Starter Voltage Step-Up Device with Flattened Conductors
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Solution Overview
Problem
Reinforced starters for motor vehicles face challenges in maintaining battery voltage during high current surges, leading to excessive voltage drops and increased wear due to additional mechanical parts, which are costly and reduce the starter's durability, especially in stop/start systems requiring high cycle reliability.
Innovation Solution
A compact starter battery voltage step-up device with a magnetic casing, featuring a primary and secondary winding circuit formed from flattened conductors, reducing length, weight, and volume, and incorporating a direct return and polarisation winding to maintain performance and extend durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If reinforced starters with higher power are used to achieve rapid starting, then starting speed is improved, but initial current surge increases causing excessive battery voltage drop
Solution Approach 1:
The patent applies preliminary action by inserting additional resistance into the starter circuit before the high current surge occurs. The control unit activates the supplementary relay to connect the resistance in advance, during the initial switching phase, to limit the current surge and prevent excessive battery voltage drop before the starter motor reaches its operating speed.
2Quantity of substance
If additional resistance and control relay are inserted to limit current surge, then battery voltage is maintained, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements multi-functionality by integrating the voltage protection function directly into the existing starter control unit. The control unit performs both the normal starter control function and the additional function of monitoring battery voltage and activating the supplementary relay when voltage drop is detected, eliminating the need for separate dedicated voltage protection hardware.
3Quantity of substance
If supplementary control relay and timing components are added to control current limitation, then voltage regulation is improved, but starter durability decreases due to mechanical wear
Solution Approach 1:
The patent replaces mechanical control components with electronic control. The control unit uses electronic sensing to detect battery voltage levels and electronically activates the supplementary relay, replacing the need for mechanical timing devices and reducing mechanical wear. The system transitions from mechanical timing-based control to electronic voltage-based control.
4Quantity of substance
If current limitation resistance is inserted in series during initial phase, then initial current surge is limited, but power delivery to starter motor is reduced
Solution Approach 1:
The patent applies dynamics by making the resistance insertion temporary and conditional. The supplementary relay is activated only during the initial switching phase when voltage drop is detected, and is automatically deactivated once the starter motor reaches sufficient speed and voltage stabilizes. This dynamic approach ensures resistance is present only when needed for voltage protection, not continuously to limit power.
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 attenuates initial current surges, maintains battery voltage, and enhances the starter's durability by reducing clearance and weight, while meeting stringent performance and cycle requirements of stop/start systems.
Implementation Method 1
a filtering device of an inductive type inserted in the power circuit of the starter... a primary winding circuit (W1) which is designed to be inserted in series in the said power circuit, and a secondary, short-circuited winding circuit (W2)
Data Source
AI summary
A starter battery voltage step-up device (LPF) intended to prevent a drop in the battery voltage (Vbat) produced by a current surge in a power circuit of the starter when the starter is powered on. The device comprises a casing of magnetic material (C, YO, CM, CM′), a primary winding circuit (W1) intended to be inserted in series in the power circuit, and a short-circuited secondary winding circuit (W2), in which the primary winding circuit (W1) and/or the secondary winding circuit (W2) comprises a winding formed by at least one flat conductor (3) wound on edge. The invention also relates to the corresponding combination (1) of a starter and a voltage step-up device.