Engine Starter Gear Fitting Mechanism Reducing Drag Losses
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Solution Overview
Problem
Existing engine starters face issues with increased size and cost due to the need for multiple solenoid devices, complex control mechanisms, and continuous dragging losses and noise from sliding components in gear fitting and disengaging operations.
Innovation Solution
A gear fitting and disengaging device that includes a rotation shaft, a driving gear, a driven gear, a restraint device, and a moving force generating mechanism to control the axial movement and engagement of the driving gear, reducing mechanical losses and noise by allowing the driving gear to move axially and engage with the driven gear using a ratchet mechanism and friction surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a tandem solenoid type engine starter is used to push out the pinion gear and control rotation independently, then the gear fitting and disengaging operation can be controlled, but the device size and cost increase
Solution Approach 1:
The patent combines the pinion gear pushing-out function and rotation control function into a single solenoid device. The solenoid plunger serves dual purposes: it pushes the pinion gear outward for engagement and simultaneously controls the rotation operation through integrated control mechanisms, eliminating the need for separate solenoid devices and reducing overall system complexity
Solution Approach 2:
The single solenoid device performs multiple functions including pushing out the pinion gear, controlling its rotation, and enabling both fitting and disengaging operations. This multi-functional design replaces the traditional tandem solenoid configuration, reducing the number of components while maintaining full operational control
2Reliability
If a constant mesh type engine starter with one-way clutch is used to prevent rotation after engine start, then the starter motor is protected, but continuous dragging losses occur affecting fuel consumption
Solution Approach 1:
The patent implements periodic engagement and disengagement of the pinion gear with the flywheel teeth. After engine start, the pinion gear is completely disengaged from the flywheel, eliminating continuous contact and dragging losses. The one-way clutch mechanism is replaced with this periodic engagement approach that stops energy loss after the starting function is fulfilled
Solution Approach 2:
The patent extracts and eliminates the continuous dragging mechanism (one-way clutch) that causes energy losses. By using a different mechanism where the pinion gear can be completely disengaged, the harmful continuous contact is removed while still achieving the protective function during the starting phase
3Productivity
If the drive source is stopped while the generator shaft is rotating in an SSS clutch, then the drive can be halted, but continuous sliding causes dragging losses and noise
Solution Approach 1:
The patent uses periodic engagement where the pinion gear is pushed out to engage with flywheel teeth for starting, then completely disengaged after start. This periodic action eliminates continuous sliding contact, stopping dragging losses and noise generation while maintaining full drive control capability during the necessary operational phases
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 enables efficient gear fitting and disengaging operations with reduced mechanical losses and noise, allowing for effective engine starting and stopping without continuous dragging losses, thus improving the efficiency and reliability of the engine starter.
Implementation Method 1
a friction surface 14c which comes into contact with the friction material 36 when the driving gear 14 is at the disengagement position, and a moving force generating mechanism which causes a friction force to be applied to the friction surface 14c of the driving gear 14 from the friction material 36
Data Source
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AI summary
When engaging a driving gear (14) with a driven gear (16) for the purpose of starting an engine (30), a pressing force is applied to the driving gear (14) towards one side in the axial direction from a cam plate (32) which is prevented from rotating, thereby moving the driving gear (14) towards the one side in the axial direction. After the engine (30) starts, a drive source (10) is stopped while the driven gear (16) rotates. However, at that time, the driving gear (14) and a guide gear (18) are not engaged with the driven gear (16), and therefore stop rotating. As a consequence, mechanical losses such as dragging losses caused by sliding do not occur between the driving gear (14) and the cam plate (32) and between the driving gear (14) and the guide gear (18).