Starter machine system and method

• US 8,829,845 B2
• Filed: 02/28/2012
• Issued: 09/09/2014
• Est. Priority Date: 02/28/2012
• Status: Active Grant

• Current Assignee: PHINIA TECHNOLOGIES INC.
• Original Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Inventors: Bradfield, Michael D.
• Primary Examiner(s): Ip, Paul
• Application Number:
  US13/407,651
• Publication Number:
  US 20130221682A1
• Time in Patent Office: 924 Days
• Field of Search: 318/51, 318/567, 318/600, 318/727, 318/778, 701/102, 701/103, 701/113, 123/179.3, 123/179.4
• US Class Current: 318/727
• 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 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 2200/022 Engine speed
• CPC Class Codes: F02N 2200/041 Starter speed
• CPC Class Codes: F02N 2200/048 Information about pinion speed, both translational or rotational speed
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing

Abstract

Embodiments of the invention provide a starter machine including an electronic control unit. The electronic control unit can be in communication with one or more sensors. The control system can include a starter machine that is in communication with the electronic control unit. The starter machine can comprise a solenoid assembly that includes a plurality of biasing members, a motor that is coupled to a pinion, and power module and controller that is coupled to the motor. In some embodiments, at least one of the power module and the controller are configured to control a speed of the pinion to substantially synchronize the pinion speed and the speed of an engine component.

Claims

1. A starter machine comprising:

a starter machine capable of being in communication with an electronic control unit in communication with one or more sensors, the starter machine further comprising;

at least one solid-state switch;

a solenoid assembly including a plurality of biasing members, the plurality of biasing members comprising at least two of a plunger return biasing member, a contact-overrun biasing member, and an auxiliary biasing member;

a motor being operatively coupled to a pinion and being at least partially disposed within a housing;

a power module and controller being electrically coupled to the motor and being at least partially disposed within the housing; and

wherein the controller is configured and arranged to move a plunger to an artificial stopping point comprising the auxiliary biasing member engaging an artificial stop; and

wherein at least one of the power module and the controller are configured and arranged to control a speed of the motor to substantially synchronize the speed of the pinion with a speed of a component of an engine when the plunger has reached the artificial stopping point, the component comprising at least a ring gear of the engine.

2. The starter machine of claim 1, wherein the at least one solid-state switch is in communication with the electronic control unit.

3. The starter machine of claim 2, wherein at least one of the sensors comprises an engine sensor, and wherein the electronic control unit is configured and arranged to control a voltage passing through the solid-state switch at least partially based on data received from the engine sensor.

4. The starter machine of claim 1, wherein the solid-state switch is electrically coupled to at least one of the power module and the controller.

5. The starter machine of claim 1, wherein the power module comprises a plurality of solid-state switches.

6. The starter machine of claim 1, wherein the controller is configured and arranged to assess a back electromotive force of the motor for use in substantially synchronizing the speed of the pinion and the speed of a component of the engine.

7. A starter machine comprising:

a starter machine being in communication with an electronic control unit that is in communication with at least one engine senor, the engine sensor being configured and arranged to sense a speed of an engine, the starter machine further comprising

a solenoid assembly comprising a plurality of biasing members and a plunger, the plurality of biasing members comprising a plunger return biasing member, a contact-overrun biasing member, and an auxiliary biasing member;

a solid-state switch being in communication with the electronic control unit,

a motor being operatively coupled to a pinion,

a power module being electrically coupled to the motor and the solid-state switch, and

a controller being in communication with at least the power module and the motor; and

wherein the controller is configured and arranged to move a plunger to an artificial stopping point comprising the auxiliary biasing member engaging an artificial stop; and

wherein the controller is configured and arranged to substantially synchronize a speed of the pinion with the speed of the engine at least partially based on a back electromotive force of the motor; and

wherein the controller is configured and arranged to substantially synchronize the speed of the pinion with a speed of a ring gear of the engine when the plunger has reached the artificial stopping point; and

wherein the controller is configured and arranged to move the plunger to a position which causes the pinion to engage the ring gear.

8. The starter machine of claim 7, wherein the solenoid assembly comprises a first coil winding electrically coupled to a first relay and a second coil winding electrically coupled to a second relay.

9. The starter machine of claim 8, wherein the electronic control unit is configured and arranged to activate the second coil winding after a predetermined time interval after activating the first coil winding.

10. The starter machine of claim 7, wherein the power module comprises one or more solid-state switches.

11. The starter machine of claim 7, wherein the electronic control unit is configured and arranged regulate the solid-state switch by pulse width modulation.

12. The starter machine of claim 7, wherein the electronic control unit is configured and arranged to control a voltage passing through the solid-state switch at least partially based on data received from the engine sensor.

13. The starter machine of claim 7, wherein the engine sensor is configured to sense a speed of the ring gear.