Integrated Starter-Generator Cam Clutch Arrangement
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Solution Overview
Problem
Conventional work vehicle power systems require separate components for engine starting and electric power generation, leading to increased size, cost, and complexity due to the need for dedicated starter and generator units, which can be cumbersome in heavy-duty machinery.
Innovation Solution
A combined engine starter and electric power generator device with an integral transmission that functions as both a starter and alternator, utilizing a gear set and clutch arrangement to provide robust power transmission in both directions, eliminating the need for separate belts and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate components are used for engine starting and electric power generation, then the system can perform both functions, but the device complexity and component count increase
Solution Approach 1:
The patent combines the starter motor and generator into a single integrated assembly that shares common components including the housing, mounting structure, and electrical connections. The starter motor is positioned with its drive gear directly engaging the engine flywheel, while the generator is mounted on the same assembly to harvest electrical energy from engine operation, thereby reducing overall system complexity while maintaining dual functionality
Solution Approach 2:
The integrated assembly serves multiple functions: the starter motor provides cranking torque to initiate engine operation, the generator converts mechanical energy to electrical energy during engine operation, and the shared housing and mounting structure provide structural support for both functions, making the assembly universal for both starting and power generation purposes
2Adaptability or versatility
If separate components are used for engine starting and electric power generation, then both functions can be performed, but the size of the power system increases
Solution Approach 1:
The generator is mounted within the same housing structure that contains the starter motor, effectively nesting one component within the other's operational space. The generator is positioned adjacent to the starter motor assembly, utilizing the same structural envelope and mounting points, thereby reducing the overall footprint of the power system while maintaining both starting and generation capabilities
3Adaptability or versatility
If separate components are used for engine starting and electric power generation, then both functions can be performed, but the cost of the power system increases
Solution Approach 1:
The integrated assembly allows for consolidated manufacturing processes where the housing, mounting brackets, and electrical connections are produced as integrated components rather than separate parts. This merging of components enables batch production of the complete assembly, reducing per-unit costs compared to manufacturing and assembling separate starter and generator components independently
4Power
If a belt is used to couple the engine to the alternator, then power transmission is achieved, but the torque demand for starting is insufficient
Solution Approach 1:
The power transmission path is segmented into distinct functional zones: the starter motor gear directly engages the flywheel to provide high-torque cranking, while the generator is coupled through a separate belt drive from the engine's accessory belt system to harvest power during operation. This segmentation allows each component to operate in its optimal torque range without compromising the other's performance
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 integrated starter-generator device enhances system reliability, improves cold starting performance, and simplifies the power generation process by reducing the number of components and complexity, while maintaining efficient power transfer between the engine and electric system.
Implementation Method 1
a gear set configured to receive rotational input from the electric machine and from the engine and to couple the electric machine and the engine in a first power flow direction and a second power flow direction
Implementation Method 2
a cam plate configured to shift the at least one clutch from a disengaged position in which the at least one clutch is decoupled from the gear set into an engaged position in which the at least one clutch is coupled to the gear set
Data Source
AI summary
A combination starter-generator device includes an electric machine and a gear set configured to couple the electric machine and the engine in first and second power flow directions. The gear set is configured to operate in one of at least a first mode, a second mode, or a third mode in the first power flow direction and at least a fourth mode in the second power flow direction. The starter-generator device includes a clutch arrangement with at least one clutch selectively coupled to the gear set to effect the first, second, and third mode in the first power flow direction and the fourth mode in the second power flow direction; and a cam plate configured to shift the at least one clutch between a disengaged position and an engaged position relative to the gear set.