Integrated Starter-Generator with Preloaded 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, particularly in heavy-duty machinery where high torque demands for engine start-up and electric power generation are challenging to manage efficiently.
Innovation Solution
A combined engine starter and electric power generator device with an integral transmission that includes an electric machine and a gear set configured for bi-directional power flow, utilizing a clutch arrangement with active and drag clutches to achieve multiple gear ratios and simplify power transmission, thereby 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 due to multiple housings and complex engine compartment layouts
Solution Approach 1:
The patent combines the starter motor and generator into a single integrated housing that performs both functions. The starter motor is positioned to engage the flywheel for engine starting, while the generator couples to the engine output shaft for power generation. This merging eliminates the need for separate housings and reduces engine compartment layout complexity while maintaining functional optimization through dedicated mounting positions for each function.
2Ease of repair
If separate starter and generator components are used, then each component can be independently maintained, but the number of components and installation complexity increase
Solution Approach 1:
The integrated housing is designed with separable sections that allow the starter motor and generator to be independently accessed and removed for maintenance. The housing includes access ports and mounting arrangements that enable technicians to service each component separately while they remain part of the integrated assembly, thus maintaining ease of repair while reducing the total number of discrete components to install.
3Adaptability or versatility
If multiple belt systems are used to couple engine to alternator and starter, then flexible power transmission is achieved, but the number of belts and tensioners increases system complexity and potential failure points
Solution Approach 1:
The integrated housing provides direct mounting positions for both the starter motor and generator on the same housing structure. The starter motor engages the flywheel directly for starting, while the generator couples to the engine output shaft for power generation. This eliminates the need for separate belt systems and tensioners, reducing potential failure points while maintaining flexible power transmission through direct mechanical 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 provides robust power transmission for both engine start-up and electric power generation, enhancing reliability, cold starting performance, and system simplicity by eliminating the need for separate starter and generator components, while allowing for efficient power transfer and reduced complexity.
Implementation Method 1
The clutch arrangement further includes at least one drag clutch to apply a drag force on the gear set to slow the electric machine
Data Source
AI summary
A combination 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 in one of multiple gear ratios in the first power flow direction and at least one gear ratio in the second power flow direction. The starter-generator device further includes a clutch arrangement with at least one active clutch selectively coupled to the gear set to effect the gear ratios in the first power flow direction and in the second power flow direction. The clutch arrangement further includes at least one drag clutch to apply a drag force on the gear set to slow the electric machine.