System for restarting internal combustion engine when engine restart request occurs

• US 8,079,340 B2
• Filed: 10/02/2009
• Issued: 12/20/2011
• Est. Priority Date: 10/04/2008
• Status: Active Grant

• Current Assignee: DENSO Corporation
• Original Assignee: DENSO Corporation
• Inventors: Okumoto, Kazushige, Kato, Akira, Senda, Takashi, Murata, Mitsuhiro, Niimi, Masami, Haruno, Kiyokazu
• Primary Examiner(s): HUYNH, HAI H
• Application Number:
  US12/588,079
• Publication Number:
  US 20100083926A1
• Time in Patent Office: 809 Days
• Field of Search: 123/179.3, 123/179.4, 123/179.25, 123/179.28
• US Class Current: 123/179.4
• CPC Class Codes: F02N 11/0814 comprising means for controlling automatic idle-start-stop
• 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 11/10 Safety devices F02N11/08 takes precedence
• CPC Class Codes: F02N 15/067 the starter comprising an electro-magnetically actuated lever
• CPC Class Codes: F02N 19/005 Aiding engine start by starting from a predetermined position, e.g. pre-positioning or reverse rotation
• CPC Class Codes: F02N 2019/008 the engine being stopped in a particular position
• CPC Class Codes: F02N 2200/021 Engine crank angle
• CPC Class Codes: H01H 9/542 Contacts shunted by static switch means
• CPC Class Codes: H02P 1/10 Manually-operated on/off switch controlling relays or contactors operating sequentially for starting a motor
• CPC Class Codes: H02P 1/18 for starting an individual dc motor

Abstract

In a system for cranking a crankshaft of an internal combustion engine, a starter is provided with a motor working to, when energized, rotatably drive an output shaft with a pinion and an actuator working to, when energized, shift the pinion toward the ring gear to be engaged with the ring gear. A power supply is electrically connected to the motor and operative to output electrical power. A first mechanical relay is electrically connected between the power supply and the motor, and works to turn on and off a supply of a current based on the electrical power to the motor for rotating the pinion. A switching element is electrically connected across the first mechanical relay, and works to turn on and off the supply of the current to the motor for rotating the pinion.

Claims

1. A system for cranking, according to an occurrence of an engine restart request, a crankshaft of an internal combustion engine that has been automatically controlled for stop thereof in response to an engine automatic stop request to thereby restart the internal combustion engine, the crankshaft having a ring gear attached thereto, the system comprising:

a starter provided with a motor working to, when energized, rotatably drive an output shaft with a pinion and an actuator working to, when energized, shift the pinion toward the ring gear to be engaged with the ring gear;

a power supply electrically connected to the motor and operative to output electrical power;

a first mechanical relay electrically connected between the power supply and the motor and working to turn on and off a supply of a current based on the electrical power to the motor for rotating the pinion;

a switching element electrically connected across the first mechanical relay and working to turn on and off the supply of the current to the motor for rotating the pinion;

a second mechanical relay electrically connected between the power supply and the actuator and working to turn on and off the supply of the current to the actuator for shifting the pinion; and

a circuit selecting unit placed between the switching element and the starter and configured to provide selectively one of;

a first circuit in which the switching element is electrically connected in parallel to the first mechanical relay; and

a second circuit in which the switching element is electrically connected in parallel to the second mechanical relay.

2. The system according to claim 1, further comprising:

a pinion-preset unit configured to energize, at a timing, the actuator to thereby shift the pinion toward the ring gear so that the pinion is meshed with the ring gear, the timing representing any one of;

a time immediately before a rotational speed of the internal combustion engine reaches zero; and

a time after the rotational speed thereof has reached zero;

an engine-stop position adjustment unit configured to, after the pinion has been meshed with the ring gear, control the current to be supplied to the motor through the switching element to thereby rotate the ring gear of the crankshaft together with the pinion so that a rotational position of the crankshaft is adjusted to a target rotational position; and

an engine restart unit configured to, after the rotational position of the crankshaft has been adjusted, cause the mechanical relay to turn on the supply of the current to the motor to thereby rotate the pinion.

3. The system according to claim 2, wherein the engine restart unit is configured to:

control the current to be supplied to the motor through the switching element until a preset time has elapsed since a start of the supply of the current to the motor through the switching element; and

cause the mechanical relay to turn on the supply of the current to the motor to thereby rotate the pinion after the preset time has elapsed since the start of the supply of the current to the motor through the switching element.

4. The system according to claim 1, further comprising:

a pinion-preset unit configured to;

when the second circuit is selected by the circuit selecting unit, control, at a timing, the supply of the current to the actuator to thereby shift the pinion toward the ring gear so that the pinion is meshed with the ring gear, the timing representing any one of;

a time immediately before a rotational speed of the internal combustion engine reaches zero; and

a time after the rotational speed thereof has reached zero; and

turn on the second mechanical relay so as to maintain the pinion being meshed with the ring gear.

5. The system according to claim 4, further comprising:

an engine-stop position adjustment unit configured to, after the pinion has been meshed with the ring gear by the pinion preset unit and the first circuit has been selected by the circuit selecting unit, control the current to be supplied to the motor through the switching element to thereby rotate the ring gear of the crankshaft together with the pinion so that a rotational position of the crankshaft is adjusted to a target rotational position.

6. The system according to claim 1, wherein the switching element has a duty cycle representing a ratio of its on duration to a sum of its on duration and off duration, further comprising:

a motor-drive start unit configured to;

when starting a drive of the motor, gradually increase the duty cycle of the switching element while causing the first mechanical relay to turn off the supply of the current to the motor to thereby increase a voltage based on the electrical power of the power supply, the voltage being applied to the motor through the switching element;

after the increase in the voltage applied to the motor, cause the first mechanical relay to turn on the supply of the current to the motor; and

after the first mechanical relay turning on the supply of the current to the motor, cause the switching element to turn off the supply of the current to the motor.

7. The system according to claim 6, wherein the motor-drive start unit is configured to, after a start of the control of the duty cycle of the switching element, cause the first mechanical relay to turn on the supply of the current to the motor when at least one of a first condition, a second condition, and a third condition is met,

the first condition is that a predetermined time has elapsed since the start of the control of the duty cycle,

the second condition is that a rotational speed of the motor is equal to or greater than a predetermined rotational speed,

the third condition is that the duty cycle of the switching element is equal to or greater than a preset percent.

8. The system according to claim 6, wherein the motor-drive start unit is configured to gradually reduce the duty cycle of the switching element when causing the switching element to turn off the supply of the current to the motor.

9. The system according to claim 1, wherein the switching element has a duty cycle representing a ratio of its on duration to a sum of its on duration and off duration, further comprising:

a motor-drive stop unit configured to;

when stopping a drive of the motor, cause the switching element to turn on the supply of the current to the motor while causing the first mechanical relay to turn on the supply of the current to the motor;

after the switching element turning on the supply of the current to the motor, cause the first mechanical relay to turn off the supply of the current to the motor; and

after the first mechanical relay turning off the supply of the current to the motor, gradually reduce the duty cycle of the switching element to thereby reduce a voltage based on the electrical power of the power supply so as to interrupt the supply of the current to the motor, the voltage being applied to the motor through the switching element.

10. The system according to claim 9, wherein the motor-drive stop unit includes an increase unit configured to gradually increase the duty cycle of the switching element when causing the switching element to turn on the supply of the current to the motor.