ENGINE START SYSTEM MINIMIZING MECHANICAL IMPACT OR NOISE

• US 20100251852A1
• Filed: 04/06/2010
• Published: 10/07/2010
• Est. Priority Date: 04/07/2009
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: SAITO, Mikio, YOSHIDA, Yasuyuki, MURATA, Mitsuhiro, USAMI, Shinji, NOTANI, Hideya
• Granted Patent: US 8,985,080 B2
• Time in Patent Office: Days
• US Class Current: 74/7.A
• CPC Class Codes: F02N 11/08 Circuits or control means specially adapted for starting of engines
• CPC Class Codes: F02N 11/0833 Vehicle conditions F02N11/0822, F02N11/0825 take precedence
• CPC Class Codes: F02N 11/0844 with means for restarting the engine directly after an engine stop request, e.g. caused by change of driver mind
• CPC Class Codes: F02N 11/0855 during engine shutdown or after engine stop before start command, e.g. pre-engagement of pinion
• CPC Class Codes: F02N 11/087 Details of the switching means in starting circuits, e.g. relays or electronic switches
• CPC Class Codes: F02N 15/04 the gearing including disengaging toothed gears
• CPC Class Codes: F02N 15/067 the starter comprising an electro-magnetically actuated lever
• CPC Class Codes: F02N 2011/0892 Two coils being used in the starting circuit, e.g. in two windings in the starting relay or two field windings in the starter
• CPC Class Codes: F02N 2300/2011 Control involving a delay; Control involving a waiting period before engine stop or engine start
• CPC Class Codes: H01H 51/065 Relays having a pair of normally open contacts rigidly fixed to a magnetic core movable along the axis of a solenoid, e.g. relays for starting automobiles details H01H50/20
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y10T 74/132 Separate power mesher

Abstract

An engine start system which may be employed in automotive idle stop systems. To start an engine, the system brings a pinion gear into engagement with a ring gear coupled to the engine and turns on an electric motor to rotate the ring gear through the pinion gear to crank the engine. When it is requested to start the engine during deceleration of the engine before stop thereof, the system thrusts the pinion into engagement with the ring gear and then turns on the motor to rotate the pinion gear, in other words, delays the activation of the motor until after the pinion gear has engaged the ring gear. This minimizes mechanical impact or noise arising from the engagement of the pinion gear with the ring gear and improves the reliability in engagement with the ring gear during the deceleration of the engine and durability of the system.

Claims

1. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a pinion actuator working to move said pinion movable body to the ring gear;

a switching mechanism working to open or close main contacts installed in the motor circuit to cut or supply the electric power from the battery to said motor;

a controller which controls operations of said pinion actuator and said switching mechanism when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said switching mechanism is to be activated to close the main contacts until after a first operation time that is a time when said pinion actuator is to be activated to move said pinion movable body when the engine is restarted, said delay means producing a time lag between the first and second operation times so as to close the main contacts through said switching mechanism to supply the electric power to said motor after said pinion movable body is moved by said pinion actuator to shift the pinion gear from a rest position to a gear engageble position where said pinion gear is engageble with the ring gear, and then said pinion gear engages the ring gear.

2. An engine start system as set forth in claim 1, wherein said delay means sets the time lag between the first and second operation times to 30 ms. or more.

3. An engine start system as set forth in claim 1, wherein said pinion actuator is implemented by a solenoid actuator which produces a first electromagnet, and said switching mechanism is implemented by a motor on-off switch which produces a second electromagnet, and wherein said controller is designed to control operations of the solenoid actuator and the motor on-off switch independently of each other and has installed therein a delay function which makes up said delay means.

4. An engine start system as set forth in claim 1, wherein said pinion actuator is implemented by a solenoid actuator which produces a first electromagnet, and said switching mechanism is implemented by a motor on-off switch which produces a second electromagnet, wherein said controller is designed to control operations of the solenoid actuator and the motor on-off switch independently of each other, and wherein said delay means is implemented by a delay circuit connected to an excitation circuit which works to excite the motor on-off switch.

5. An engine start system as set forth in claim 3, wherein said controller changes the time lag between when the engine is requested to be restarted during the deceleration of the engine and when the engine is requested to be restarted after a complete stop of the engine.

6. An engine start system as set forth in claim 3, wherein said solenoid actuator and said motor on-off switch are aligned in series with each other in an axial direction thereof.

7. An engine start system as set forth in claim 6, wherein said solenoid actuator and said motor on-off switch have casings, respectively, which are arrayed integrally in the axial direction and constitute a magnetic circuit.

8. An engine start system as set forth in claim 1, further comprising a magnetic coil producing an electromagnet when energized, a plunger which is movable along an inner periphery of said magnetic coil in an axial direction thereof, and a single electromagnetic switch designed to perform both an operation of said pinion actuator and an operation of the switching mechanism following movement of said plunger, and wherein the time lag is provided by a plunger stroke that is a distance which said plunger moves from a time when said plunger starts to be moved by attraction, as produced by the electromagnetic, until the main contacts are closed.

9. An engine start system as set forth in claim 1, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

10. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a pinion actuator working to move said pinion movable body to the ring gear;

a switching mechanism working to open or close main contacts installed in the motor circuit to cut or supply the electric power from the battery to said motor;

a controller which controls operations of said pinion actuator and said switching mechanism when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said switching mechanism is to be activated to close the main contacts until after a first operation time that is a time when said pinion actuator is to be activated to move said pinion movable body when the engine is restarted, said delay means producing a time lag between the first and second operation times so as to close the main contacts through said switching mechanism to supply the electric power to said motor after said pinion movable body is moved by said pinion actuator to advance the pinion gear from a rest position to a maximum movable position where engagement of said pinion gear with the ring gear is to be achieved, and then said pinion gear has engaged the ring gear.

11. An engine start system as set forth in claim 10, wherein said delay means sets the time lag between the first and second operation times to 30 ms. or more.

12. An engine start system as set forth in claim 10, wherein said pinion actuator is implemented by a solenoid actuator which produces a first electromagnet, and said switching mechanism is implemented by a motor on-off switch which produces a second electromagnet, and wherein said controller is designed to control operations of the solenoid actuator and the motor on-off switch independently of each other and has installed therein a delay function which makes up said delay means.

13. An engine start system as set forth in claim 10, wherein said pinion actuator is implemented by a solenoid actuator which produces a first electromagnet, and said switching mechanism is implemented by a motor on-off switch which produces a second electromagnet, wherein said controller is designed to control operations of the solenoid actuator and the motor on-off switch independently of each other, and wherein said delay means is implemented by a delay circuit connected to an excitation circuit which works to excite the motor on-off switch.

14. An engine start system as set forth in claim 12, wherein said controller changes the time lag between when the engine is requested to be restarted during the deceleration of the engine and when the engine is requested to be restarted after a complete stop of the engine.

15. An engine start system as set forth in claim 12, wherein said solenoid actuator and said motor on-off switch are aligned in series with each other in an axial direction thereof.

16. An engine start system as set forth in claim 15, wherein said solenoid actuator and said motor on-off switch have casings, respectively, which are arrayed integrally in the axial direction and constitute a magnetic circuit.

17. An engine start system as set forth in claim 10, further comprising a magnetic coil producing an electromagnet when energized, a plunger which is movable along an inner periphery of said magnetic coil in an axial direction thereof, and a single electromagnetic switch designed to perform both an operation of said pinion actuator and an operation of the switching mechanism following movement of said plunger, and wherein the time lag is provided by a plunger stroke that is a distance which, said plunger moves from a time when said plunger starts to be moved by attraction, as produced by the electromagnetic, until the main contacts are closed.

18. An engine start system as set forth in claim 10, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

19. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a pinion solenoid actuator which produce magnetic attraction to thrust said pinion movable body toward the ring gear;

a motor on-off switch which opens or closes main contacts installed in the motor circuit to cut or supply the electric power to said motor;

a first relay disposed in an excitation circuit which supplies electric power from the battery to said pinion solenoid actuator;

a second relay disposed in an excitation circuit which supplies electric power from the battery to said motor on-off switch;

a controller which electrically controls an operation of said pinion solenoid actuator through said first relay and an operation of said motor on-off switch through said second relay when the engine is restarted during deceleration of the engine prior to stop of the engine;

a delay circuit which delays a second operation time that is a time when said second relay is to be energized until after a first operation time that is a time when said first relay is to be energized when the engine is restarted; and

a single electric wire connecting with an output port of said controller, said electric wire having a first relay branch line leading to said first relay and a second relay branch line leading to said second relay through said delay circuit,

wherein said delay circuit produces a time lag between the first and second operation times so as to close said motor on-off switch to supply the electric power to said motor after said pinion gear is moved by said pinion solenoid actuator from a rest position to a gear engageble position where said pinion gear is engageble with the ring gear and then engages the ring gear or from the rest portion to a maximum movable position where engagement of said pinion gear with the ring gear is to be established and then engages the ring gear.

20. An engine start system as set forth in claim 19, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

21. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a solenoid switch which works to produce a magnetic attraction to attract a plunger to thrust said pinion gear toward the ring gear and also open or close main contacts installed in the motor circuit interlocking with movement of the plunger for cutting or supplying the electric power to said motor;

a motor on-off relay which has relay contacts disposed in the motor circuit and opens or closes the relay contacts electrically;

a controller which electrically controls an operation of said solenoid switch and an operation of said motor on-off relay when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said motor on-off relay is to be energized until after a first operation time that is a time when said solenoid switch is to be energized when the engine is restarted, said delay means producing a time lag between the first and second operation times so as to turn on said motor on-off relay to supply the electric power to said motor after said pinion gear is moved by said solenoid switch to the ring gear and then engages the ring gear at least partially or to a maximum movable position where engagement of said pinion gear with the ring gear is to be established and then engages the ring gear, and after the main contacts are closed.

22. An engine start system as set forth in claim 21, wherein said delay means is implemented by a delay circuit connected to an excitation circuit which works to excite said motor on-off relay and is built in said motor on-off relay.

23. An engine start system as set forth in claim 21, wherein said motor on-off relay has the relay contacts disposed upstream of the main contacts of the motor circuit.

24. An engine start system as set forth in claim 21, wherein said motor on-off relay is installed on a housing of a starter in which said motor is installed.

25. An engine start system as set forth in claim 21, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

26. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said to motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a solenoid switch which works to produce a magnetic attraction to attract a plunger to thrust said pinion gear toward the ring gear and has an external terminal which is connected to the motor circuit and through which the electric power is supplied to said motor;

a motor on-off relay which has relay contacts disposed in the motor circuit and opens or closes the relay contacts electrically;

a controller which electrically controls an operation of said solenoid switch and an operation of said motor on-off relay when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said motor on-off relay is to be energized until after a first operation time that is a time when said solenoid switch is to be energized on when the engine is restarted, said delay means producing a time lag between the first and second operation times so as to turn on said motor on-off relay to supply the electric power to said motor after said pinion gear is moved by said solenoid switch to the ring gear and then engages the ring gear at least partially or to a maximum movable position where engagement of said pinion gear with the ring gear is to be established and then engages the ring gear.

27. An engine start system as set forth in claim 26, wherein said solenoid switch has a first terminal bolt and a second terminal bolt, the first terminal bolt serving as said external terminal, the second terminal bolt connecting with said motor through a motor lead, the first and second terminal bolts being connected electrically through a terminal-to-terminal connector.

28. An engine start system as set forth in claim 26, wherein said solenoid switch has a first terminal bolt and a second terminal bolt, the first terminal bolt serving as said external terminal connecting with said motor through a motor lead, the second terminal bolt being isolated from said motor circuit.

29. An engine start system as set forth in claim 26, wherein said solenoid switch has a first terminal bolt and a second terminal bolt, the first terminal bolt being isolated from the motor circuit, the second terminal bolt serving as said external terminal connecting with said motor through a motor lead.

30. An engine start system as set forth in claim 26, wherein said motor on-off relay has the relay contacts in said motor circuit upstream of said external terminal.

31. An engine start system as set forth in claim 26, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

32. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a solenoid switch which works to produce a magnetic attraction to attract a plunger to thrust said pinion gear toward the ring gear and has a first and a second terminal bolt connectable with the motor circuit;

a motor on-off relay which has relay contacts disposed in the motor circuit and opens or closes the relay contacts electrically;

a controller which electrically controls an operation of said solenoid switch and an operation of said motor on-off relay when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said motor on-off relay is to be energized until after a first operation time that is a time when said solenoid switch is to be energized on when the engine is restarted,

wherein said solenoid switch does not work to establish or block flow of the electric power to said motor and has the first and second terminal bolts disconnected from the motor circuit,

wherein said motor on-off relay works to open or close the relay contacts to block or establish flow of the electric power from the battery to said motor, and

wherein said delay means produces a time lag between the first and second operation times so as to turn on said motor on-off relay to establish the flow of the electric power to said motor after said pinion gear is moved by said solenoid switch to the ring gear and then engages the ring gear at least partially or to a maximum movable position where engagement of said pinion gear with the ring gear is to be established and then engages the ring gear.

33. An engine start system as set forth in claim 32, wherein said motor on-off relay has the relay contacts disposed upstream of the main contacts of the motor circuit.

34. An engine start system as set forth in claim 32, wherein said motor on-off relay is installed on a housing of a starter in which said motor is installed.

35. An engine start system as set forth in claim 32, wherein the engine start system is installed in a vehicle equipped with, an idle stop system working to stop and restart the engine automatically.

36. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a solenoid switch which works to produce a magnetic attraction to attract a plunger to thrust said pinion gear toward the ring gear and also open or close main contacts installed in the motor circuit interlocking with movement of the plunger for cutting or supplying the electric power to said motor;

a normally closed type of motor on-off relay which has relay contacts disposed in the motor circuit, when deenergized, said motor on-off relay keeping the relay contacts closed;

a starter relay which is disposed in an excitation circuit working to supply an excitation current to said solenoid switch from the battery;

a motor on-off sub-relay which is disposed in an excitation circuit working to supply an excitation current to said motor on-off relay from the battery;

a controller which electrically controls an operation of said solenoid switch through said starter relay and an operation of said motor on-off relay through said motor on-off sub-relay when the engine is restarted during deceleration of the engine prior to stop of the engine; and

delay means for delaying a second operation time that is a time when said motor on-off relay is to be energized until after a first operation time that is a time when said solenoid switch is to be energized on when the engine is restarted, said delay means producing a time lag between the first and second operation times so as to tarn on said motor on-off relay to supply the electric power to said motor after said pinion gear is moved by said solenoid switch to the ring gear and then engages the ring gear at least partially or to a maximum movable position where engagement of said pinion gear with the ring gear is to be established and then engages the ring gear, and after the main contacts are closed,

wherein said controller energizes said motor on-off sub-relay to open said motor on-off relay before said main contacts are closed by the solenoid switch and then closes said motor on-off relay following the first operation time.

37. An engine start system as set forth in claim 36, wherein said motor on-off relay has the relay contacts disposed upstream of the main contacts of the motor circuit.

38. An engine start system as set forth in claim 36, wherein said motor on-off relay is installed on a housing of a starter in which said motor is installed.

39. An engine start system as set forth in claim 36, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.

40. An engine start system comprising:

a motor which is energized by supply of electric power from a battery through a motor circuit to produce torque;

an output shaft which rotates when subjected to the torque, as produced by said motor;

a pinion gear through which the torque, as produced by said motor, is transmitted to a ring gear coupled to an engine;

a pinion movable body which is movable along said output shaft together with said pinion gear;

a solenoid switch which works to produce a magnetic attraction to attract a plunger to thrust said pinion gear toward the ring gear and also open or close main contacts installed in the motor circuit interlocking with movement of the plunger for cutting or supplying the electric power to said motor;

a motor on-off relay which has relay contacts disposed in the motor circuit and opens or closes the relay contacts electrically; and

a controller which electrically controls an operation of said solenoid switch and an operation of said motor on-off relay, during deceleration of the engine prior to stop of the engine, said controller energizing said solenoid switch to move said pinion gear and delaying the operation of said motor on-off relay until after said pinion bear engages the ring gear at least partially or said pinion is moved to a maximum movable position wherein engagement of the pinion gear with the ring gear is to be established and then engages the ring gear, and the main contacts are closed, after which an engine restart request signal is inputted to said controller.

41. An engine start system as set forth in claim 40, wherein said motor on-off relay has the relay contacts disposed upstream of the main contacts of the motor circuit.

42. An engine start system as set forth in claim 40, wherein said motor on-off relay is installed on a housing of a starter in which said motor is installed.

43. An engine start system as set forth in claim 40, wherein the engine start system is installed in a vehicle equipped with an idle stop system working to stop and restart the engine automatically.