Magnetic brake system for starter motor

• US 7,954,469 B2
• Filed: 09/04/2008
• Issued: 06/07/2011
• Est. Priority Date: 09/04/2008
• Status: Expired due to Fees

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Inventors: Cai, William, Park, Dong Ju, Lee, Kook-Ju
• Primary Examiner(s): Cronin; Stephen K
• Assistant Examiner(s): Bacon; Anthony L
• Application Number:
  US12/230,755
• Publication Number:
  US 20100050971A1
• Time in Patent Office: 1,006 Days
• Field of Search: 123/179.25, 290/38.R, 290/38.C, 74/6, 74/7.C, 74/7.E
• US Class Current: 123/179.25
• CPC Class Codes: F02N 11/00 Starting of engines by means of electric motors
• CPC Class Codes: F02N 15/003 Starters comprising a brake mechanism
• CPC Class Codes: F02N 15/023 of the overrunning type
• CPC Class Codes: F02N 15/046 of the planetary type
• CPC Class Codes: H02K 7/104 with eddy-current brakes
• CPC Class Codes: H02K 7/108 with friction clutches
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: Y10T 74/134 Clutch connection
• CPC Class Codes: Y10T 74/137 Reduction gearing

Abstract

An engine starter system is disclosed. The starter system includes an electric cranking motor having a shaft and configured to crank the engine. The starter system further includes a planetary-type reduction gear unit that has a starter motor ring gear. The starter system has a pinion mechanism mounted on the shaft and configured to selectively engage a ring gear of the engine. A clutch assembly is configured to transmit torque between the shaft and the pinion mechanism. The clutch assembly includes a current conducting material and the starter motor ring gear includes one or more permanent magnets. The starter system employs the principle of Lenz'"'"'s law to reduce the overrunning rotational speed of the cranking motor upon disengagement of the pinion mechanism from the engine'"'"'s ring gear after the engine has started.

Claims

1. A starter assembly, comprising:

a starter motor having a shaft and configured to crank an engine;

a planetary-type reduction gear unit including a starter motor ring gear, the ring gear including a permanent magnet;

a pinion mechanism mounted on the shaft and configured to selectively engage a ring gear of the engine;

a clutch assembly made of a first material and configured to transmit torque between the shaft and the pinion mechanism;

wherein the periphery of the clutch assembly made of the first material is surrounded by a band of current conducting material different from the first material; and

wherein the permanent magnet and the current conducting material are configured such that interaction therebetween reduces the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

2. The starter assembly of claim 1, wherein the current conducting material includes copper.

3. The starter assembly of claim 1, wherein eddy currents in the current conducting material of the clutch assembly operate to reduce the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

4. The starter assembly of claim 1, wherein the permanent magnet includes a plurality of magnets embedded in the starter motor ring gear.

5. The starter assembly of claim 1, wherein a side of the permanent magnet facing the clutch assembly is free from engagement with another magnet.

6. The starter assembly of claim 1, wherein the first material is low carbon steel and the current conducting material is copper.

7. A method of slowing down overrunning of a starter system, including:

mounting a pinion mechanism on a shaft of a starter motor configured to crank an engine;

engaging selectively, a ring gear of the starter motor, the ring gear of the starter motor including one or more permanent magnets;

transmitting torque between the shaft and the pinion mechanism by a clutch assembly, the clutch assembly including a first material and a second current conducting material, wherein the second current conducting material forms a band around the periphery of the first material; and

disengaging the pinion mechanism from engine cranking;

wherein said disengaging the pinion mechanism from engine cranking further includes exposing the current conducting material of the clutch assembly to the one or more permanent magnets of the ring gear of the starter motor such that interaction therebetween reduces the speed of the electric motor.

8. The method of claim 7, wherein the second current conducting material includes copper.

9. The method of claim 7, further including eddy currents in the second current conducting material of the clutch assembly operating to reduce the speed of the starter motor upon disengagement of the pinion mechanism from engine cranking.

10. The method of claim 7, wherein the ring gear of the starter motor is included in a planetary-type reduction gear unit further including a sun gear and at least one planetary gear.

11. A machine, comprising:

a combustion engine configured to power operations of the machine;

an interface configured to receive input from a machine operator to start the engine;

a starter motor having a shaft and configured to crank the engine;

a planetary-type reduction gear unit including a starter motor ring gear, a sun gear, and at least one planetary gear, wherein the ring gear includes at least one permanent magnet;

a pinion mechanism mounted on the shaft and configured to selectively engage a ring gear of the engine;

a clutch assembly made of a first material and configured to transmit torque between the shaft and the pinion assembly; and

wherein the periphery of the clutch assembly made of the first metal is surrounded by a band of current conducting material different from the first material; and

wherein the at least one permanent magnet and the current conducting material are configured such that interaction therebetween reduces the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

12. The machine of claim 11, wherein the current conducting material includes copper.

13. The machine of claim 11, wherein eddy currents in the current conducting material of the clutch assembly operate to reduce the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

14. A starter assembly, comprising:

a starter motor having a shaft and configured to crank an engine;

a planetary-type reduction gear unit including a starter motor ring gear, the starter motor ring gear made of a first material;

a pinion mechanism mounted on the shaft and configured to selectively engage a ring gear of the engine;

a clutch assembly configured to transmit torque between the shaft and the pinion mechanism;

wherein a radial inner surface of the starter motor ring gear made of the first material includes a band of current conducting material different than the first material, and the clutch assembly includes one or more permanent magnets; and

wherein the one or more permanent magnets and the current conducting material are configured such that interaction therebetween reduces the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

15. The starter assembly of claim 14, wherein the starter motor ring gear is constructed from low carbon steel.

16. The starter assembly of claim 14, wherein eddy currents in the current conducting material of the clutch assembly operate to reduce the speed of the electric motor upon disengagement of the pinion mechanism from engine cranking.

17. The starter assembly of claim 14, wherein the permanent magnets are embedded in the clutch assembly.