Starter Connecting Member Integrating Magnetic Switch and Motor

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Solution Overview

Problem

Conventional starters for engines require numerous connecting parts, leading to increased manufacturing and assembly costs, size, weight, and complexity, which hinders the improvement of reliability and durability.

Innovation Solution

A starter design that integrates a magnet switch and motor with a connecting member, where the connecting member directly supplies power from the magnet switch to the motor, eliminating the need for external terminals, leads, washers, and nuts, and using an elastic bush to secure the terminal, thereby simplifying assembly and enhancing durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional connecting parts (terminals, leads, washers, nuts) are used to connect the magnet switch to the motor, then the electrical connection can be established, but the number of parts and assembly steps increases, leading to increased manufacturing costs and device complexity

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidnumber of connecting parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the connecting member with the magnet switch housing, integrating the electrical connection function directly into the switch structure. The connecting member is formed as an integral part of the housing, eliminating the need for separate terminals, leads, washers, and nuts, thereby reducing part count while maintaining reliable electrical connection between the magnet switch and motor

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If multiple connecting parts are used in the starter assembly, then the electrical circuitry can be constructed, but the overall size and weight of the starter increase

Engineering Contradiction:

Improveelectrical circuitry reliabilityVSAvoidstarter weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The connecting member is integrated into the magnet switch housing as a single unified structure, eliminating multiple separate components. This integration reduces the total weight of the starter by removing redundant connecting parts while maintaining the necessary electrical circuitry functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing serves multiple functions: it provides structural support, encloses the magnet switch components, and simultaneously acts as the connecting member for electrical connection to the motor. This multi-functionality reduces the need for additional dedicated connecting parts, thereby reducing overall weight

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If multiple connecting parts and assembly steps are required, then the electrical connection can be established, but the manufacturing and assembly costs increase

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmanufacturing and assembly cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The connecting member is formed as an integral part of the magnet switch housing through injection molding or similar manufacturing processes. This integration eliminates the need for separate manufacturing of terminals, leads, washers, and nuts, as well as reducing assembly steps, thereby significantly reducing manufacturing and assembly costs while maintaining reliable electrical connection

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If conventional connecting structure is used, then the magnet switch and motor can be connected, but the number of parts prevents reduction in size

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidstarter size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The connecting member is integrated into the magnet switch housing, consolidating multiple functions into a single structure. This integration eliminates the space required for separate connecting parts and reduces the overall volume of the starter while maintaining reliable electrical connection between the magnet switch and motor

Inventive Principle:

Principle #5Merging (Combining)

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 reduces manufacturing and assembly costs, minimizes size and weight, and improves reliability and durability by simplifying the connecting structure and using an elastic bush to absorb impact and vibrations.

Implementation Method 1

using an elastic bush to absorb impact and vibrations

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7626280B2Starter having connecting member electrically connecting magnetic switch and motor

Publication Date: 2009.12.01 DENSO CORP

AI summary

A starter includes a magnetic switch, a motor, and a terminal. The terminal fixed to both the magnetic switch and the motor and has two end portions in the longitudinal direction of the terminal. An end portion of the terminal confronts a movable contact within the magnetic switch. The other end portion of the terminal is connected to an electric circuitry of the motor therewithin.