Explosion-Proof Starter Solenoid Layout for Spark Isolation
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Solution Overview
Problem
Existing starter systems do not adequately address the potential fire hazard or explosion risk from ignition sparks during the application of a cranking current signal to a starter motor, particularly in environments with flammable or explosive substances.
Innovation Solution
An explosion proof starter system utilizing multiple physically isolated starter solenoids, where a first solenoid mechanically couples the starter motor with the engine, and a second solenoid within an explosion proof structure delivers a cranking current signal to the starter motor windings, with a non-incendive circuit isolating any spark or ignition source.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single integrated starter solenoid system is used, then the device complexity is reduced, but the safety reliability deteriorates due to potential spark ignition in hazardous environments
Solution Approach 1:
The starter system is divided into two separate solenoids: a first solenoid for mechanical engagement and a second solenoid for electrical connection. This segmentation isolates the high-current electrical contacts from the mechanical drive mechanism, preventing sparks from igniting hazardous substances while maintaining functional effectiveness.
Solution Approach 2:
The second solenoid (electrical connection component) is extracted and positioned within an explosion-proof housing that is physically isolated from the first solenoid and starter motor. This extraction removes the ignition hazard source from the hazardous environment, allowing the system to operate safely in explosive atmospheres.
2Volume of moving object
If the starter solenoid is positioned close to the starter motor for compact design, then the volume is reduced, but the safety distance for spark isolation is insufficient
Solution Approach 1:
The second solenoid is nested within an explosion-proof housing that contains and isolates any potential sparks. This nested structure allows close positioning of components for compact overall volume while maintaining safety isolation through the protective housing barrier.
Solution Approach 2:
The explosion-proof housing acts as a sacrificial protective barrier that can contain minor spark events without compromising the overall system. This allows compact design while maintaining safety, as the housing provides a contained environment for any potential ignition events.
3Reliability
If multiple separate solenoids are used with explosion proof housing, then the explosion safety is improved, but the device complexity increases
Solution Approach 1:
The first solenoid performs multiple functions: mechanical engagement of the starter motor and activation of the second solenoid through its contact element. This multi-functionality reduces the need for additional separate control components, simplifying the overall system despite the presence of multiple solenoids.
Solution Approach 2:
The contact element of the first solenoid acts as an intermediary that mechanically triggers the second solenoid. This intermediary mechanism provides a reliable connection between the two solenoids without requiring complex electrical wiring or additional control circuits, simplifying the system architecture.
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 reduces the risk of explosions by physically isolating the solenoids and circuits, preventing spark events that could ignite flammable substances, ensuring safe engine starting in hazardous environments.
Implementation Method 1
a starting current signal may be delivered from a battery to a starter-mounted solenoid to linearly move a drive shaft, of the starter motor, to engage a pinion gear with a flywheel of an engine
Implementation Method 2
The starting current signal delivered to the starter-mounted solenoid may cause a contact disk, mounted to a plunger of the starter-mounted solenoid, to move in a linear direction to ground an isolated, low current non-incendive control circuit
Implementation Method 3
a contact disk (of the starter motor energization solenoid) moves in a linear direction to conduct a cranking current signal directly to the windings of the starter motor to drive the starter motor to start the engine
Data Source
AI summary
Various implementations disclosed herein include devices, systems, and methods for implementing a starter system that utilizes multiple starter solenoids physically isolated from each other. For example, the system may include a first solenoid mechanically connected to a starter motor. The first solenoid may be configured to receive a first starting current signal and mechanically couple the starter motor with an engine. The system may further include a second solenoid mounted within an explosion proof structure physically isolating the second solenoid from the first solenoid and the starter motor. The system may further include a non-incendive circuit mounted within the explosion proof structure. The non-incendive circuit may be configured to indicate that the starter motor is coupled with the engine and signal the second solenoid for activation to supply a cranking current signal to windings of the starter motor for operation.