Integrated Starter-Generator with Gear Set for Work Vehicles
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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 space is limited and reliability is critical.
Innovation Solution
A combined engine starter and electric power generator with an integral transmission, utilizing a gear set and clutch assembly to automatically switch between power flow directions, eliminating the need for separate components and belt drives, and providing robust power transmission for both starting and generating functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate starter and alternator components are used with belt drives, then the system can perform starting and generating functions, but the device complexity increases and reliability decreases
Solution Approach 1:
The patent combines the starter motor and alternator into a single integrated starter-generator assembly that directly couples to the engine crankshaft. This merging eliminates the need for separate belt-driven components, reducing device complexity while improving reliability through direct mechanical coupling. The single assembly performs both starting and power generation functions without requiring separate drive systems.
Solution Approach 2:
The integrated starter-generator assembly serves multiple functions: it acts as a starter motor during engine cold starting, operates as an alternator during engine operation to generate electrical power, and provides a direct mechanical coupling for power transmission. This multi-functionality eliminates the need for separate dedicated starter and alternator components, resolving the technical contradiction between reliability and device complexity.
2Area of stationary object
If separate starter and alternator components are used, then the system can perform starting and generating functions, but the engine compartment layout becomes complicated and space consumption increases
Solution Approach 1:
By merging the starter and alternator into a single integrated assembly that directly couples to the engine crankshaft, the patent significantly reduces the space required in the engine compartment. The direct coupling eliminates the need for belt routing paths and associated tensioners, allowing for a more compact and simplified engine compartment layout.
Solution Approach 2:
The invention extracts the belt drive system entirely from the power transmission path, removing belts, pulleys, and tensioners that occupy valuable engine compartment space. This extraction of the intermediate belt transmission mechanism directly reduces space consumption and simplifies the overall layout.
3Reliability
If belt drives are used to couple engine to alternator, then power transmission is achieved, but unreliability is introduced
Solution Approach 1:
The patent extracts and eliminates the belt drive system from the power transmission path, removing the source of unreliability associated with belts (slipping, breaking, tension maintenance). Instead, the alternator is directly coupled to the engine crankshaft through a rigid mechanical connection, ensuring reliable and consistent power transmission without the harmful factors introduced by belt drives.
4Reliability
If integrated starter-generator with direct coupling is used, then reliability improves and space is reduced, but robust power transmission for both starting and generating must be achieved
Solution Approach 1:
The integrated starter-generator assembly incorporates a clutch mechanism that dynamically engages and disengages the connection between the assembly and the engine crankshaft. During engine starting, the clutch engages to transmit high torque from the starter motor to the crankshaft. During power generation, the clutch engages to transmit mechanical power from the crankshaft to the alternator. This dynamic engagement ensures robust power transmission capability while maintaining the benefits of direct coupling.
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 reliability, improves cold-starting performance, and simplifies engine compartment layouts by directly coupling mechanical power to the engine, reducing complexity and increasing system efficiency in generating electric power.
Implementation Method 1
a gear set and a clutch assembly mechanically coupled to the gear set. The gear set is configured to receive rotational input from the electric machine and from the engine
Implementation Method 2
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.