Patent Grant
7520190
The present application claims the benefits of Japanese Patent Application No. 2004-364878 filed on Dec. 16, 2004, the disclosure of which is incorporated herein by reference.
1. Technical Field of the Invention
The present invention relates generally to a starter which may be employed in starting an automotive engine, and more particularly to an improved structure of such a starter equipped with a planetary gear speed reducer working to reduce the speed of rotation of an electric motor and transmit it to an output shaft for cranking the engine.
2. Background Art
Japanese Patent First Publication No. 58-214668 discloses a typical engine starter equipped with a planetary gear train working as a speed reducer. The starter also includes a one-way clutch which has an outer in which support pins (also called planet gear pins) are installed to support planet gears of the planetary gear train rotatably and to which orbital motion of the planet gears is transmitted directly to transfer torque to an output shaft of the starter. The torque of the output shaft is transmitted to a pinion gear fitted on the output shaft slidably through a shift lever. The pinion gear is selectively brought into engagement with a ring gear to crank the engine. The starter further includes a partition plate and a thrust washer. The partition plate is disposed between the motor and the planetary gear train within a starter casing and extends in a radial direction of the starter casing. The thrust washer is of a typical flat shape and disposed between the planetary gear train and the partition plate.
After start-up of the engine, the pinion gear is returned backward through the shift lever along the output shaft and hits a wall provided on the output shaft. The impact arising from the hit is transmitted to the output shaft as a thrust load. The thrust load then acts on the planetary gear train through the one-way clutch (especially, a carrier of the clutch) and urges the planetary gear train (especially, the support pins and the planet gears) against the partition plate, which may result in wear of the partition plate. In order to avoid such wear, the thrust washer works to block direct transmission of the thrust load to the partition plate.
The thrust washer, however, undergoes rotational attraction arising from the rotation of the planet gears, thus resulting in mechanical noises. In order to eliminate such noises, a washer lock mechanism may be used, but it leads to a complicated structure of the starter. Engine vibrations usually cause an internal gear of the planetary gear train to vibrate in the axial direction of the starter. In order to absorb such vibrations of the internal gear, a wave washer or a rubber gasket may additionally be used between the internal gear and the partition plate, but it will result in an increase in total manufacturing cost of the starter.
It is therefore a principal object of the invention to avoid the disadvantages of the prior art.
It is another object of the invention to provide an improved simple structure of a starter designed to bear a thrust load transmitted from a planetary gear train to a partition plate and to ensure the stability of location of an internal gear of the planetary gear train.
According to one aspect of the invention, there is provided a starter which may be employed in starting an automotive engine. The starter comprises: (a) a casing having; (b) an electric motor disposed within a motor chamber defined in the casing, the motor having an output shaft projecting from an front end thereof; (c) a one-way clutch disposed frontward of the motor within the casing; (d) a planetary gear train disposed between the motor and the one-way clutch within the casing, the planetary gear train working as a speed reducer to reduce a speed of rotation of the output shaft of the motor to transmit torque of the output shaft to the one-way clutch; (e) a starter output shaft retained in the casing rotatably for outputting the torque of the output shaft of the motor, as transmitted through the one-way clutch; (f) a partition plate extending so as to traverse an axial direction of the starter between the motor and the planetary gear train within the casing to isolate the planetary gear train from the motor chamber; and (g) a thrust washer extending so as to traverse the axial direction of the starter between the partition plate and the planetary gear train in abutment with a front end surface of the partition plate so as to receive a thrust load, as transmitted from the planetary gear train. The thrust washer includes an outer peripheral portion. The peripheral portion is placed between a rear end surface of an internal gear of the planetary gear train and the front end surface of the partition plate and has an elastic mechanism working to elastically urge the internal gear of the planetary gear train frontward in the axial direction of the starter.
The thrust load is usually transmitted from the starter output shaft to the planetary gear train. The thrust washer works to bear such a thrust load, thereby minimizing wear of the partition plate and ensuring the stability of braking of the starter output shaft.
The thrust washer, as described above, extends so as to traverse the axial direction of the starter. The elastic mechanism works to urge the internal gear frontward, thereby ensuring the stability of location of the internal gear and minimizing the play thereof. The thrust washer may be implemented by a disc spring or alternatively of a shape, as illustrated in
In the preferred mode of the invention, the elastic mechanism of the thrust washer is implemented by a cut-out portion which is formed by cutting out a thickness of the outer peripheral portion and bent in a thickness-wise direction of the thrust washer. This results in a decrease in manufacturing cost of the starter.
The outer peripheral portion of the thrust washer has a rotation stopper which protrudes outwardly in a radius direction of the thrust washer and engages an inner peripheral wall of the casing. This holds the thrust washer from rotating, thus minimizing wear of the partition plate.
The rotation stopper of the thrust washer may be so formed as to extend from an end of the cut-out portion. This ensures the holding of the thrust washer without sacrificing the stability in urging the internal gear.
The internal gear has a rotation stopper protruding from an outer periphery thereof. The thrust washer having a rotation stopper protruding from the cut-out portion. The casing has formed therein a groove in which the rotation stoppers of the internal gear and the thrust washer are fitted.
The casing has formed therein a groove in which the rotation stopper of the thrust washer is fitted and urged under pressure by the partition plate in the axial direction of the starter.
The elastic mechanism of the thrust washer may alternatively be implemented by cut-out portions which are formed in the outer peripheral portion and bent in a thickness-wise direction of the thrust washer. The cut-out portions extend in a circumferential direction of the thrust washer and have inside edges extending along an imaginary circle having a diameter greater than or equal to a root diameter of the internal gear of the planetary gear train. This permits an area of the thrust washer other than the cut-out portions to be made flat, thus assuring the ability of bearing the thrust load as exerted from the rear end surface of the planetary gear train.
The thrust washer may include a center portion extending inwardly of the outer peripheral portion and necks extending at inside ends thereof outwardly from an outer periphery of the center portion. The cut-out portions may be made of tabs extending from outside ends of the necks in the circumferential direction of the thrust washer. This permits the cut-out portions to produce elastic pressure which act on a radial width of the internal gear effectively.
A gap is provided between the rear end surface of the internal gear of the planetary gear train and the front end surface of the partition plate. The gap is greater than a thickness of the cut-out portion which is identical with a thickness of the thrust washer, thereby enabling the cut-out portion(s) to be deformed elastically to provide a spring pressure to the internal gear.
The present invention will be understood more fully from the detailed description given hereinbelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments but are for the purpose of explanation and understanding only.
In the drawings:
Referring to the drawings, wherein like reference numbers refer to like parts in several views, particularly to
The starter 1 consists essentially of a housing 10, an electric motor 2, an output shaft 3, a pinion gear 4, a magnet switch 5, a planetary gear train 6, a one-way clutch (also called an overrunning clutch) 7, a shift lever 8, and a circular partition plate 13. The pinion gear 4 is movable into engagement with a ring gear 9 connected to an engine (not shown). The partition plate 13 is made up of a hollow cylinder and a flange extending from an end of the cylinder.
The housing 10 serves as a starter casing and is made up of a cup-shaped front frame 11 having an open rear end, a center case 12, a hollow cylindrical yoke 14 with open ends, and a cup-shaped end frame 15 with an open rear end. These components are joined in alignment to define a length of the starter 1. The center case 12 has defined in an upper portion thereof a switch chamber with an open rear end within which the magnet switch 5 is disposed and in a lower portion thereof a torque transmission mechanism chamber 150 with an open rear end within which the planetary gear train 6 and the one-way clutch 7 are disposed. The yoke 14 and the end frame 15 have defined therein a motor chamber within which the motor 2 is disposed.
The front frame 11 and the end frame 15 are joined together by through-bolts 16 to retain the center case 12 and the yoke 14 therebetween in alignment. This holds the partition plate 13 between the center case 12 and the yoke 14 to block between the torque transmission mechanism chamber of the center case 12 and the motor chamber of the yoke 14.
Within the front frame 11, the shift lever 8 is disposed. Within the torque transmission mechanism chamber 150 of the center case 12, the planetary gear train 6 and the one-way clutch 7 are disposed. Within the switch chamber of the center case 12, the magnet switch 5 is disposed. Within the motor chamber defined by an assembly of the yoke 14 and the end frame 15, the motor 2 is disposed.
The motor 2 is a dc motor which includes an output shaft 20. The output shaft 20 is retained rotatably by the partition plate 13 and the end frame 15 through a bearing. The yoke 14 has a field winding 21 and an armature 22 disposed therein. The end frame 15 has a commutator 23 and brushes 24 disposed therein. The yoke 14 is made of a stationary iron member serving to form a part of a magnetic circuit of the motor 2. The armature 22 and the commutator 23 are fixed on the output shaft 20 of the motor 2. The output shaft 20 has an end or head extending through the partition plate 13 into the torque transmission mechanism chamber of the center case 12. The motor 2 is of the structure known in itself and explanation thereof in detail will be omitted here.
The planetary gear train 6 is disposed in the lower portion of the center case 12 in contact with the partition plate 13. The planetary gear train 6 serves as a speed reducer and is made up of a sun gear 61, a ring-shaped internal gear 62, planet gears 63, and a carrier 65. The sun gear 61 is formed on the end of the output shaft 20 of the motor 2. The internal gear 62 is retained fixedly by the center case 12. The planet gears 63 are placed in mesh with the gears 61 and 62. The carrier 65 bears the planet gears 63 through bearings fitted on support pins (also called planet gear pins) 64 installed in the planet gears 64. The planetary gear train 6 works to reduce a rotational speed of the output shaft 20 of the motor 2 to an orbital speed of the planet gears 63. Each of the planet gears 63 is retained rotataby by one of the support pins 64. The support pins 64 are press fit in the carrier 65. The carrier 65 also servers as a clutch outer 71, as will be described later in detail. The internal gear 62 has, as clearly illustrated in
The one-way clutch 7 is, as clearly shown in
The output shaft 3 is disposed at a rear end thereof within the tube 72 in alignment with the output shaft 20 of the motor 2. The output shaft 3 is retained by the bearing 72a of the tube 72 to be movable in an axial direction of the starter 1. The output shaft 3 has formed on a rear end portion thereof an external helical spline 3a meshing with the internal helical spline 72c formed on an inner wall of the tube 72. The helical spline 72c extends from a rear end surface of the tube 72 to the bearing 72a. Specifically, the bearing 72a has no helical spline formed on an inner wall thereof, so that the front end of the helical spline 72c servers as a stopper to stop further travel of the output shaft 3 when moved toward the engine (i.e., the left in the drawing), and the external helical spline 3a hits the rear end of the bearing 72a. Another type of stopper may alternatively be provided at another location. The output shaft 3 is retained at the front end thereof rotatably and movably by the front frame 11 through a bearing.
The pinion gear 4 is jointed to the head of the output shaft 3 (i.e., a portion of the output shaft 3 projecting from the front frame 11) in a spline fashion to be rotatable in unison with the output shaft 3 and movable relative to the output shaft 3. The pinion gear 4 is also urged frontward (i.e., the left in
The center case 12 isolates the magnet switch 5 physically from the one-way clutch 7 and the planetary gear train 6. The magnet switch 5 includes a coil 34 which is excited upon closing of a starter switch (not shown) of the vehicle, a plunger 50 slidable within the coil 34, and a return spring 51. The head of the plunger 50 projects into the front frame 11. When the coil 34 is energized by the starter switch, it will cause the plunger 50 to be attracted frontward (i.e., the rightward, as viewed in
The shift lever 8 is supported by a lever holder 80 to be swingable. The lever holder 80 is secured to the center case 12. The shift lever 8 has an upper portion, as viewed in
In
In operation of the starter 1, when the starter switch is closed to energize the coil 34 of the magnet switch 5, it will cause the plunger 50 to be attracted backward to advance the output shaft 3 away from the motor 2 through the shift lever 8. When the pinion gear 4 on the output shaft 3 meshes with the ring gear 9 of the engine, a movable contact of the magnet switch 5 is brought into contact with a pair of fixed contacts of a driver circuit of the motor 2 to energize the motor 2, so that the armature 22 produces torque. Upon completion of the meshing of the pinion gear 4 with the ring gear 9, the torque of the pinion gear 4 is transmitted to the ring gear 9 to crank the engine.
After the start-up of the engine, the starter switch is opened to deenergize the coil 34 of the magnet switch 5. This causes the plunger 50 to be moved frontward or returned by the return spring 51. The movable contact of the magnet switch 5 are then moved out of contact with the fixed contacts of the motor drive circuit to cut the supply of power to the armature 22. Additionally, the frontward movement of the plunger 50 causes the output shaft 3 to be moved by the shift lever 8 toward the motor 2, so that the rear end of the output shaft 3 hits on the clutch outer 71 and stops.
The structure of the starter 1 features use of a thrust washer 100. The thrust washer 100 will be described below with reference to
The front end of the yoke 14 is fitted into a rear opening of the torque transmission mechanism chamber 150.
The thrust washer 100 extends radially of the partition plate 13 (i.e., the housing 10 of the starter 1) in abutment with the front end surface of the partition plate 13. The thrust washer 100 has an outer periphery which is placed in abutment with the end surface of the internal gear 62 to exert an elastic pressure (i.e., a spring load) thereon in an axial direction of the starter 1. The center case 12 has a step or shoulder 121 defined by an annular groove 120 formed in the inner wall of the open rear end portion of the center case 12. The partition plate 13 is retained between the shoulder 121 of the center case 12 and the front end surface of the yoke 14 firmly by the pressure produced by fastening the through-bolts 16. The thrust washer 100 is in abutment at the front end surface thereof with the rear end surfaces of the internal gear 62 and the support pins 64 of the planetary gear train 6.
The thrust washer 100 is made of a wear-resistant disc of a circular shape as a whole and consists essentially of a ring-shaped center portion 101, five protrusions or necks 102, ten cutout tabs 103, and eight claws 104. The center portion 101 has a hole 109 formed in the center thereof. The necks 102 are arrayed at equi-angular intervals and extend radially from the outer periphery of the center portion 101. Two of the tabs 103 extend from each of the necks 102 in opposite directions along the circumference of the center portion 101. The claws 104 extend outwardly from the ends of eight of the tabs 103 in the radial direction of the thrust washer 100 and server as rotation stoppers. The thrust washer 100 has arc-shaped grooves 105 to define the outer periphery of the center portion 101 and the inside edges of the tabs 103. Each of the tabs 103 is bent, as illustrated in
The thrust washer 100 is geometrically so shaped that when the thrust washer 100 is disposed between the partition plate 13 and the planetary gear train 6, the center portion 101 is placed in a nip formed by the support pins 64 of the planetary gear train 6 and the partition plate 13, and the tabs 103 are in direct contact with the rear end surface of the internal gear 62 to urge the internal gear 62 frontward elastically. The grooves 105, as clearly illustrated in
The eight claws 104 are urged elastically against the rear end surface of the internal gear 62. The claws 104, as described above, serve as the rotation stoppers and are fitted together with the protrusions 66 of the internal gear 62 in the grooves 122 which are formed in the inner wall of the center case 12 deeper than the shoulder 121 to hold the thrust washer 100 from rotating. Four grooves are formed in the inner wall of the center case 12 at equi-angular intervals. Three of them are the grooves 122, and a remaining one is a groove 122a in which a protrusion formed on the periphery of the partition plate 13 is fitted to hold the partition plate 13 from rotating. The shoulder 121 is located deeper than the annular groove 120 which is machined in the inner peripheral wall of the center case 12 to open rearward. Adjacent two of the tabs 104 are fitted in each of the grooves 122, thereby also minimizing deformation of the thrust washer 100 in the radial direction thereof.
The overall thickness of the thrust washer 100 is constant and smaller than the gap between the rear end surface of the internal gear 62 and the front end surface of the partition plate 13. The tabs 103 are, as described above, bent frontward in the axial direction of the starter 1 to serve as elastic springs to urge the internal gear 62 elastically. The thrust washer 100, thus, works to receive and bear the backward thrust transmitted from the output shaft 3 to the support pins 64 of the planetary gear train 6 when the output shaft 3 is moved backward by the shift lever 8. This causes the friction between the support pins 64 and the thrust washer 100 to work to consume or absorb the energy of inertia rotation of the output shaft 3, thereby stopping the rotation of the output shaft 3 immediately.
The tabs 103, as clearly shown in
The tabs 103 have no claws. Instead, protrusions claws 204 extend from three of the necks 102 radially of the thrust washer 100 and serve as rotation stoppers fitted firmly in the center case 12 to hold the thrust washer 100 from rotating.
As apparent from the above discussion, the thrust washer 100 is disposed on the front end surface of the partition plate 13 which isolates the motor chamber from the torque transmission mechanism chamber 150 of the center case 12. The thrust washer 100 works to receive the backward thrust of the output shaft 3 through the support pins 64 of the planetary gear train 6 and also urge the internal gear 62 elastically frontward. The thrust washer 100 is nipped at the center portion 101 between the partition plate 13 and the internal gear 62 and held by the engagement with the grooves 122 of the center case 12 from rotating and deforming in the radial direction thereof. This minimizes the wear of the partition plate 13 and ensures the stability of movement of the output shaft 3 and also eliminates the need for an elastic member required in the conventional structure to decrease the play of the internal gear 62. The elastically urging of the internal gear 62 against the center case 12 is achieved by spring loads produced by the tabs 103 bent frontward of the thrust washer 100. The tabs 103 are made by cutting out the thickness of the thrust washer 100 to form the grooves 105, thereby permitting the spring load to be created which acts on the internal gear 61 in the axial direction of the starter 1 in a simple manner. Further, the thrust washer 100 is held by the claws 104 (204) from rotating, thus avoiding the wear of the partition plate 13 arising from rotation thereof accompanying the rotation of the thrust washer 100 and improves the braking of the output shaft 3.
While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention as set forth in the appended claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2706491 | Kohler | Apr 1955 | A |
| 5857380 | Kajino et al. | Jan 1999 | A |
| 6286378 | Kamei et al. | Sep 2001 | B1 |
| 20050193840 | Murase et al. | Sep 2005 | A1 |
| Number | Date | Country |
|---|---|---|
| 58-214668 | Dec 1983 | JP |
| A-UM-S58-180379 | Dec 1983 | JP |
| A-UM-S61-148932 | Sep 1986 | JP |
| A-UM-S62-152075 | Sep 1987 | JP |
| A-H09-310667 | Dec 1997 | JP |
| 2005-240679 | Sep 2005 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20060130600 A1 | Jun 2006 | US |
