Granted Patent B2

US 7,237,447 · App. 10/742,096 · Granted Jul 3, 2007

Abstract

Claims (40)

1. An apparatus for starting an internal combustion engine comprising:

a torque transfer element coupled to a crankshaft of the engine and arranged to be driven by a starter motor, wherein

the torque transfer element includes a gear mechanism arranged to allow said starter motor to rotate for a period of time prior to transferring rotational torque to the crankshaft to start the engine, said gear mechanism including a driven member selectively rotated by said starter motor relative to the crankshaft, said driven member being stopped to transfer kinetic energy from said gear mechanism to the crankshaft to rotate the crankshaft.

2. The apparatus of claim 1 wherein the driven member is a ring gear.

3. The apparatus of claim 2 wherein said gear mechanism comprises a planetary gear set having:

a sun gear splined for rotation with said starter motor;

at least one gear in meshed engagement with said sun gear; and

a planet carrier journally supporting said pinion gear and operable to rotate with said pinion gear relative to said sun gear and said ring gear;

wherein said ring gear axially surrounds and is in meshed engagement with said pinion gear and is operable to rotate relative to said pinion pear.

4. The apparatus of claim 3 further comprising a first pulley fixed for rotation with said planet carrier, said first pulley driven by said planet carrier when said kinetic energy is transferred from said sun gear to said planet carrier in response to said ring gear being stopped.

5. The starter system of claim 4 further comprising a second pulley disposed proximate said first pulley, said first pulley operable to rotate said second pulley and said second pulley operable to rotate said first pulley.

6. The starter system of claim 5 further comprising a belt or chain disposed between said first and second pulleys, said belt or chain operable to transfer loads between said first and second pulleys.

7. The starter system of claim 5 wherein said second pulley is splined for rotation with a crankshaft of the engine.

8. The starter system of claim 3 wherein said ring gear includes an engagement arm, said engagement arm operable to selectively restrict rotation of said ring gear.

9. The starter system of claim 8 further comprising a stop plate, said stop plate operable to engage said engagement arm of said ring gear to selectively restrict movement of said ring gear and allow said sun gear to transfer said kinetic energy to said planet carrier.

10. The starter system of claim 9 wherein said stop plate includes a first and second engagement surface, said first engagement surface operable to receive said stop arm to restrict rotational movement of said ring gear when said output shaft of said starter motor is driving said ring gear and said second engagement surface operable to receive said stop arm to restrict rotational movement of said ring gear when said output shaft is driven by the engine.

11. A starter system for use with an engine comprising:

a starter motor;

an output shaft rotatably driven by said starter motor;

a sun gear fixed for rotation with said output shaft;

a plurality of pinion gears axially disposed around, and in meshed engagement with, said sun gear;

a ring gear axially surrounding, and in meshed engagement with, said plurality of pinion gears, said ring gear operable to rotate relative to said pinion gears to allow said output shaft to rotate and build up kinetic energy;

a planet carrier journally supporting said pinion gears, said planet carrier rotatable through rotation of said pinion gears relative said sun gear;

a first pulley fixed for rotation with said planet carrier;

a second pulley in mechanical communication with said first pulley, said second pulley operably engaged with a crankshaft of the engine, said second pulley operable to deliver a rotational torque from said output shaft of said starter motor to said crankshaft at a predetermined torque when said kinetic energy is transferred from said sun gear to said planet carrier in response to said ring gear being abruptly stopped.

12. The starter system of claim 11 further including a stop plate, said stop plate having a first side and a second side, and wherein said ring gear further includes a stop arm, said stop arm operable to selectively engage said stop plate on said first side and restrict further rotation of said ring gear when said ring gear is sufficiently rotated by said pinion gears to deliver a predetermined torque to the engine via said planet carrier and said first and second pulleys.

13. The starter system of claim 12 wherein said stop arm is operable to engage said stop plate on said second side to restrict further rotation of said ring gear when said second pulley drives the output shaft of said starter via said first pulley, said pinion gears, and said sun gear.

14. The starter system of claim 13 wherein said starter motor is operable to generate electrical energy when said stop arm is engaged with said second side of said stop plate and said output shaft of said starter motor is driven by said second pulley.

15. A method for starting an engine comprising:

coupling a planetary gear set to a starter motor;

allowing said starter motor to rotate a driven member to accumulate kinetic energy without concurrently driving an output of said planetary gear set;

transferring said kinetic energy from said starter motor to said output of said planetary gear set by stopping said driven member;

driving a crankshaft of the engine with said output of said planetary gear set; and

rotating said crankshaft in response to rotation of said output of said planetary gear set to thereby start the engine.

16. The method of claim 15 further comprising fixing a first pulley for rotation with said output of said planetary gear set and fixing a second pulley for rotation with said crankshaft said first and second pulleys operable to transmit rotational forces therebetween.

17. The method of claim 16 further comprising driving said second pulley by the engine when a rotational speed of said crankshaft is greater than a rotational speed of said starter motor.

18. The method of claim 17 further comprising driving said first pulley, said planetary gear set, and said output shaft of said starter motor by said second pulley when the rotational speed of said crankshaft is greater than the rotational speed of said starter motor.

19. The method of claim 18 further comprising generating electrical energy through rotation of said starter motor when said starter motor is driven by said second pulley.

20. The method of claim 15 further comprising driving said planetary gear set with the engine to rotate said starter motor when said starter motor is not engaged to start the engine.

21. The method of claim 15 further comprising providing a stop plate, said stop plate operable to engage said driven member and transfer said kinetic energy from said starter motor to said output of said planetary gear set.

Assignments (20)