Starter System Relay Switch Controller for Click-No-Crank Correction
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Solution Overview
Problem
Conventional starter systems face issues such as 'click-no-crank' occurrences, premature starter motor energization, damage from improper engagement with the ring gear, solenoid chatter due to low battery voltage, overcranking, and overrunning of the starter motor, which can lead to thermal degradation and inefficient cranking performance.
Innovation Solution
A starter system with an intelligent integral magnetic switch (iIMS) regulated by a controller that monitors and controls the relay switch to prevent these failures, featuring starter engagement monitoring, auto-retry, rapid re-engagement lockout, running engine lockout, low voltage lockout, time-limited cranking, and automatic disengagement at engine start, allowing for independent operation without external engine speed signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the relay switch is closed during starting operation to energize the starter motor, then the engine can be cranked, but click-no-crank events occur when the pinion fails to engage the ring gear properly
Solution Approach 1:
The controller monitors motor energization voltage and provides feedback to detect click-no-crank events. When voltage drops below a threshold within a predetermined time period after relay closure, the controller identifies improper engagement and responds by opening and reclosing the relay switch to correct the event.
Solution Approach 2:
The system performs preliminary monitoring of motor energization voltage immediately after the relay switch closes during starting operation. By detecting voltage drops that indicate click-no-crank events before they cause damage or failure, the system can take corrective action by reclosing the relay switch.
2Speed
If the starter motor is energized prematurely before pinion engagement, then the starter motor may rotate without loading, but damage can occur from improper engagement with the ring gear
Solution Approach 1:
The controller performs preliminary monitoring of motor energization voltage to detect the timing and conditions of starter motor energization. By identifying premature energization before proper pinion engagement, the system can prevent mechanical damage through controlled relay switch operation.
Solution Approach 2:
The system continuously monitors motor energization voltage and provides feedback to detect conditions indicating improper engagement. When damage-risk conditions are detected, the controller responds by opening and reclosing the relay switch to correct the engagement state.
3Duration of action of moving object
If the solenoid assembly is energized continuously to maintain pinion engagement, then the engine can be cranked for extended periods, but thermal degradation occurs from overheating
Solution Approach 1:
The controller implements periodic control of the relay switch based on monitored engine starting conditions and time elapsed. By cycling the relay switch open and closed based on predetermined time periods and voltage thresholds, the system enables extended cranking duration while preventing thermal degradation through periodic interruption of power to the solenoid assembly.
4Reliability
If the relay switch is opened and reclosed to correct click-no-crank events, then engagement reliability is improved, but the number of switching operations increases
Solution Approach 1:
The controller uses feedback from motor energization voltage monitoring to determine when click-no-crank events occur. The relay switch is opened and reclosed only when specific voltage threshold conditions are met within predetermined time periods, providing automated correction of engagement failures without requiring complex manual intervention or excessive switching 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
The system effectively corrects 'click-no-crank' events, prevents damage, manages battery voltage, limits overcranking, and avoids thermal issues, ensuring reliable and efficient engine starting operations.
Implementation Method 1
relay switch (83) that is closed during a starting operation
Implementation Method 2
solenoid assembly and pinion moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position
Data Source
AI summary
A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct “click-no-crank” events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.