The present disclosure relates to a starter assembly for an internal combustion engine. In particular, to a starter assembly with a starter having a reversible motor and an axially fixed pinion gear.
Known starter motors include a retractable pinion gear disengageable from a flywheel of a combustion engine after a starting sequence. The engagement and disengagement of the pinion gear can cause damage to respective gear teeth on the pinion gear and flywheel and also places a high current load on the starter motor, which can lead to premature failure of the rotor and brushes. Further, the pinion gear and the ring gear may clash if the ring gear is rotating when the pinion gear is engaged with the ring gear.
It is known to use a wrap spring clutch to rotate a torque converter shell with a starter motor to start an internal combustion engine. The clutch is wrap, or wound, about the shell and then rotated in a first circumferential direction. However, at times the clutch does not properly unwind in a second, opposite, circumferential direction to terminate the starting process.
According to aspects illustrated herein, there is provided a starter assembly for a motor vehicle, including a starter and a starting device. The starter includes: a housing; an electric motor located within the housing and including a motor shaft; an axis of rotation for the motor shaft; an output shaft non-rotatably connected to the motor shaft; and a one-way clutch including a first race including a pinion gear, the pinion gear fixed with respect to axial movement, parallel to the axis of rotation, with respect to the housing and a second race non-rotatably connected to the output shaft.
The starting device includes a wrap spring clutch with a first end and a second end. The first race and the pinion are non-rotatably connected. For a start mode: the electric motor is arranged to rotate the motor shaft and the pinion gear in a first circumferential direction; the pinion gear is arranged to rotate the second end, with respect to the first end, in the first circumferential direction; and, the wrap spring clutch is arranged to rotate a torque converter shell in the first circumferential direction. For a first phase of a release mode: the electric motor is arranged to rotate the second race in a second circumferential direction, opposite the first circumferential direction; and the first race rotates in the second circumferential direction.
According to aspects illustrated herein, there is provided a starter assembly for a motor vehicle, including a starter and a starting device. The starter includes: a housing; an electric motor located within the housing and including a motor shaft; an axis of rotation for the motor shaft; an output shaft non-rotatably connected to the motor shaft; and a one-way clutch including a first race including a pinion gear, the pinion gear fixed with respect to axial movement, parallel to the axis of rotation, with respect to the housing, a second race non-rotatably connected to the output shaft and a resilient element frictionally engaged with the first and second races. The starting device includes a wrap spring clutch with a first end and a second end. The first race and the pinion are non-rotatably connected. For a start mode: the electric motor is arranged to rotate the motor shaft and the pinion gear in a first circumferential direction; the pinion gear is arranged to rotate the second end, with respect to the first end, in the first circumferential direction; and the wrap spring clutch is arranged to rotate a torque converter shell in the first circumferential direction. For a first phase of a release mode: the electric motor is arranged to rotate the second race in a second circumferential direction, opposite the first circumferential direction; and the resilient element, the first race and the second race are arranged to rotate in the first circumferential direction.
According to aspects illustrated herein, there is provided a starter assembly for a motor vehicle, including a starter and a starting device. The starter includes: a housing; an electric motor located within the housing and including a motor shaft; an axis of rotation for the motor shaft; an output shaft non-rotatably connected to the motor shaft; and a one-way clutch including a first race including a pinion gear, the pinion gear fixed with respect to axial movement, parallel to the axis of rotation, with respect to the housing and a second race non-rotatably connected to the output shaft. The starting device includes: a wrap spring clutch with a first end, a center portion connected to the first end and a second end connected to the center portion; a ring gear drivingly engaged with the pinion gear; and a ring support plate drivingly engaged with the ring gear and the second end. The first race and the pinion are non-rotatably connected. For a start mode: the electric motor is arranged to rotate the pinion, the ring gear, the ring support gear in a first circumferential direction and rotate the second end, with respect to the first end, in the first circumferential direction; and the center portion is arranged to engage and rotate a torque converter shell in the first circumferential direction. To transition from the start mode to a first phase of a release mode, the electric motor is arranged to rotate: the pinion gear, the ring gear and the ring support plate in a second circumferential direction, opposite the first circumferential direction; and the second end, with respect to the first end, in the second circumferential direction.
Various embodiments are disclosed, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, in which:
At the outset, it should be appreciated that like drawing numbers on different drawing views identify identical, or functionally similar, structural elements of the disclosure. It is to be understood that the disclosure as claimed is not limited to the disclosed aspects.
Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present disclosure.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure.
By “non-rotatably connected” first and second components we mean that the first component is connected to the second component so that any time the first component rotates, the second component rotates with the first component, and any time the second component rotates, the first component rotates with the second component. Axial displacement between the first and second components is possible. It is not necessary for the first and second components to rotate at the same rate.
To clarify the spatial terminology, objects 12, 13, and 14 are used. As an example, an axial surface, such as surface 15A of object 12, is formed by a plane co-planar with axis 11. However, any planar surface parallel to axis 11 is an axial surface. For example, surface 15B, parallel to axis 11 also is an axial surface. An axial edge is formed by an edge, such as edge 15C, parallel to axis 11. A radial surface, such as surface 16A of object 13, is formed by a plane orthogonal to axis 11 and co-planar with a radius, for example, radius 17A. A radial edge is co-linear with a radius of axis 11. For example, edge 16B is co-linear with radius 17B. Surface 18 of object 14 forms a circumferential, or cylindrical, surface. For example, circumference 19, defined by radius 20, passes through surface 18.
Axial movement is in direction axial direction AD1 or AD2. Radial movement is in radial direction RD1 or RD2. Circumferential, or rotational, movement is in circumferential direction CD1 or CD2. The adverbs “axially,” “radially,” and “circumferentially” refer to movement or orientation parallel to axis 11, orthogonal to axis 11, and about axis 11, respectively. For example, an axially disposed surface or edge extends in direction AD1, a radially disposed surface or edge extends in direction RD1, and a circumferentially disposed surface or edge extends in direction CD1.
In an example embodiment, starter 100 includes: sun gear 122A fixed to shaft 120, planetary carrier 110B formed by output shaft 110, planet gears 122B which rotate on shafts extending from planet carrier 110B, and ring gear 122C non-rotatably connected, or grounded, to housing 102. Planet gears 122B are meshed with the sun gear and ring gear 122C. By two or more components “non-rotatably connected” we mean that whenever any one of the components rotates, the other components rotate as well. That is, the components are fixed to each other with respect to rotation.
One-way clutch 132 includes resilient element 130 directly engaged with races 133A and 133B. Element 130 can be in direct contact with races 133A and 133B or can be in direct contact with respective components non-rotatably connected to races 133A and 133B. Resilient element 130 reacts against race 133B to apply a frictional force to race 133A, or resilient element 130 reacts against race 133A to apply a frictional force to race 133B.
In an example embodiment, element 130 is a diaphragm spring with an inner circumference engaged with race 133B and an outer circumference engaged with race 133A. In an example embodiment, element 130 is in contact with a component non-rotatably connected to race 133A and/or with a component non-rotatably connected to race 133B. In an example embodiment (not shown), element 130 includes: an inner circumference engaged with race 133A; and an outer circumference engaged with race 133B.
In an example embodiment, at least a portion of race 133A is located outward of race 133B in direction RD orthogonal to axis of rotation AR. In an example embodiment, one-way clutch 132 is a trapped roller clutch including cylindrical rolling elements 137 radially disposed between races 133A and 133B.
Spring support ring 330 encircles clutch 332, and is frictionally engaged with friction end 334 of the clutch at circumferential groove 335. Clutch 332 also includes center portion 336 connected to end 334 and arranged for compressive engagement with shell TCS, and driven end 338 connected to center portion 336 and arranged for rotational displacement in circumferential direction CD1 relative to end 334 to compressively engage the clutch center portion 336 with shell TCS. That is, end 334 has an increased pitch and is radially compressed when it is inserted into groove 335, such that rotation of end 334 is prevented until the frictional force between end 334 and ring 330 is overcome. Otherwise stated, friction between end 334 and ring 330 resists displacement of end 334 relative to ring 330 so that end 338 may rotate relative to end 334.
Because ends 334 and 338, and portion 336 are connected, and, in some embodiments, are continuous, rotation of end 338 relative to end 334 decreases diameter 342 of center portion 336 to compressively engage shell TCS. Otherwise stated, diameter 342 of the center portion of clutch 332 decreases when end 338 is rotationally displaced relative to end 334 in direction CD1 and clutch 332 becomes drivingly engaged with shell TCS. In the embodiment shown in
Starting device 300 also includes gear support plate 346. Plate 344 is fixed to support ring 330 at rivets 347 and fixed between the engine and bellhousing BH. Plate 344 may be fixed by bolts (not shown) connecting the engine and transmission or clamped between the engine and transmission when the connecting bolts are installed. Plate 344 provides centering of assembly 300 and prevents rotation of support ring 330 relative to bellhousing BH. Gear support plate 346 is drivingly engaged with clutch end 338 and rotatably connected to centering plate 344 at spacer rivets 348. By rotatably connected, we mean that plate 346 can rotate relative to plate 344, but may be restricted from motion in other directions. Rivets 348 include axially positioning rings, pulleys or wheels, 349 for locating plate 346 with low friction. That is, rivets 348 and rings 349 permit free rotation of plate 346 relative to centering plate 344. Ring gear 350 is fixed to gear support plate 346.
Ring gear 350 is drivingly engaged with pinion gear 121 such that electric motor 111 rotates gear 350 to engage clutch 332 with shell TCS to rotate a vehicle engine as described in more detail below. Gear 350 is in constant mesh with pinion gear 121. Reverse rotation of clutch 332 radially expands portion 336 against ring 330, preventing the spring from vibrating or coming out of location when the system is not in use. Ring 330 provides a continuous surface to unwind the wrap spring against.
For a start mode for assembly 200 (used to start an internal combustion engine): electric motor 111 is arranged to rotate motor shaft 120 and pinion gear 121 in circumferential direction CD1; pinion gear 121 is arranged to rotate end 138, with respect to end 134, in circumferential direction CD1; and clutch 132 is arranged to rotate torque converter shell TCS in circumferential direction CD1. For the start mode, race 133B is non-rotatably connected to race 133A.
For a first phase of a release mode for assembly 200: electric motor 111 is arranged to rotate race 133A in circumferential direction CD2, opposite circumferential direction CD1; and race 133B rotates with race 133A in circumferential direction CD2. For the first phase of the release mode, pinion gear 121 is arranged to rotate end 138, with respect to end 134, in circumferential direction CD2.
For a second phase of the release mode: electric motor 111 is arranged to rotate race 133A in circumferential direction CD2; clutch 132 is arranged to block rotation of pinion gear 121 in circumferential direction CD2; and race 133A is arranged to rotate, with respect to race 133B, in circumferential direction CD2. For example, end 138 is arranged to block rotation of pinion gear 121 in circumferential direction CD2. For example, clutch 332 is unwound and in contact with support ring 330 so that further rotation of end 338 in direction CD2 is blocked.
For the first phase of the release mode, electric motor 111 is arranged to rotate resilient element 130, race 133B and race 133A in circumferential direction CD2. For the second phase of the release mode, electric motor 111 is arranged to rotate race 133A in the circumferential direction CD2. For the second phase of the release mode: race 133A is arranged to rotate, in circumferential direction CD2, with respect to resilient element 130 and race 133B; or race 133A and resilient element 130 are arranged to rotate, in circumferential direction CD2, with respect to race 133B.
The frictional connections between resilient element 130, race 133A and race 133B can be non-rotatable connections or there can be slip between resilient element 130 and one or both of races 133A and 133B. For example: motor 111 rotates race 133A, in direction CD2, at a first speed and race 133B rotates at the first speed as well (non-rotatable connection of element 130 with races 133A and 133B); or, motor 111 rotates race 133A, in direction CD2, at a first speed and the slip/respective frictional connections result in element 130 rotating race 133B, but at a lower speed than the first speed (slip between resilient element 130 and one or both of races 133A and 133B). The slip can be between element 130 and one or both of races 133A and 133B. For example: resilient element 130 can be non-rotatably connected to race 133A and slip with respect to race 133B; resilient element 130 can be non-rotatably connected to race 133B and slip with respect to race 133A; or resilient element 130 can slip with respect to both races 133A and 133B.
In an example embodiment, element 130 is a diaphragm spring with an inner circumference engaged with race 133B and an outer circumference engaged with race 133A. In an example embodiment, element 130 is in contact with a component non-rotatably connected to race 133A and/or with a component non-rotatably connected to race 133B. In an example embodiment (not shown), element 130 includes: an inner circumference engaged with race 133A; and an outer circumference engaged with race 133B.
For the second phase, pinion gear 121 is arranged to resist, with a second force, greater than the first force, rotation in circumferential direction CD2 (for example due to the rotational fixing of end 338) and race 133A and motor shaft 120 are arranged to rotate in circumferential direction CD2 with respect to race 133B and gear 121. That is, torque from rotation of race 133A in circumferential direction CD2 is greater than the frictional force.
For the start mode: pinion gear 121 is arranged to rotate ring gear 350, ring support plate 346 and end 338 in circumferential direction CD1; and center portion 336 is arranged to rotate torque converter shell TSC in circumferential direction CD1. To transition from the start mode to the first phase of the release mode, electric motor 111 is arranged to rotate pinion gear 121, ring gear 350, ring support plate 346 and end 338 in circumferential direction CD2.
In an example embodiment, for the start mode, control circuit 150 is configured to close switch 152 to: initiate a first time interval by triggering timer 153; and supply power to solenoid 158 to rotate motor shaft 120 in direction CD1. In an example embodiment, for the release mode, control circuit 150 is configured to close switches 154 and 156, upon expiration of the first time interval to. Switch 154 supplies power to solenoid 159 to rotate motor shaft 120 in circumferential direction CD2. Switch 156 initiates a second time interval by triggering timer 155. Upon expiration of the second time interval: circuit 150 is arranged to open switch 154 to turn off power to electric motor 111 and open switch 156.
Advantageously, assembly 200 and starter 100 eliminate the problem noted above with respect to an axially displaceable pinion for a starter engaging with and disengaging from a ring gear. Specifically, output shaft 310 remains engaged with a ring gear at all times, not just during a starting sequence.
Advantageously, assembly 200 and starter 100 eliminate the problem noted above with respect to a wrap spring clutch not properly unwinding to terminate a starting mode. Specifically, once the start mode is complete and clutch 332 is fully wound in direction CD1, motor 111 rotates, during the first phase of the release mode, pinion gear 121 and ring gear 350 in direction CD2 to displace end 338 in direction CD2 and initiate the unwinding of clutch 332. Without resilient element 130, race 133B would free wheel with respect to race 133A for rotation of motor 111 in direction CD2. However, as noted above, a friction force between element 130 and races 133A and 133B keeps races 133A and 133B rotating in direction CD1. Pinion gear 121 continues to rotate ring gear 350 and end 338 to ensure a smooth and continuous unwinding of clutch 332.
When clutch 332 is fully unwound in the second phase of the release mode, further rotation of end 338 in direction CD2 is blocked. Thus, rotation of ring 350 and pinion gear 121 in direction CD2 also is blocked. However, damage to motor 111 caused by attempting to rotate shaft 120 in direction CD2 when rotation of races 133A and 133B in direction CD2 is blocked, is prevented. Specifically, the torque from motor 111 overcoming the friction force connecting races 133A and 133B, enabling clutch 132 to free-wheel. The magnitude of the friction force can be selected to enable successful completion of the first phase of the release mode, while minimizing the torque needed to initiate the second phase of the release mode.
It should be understood that directions CD1 and CD2 can be reversed from the orientation shown in the figures.
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
This is a continuation-in-part patent application under 35 U.S.C. 120 of U.S. patent application Ser. No. 14/717,682, filed May 20, 2015, which application is incorporated herein by reference in its entirety.
Number | Date | Country | |
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Parent | 14717682 | May 2015 | US |
Child | 15606946 | US |