Starter system and method

• US 9,429,131 B2
• Filed: 01/24/2014
• Issued: 08/30/2016
• Est. Priority Date: 03/18/2013
• Status: Expired due to Fees

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Remy Technologies LLC (BorgWarner Incorporated)
• Inventors: Bradfield, Michael D.
• Primary Examiner(s): Moulis, Thomas
• Assistant Examiner(s): Campbell, Joshua A
• Application Number:
  US14/163,336
• Publication Number:
  US 20150211465A1
• Time in Patent Office: 949 Days
• Field of Search: 123/179.3, 123/179.4, 123/179.26, 903/914, 701/113
• US Class Current: 1/1
• CPC Class Codes: F02N 11/00 Starting of engines by means of electric motors
• 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 15/02 Gearing between starting-engines and started engines; Engagement or disengagement thereof
• CPC Class Codes: F02N 15/022 the starter comprising an intermediate clutch
• CPC Class Codes: F02N 15/046 of the planetary type
• CPC Class Codes: F02N 15/067 the starter comprising an electro-magnetically actuated lever
• CPC Class Codes: F02N 2015/061 said axial displacement being limited, e.g. by using a stopper
• CPC Class Codes: F02N 2200/022 Engine speed
• CPC Class Codes: F02N 2200/023 Engine temperature
• CPC Class Codes: F02N 2200/041 Starter speed
• CPC Class Codes: F02N 2300/2002 using different starting modes, methods, or actuators depending on circumstances, e.g. engine temperature or component wear
• CPC Class Codes: F02N 2300/2011 Control involving a delay; Control involving a waiting period before engine stop or engine start

Abstract

A method for controlling an engine starter system including a starter capable of being controlled by an electronic control unit and having an electric motor and a pinion coupled together for transferring rotational torque from the motor to the pinion when the motor is activated; controlling activation of the motor with an electronic control unit output motor signal in response to an engine speed input signal; determining the pinion speed in an open loop manner based solely on the time since activation of the motor and the voltage applied to the motor; and selectively moving the pinion between a retracted state and an extended state in response to an electronic control unit output pinion signal, whereby the starter is capable of selectively engaging an engine for cranking the engine. Also, a starter system that facilitates this method.

Claims

1. A method for controlling an engine starter system, said method comprising:

providing an electronic control unit having an engine speed input and at least one output;

providing a starter capable of being controlled by the electronic control unit and having an electric motor and a pinion, the motor and pinion coupled together for transferring rotational torque from the motor to the pinion when the motor is activated;

controlling activation of the motor with an electronic control unit output motor signal in response to an engine speed input signal;

determining with the electronic control unit the pinion speed in an open loop manner based solely on the time since activation of the motor and the voltage applied to the motor; and

selectively moving the pinion between a retracted state and an extended state in response to an electronic control unit output pinion signal, whereby the starter is capable of selectively engaging an engine for cranking the engine.

2. The method of claim 1, wherein the electronic control unit output motor signal and the electronic control unit output pinion signal are signals separately outputted from the electronic control unit.

3. The method of claim 2, wherein the electronic control unit output motor signal and the electronic control unit output pinion signal are substantially simultaneously outputted from the electronic control unit.

4. The method of claim 1, wherein the electronic control unit output motor signal and the electronic control unit output pinion signal are a single signal outputted from the electronic control unit.

5. The method of claim 1, wherein the pinion speed determined by the electronic control unit is expressible as an explicit, closed form equation based on elapsed time since activation of the motor and the voltage applied to the motor.

6. The method of claim 5, wherein the explicit, closed form equation is a quartic equation.

7. The method of claim 1, wherein in determining the pinion speed with the electronic control unit the voltage applied to the motor is substantially battery voltage.

8. The method of claim 1, wherein in determining the pinion speed with the electronic control unit the voltage applied to the motor is presumed to be a constant value.

9. The method of claim 1, wherein the pinion speed is a presumed predetermined speed after an identified period of time has elapsed since motor activation.

10. The method of claim 1, wherein the pinion speed is determined based at least in part as a function of actual applied motor voltage.

11. The method of claim 1, further comprising calculating the differential between the determined pinion speed and the engine speed input.

12. The method of claim 11, wherein the voltage applied to the motor is maintained if the determined pinion speed is less than the engine speed input.

13. The method of claim 11, wherein the pinion is capable of being engaged with an engine ring gear if the determined pinion speed is at least the engine speed input.

14. A starter system for cranking an engine, comprising:

a starter comprising an electric motor and a pinion coupled together, rotational torque from the motor transferable to the pinion; and

an electronic control unit having an engine speed input and at least one output, the motor adapted for being activated under control of the electronic control unit in response to a motor signal outputted from the electronic control unit, the pinion adapted for being moved axially between a retracted state and an extended state in response to a pinion signal outputted from the electronic control unit, the starter capable of engaging and cranking an engine in the pinion extended state, the electronic control unit capable of determining the pinion speed in an open loop manner based solely on the time since activation of the motor and the voltage applied to the motor.

15. The starter system of claim 14, wherein the electronic control unit is adapted to determine pinion speed based at least in part as a function of the voltage applied to the motor being substantially battery voltage.

16. The starter system of claim 14, wherein the electronic control unit is adapted to determine pinion speed based at least in part as a function of the voltage applied to the motor being presumed to be a constant value.

17. The starter system of claim 14, wherein the electronic control unit is adapted to adjust the pinion speed on the basis of a comparison by the electronic control unit between the determined pinion speed and the engine speed input.

18. The starter system of claim 14, wherein the electronic control unit has a motor output from which the motor signal is outputted from the electronic control unit and a separate pinion output from which the pinion signal is outputted from the electronic control unit.

19. The starter system of claim 18, wherein the electronic control unit is capable of outputting the motor signal from the motor output and the pinion signal from the pinion output substantially simultaneously.

20. The starter system of claim 14, wherein the electronic control unit output is a single output from which a single motor and pinion signal is outputted.