Integrated Starter-Generator Gear Set for Work Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional work vehicles require separate starter and alternator components, which occupy space, introduce unreliability due to belt drives, and complicate engine compartment layouts, especially in heavy-duty machinery where high torque demands are challenging for cold-starting and electric power generation.
Innovation Solution
A combined engine starter and electric power generator with an integral transmission, featuring a gear set and clutch assembly that automatically shifts gear ratios based on torque direction, eliminating the need for belts and allowing a single electric machine to handle both engine start-up and power generation tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate starter and alternator components are used with belt drives, then the engine compartment layout is flexible, but reliability deteriorates due to belt drive failures and space requirements increase
Solution Approach 1:
The patent combines the starter motor and alternator into a single integrated starter-generator assembly that is directly coupled to the engine crankshaft. This eliminates the need for separate belt-driven components, removing belts entirely from the system. The merged design reduces the total space occupied in the engine compartment while improving reliability by eliminating belt-driven failures.
Solution Approach 2:
The integrated starter-generator assembly performs multiple functions: it acts as a starter motor to crank the engine during startup, and as an alternator to generate electrical power during engine operation. This multi-functional component replaces what would traditionally require separate starter and alternator units, reducing space requirements while maintaining all necessary functions.
2Adaptability or versatility
If separate starter and alternator components are used, then each component can be optimized independently, but device complexity increases and space is consumed
Solution Approach 1:
The patent merges the starter motor and alternator into a single integrated assembly with a common mounting structure and direct crankshaft coupling. This consolidation reduces device complexity by eliminating duplicate mounting brackets, separate drive mechanisms, and multiple belt systems. The unified design maintains adaptability through internal optimization of the combined component.
3Ease of manufacture
If belt drives are used to couple engine to alternator, then installation is simplified, but unreliability increases due to belt failures
Solution Approach 1:
The patent extracts and removes the belt drive system entirely from the engine-starting and power-generation mechanism. By eliminating belts, pulleys, and tensioners, the design removes the source of belt-related failures while maintaining installation simplicity through the direct-coupled integrated assembly that requires no belt routing or tensioning adjustments.
4Force
If high torque is required for cold-starting large diesel engines, then engine starting capability is achieved, but the starter motor size and power requirements increase
Solution Approach 1:
The integrated starter-generator assembly is designed to provide high torque for engine cold-starting while also functioning as a power-generating alternator during engine operation. The unified design allows the same motor/generator to operate in motor mode during starting (requiring high torque) and in generator mode during operation (producing electrical power), optimizing power utilization without requiring separate high-power components.
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 solution enhances reliability, reduces space requirements, and improves cold-starting and power generation performance by providing robust power transmission in both directions without the need for external controls, thus simplifying the vehicle electrical system.
Implementation Method 1
the gear set effects a first gear ratio and in the second power flow direction the gear set effects a second gear ratio
Implementation Method 2
an electric machine and a gear set mounted to the electric machine
Implementation Method 3
The device is configured to receive rotational input from the electric machine and from the engine
Implementation Method 4
The clutch assembly includes two one-way clutches. A first one-way clutch is engaged when the gear set moves in the first power flow direction and is disengaged when the gear set moves in the second power flow direction
Data Source
AI summary
A combination engine starter and electric power generator device for a work vehicle has an electric machine and a gear set mounted to the electric machine. The gear set is configured to receive rotational input from the electric machine and from the work vehicle engine. The gear set mechanically couples the electric machine and the engine in first and second power flow directions in which in the first power flow direction the gear set effects a first gear ratio and in the second power flow direction the gear set effects a second gear ratio.