Starter Machine Pinion Speed Synchronization Control
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Solution Overview
Problem
Existing starter machines for vehicles lack efficient synchronization of pinion and engine component speeds during engine restart, which can lead to potential damage and inefficient starting processes.
Innovation Solution
A starter machine system that includes a solenoid assembly with biasing members and a motor operatively coupled to a pinion, controlled by an electronic control unit and power module, which synchronizes the speeds of the pinion and engine components through coordinated control of coil windings and solid-state switches to ensure smooth engagement and disengagement with the ring gear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the starter machine uses a conventional solenoid assembly without multiple biasing members, then the device complexity is reduced, but the reliability of pinion engagement and disengagement deteriorates
Solution Approach 1:
The solenoid assembly is segmented into multiple functional components including first and second biasing members with distinct functions. The first biasing member handles initial engagement while the second biasing member manages disengagement, dividing the overall function into specialized segments that improve reliability without requiring a complete redesign of the solenoid assembly.
Solution Approach 2:
The first biasing member performs preliminary engagement action by initially engaging the pinion with the ring gear before the second biasing member acts. This preliminary action ensures the pinion is properly positioned and engaged before the main engagement force is applied, improving the reliability of the starting sequence.
2Object-affected harmful factors
If the starter machine operates without speed synchronization control, then the device complexity is reduced, but the harmful factors during engine restart deteriorate
Solution Approach 1:
The electronic control unit receives feedback signals from sensors that monitor engine speed and starter motor speed. This feedback enables the controller to adjust the operation of the starter motor to synchronize its speed with the engine speed, preventing damage during restart while maintaining control through a manageable electronic system.
Solution Approach 2:
The system dynamically changes operational parameters including current flow to the motor and engagement timing based on real-time speed conditions. By adjusting these parameters, the system synchronizes pinion and engine component speeds to prevent mechanical damage during restart operations.
3Ease of operation
If the starter machine uses a single biasing member, then the device complexity is reduced, but the ease of operation during stop-start cycles deteriorates
Solution Approach 1:
The biasing function is segmented into two distinct members: the first biasing member that facilitates initial engagement during start-up, and the second biasing member that enables smooth disengagement during stop-start cycles. This segmentation allows each member to be optimized for its specific function, improving overall ease of operation.
Solution Approach 2:
The first biasing member performs preliminary engagement action during stop-start cycles by initially engaging the pinion before the second biasing member acts to disengage it. This preliminary action ensures smooth operation during the transition states of stop-start cycling.
4Productivity
If the starter machine lacks coordinated current flow control, then the device complexity is reduced, but the productivity of engine starting cycles deteriorates
Solution Approach 1:
The electronic control unit monitors engine speed and starter motor performance through sensor feedback, enabling real-time adjustment of current flow to the motor. This feedback control optimizes the starting cycle by adjusting power delivery based on actual operating conditions, improving productivity.
Solution Approach 2:
The system dynamically changes electrical parameters including current magnitude and timing based on engine conditions. By coordinating current flow adjustments with mechanical engagement and speed synchronization, the system optimizes starting efficiency while managing power delivery through controlled electrical parameter changes.
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 system effectively synchronizes the speeds of the pinion and ring gear, reducing the risk of damage and improving the efficiency of engine starting and restarting processes, including stop-start and change of mind scenarios.
Implementation Method 1
a solenoid assembly that can include a plurality of biasing members and a motor operatively coupled to a pinion
Implementation Method 2
a motor operatively coupled to a pinion... configured and arranged to control a speed of the motor to substantially synchronize the speeds of the pinion and a component of an engine
Data Source
AI summary
Embodiments of the invention provide a starter machine including an electronic control unit. The electronic control unit can be in communication with one or more sensors. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes a plurality of biasing members, a motor that is coupled to a pinion, and power module and controller that is coupled to the motor. In some embodiments, at least one of the power module and the controller are configured to control a speed of the pinion to substantially synchronize the pinion speed and the speed of an engine component.