Integrated Starter Switching Apparatus Current Suppression
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Solution Overview
Problem
Conventional starter systems for engines face issues with high inrush currents during motor startup, leading to terminal voltage drops and equipment failures, and require additional space and wiring for separate electromagnetic switches and relays, increasing manufacturing costs and complexity.
Innovation Solution
A compact switching apparatus that integrates pinion-pushing, main-contact-switching, resistor, and energizing-path-switching functions within a single housing, using a resistor to suppress startup currents and switch between higher and lower resistance paths to manage motor energization, thereby reducing inrush currents and simplifying installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resistor is added to suppress startup current, then inrush current is reduced and terminal voltage stability is improved, but device complexity and installation space increase
Solution Approach 1:
The patent combines the resistor and electromagnetic relay into a single integrated housing that also contains the electromagnetic switch. This merging of components reduces the overall number of separate parts, simplifies installation, and eliminates the need for additional wiring while still providing the current suppression function through the resistor.
Solution Approach 2:
The housing serves multiple functions: it protects the electromagnetic switch, accommodates the resistor for current suppression, and houses the electromagnetic relay. This multi-functional design reduces device complexity by eliminating the need for separate enclosures and mounting structures for each component.
2Ease of operation
If a separate electromagnetic relay is added to switch energizing paths, then startup current control is improved, but the number of cables and wiring complexity increase
Solution Approach 1:
The electromagnetic relay is integrated into the same housing as the electromagnetic switch and resistor, with all internal connections made through terminals within the housing. This eliminates the need for external cables to connect separate relay and switch assemblies, reducing wiring complexity while maintaining the ability to control startup current through the relay's switching action.
3Device complexity
If resistor and electromagnetic relay are integrated in single housing, then installation space and wiring are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The integrated housing is designed with distinct compartments and mounting areas for the electromagnetic switch, resistor, and electromagnetic relay. This segmentation allows each component to be positioned and secured in its designated location, facilitating assembly while maintaining the benefits of integration. The housing structure itself provides precise positioning features that reduce the need for high-precision manufacturing of individual components.
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 solution effectively reduces motor startup currents, prevents terminal voltage drops, enhances installation efficiency by reducing the number of cables and components, and increases motor rotation speed, while maintaining durability and reliability.
Implementation Method 1
a resistor (4) adapted to suppress a startup current to be applied from a battery (3) to a motor (2) when the motor (2) is started
Implementation Method 2
an electromagnetic relay (5) adapted to switch between an energizing path (higher-resistance energizing path) through the resistor (4) and an energizing path (lower-resistance energizing path) that bypasses the resistor (4)
Implementation Method 3
an electromagnetic switch (6) adapted to open and close a main contact for a motor circuit for supplying electrical power from a battery (3) to a motor (2)
Data Source
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AI summary
There is disclosed a switching apparatus for a starter (1) comprising a resistor (4) for suppressing a startup current of a motor (2) when an engine is started, an electromagnetic relay (5) for bypassing the resistor to energize the motor after the motor is started, a function for pushing a pinion of the starter toward a ring gear, an electromagnetic switch (6) for opening and closing a main contact of the motor circuit. The resistor (4), the electromagnetic relay (5), and the electromagnetic switch (6) are integrally accommodated inside a housing formed of a metallic bottomed frame (8) and a contact cover (9), and are connected to the motor circuit via two external connection terminals (11, 12) fixed to the contact cover (9). The apparatus can facilitate connectivity to the vehicle side by reducing the number of cables and can enhance an installation property.