Compact Starter with Coaxial Switch and Solenoid
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Solution Overview
Problem
Existing engine starters with separate electromagnetic switches and solenoids for opening motor circuits and pushing pinion gears are bulky, leading to increased installation space requirements and potential interference with other engine components, and require improved durability due to increased startup frequency and material wear.
Innovation Solution
A starter design featuring a coaxial arrangement of the electromagnetic switch and solenoid, with a unitary structure that minimizes axial dimensions and reduces the number of components, allowing for compact installation and increased resistance to vibrations, while maintaining functionality in starting the engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electromagnetic switch and solenoid are formed as separate bodies and placed in parallel around the motor periphery, then each component can be independently designed and manufactured, but the starter dimension increases in radial directions causing interference with other engine components
Solution Approach 1:
The electromagnetic switch and solenoid are merged into a single integrated body structure. The electromagnetic switch is positioned concentrically inside the solenoid, with the solenoid case forming an outer cylindrical structure and the electromagnetic switch case positioned within it. This merging eliminates the need for separate parallel placement of components, reducing the radial dimension of the starter while maintaining independent functionality of both components.
2Area of stationary object
If the starter size is reduced to minimize installation space, then installation capability increases, but the durability of brushes and meshing components may be compromised due to increased startup frequency from idle stop function
Solution Approach 1:
The integrated structure of the electromagnetic switch and solenoid allows for optimized space utilization, enabling a compact starter design that fits in smaller installation spaces. The concentric arrangement maximizes the use of available radial space, reducing the overall starter footprint while maintaining component functionality and durability through proper structural support and spacing.
Solution Approach 2:
The electromagnetic switch is designed to close the main contact before the pinion gear fully engages with the ring gear. This preliminary action ensures that the motor circuit is activated in advance, allowing the motor to begin rotating and reducing the load on the brushes and gear meshing during the engagement process, thereby extending component life.
3Area of stationary object
If the electromagnetic switch is moved along the circumferential direction at an appropriate angle, then interference with other components is avoided, but the structural complexity and positioning precision requirements increase
Solution Approach 1:
The electromagnetic switch is positioned asymmetrically within the solenoid structure, with its axis offset from the solenoid axis by a predetermined angle. This asymmetric positioning allows the electromagnetic switch to be located in a space that does not interfere with other engine components while maintaining a compact overall structure. The asymmetric design eliminates the need for complex circumferential movement or adjustment mechanisms.
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 coaxial arrangement of the electromagnetic switch and solenoid reduces the starter's overall size, minimizes interference with other components, and enhances durability, enabling efficient engine starting with reduced installation space and lower costs.
Implementation Method 1
an electromagnetic switch operative to open or close a main contact of a motor circuit
Implementation Method 2
a solenoid for pushing a pinion gear toward a ring gear of an engine
Data Source
AI summary
An electromagnetic switch is disclosed as having an electromagnetic switch, operative to open or close a main contact of a motor circuit, and a solenoid having a function to push a pinion gear to a position away from a motor. The electromagnetic switch and the solenoid are placed in series in a unitary structure such that the electromagnetic switch and the solenoid have a switch case and a solenoid case both of which are integrally formed with each other to be contiguous in an axial direction.Further, a stationary core for the electromagnet and a stationary core for the solenoid are integrally formed and an operational direction of a plunger for the electromagnet and an operational direction of a plunger for the solenoid are set to be opposite in direction.