Integrated Starter-Generator with Electromagnetic Clutch Actuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional work vehicle power systems require separate starter and generator components, leading to increased size, cost, and complexity due to the need for multiple housings and complex engine compartment layouts, particularly in heavy-duty machinery where high torque demands are a challenge for engine starting and electric power generation.
Innovation Solution
A combined engine starter and electric power generator device with an integral transmission that includes an electric machine, gear set, clutch, and actuator assembly, allowing for dual functionality of engine cranking and electric power generation with bi-directional power flow and automatic gear ratio shifting, reducing the need for separate components and belts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate starter and generator components are used, then each component can be optimized for its specific function, but the overall system size, cost, and complexity increase
Solution Approach 1:
The patent combines separate starter and generator components into a single integrated starter-generator assembly. The electric machine serves dual functions as both starter motor and generator, with a shared housing, mounting structure, and connection interface to the engine. This merging eliminates the need for separate components while maintaining functional optimization through mode-specific control.
Solution Approach 2:
The electric machine is designed as a universal component that performs multiple functions: starting the engine by rotating the crankshaft and generating electrical power when driven by the engine. The device includes mode-indicating structures and control systems that enable the single electric machine to adapt between starter and generator operations, reducing overall system complexity.
2Adaptability or versatility
If multiple separate components are used for starting and power generation, then functional requirements can be met, but the engine compartment layout becomes more complex
Solution Approach 1:
The integrated starter-generator assembly consolidates multiple functions into a single compact unit with a shared housing and mounting structure. This merging significantly reduces the space required in the engine compartment compared to separate starter and generator installations, while maintaining full functional capability for both engine starting and power generation.
Solution Approach 2:
The design incorporates nested structural elements where the clutch assembly is positioned within the housing, and the gear set is integrated into the power transmission path. The mode-indicating structures are embedded within the assembly, allowing compact arrangement that minimizes engine compartment space while preserving all necessary functions.
3Ease of manufacture
If conventional belt-driven alternators are used, then power transmission is simple, but torque demands for engine starting are insufficient
Solution Approach 1:
The patent replaces the conventional belt-driven alternator system with a direct-drive electric machine that couples to the engine through a gear set and clutch assembly. This substitution eliminates belt-driven mechanical transmission, providing direct mechanical power transmission capable of delivering high starting torque to the engine crankshaft while maintaining manufacturing simplicity.
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 provides robust power transmission and reduces complexity by eliminating the need for separate starter and generator components, enhancing reliability and efficiency in both engine starting and electric power generation, while occupying less space in the engine compartment.
Implementation Method 1
an actuator assembly including at least one electromagnet configured to selectively 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
Implementation Method 2
the at least one electromagnet configured to be selectively energized in a first energized state to generate an opposite orientation magnetic field relative to the at least one permanent magnet such that the at least one permanent magnet is attracted to the at least one electromagnet and a second energized state to generate a common orientation magnetic field relative to the at least one permanent magnet such that the at least one permanent magnet is repelled by the at least one electromagnet
Data Source
AI summary
A combination starter-generator device is provided for a work vehicle having an engine. The starter-generator device includes an electric machine; a gear set configured to couple the electric machine and the engine in first and second power flow directions, the gear set configured to operate in one of at least first, second, and third gear ratios in the first power flow direction and at least a fourth gear ratio in the second power flow direction; at least one clutch selectively coupled to the gear set to effect the first, second, and third gear ratios in the first power flow direction and the fourth gear ratio in the second power flow direction; and an actuator assembly including at least one electromagnet configured to selectively shift the at least one clutch between disengaged and engaged positions.