Starter Relay Pulsing for Engine Start Reliability
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Solution Overview
Problem
Existing starter systems for internal combustion engines face difficulties in actuating the starter due to icing-up of relay contacts and mechanical blockages, leading to delayed or failed engine start-ups, especially in adverse weather conditions, and require complex and costly solutions.
Innovation Solution
A method and system where the starter relay is actuated in a controlled manner with a sequence of pulses to break ice layers on contacts and release mechanical blockages, using a control unit to determine error states and terminate actuations based on predetermined conditions, allowing for efficient and precise start-up of the engine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heating wire is used to thaw ice on contacts, then ice removal is achieved, but start-up time is extended and additional control components are required
Solution Approach 1:
The patent applies periodic action by repeatedly closing and opening the starter relay contacts in a pulsing manner. This mechanical pulsing action generates impact forces that break ice layers on contacts, enabling rapid ice removal without the need for heating elements. The periodic contact closure provides both ice breaking functionality and immediate starter activation, eliminating the time delay associated with thermal thawing methods.
Solution Approach 2:
The patent replaces the thermal field approach (heating wires) with a mechanical field approach (impact forces from contact closure). By substituting thermal energy with mechanical impact energy, the system achieves faster ice removal and eliminates the need for additional heating control components, directly addressing the time loss and complexity issues.
2Reliability
If grooved profile is used on contact surfaces, then ice layer breaking is enabled, but impact force is insufficient for intense icing and structural changes are required
Solution Approach 1:
The patent employs periodic action through repeated relay contact closure, generating successive impact forces that progressively break down even intense ice layers. This dynamic pulsing approach overcomes the limitation of static grooved profiles by applying cumulative mechanical energy that can penetrate and fracture thick ice formations.
Solution Approach 2:
The patent applies preliminary action by performing multiple preliminary contact closures before full starter operation. These preliminary pulses serve to break up ice layers in advance, preparing the contact surfaces for reliable electrical connection and starter activation, thereby addressing intense icing conditions that would otherwise prevent operation.
3Reliability
If two-step starter operation is implemented, then de-icing and speed control are achieved, but device complexity increases
Solution Approach 1:
The patent applies universality by making the starter relay contact perform multiple functions: normal circuit closure, ice breaking through impact, and preliminary de-icing action. By consolidating these functions into the existing relay contact mechanism, the system eliminates the need for separate heating elements or complex two-step solenoid switches, reducing overall device complexity while maintaining de-icing capability.
Solution Approach 2:
The patent implements self-service by using the starter relay's own contact closure mechanism to generate the necessary impact forces for ice breaking. The system leverages its inherent operational characteristics (contact bounce and closure force) to perform de-icing functions without requiring external heating components or additional control circuitry, thereby simplifying the overall device structure.
4Reliability
If multiple relay actuations are performed, then ice breaking and blockage release are achieved, but actuation time is extended
Solution Approach 1:
The patent uses periodic action with optimized pulse timing, where multiple relay actuations are performed in rapid succession with minimal intervals. This high-frequency pulsing approach efficiently breaks ice and releases blockages while minimizing total actuation time, balancing reliability improvement with time efficiency.
Solution Approach 2:
The patent applies skipping by rapidly executing multiple relay actuations in succession without prolonged delays between pulses. This rushed sequence of actions quickly overcomes ice and blockage obstacles, achieving reliable starter activation with minimal total time extension, thereby reducing the actuation duration penalty.
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
Enables reliable and quick start-up of internal combustion engines under conditions of icing and mechanical blockages without additional structural changes or manual interventions, improving start-up reliability and reducing production costs.
Implementation Method 1
the impact force of the contacts is often only small, with the result that in particular when the icing-up is more intense, the ice cannot be broken by actuating the switch
Implementation Method 2
a heating wire that is arranged around the contacts of the solenoid switch in order by means of the heat that is generated in this manner to thaw out the ice that has formed on the contact surfaces
Data Source
AI summary
A method actuates a starter of an internal combustion engine by way of a starter relay. The starter relay is configured to supply the starter optionally with current via an on-board electrical system. The method has the following steps: determining an error status of the internal combustion engine; commencing repeated actuations of the starter relay; determining a current status of the internal combustion engine, wherein the current status of the internal combustion engine displays at least one error status or at least one operating status; and, if the current status displays at least one operating status, ending the repeated actuation of the starter relay, otherwise once again determining the current status. A system for actuating a starter of an internal combustion engine includes a control device, a power source, a starter relay, connected to the control device and configured to supply the starter of the internal combustion engine optionally with current from the power source via an on-board electrical system, wherein the control device is configured to carry out the method.