Starter Generator Belt Tensioner Single-Hand Locking
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Solution Overview
Problem
Existing belt tensioners for internal combustion engine starter generators require two hands to move tensioning rollers apart for belt replacement or assembly, especially when the belt is broken, due to lack of support, necessitating a second mechanic to set the detent in the spaced position.
Innovation Solution
Incorporating a further locking mechanism with bores and a locking pin that allows one tensioning lever to be rotationally fixed relative to the starter generator, enabling single-handed operation for locking and unlocking, simplifying the belt drive assembly and replacement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a belt tensioner with two tensioning rollers is used to pre-tension the belt before and after the pulley, then the belt can be properly tensioned during generator operation, but two hands are required to move the tensioning rollers apart for belt replacement or assembly, necessitating a second mechanic
Solution Approach 1:
The locking mechanism is segmented into multiple independent components: a first locking element on the first tensioning lever, a second locking element on the second tensioning lever, and corresponding recesses in the housing. This segmentation allows each tensioning lever to be locked independently, enabling one-handed operation where one hand stabilizes the housing while the other manipulates the locking mechanism.
Solution Approach 2:
The locking elements and recesses are pre-positioned on the tensioning levers and housing respectively. Before belt replacement, the tensioning levers can be预先 locked in a spaced-apart position using these pre-positioned locking features, preparing the system for easy one-handed belt installation without requiring simultaneous two-handed coordination.
2Ease of operation
If the tensioning levers are locked relative to each other in a spaced position to allow belt fitting, then the belt can be installed without obstruction, but the locking mechanism requires two hands to operate simultaneously
Solution Approach 1:
The locking functionality is merged into the existing tensioning lever structure rather than adding a separate complex locking system. The locking elements are integrated onto the tensioning levers themselves, and the recesses are formed directly in the housing, combining multiple functions (tensioning and locking) into unified components.
Solution Approach 2:
The locking mechanism is designed to be self-contained and self-operating. The locking elements on the tensioning levers engage with the recesses in the housing through simple rotational movement, allowing the mechanism to lock itself without requiring external tools or complex actuation systems.
3Ease of operation
If the tensioning rollers are moved away from each other to allow belt fitting, then the belt can be fitted without hindrance, but both tensioning levers would rotate together without belt support, requiring a second mechanic to engage the locking mechanism
Solution Approach 1:
The stabilization function is segmented and assigned to individual locking elements on each tensioning lever. The first locking element stabilizes the first tensioning lever, while the second locking element stabilizes the second tensioning lever. This segmentation allows one hand to stabilize the housing while the other hand operates the locking mechanism, providing stability without requiring a second mechanic.
Solution Approach 2:
The locking elements act as intermediaries between the tensioning levers and the housing. These intermediary components transfer and distribute the stabilizing force from the housing to the individual tensioning levers, preventing unwanted rotation while allowing controlled movement for locking and unlocking operations.
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 simplifies the belt drive assembly by allowing single-handed operation of the belt tensioner, reducing the need for additional mechanics during belt replacement or assembly, especially when the belt is broken, and enhances ease of use during transport.
Implementation Method 1
a spring element clamped between the tensioning levers which moves the tensioning rollers towards each other while generating the pretension
Implementation Method 2
both locking means each comprise two recesses or bores movable relative to each other into a locking position, into which a locking pin can be inserted or is inserted in the locking position
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a generator arrangement for an auxiliary-assembly belt drive of an internal combustion engine, having a starter generator (1) with a belt pulley (6) and a belt tensioner (2) which comprises the following: - a first tensioning lever (8) with a first tensioning roller (4), - a second tensioning lever (9) with a second tensioning roller, said tensioning rollers being arranged in front of and behind the belt pulley in the rotational direction of the belt (3) and applying a pretensioning force onto the belt, - a spring means (7) which is stretched between the tensioning levers and which moves the tensioning rollers towards each other, thereby generating the pretensioning force, - and a locking means (11), by means of which the tensioning levers can be locked relative to each other in a position in which the tensioning rollers are moved away from each other, thereby reducing or canceling the pretensioning force. The generator arrangement is to comprise another locking means (15) by means of which one of the tensioning levers can be locked relative to the starter generator.