WO2012031191A1 - Soft-start systems and methods for vehicle starters - Google Patents

Soft-start systems and methods for vehicle starters Download PDF

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Publication number
WO2012031191A1
WO2012031191A1 PCT/US2011/050312 US2011050312W WO2012031191A1 WO 2012031191 A1 WO2012031191 A1 WO 2012031191A1 US 2011050312 W US2011050312 W US 2011050312W WO 2012031191 A1 WO2012031191 A1 WO 2012031191A1
Authority
WO
WIPO (PCT)
Prior art keywords
plunger
contact bar
terminal
solenoid
coil
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2011/050312
Other languages
French (fr)
Inventor
Aleksander Hrnjak
James David Plenzler
Robert David Hall
Clive Harley
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Prestolite Electric Inc
Original Assignee
Prestolite Electric Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Prestolite Electric Inc filed Critical Prestolite Electric Inc
Priority to EP11822709.9A priority Critical patent/EP2612341A4/en
Priority to CN201180052002.XA priority patent/CN103250223B/en
Priority to CA2810397A priority patent/CA2810397C/en
Priority to MX2013002514A priority patent/MX2013002514A/en
Publication of WO2012031191A1 publication Critical patent/WO2012031191A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/44—Magnetic coils or windings
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N11/087—Details of the switching means in starting circuits, e.g. relays or electronic switches
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/02—Non-polarised relays
    • H01H51/04—Non-polarised relays with single armature; with single set of ganged armatures
    • H01H51/06—Armature is movable between two limit positions of rest and is moved in one direction due to energisation of an electromagnet and after the electromagnet is de-energised is returned by energy stored during the movement in the first direction, e.g. by using a spring, by using a permanent magnet, by gravity
    • H01H51/065—Relays having a pair of normally open contacts rigidly fixed to a magnetic core movable along the axis of a solenoid, e.g. relays for starting automobiles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N2011/0881—Components of the circuit not provided for by previous groups
    • F02N2011/0892—Two coils being used in the starting circuit, e.g. in two windings in the starting relay or two field windings in the starter
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H51/00—Electromagnetic relays
    • H01H51/02—Non-polarised relays
    • H01H51/20—Non-polarised relays with two or more independent armatures

Definitions

  • a soft start is to run the motor initially with reduced torque in the powertrain, which can allow the pinion to fully engage the ring gear prior to the motor being run at full power.
  • present vehicle motors include a relay between the ignition switch and the solenoid that provides operating current to the motor. Examples of patent references that describe such
  • FIG. 1 A schematic of a prior art vehicle start system 100 that includes a relay 102 between the ignition switch 104 and the solenoid 106 is depicted in FIG. 1.
  • the system 100 also includes a battery 108 and motor 110.
  • the ignition switch 104 allows power (about 1-5 amps, for example) to flow from battery 108 to relay 102.
  • Relay 102 then allows power (about 250 amps, for example) to flow from battery 108 to solenoid 106.
  • Energizing solenoid 106 allows power (about 250 amps, for example) to flow to motor 110 and begins solenoid plunger moving toward contacts 114 and 116.
  • solenoid plunger 112 When solenoid plunger 112 abuts contacts 114 and 116, higher power (about 2000 amps, for example) flows from battery 108 to motor 110 via solenoid 106. The initial period when the motor is supplied lower power (about 250 amps, for example) provides a soft start.
  • Embodiments of the present technology provide improved soft-start systems and methods.
  • FIG. 1 is a schematic of a prior art vehicle start system.
  • FIG. 2 is a schematic of a vehicle start system used in accordance with an embodiment of the present technology in a first state.
  • FIG. 3 is a schematic of the vehicle start system of FIG. 2 in a second state.
  • FIG. 4 is a schematic of the vehicle start system of FIG. 2 in a third state.
  • FIG. 5 is a schematic of the vehicle start system of FIG. 2 in a fourth state.
  • FIG. 6 depicts a side-sectional view of a solenoid used in accordance with an embodiment of the present technology.
  • FIG. 7 depicts a perspective view of the solenoid of FIG. 6.
  • FIG. 8 depicts a side-sectional view of the solenoid of FIG. 6.
  • FIG. 9 depicts a side-sectional view of the solenoid of FIG. 6.
  • FIG. 10 depicts a side- sectional view of the solenoid of FIG. 6.
  • Embodiments of the present technology provide improved soft-start systems and methods.
  • like elements are identified with like indicators.
  • FIG. 1 is a schematic of a prior art vehicle start system 100 that is described in the background section.
  • FIG. 2 is a schematic of a vehicle start system 200 used in accordance with an embodiment of the present technology in a first state.
  • the vehicle start system 200 includes key switch 202, solenoid 203, battery 204, motor 206 and ground 208.
  • Solenoid 203 includes hold coil 210, pull coil 212, first plunger with contact bar 214, first terminal 215, second plunger with contact bar 216, and second terminal 217.
  • key switch 202 is open/off such that: (1) power does not flow to solenoid 203 from battery 204 via connection Bi; (2) power does not flow to solenoid 203 from battery 204 via connection B 2 ; and (3) power does not flow to solenoid 203 from battery 204 via connection B 3 .
  • This is the state of the vehicle start system 200 when motor 206 is not running and vehicle ignition has not been triggered, for example, by an operator of the vehicle turning a key in the ignition.
  • FIG. 3 is a schematic of the vehicle start system 200 in a second state. This is the state of the vehicle start system 200 immediately after a vehicle ignition is triggered, for example, by an operator of the vehicle turning a key in the ignition.
  • key switch 202 is closed/on such that power (about 1-10 amps, for example) is allowed to flow to solenoid 203 from battery 204 via connection Bi.
  • Supplying power to solenoid 203 via connection Bi energizes hold coil 210 causing first plunger with contact bar 214 to move laterally toward first terminal 215.
  • Motor 206 is not running in this state.
  • FIG. 4 is a schematic of the vehicle start system 200 in a third state. This is the state of the vehicle start system 200
  • first plunger immediately after contact bar 214 of first plunger abuts first terminal 215. Abutting contact bar 214 to first terminal 215 energizes pull coil 212 via connection B 3 , thereby allowing power (about 200 amps, for example) to flow to motor 206 from battery 204 via solenoid 203 and connection B 3 , and causing second plunger with contact bar 216 to move laterally toward second terminal 217. Motor 206 is running in this state at lower power (about 200 amps, for example) providing a soft-start.
  • FIG. 5 is a schematic of the vehicle start system 200 in a fourth state. This is the state of the vehicle start system 200
  • FIG. 6 depicts a side-sectional view of a solenoid 600 used in accordance with an embodiment of the present technology.
  • Solenoid 600 includes the elements of solenoid 203 described above in connection with FIGs. 2-5. Solenoid 600 also includes body 602, bobbin 604 and anvil 606, and depicts the first plunger 608 with contact bar 214 and the second plunger 610 with contact bar 216.
  • FIG. 7 depicts a perspective view of the solenoid of FIG. 6.
  • FIGs. 8-10 depict side- sectional views of the solenoid of FIG. 6.
  • FIG. 8 depicts solenoid 600 in the first state described above in connection with FIG. 2.
  • first state there is a first gap 802 that first plunger 608 with contact bar 214 can traverse prior to contact bar abutting first terminal 215.
  • second gap 804 there is also a second gap 804 that second plunger 610 with contact bar 216 can traverse prior to contact bar abutting first terminal 217.
  • FIG. 9 depicts solenoid 600 in the third state described above in connection with FIG. 4.
  • first plunger 608 with contact bar 214 abuts first terminal 215, but second plunger 610 with contact bar 216 does not abut second terminal 217.
  • an attached motor would be running at lower power (about 200 amps, for example) providing a soft-start.
  • FIG. 10 depicts solenoid 600 in the fourth state described above in connection with FIG. 5.
  • first plunger 608 with contact bar 214 abuts first terminal 215, and second plunger 610 with contact bar 216 abuts second terminal 217.
  • an attached motor would be running at higher power (about 2000 amps, for example).
  • FIGs. 9-10 also depict the magnetic path 902 of the solenoid coils 210, 212.
  • a solenoid and/or vehicle start system as described herein can provide a soft-start for a motor without requiring an additional relay.
  • Certain embodiments of the present invention include methods of starting an engine using a solenoid and/or vehicle start system as described herein.
  • Certain embodiments of the present invention include methods of making a solenoid and/or vehicle start system as described herein.
  • Certain embodiments of the inventive solenoids and/or vehicle start systems can provide for: (1) improved use of space by eliminating the additional relay; (2) removal of a potential point of failure; and/or (3) lower cost.

Landscapes

  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)
  • Electromagnets (AREA)
  • Hybrid Electric Vehicles (AREA)
  • Motor And Converter Starters (AREA)

Abstract

Soft-start systems and methods for vehicle starters are provided. Embodiments provide a solenoid including: a first coil that receives power when an ignition switch is closed; a first plunger actuated when the first coil receives power; a first terminal configured to be abutted by a contact bar of the first plunger; a second coil that receives power when the contact bar of the first plunger abuts the first terminal; a second plunger actuated when the second coil receives power; and a second terminal configured to be abutted by a contact bar of the second plunger. Such a solenoid is configured to provide power at a first level to an attached motor when the contact bar of the first plunger abuts the first terminal and at a second level that is higher than the first level when the contact bar of the second plunger abuts the second terminal.

Description

SOFT-START SYSTEMS AND METHODS FOR VEHICLE
STARTERS
Background of the Invention
[0001] During vehicle start-up, it has been found desirable to run the motor initially at reduced power. This practice is referred to as a "soft- start." One advantage of a soft start is to run the motor initially with reduced torque in the powertrain, which can allow the pinion to fully engage the ring gear prior to the motor being run at full power. In order to achieve a soft-start, present vehicle motors include a relay between the ignition switch and the solenoid that provides operating current to the motor. Examples of patent references that describe such
configurations include US. Patent No. 5,475,270, US. Patent No. 5,892,422 and U.S. App. Pub. No. 2009/0002105.
[0002] A schematic of a prior art vehicle start system 100 that includes a relay 102 between the ignition switch 104 and the solenoid 106 is depicted in FIG. 1. The system 100 also includes a battery 108 and motor 110. In operation, when a vehicle operator turns the key, the ignition switch 104 allows power (about 1-5 amps, for example) to flow from battery 108 to relay 102. Relay 102 then allows power (about 250 amps, for example) to flow from battery 108 to solenoid 106. Energizing solenoid 106 allows power (about 250 amps, for example) to flow to motor 110 and begins solenoid plunger moving toward contacts 114 and 116. When solenoid plunger 112 abuts contacts 114 and 116, higher power (about 2000 amps, for example) flows from battery 108 to motor 110 via solenoid 106. The initial period when the motor is supplied lower power (about 250 amps, for example) provides a soft start.
[0003] However, the extra relay takes up space, is a potential point of failure and adds cost to the vehicle starting system.
[0004] Thus, there is a need for improved soft-start systems and methods for vehicles.
Summary of the Invention
[0005] Embodiments of the present technology provide improved soft-start systems and methods.
Brief Description of the Drawing(s)
[0006] FIG. 1 is a schematic of a prior art vehicle start system. [0007] FIG. 2 is a schematic of a vehicle start system used in accordance with an embodiment of the present technology in a first state.
[0008] FIG. 3 is a schematic of the vehicle start system of FIG. 2 in a second state.
[0009] FIG. 4 is a schematic of the vehicle start system of FIG. 2 in a third state.
[0010] FIG. 5 is a schematic of the vehicle start system of FIG. 2 in a fourth state.
[0011] FIG. 6 depicts a side-sectional view of a solenoid used in accordance with an embodiment of the present technology.
[0012] FIG. 7 depicts a perspective view of the solenoid of FIG. 6.
[0013] FIG. 8 depicts a side-sectional view of the solenoid of FIG. 6.
[0014] FIG. 9 depicts a side-sectional view of the solenoid of FIG. 6.
[0015] FIG. 10 depicts a side- sectional view of the solenoid of FIG. 6. [0016] The foregoing summary, as well as the following detailed description of embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, certain embodiments are shown in the drawings. It should be understood, however, that the present invention is not limited to the arrangements and
instrumentalities shown in the attached drawings.
Detailed Description of Preferred Embodiment(s)
[0017] Embodiments of the present technology provide improved soft-start systems and methods. In the figures, like elements are identified with like indicators.
[0018] FIG. 1 is a schematic of a prior art vehicle start system 100 that is described in the background section.
[0019] FIG. 2 is a schematic of a vehicle start system 200 used in accordance with an embodiment of the present technology in a first state. The vehicle start system 200 includes key switch 202, solenoid 203, battery 204, motor 206 and ground 208. Solenoid 203 includes hold coil 210, pull coil 212, first plunger with contact bar 214, first terminal 215, second plunger with contact bar 216, and second terminal 217. In the first state depicted in FIG. 2, key switch 202 is open/off such that: (1) power does not flow to solenoid 203 from battery 204 via connection Bi; (2) power does not flow to solenoid 203 from battery 204 via connection B2; and (3) power does not flow to solenoid 203 from battery 204 via connection B3. This is the state of the vehicle start system 200 when motor 206 is not running and vehicle ignition has not been triggered, for example, by an operator of the vehicle turning a key in the ignition.
[0020] FIG. 3 is a schematic of the vehicle start system 200 in a second state. This is the state of the vehicle start system 200 immediately after a vehicle ignition is triggered, for example, by an operator of the vehicle turning a key in the ignition. In the second state depicted in FIG. 3, key switch 202 is closed/on such that power (about 1-10 amps, for example) is allowed to flow to solenoid 203 from battery 204 via connection Bi. Supplying power to solenoid 203 via connection Bi energizes hold coil 210 causing first plunger with contact bar 214 to move laterally toward first terminal 215. Motor 206 is not running in this state. [0021] FIG. 4 is a schematic of the vehicle start system 200 in a third state. This is the state of the vehicle start system 200
immediately after contact bar 214 of first plunger abuts first terminal 215. Abutting contact bar 214 to first terminal 215 energizes pull coil 212 via connection B3, thereby allowing power (about 200 amps, for example) to flow to motor 206 from battery 204 via solenoid 203 and connection B3, and causing second plunger with contact bar 216 to move laterally toward second terminal 217. Motor 206 is running in this state at lower power (about 200 amps, for example) providing a soft-start.
[0022] FIG. 5 is a schematic of the vehicle start system 200 in a fourth state. This is the state of the vehicle start system 200
immediately after second plunger with contact bar 216 abuts second terminal 217. Abutting contact bar 216 of second plunger to second terminal 217 allows higher power (about 2000 amps, for example) to flow to motor 206 from battery 204 via solenoid 203 and connection B2. Motor 206 is running in this state at higher power (about 2000 amps, for example). [0023] When the motor is stopped, for example by an operator of the vehicle turning a key in the ignition, the vehicle start system 200 will return to the first state depicted in FIG. 2.
[0024] FIG. 6 depicts a side-sectional view of a solenoid 600 used in accordance with an embodiment of the present technology.
Solenoid 600 includes the elements of solenoid 203 described above in connection with FIGs. 2-5. Solenoid 600 also includes body 602, bobbin 604 and anvil 606, and depicts the first plunger 608 with contact bar 214 and the second plunger 610 with contact bar 216.
FIG. 7 depicts a perspective view of the solenoid of FIG. 6.
[0025] FIGs. 8-10 depict side- sectional views of the solenoid of FIG. 6. FIG. 8 depicts solenoid 600 in the first state described above in connection with FIG. 2. In the first state, there is a first gap 802 that first plunger 608 with contact bar 214 can traverse prior to contact bar abutting first terminal 215. There is also a second gap 804 that second plunger 610 with contact bar 216 can traverse prior to contact bar abutting first terminal 217.
[0026] FIG. 9 depicts solenoid 600 in the third state described above in connection with FIG. 4. In the third state, first plunger 608 with contact bar 214 abuts first terminal 215, but second plunger 610 with contact bar 216 does not abut second terminal 217. In this state, an attached motor would be running at lower power (about 200 amps, for example) providing a soft-start.
[0027] FIG. 10 depicts solenoid 600 in the fourth state described above in connection with FIG. 5. In the fourth state, first plunger 608 with contact bar 214 abuts first terminal 215, and second plunger 610 with contact bar 216 abuts second terminal 217. In this state, an attached motor would be running at higher power (about 2000 amps, for example).
[0028] FIGs. 9-10 also depict the magnetic path 902 of the solenoid coils 210, 212.
[0029] In operation, a solenoid and/or vehicle start system as described herein can provide a soft-start for a motor without requiring an additional relay. Certain embodiments of the present invention include methods of starting an engine using a solenoid and/or vehicle start system as described herein. Certain embodiments of the present invention include methods of making a solenoid and/or vehicle start system as described herein. [0030] Certain embodiments of the inventive solenoids and/or vehicle start systems can provide for: (1) improved use of space by eliminating the additional relay; (2) removal of a potential point of failure; and/or (3) lower cost.
[0031] While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood that the invention is not limited thereto since
modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings.

Claims

What is claimed is:
1. A solenoid for use in a vehicle starting system
comprising:
a first coil configured to receive power when an ignition switch is closed;
a first plunger comprising a contact bar operatively connected to the first coil such that the first plunger is actuated when the first coil receives power;
a first terminal configured to be abutted by the contact bar of the first plunger after the first plunger is actuated;
a second coil configured to receive power when the contact bar of the first plunger abuts the first terminal;
a second plunger comprising a contact bar operatively connected to the second coil such that the second plunger is actuated when the second coil receives power; and
a second terminal configured to be abutted by the contact bar of the second plunger after the second plunger is actuated,
the solenoid configured to provide power at a first level to an attached motor when the contact bar of the first plunger abuts the first terminal and the contact bar of the second plunger does not abut the second terminal, and
the solenoid configured to provide power to an attached motor at a second level that is higher than the first level when the contact bar of the second plunger abuts the second terminal.
2. A method of starting a vehicle using a solenoid
comprising:
providing power to a first coil of a solenoid when an ignition switch is closed;
actuating a first plunger comprising a contact bar operatively connected to the first coil when the first coil receives power;
abutting the contact bar of the first plunger with a first terminal; providing power to a second coil when the contact bar of the first plunger abuts the first terminal;
providing power to a motor at a first level when the contact bar of the first plunger abuts the first terminal;
actuating a second plunger comprising a contact bar operatively connected to the second coil when the second coil receives power; abutting the contact bar of the second plunger with a second terminal; and
providing power to a motor at a second level that is higher than the first level when the contact bar of the second plunger abuts the second terminal.
PCT/US2011/050312 2010-09-02 2011-09-02 Soft-start systems and methods for vehicle starters Ceased WO2012031191A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
EP11822709.9A EP2612341A4 (en) 2010-09-02 2011-09-02 Soft-start systems and methods for vehicle starters
CN201180052002.XA CN103250223B (en) 2010-09-02 2011-09-02 Soft start system and method for vehicle starter
CA2810397A CA2810397C (en) 2010-09-02 2011-09-02 Soft-start systems and methods for vehicle starters
MX2013002514A MX2013002514A (en) 2010-09-02 2011-09-02 Soft-start systems and methods for vehicle starters.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US37942810P 2010-09-02 2010-09-02
US61/379,428 2010-09-02

Publications (1)

Publication Number Publication Date
WO2012031191A1 true WO2012031191A1 (en) 2012-03-08

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PCT/US2011/050312 Ceased WO2012031191A1 (en) 2010-09-02 2011-09-02 Soft-start systems and methods for vehicle starters

Country Status (6)

Country Link
US (2) US8476997B2 (en)
EP (1) EP2612341A4 (en)
CN (2) CN105118743A (en)
CA (2) CA2871444C (en)
MX (1) MX2013002514A (en)
WO (1) WO2012031191A1 (en)

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KR20150128993A (en) * 2013-03-15 2015-11-18 레미 테크놀러지스 엘엘씨 Variable flux starter and switch system
US20140283533A1 (en) * 2013-03-22 2014-09-25 Aura Systems, Inc. Apparatus and Method for Electrical Transport Refrigeration in a Tractor-Trailer System
JP6078434B2 (en) * 2013-08-08 2017-02-08 株式会社デンソー Solenoid device
DE102015119352B4 (en) * 2015-11-10 2018-06-07 Lisa Dräxlmaier GmbH ELECTROMECHANIC PROTECTION SWITCH
CN112930438B (en) * 2018-11-09 2023-01-03 三菱电机株式会社 Electromagnetic switch device

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US20020053961A1 (en) * 2000-11-06 2002-05-09 Sadayoshi Kajino Starter motor magnetic switch having auxiliary relay
US20020158519A1 (en) * 2001-03-13 2002-10-31 Delco Remy America, Inc. Multiple coil pull-in coil for a solenoid assembly for a starter motor assembly
US20090002105A1 (en) * 2007-06-29 2009-01-01 Remy International, Inc. Integrated solenoid and ignition magnetic switch
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Publication number Publication date
EP2612341A1 (en) 2013-07-10
CA2871444C (en) 2015-11-03
US8476997B2 (en) 2013-07-02
EP2612341A4 (en) 2014-08-20
MX2013002514A (en) 2013-10-28
CA2810397A1 (en) 2012-03-08
CN103250223B (en) 2015-08-19
CN105118743A (en) 2015-12-02
CN103250223A (en) 2013-08-14
US8669835B2 (en) 2014-03-11
CA2810397C (en) 2015-03-03
US20130285772A1 (en) 2013-10-31
CA2871444A1 (en) 2012-03-08
US20120139677A1 (en) 2012-06-07

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