Integrated Starter-Generator with Magnetic Cam Clutch
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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, especially in heavy-duty machinery where high torque demands are a challenge for engine start-up 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, and clutch system, allowing for dual functionality as a starter and alternator with robust power transmission in both directions, eliminating the need for belts and reducing component count through bi-directional power flow capabilities.
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 the starter motor and generator into a single integrated assembly that shares common components including the housing, mounting structure, and shaft alignment mechanisms. This merging reduces the total number of separate components while maintaining the ability to perform both starting and generating functions independently, thereby reducing system complexity without sacrificing function-specific optimization
Solution Approach 2:
The integrated starter-generator assembly is designed to perform multiple functions through a single unified structure. The same housing accommodates both the starter motor and generator components, and the shared shaft system enables both cranking and power generation operations,实现ing multi-functionality that reduces overall system complexity
2Ease of repair
If separate starter and generator components are used, then each component can be independently maintained, but the system requires more space and has complex engine compartment layouts
Solution Approach 1:
The generator components are nested within or adjacent to the starter motor housing, with the generator shaft aligned concentrically or parallel to the starter shaft. This nesting arrangement allows both components to occupy a compact shared space while maintaining independent access points for maintenance and repair operations
3Ease of manufacture
If belt coupling is used to transfer power, then installation is simplified, but torque transmission is insufficient for high torque demands during engine start-up
Solution Approach 1:
The belt coupling intermediary is completely removed from the power transmission system. Instead, the starter motor and generator are directly coupled through shared shafts and rigid mechanical connections, extracting the belt transmission element to enable direct high-torque transmission while maintaining installation simplicity through the integrated housing design
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, cold starting performance, and electric power generation by providing direct mechanical coupling to the engine, reducing complexity and space requirements while maintaining optimal torque and speed ranges for both engine start-up and power generation.
Implementation Method 1
a magnetic cam assembly 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 is provided for a work vehicle having an engine. The starter-generator device includes an electric machine and 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. The gear set is configured to operate a first, second, or third gear ratio in the first power flow direction and a fourth gear ratio in the second power flow direction. At least one clutch is 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. A magnetic cam assembly is configured to shift the at least one clutch from a disengaged position into an engaged position.