Auxiliary Mesh Starter Coil Control
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Solution Overview
Problem
Conventional auxiliary mesh type starters face issues such as limited torque for meshing, excessive current flow leading to electromagnetic switch failure, high temperature due to high current density, and potential for gear damage due to excessive force, along with reliability concerns in abnormal conditions.
Innovation Solution
The starter features an electromagnetic switch with the head ends of the attracting and holding coils connected separately and controlled by different relays, allowing for adjustable turns and using materials with higher resistivity, along with time relays to manage coil operation, thereby controlling current flow and reducing thermal issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the attracting coil and holding coil are connected together and have substantially equal turns, then the electromagnetic switch can be simplified in structure, but the current flow becomes excessive leading to switch failure and high temperature
Solution Approach 1:
The patent segments the control of the two coils by providing separate connection terminals (first terminal for attracting coil, second terminal for holding coil) instead of connecting them together. This allows independent current control for each coil, preventing excessive current flow and thermal damage while maintaining structural simplicity.
2Ease of manufacture
If the number of turns of attracting coil and holding coil are made equal, then the manufacturing process is simplified, but the torque control becomes limited and meshing capability is reduced
Solution Approach 1:
The patent allows different number of turns for the attracting coil and holding coil according to their specific functional requirements. The attracting coil can have fewer turns for rapid engagement, while the holding coil can have more turns for sustained meshing force, optimizing local quality for each coil's specific purpose.
3Force
If high current is applied to energize the coils, then the meshing force is sufficient, but the current density becomes excessive causing high temperature and potential failure
Solution Approach 1:
By providing separate terminals for the attracting coil and holding coil, the patent enables segmented current control. This allows the total current to be distributed across different coils at different times, reducing peak current density in any single coil and thereby minimizing thermal accumulation while maintaining sufficient meshing force.
4Productivity
If the attracting coil has low resistance to allow sufficient current flow, then the meshing action is effective, but the holding coil also draws excessive current leading to thermal issues
Solution Approach 1:
The separate terminal configuration enables segmented power delivery where the attracting coil can operate with low resistance for effective meshing action, while the holding coil can be controlled separately with appropriate resistance to minimize energy loss during the holding phase.
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 enhances torque control, reduces the risk of electromagnetic switch failure, minimizes gear damage, and improves reliability by allowing separate control of coil turns and managing current flow, ensuring efficient and durable operation.
Implementation Method 1
An electromagnetic attraction force in the B-direction as shown in FIG. 1 is generated in the plunger 8 by energizing the attracting coil 36 and the holding coil 37 of the electromagnetic switch 3
Implementation Method 2
a return spring 14 applies a return force to the plunger 8
Implementation Method 3
a motor 1, an electromagnetic switch 3 and relays 12
Data Source
AI summary
An auxiliary mesh type starter, including a motor, an electromagnetic switch connected with the motor and relays connected with the electromagnetic switch, wherein the electromagnetic switch includes a holding coil, an attracting coil, a stop seat arranged at the rear end parts of the holding coil and the attracting coil, a plunger arranged on the inner circumferences of the holding coil and the attracting coil and capable of sliding in an axial direction, a return spring for applying return force to the plunger, and a contact point arranged at the rear end of the plunger; and the relays are connected to a key switch, wherein the relays include a first relay and a second relay, with the head end of the attracting coil connects to the key switch via the first relay, and the head end of the holding coil connects to the key switch via the second relay.