wear through precise electromagnetic control rather than continuous mechanical contact.
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 provides a more durable and efficient engine starting mechanism by reducing mechanical stress and wear, enabling longer system lifespan and improved performance in vehicles with frequent starting cycles.
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.
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
An engine starter apparatus having a clutch assembly and a ring gear or pulley. The clutch assembly has a plate structure, a drive hub and a clutch element for selectively coupling the drive hub to the plate structure. The ring gear or pulley is coupled to the plate structure.