Starter System Solenoid Control for Torque and Speed
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Solution Overview
Problem
Existing starter systems for vehicles face challenges in efficiently operating under high-speed low-torque and low-speed high-torque conditions, particularly in cold crank and warm start scenarios, requiring improved engagement with the drivetrain and reduced energy consumption.
Innovation Solution
A starter system comprising a motor, solenoid assemblies, and a plunger coupled to a pinion, controlled by an electronic control unit, with solenoid windings and power isolation switches to manage current flow efficiently, allowing for precise control of pinion engagement and disengagement with the ring gear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the starter operates at high speed, then it meets cold crank requirements, but torque demand becomes insufficient for warm start scenarios
Solution Approach 1:
The patent applies dynamics by making the solenoid winding configuration adjustable and variable. The system dynamically switches between different solenoid winding connections (series/parallel combinations) based on operating conditions (cold crank vs warm start), allowing the electrical characteristics and resulting mechanical output to adapt in real-time to meet varying torque and speed requirements
Solution Approach 2:
The patent changes electrical parameters (resistance, inductance) by reconfiguring solenoid windings between series and parallel connections. This parameter adjustment allows the system to optimize current flow characteristics for different starting conditions, thereby controlling both pinion speed and torque output to match specific operational scenarios
2Force
If the starter is designed for high torque output, then it meets cold crank requirements, but energy consumption increases
Solution Approach 1:
The patent applies partial action by using only the necessary solenoid windings and current flow required for each specific starting condition. Instead of always engaging all windings at full capacity, the system selectively activates appropriate winding configurations, consuming only the energy needed to achieve the required torque for that moment
Solution Approach 2:
By changing electrical parameters through winding reconfiguration, the system optimizes the balance between torque output and energy input. The control module adjusts resistance and inductance values to match the minimum energy requirement for achieving successful engine starting under varying conditions
3Device complexity
If the starter uses a single solenoid winding configuration, then the structure is simple, but it cannot optimize performance across varying speed and torque conditions
Solution Approach 1:
The patent segments the solenoid assembly into multiple independent winding sets (first, second, third windings) that can be selectively connected. This segmentation allows each winding to serve specific functions under different operating conditions, with the control module selecting appropriate combinations to achieve desired performance
Solution Approach 2:
The solenoid assembly is designed with multi-functionality, where the same physical components (solenoid windings and plunger mechanism) serve multiple purposes: driving pinion engagement, controlling motor current, and adapting to different starting scenarios. The universal design eliminates the need for separate mechanisms for different operating modes
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 achieves effective engagement and disengagement of the starter with the drivetrain across varying speed and torque conditions, enhancing reliability and reducing energy consumption, while maintaining efficient operation in both cold crank and warm start scenarios.
Implementation Method 1
a plurality of solenoid assemblies, and a plunger movably coupled to a pinion... the plunger is configured and arranged to be electromagnetically coupled to at least one solenoid assembly
Implementation Method 2
a motor coupled to a circuit... the motor and the plurality of solenoid assemblies is configured and arranged to be capable of being controlled by an electronic control unit
Data Source
AI summary
Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit.