Diagnostic system and method for vehicle starter
First Claim
1. A diagnostic system for a vehicle with an internal combustion engine and a starter-based stop-start system comprising:
- an electronic control unit configured to control the operation of the stop-start system;
a starter having an electric motor drivingly coupled with a shaft assembly;
a first gear mounted on the shaft assembly;
a solenoid operably coupled with the shaft assembly wherein operation of the solenoid shifts the first gear into and out of engagement with a second gear, the second gear being coupled with the engine and wherein the engine is startable by rotating the second gear with the first gear;
a sensor operably coupled with the shaft assembly for detecting rotational movement of the shaft assembly in a first position wherein the first gear is disengaged from the second gear;
the electronic control unit being operably coupled with the starter motor, the solenoid and the sensor, wherein the electronic control unit performs at least one of a first diagnostic check and a second diagnostic check before stopping the engine as a function of the stop-start system wherein;
in the first diagnostic check the electronic control unit energizes the starter motor with the first gear disengaged from the second gear and then, with the shaft assembly in the first position, uses the sensor to determine if the shaft assembly is rotating wherein a rotating shaft assembly indicates that the starter motor is operable and a non-rotating shaft assembly indicates a starter motor failure; and
in the second diagnostic check, the electronic control unit detects the rotational speed of the shaft assembly with the sensor while the shaft assembly is in the first position and the shaft assembly is rotating, the electronic control unit then energizes the solenoid to move the shaft assembly out of the first position to a second position where the sensor cannot detect rotation of the shaft assembly and then analyzes the signals provided by the sensor after energizing the solenoid wherein sensor signals representing no detected rotation of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates that the solenoid is operable and sensor signals representing a non-zero rotational speed of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates a solenoid failure due to the solenoid failing to move the shaft assembly out of the first position; and
wherein, if a starter motor failure or a solenoid failure is detected when conducting the at least one of the first and second diagnostic checks, the electronic control unit suspends operation of the stop-start system.
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Accused Products
Abstract
A diagnostic system and method for a vehicle with a starter-based stop-start system. At least one diagnostic check is performed before stopping the engine as a function of the stop-start system. Both diagnostic checks may be performed. If a diagnostic check indicates a failure of the starter motor or solenoid, operation of the stop-start system is suspended. The system utilizes a sensor to determine if the starter shaft is rotating when the shaft is in a position wherein a gear on the shaft is disengaged. Operability of the starter motor is checked by energizing and then de-energizing the motor without engaging the gear and determining if the shaft rotates. Operability of the solenoid is checked by sensing the rotation of the starter shaft and then energizing the solenoid to move the shaft into a position where the sensor cannot detect rotation of the shaft.
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Citations
20 Claims
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1. A diagnostic system for a vehicle with an internal combustion engine and a starter-based stop-start system comprising:
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an electronic control unit configured to control the operation of the stop-start system; a starter having an electric motor drivingly coupled with a shaft assembly; a first gear mounted on the shaft assembly; a solenoid operably coupled with the shaft assembly wherein operation of the solenoid shifts the first gear into and out of engagement with a second gear, the second gear being coupled with the engine and wherein the engine is startable by rotating the second gear with the first gear; a sensor operably coupled with the shaft assembly for detecting rotational movement of the shaft assembly in a first position wherein the first gear is disengaged from the second gear; the electronic control unit being operably coupled with the starter motor, the solenoid and the sensor, wherein the electronic control unit performs at least one of a first diagnostic check and a second diagnostic check before stopping the engine as a function of the stop-start system wherein; in the first diagnostic check the electronic control unit energizes the starter motor with the first gear disengaged from the second gear and then, with the shaft assembly in the first position, uses the sensor to determine if the shaft assembly is rotating wherein a rotating shaft assembly indicates that the starter motor is operable and a non-rotating shaft assembly indicates a starter motor failure; and in the second diagnostic check, the electronic control unit detects the rotational speed of the shaft assembly with the sensor while the shaft assembly is in the first position and the shaft assembly is rotating, the electronic control unit then energizes the solenoid to move the shaft assembly out of the first position to a second position where the sensor cannot detect rotation of the shaft assembly and then analyzes the signals provided by the sensor after energizing the solenoid wherein sensor signals representing no detected rotation of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates that the solenoid is operable and sensor signals representing a non-zero rotational speed of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates a solenoid failure due to the solenoid failing to move the shaft assembly out of the first position; and wherein, if a starter motor failure or a solenoid failure is detected when conducting the at least one of the first and second diagnostic checks, the electronic control unit suspends operation of the stop-start system. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A method of performing a diagnostic check for a vehicle with an internal combustion engine and a starter-based stop-start system comprising:
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providing a starter having an electric motor drivingly coupled with a shaft assembly; providing a first gear on the shaft assembly; operably coupling a solenoid with the shaft assembly wherein the solenoid selectively shifts the first gear into and out of engagement with a second gear, the second gear being coupled with the engine and wherein the engine is startable by rotating the second gear with the first gear; operably coupling a sensor with the shaft assembly wherein the sensor detects rotational movement of the shaft assembly when the shaft assembly is in a first position with the first gear disengaged from the second gear; performing at least one of a first diagnostic check and a second diagnostic check before stopping the engine as a function of the stop-start system wherein; the first diagnostic check includes energizing the starter motor with the first gear disengaged from the second gear and then, with the shaft assembly in the first position, using the sensor to determine if the shaft assembly is rotating wherein a rotating shaft assembly indicates that the starter motor is operable and a non-rotating shaft assembly indicates a starter motor failure; and the second diagnostic check includes detecting the rotational movement of the shaft assembly with the sensor while the shaft assembly is in the first position and the shaft assembly is rotating and then energizing the solenoid to move the shaft assembly out of the first position to a second position where the sensor cannot detect rotation of the shaft assembly and analyzing the signals provided by the sensor after energizing the solenoid wherein sensor signals representing no detected rotation of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates that the solenoid is operable and sensor signals representing a non-zero rotational speed of the shaft assembly after energizing the solenoid to move the shaft assembly to the second position indicates a solenoid failure due to the solenoid failing to move the shaft assembly out of the first position; and suspending operation of the stop-start system if a starter motor failure or a solenoid failure is detected by the at least one of the first and second diagnostic checks. - View Dependent Claims (16, 17, 18, 19, 20)
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Specification