Starter system

• US 9,200,608 B2
• Filed: 11/15/2012
• Issued: 12/01/2015
• Est. Priority Date: 11/15/2011
• Status: Active Grant

• Current Assignee: PHINIA TECHNOLOGIES INC.
• Original Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Inventors: Neet, Kirk, Fulton, David
• Primary Examiner(s): Kwon, John
• Assistant Examiner(s): Hoang, Johnny H
• Application Number:
  US13/678,515
• Publication Number:
  US 20130133605A1
• Time in Patent Office: 1,111 Days
• Field of Search: 123/179.1, 123/179.3, 123/179.4, 123/179.25, 123/185.1, 701/110, 701/112, 701/113, 290/10, 290/18, 290/22, 290/27, 290/28, 290/31, 290/36.R, 290/38.R, 290 46- 48
• US Class Current: 1/1
• CPC Class Codes: F02N 11/08 Circuits or control means specially adapted for starting of engines
• CPC Class Codes: F02N 11/0814 comprising means for controlling automatic idle-start-stop
• 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 11/0851 characterised by means for controlling the engagement or disengagement between engine and starter, e.g. meshing of pinion and engine gear
• 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 15/067 the starter comprising an electro-magnetically actuated lever
• 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: F02N 2300/2002 using different starting modes, methods, or actuators depending on circumstances, e.g. engine temperature or component wear

Abstract

Some embodiments of the invention provide a starter system including a starter, capable of being in communication with an electronic control unit. The starter can include a motor coupled to a circuit and a pinion including a plunger, and a plurality of solenoid assemblies including a plurality of biasing members. The plurality of solenoid assemblies can include at least one solenoid winding capable of moving the plunger, and at least one solenoid assembly capable of holding the plunger, and at least one solenoid assembly capable of controlling current flow to the motor. Some embodiments include a first switch coupled to the circuit that is capable of being activated by the plunger to control current flowing to at least a portion of the circuit. Some embodiments include at least two power isolation switches capable of controlling a current flow within the circuit.

Claims

1. A system for restarting an engine, wherein the engine has been automatically deactivated and a restart signal is received while the engine is coasting, the system comprising:

a starter capable of being controlled by an electronic control unit, the starter further comprising;

a motor coupled to a circuit;

a plunger moveably coupled to a pinion;

a first solenoid assembly comprising a plunger-return biasing member and at least one solenoid winding;

a secondary solenoid assembly comprising a secondary solenoid winding at least partially circumscribing a secondary plunger, the secondary plunger being configured and arranged to electrically couple with a set of secondary solenoid assembly contacts;

wherein the engine comprises;

a ring gear positioned to enable the pinion to engage with the ring gear when movement of the plunger causes movement of the pinion;

a ring gear speed sensor configured and arranged to measure a ring gear speed; and

wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is substantially zero RPM when the electronic control unit receives the restart signal in a zone wherein the speed of the ring gear is below a certain value and not equal to zero RPM.

2. The system for restarting an engine of claim 1, wherein the electronic control unit is configured and arranged to receive the restart signal when the engine is in an oscillation zone.

3. The system for restarting an engine of claim 2, wherein the electronic control unit is configured and arranged to receive the restart signal when the engine speed is negative.

4. The system for restarting an engine of claim 1, wherein the pinion speed and the ring gear speed are substantially synchronized at zero RPM.

5. The system for restarting an engine of claim 1, wherein the starter further comprises a pinion speed sensor.

6. The system for restarting an engine of claim 1, wherein the electronic control unit is configured and arranged to engage the pinion with the ring gear by energizing the at least one solenoid winding of the first solenoid assembly.

7. The system for restarting an engine of claim 6, wherein the electronic control unit is configured and arranged to energize the secondary solenoid assembly after the electronic control unit energizes the first solenoid assembly.

8. The system for restarting an engine of claim 7, wherein the electronic control unit is configured and arranged to energize the secondary solenoid assembly to cause the engaged pinion to move and cause the ring gear to move and start the engine.

9. The system for restarting an engine of claim 5, wherein an engine speed of the engine comprises a zone 2, the zone 2 comprising an engine speed less than a value where the engine can restart without the starter.

10. The system for restarting an engine of claim 9, wherein the electronic control unit is configured and arranged to energize the secondary solenoid assembly prior to energizing the first solenoid assembly when the engine speed is within zone 2.

11. The system of restarting an engine of claim 10, wherein the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear when the engine speed is within zone 2.

12. A system for restarting an engine, wherein the engine has been automatically deactivated and a restart signal is received while the engine is coasting, the system comprising:

a starter capable of being controlled by an electronic control unit, the starter further comprising;

a motor coupled to a circuit;

a plunger moveably coupled to a pinion;

a first solenoid assembly comprising a plunger-return biasing member and at least one solenoid winding;

a secondary solenoid assembly comprising a secondary solenoid winding at least partially circumscribing a secondary plunger, the secondary plunger being configured and arranged to electrically couple with a set of secondary solenoid assembly contacts;

wherein the engine comprises;

a ring gear positioned to enable the pinion to engage with the ring gear when movement of the plunger causes movement of the pinion;

a ring gear speed sensor configured and arranged to measure a ring gear speed; and

wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is a positive speed when the electronic control unit receives the restart signal in a portion of the oscillation zone when the speed of the ring gear is a negative speed.

13. The system for restarting an engine of claim 12, wherein the starter further comprises a pinion speed sensor, and wherein the electronic control unit is configured and arranged to energize the secondary solenoid assembly prior to energizing the first solenoid assembly.

14. The system of restarting an engine of claim 13, wherein the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear.

15. The system of restarting an engine of claim 14, wherein the electronic control unit is configured and arranged to receive the restart signal when the speed of the ring gear is greater than zero, and energizes the secondary solenoid assembly prior to energizing the first solenoid assembly;

and wherein the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear.

16. A system for restarting an engine, wherein the engine has been automatically deactivated and a restart signal is received while the engine is coasting, the system comprising:

a starter capable of being controlled by an electronic control unit, the starter further comprising;

a motor coupled to a circuit;

a plunger moveably coupled to a pinion;

a pinion speed sensor;

a first solenoid assembly comprising a plunger-return biasing member and at least one solenoid winding;

a secondary solenoid assembly comprising a secondary solenoid winding at least partially circumscribing a secondary plunger, the secondary plunger being configured and arranged to electrically couple with a set of secondary solenoid assembly contacts;

wherein the engine further comprises;

a ring gear positioned to enable the pinion to engage with the ring gear when movement of the plunger causes movement of the pinion;

a ring gear speed sensor configured and arranged to measure a ring gear speed; and

wherein the electronic control unit is configured and arranged to control the restart following receipt of a restart signal based on at least one zone, the at least one zone determined by the speed of the engine when the electronic control unit receives the restart signal;

wherein the at least one zone comprises (a) a zone 1 where the electronic control unit is configured and arranged to restart the engine without using the starter;

and (b) a zone 2 where the electronic control unit is configured and arranged to energize the secondary solenoid assembly prior to energizing the first solenoid assembly and the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear.

17. The system of restarting an engine of claim 16, wherein the at least one zone further comprises a zone 4 wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is substantially zero RPM.

18. The system of restarting an engine of claim 16, wherein the at least one zone further comprises a zone 4 wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is in a zone 3.

19. The system of restarting an engine of claim 18 where the electronic control unit is configured and arranged to energize the secondary solenoid assembly prior to energizing the first solenoid assembly and the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear.

20. The system of restarting an engine of claim 16 wherein the at least one zone further comprises an oscillation zone, wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is substantially zero RPM.

21. The system of restarting an engine of claim 16 wherein the at least one zone further comprises an oscillation zone, wherein the electronic control unit is configured and arranged to delay the engagement of the pinion with the ring gear until the speed of the ring gear is a positive speed.

22. The system of restarting an engine of claim 16 wherein the at least one zone further comprises a zone 3 where the electronic control unit is configured and arranged to receive the restart signal and the electronic control unit is configured and arranged to energize the secondary solenoid assembly prior to energizing the first solenoid assembly and the electronic control unit is configured and arranged to wait until the speed of the pinion is substantially synchronized with the speed of the ring gear to energize the first solenoid to engage the pinion with the ring gear.