Integrated Starter-Generator Mounting via Ring Gear Castellations
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Solution Overview
Problem
Conventional work vehicle power systems require separate components for engine starting and electric power generation, leading to increased size, cost, and complexity due to the need for multiple devices and complex mounting arrangements, particularly in heavy-duty machinery where space is limited.
Innovation Solution
A combined engine starter and electric power generator device with an integral transmission that functions as both a starter and alternator, utilizing a gear set and clutch system to provide bi-directional power flow, reducing the need for separate components and simplifying the power transmission system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components are used for engine starting and electric power generation, then the system can provide dedicated functionality for each task, but the device complexity and space requirements increase
Solution Approach 1:
The patent combines the starter motor and alternator into a single integrated unit that serves both engine starting and electric power generation functions. The housing contains both the starter motor assembly and alternator assembly, sharing common mounting structures and spatial arrangement, thereby reducing the total number of separate components while maintaining dedicated functionality for each task
Solution Approach 2:
The integrated unit provides multi-functionality by enabling the same physical assembly to perform both starting and generation tasks. The starter motor can engage the engine flywheel for starting, while the alternator simultaneously or separately generates electrical power, making the device universal for multiple power-related functions
2Adaptability or versatility
If multiple separate components are used for starting and generation, then each component can be optimized for its specific function, but the mounting arrangement complexity increases
Solution Approach 1:
The housing integrates mounting structures that simultaneously support both the starter motor and alternator. Common mounting brackets, fastening points, and structural elements are shared between the two assemblies, simplifying the overall mounting arrangement while allowing each component to maintain its functionally optimized design
3Ease of repair
If separate starter and alternator components are used, then each can be independently maintained, but the overall system size and cost increase
Solution Approach 1:
The starter motor and alternator are housed in a common housing that allows both components to be serviced within the same accessible space. The housing design provides openings and access points that enable independent maintenance of each component without requiring separate installation locations, thereby reducing the overall system footprint while maintaining serviceability
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, reduces complexity, and improves performance by providing robust power transmission in both engine starting and electric power generation modes, while occupying less space and reducing costs.
Implementation Method 1
The flex plate includes a row of engagement apertures configured to receive the castellations of the ring gear to rotationally couple the ring gear to the engine via the mounting arrangement
Implementation Method 2
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
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 the engine. The gear set includes a ring gear formed by a cylindrical base with a perimeter surface facing the engine and a circumferential row of castellations extending in a radial direction from the perimeter surface. The starter-generator device further includes a mounting arrangement comprising a drive plate configured to be secured to a crank shaft of the engine and a flex plate mounted to the drive plate. The flex plate includes a row of engagement apertures configured to receive the castellations of the ring gear to rotationally couple the ring gear to the engine via the mounting arrangement.