Starter System Solenoid Winding Configuration for Torque Control
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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 moveably coupled to a pinion, controlled by an electronic control unit, with solenoid windings and power isolation switches to manage current flow efficiently, enabling precise control of the pinion's engagement with the ring gear for synchronized starting and reduced wear.
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 changeable during operation. The system transitions from a first solenoid winding configuration during engagement to a second solenoid winding configuration during motor operation, allowing the starter to adapt its magnetic field strength dynamically to match varying torque demands across different operating conditions.
Solution Approach 2:
The patent changes the electrical parameters of the solenoid assembly by switching between different winding configurations. This parameter change allows the system to adjust the magnetic field characteristics, enabling the same hardware to deliver different torque outputs at different speeds without requiring multiple physical components.
2Device complexity
If the starter uses traditional solenoid assembly configurations, then结构简单性 is maintained, but engagement precision and synchronized starting capability deteriorate
Solution Approach 1:
The patent segments the solenoid winding function into two distinct configurations: engagement windings for precise pinion engagement and drive windings for motor operation. This segmentation allows each winding set to be optimized for its specific function, improving engagement precision while maintaining overall structural simplicity through the use of a single solenoid assembly.
3Device complexity
If the starter operates without optimized current flow management, then device complexity is reduced, but energy consumption increases
Solution Approach 1:
The patent implements periodic action through the sequential activation of different solenoid winding configurations. The system first activates engagement windings to achieve precise pinion engagement, then switches to drive windings for motor operation. This periodic switching optimizes energy consumption by applying magnetic force only when and where needed, rather than maintaining continuous high-energy fields.
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 efficient operation across varying torque demands, enhances starter engagement with the drivetrain, and reduces energy consumption by optimizing current flow and synchronization of pinion and ring gear speeds, thereby improving reliability and reducing wear.
Implementation Method 1
a plurality of solenoid assemblies, and a plunger moveably 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... capable of being controlled by an electronic control unit
Data Source
AI summary
Some embodiments include a starter system with an electronic control unit controllable starter that includes a motor coupled to a circuit, and a plunger moveably coupled to a pinion. The system can include a first switch coupled to the circuit that includes two contacts, and a solenoid assembly that includes a first and second solenoid winding that can reversibly move the plunger to couple and decouple from the two contacts. A secondary solenoid assembly includes a third solenoid winding that can electrically couple with secondary solenoid assembly contacts, and two power isolation switches including a second switch and a third switch. The third switch can enable current to flow through the third solenoid winding and in the second solenoid winding after movement of the plunger has coupled the two contacts of the first switch, and the second switch is can enable current to flow to the first solenoid winding.