Denso Corporation

Nippondenso Co., Ltd.

Masahiro Katoh

Masami Niimi

Tsutomu Shiga

Mikio Saito

Masanori Ohmi

Yasuyuki Wakahara

Kiyokazu Haruno

Takeshi Araki

Hideki Ichikawa

Masahiko Osada

Nobuyuki Hayashi

Shinji Usami

Tatsuya Saito

Akifumi Hosoya

Kazuhiro Ando

Yasuhiro Nagao

Kazuhiro Andoh

Masahiro Takada

Yasuyuki Yoshida

Tetsunori Inoguchi

Masato Hanai

Kazuo Hirama

Hiroshi Kaneda

Hiroshige Kako

A starter with an intermediate gear includes a front bearing portion formed with a mounting hole for supporting the front end portion of an intermediate shaft and a retaining hole located at a position offset from a center of the mounting hole in a radial direction in such a manner as to intersect the mounting hole, and a screw member threaded into the retaining hole and remaining in engagement with the intermediate shaft to retain the intermediate shaft in a fixed position against removal from housing.

Starter with intermediate gear

A method of manufacturing a yoke includes a step of cutting a steel plate into a rectangular sheet having a plurality of first dovetail convexities at one end thereof and a plurality of second dovetail convexities at the other end, a step of rolling the rectangular sheet into a cylinder to fit the first dove tails and the second dove tails to each other and a step of punching border portions of the first dove tails and the second dove tails. The second dovetail convexities are formed to be the same in shape as the first dovetail convexities so that they can fit to the first dovetail convexities. A smooth-faced yoke can be manufacture without using an expensive welder.

Method of manufacturing yoke of rotary electric machine

In an electromagnetic switch of a starter, a bobbin has two terminal holders on a flange. Each of the terminal holders defines a slot on its end surface and a terminal is press-fitted in the slot in an axial direction of the bobbin. An end of an excitation coil wound around the bobbin is pulled out the bobbin and connected to the terminal. A molded cover provides a through hole and is mounted on the terminal so that the terminal passes through the through hole. A sealing member is press-fitted on the terminal to air-tightly seal the through hole. A rod cover fitted on a rod supporting a movable contact has slits on its cylindrical part in the axial direction. The slits are closed before a distal end of the cylindrical part.

Electromagnetic switch for starter

A center case has a force-receiving wall and a fixed wall, and is rigidly fixed in a starter. A gear-forming section is coaxially arranged with the center case, and has a forcing wall and a movable wall on the side of the center case. A cushion member is elastically received between the force-receiving wall of the center case and the forcing wall of the gear-forming section. The fixed wall of the center case and the movable wall of the gear-forming section are arranged to have a gap, and oppose each other. When an excessive torque works on the gear-forming section via an internal gear, the cushion member absorbs an impact force to move the movable wall by a predetermined distance. In this case, the movable wall contacts the fixed wall so that a compression rate of the cushion member can be restricted.

Starter having rotation restricting structure

A starting apparatus for starting an engine has a drive motor and a reduction gear. The reduction gear includes a shock absorbing member and restricting members. The shock absorbing member is provided to elastically receive a reaction force exerted to an internal gear. The restricting members are provided to restrict a compressed amount of the shock absorbing member by making contact with each other. When bringing into contact with each other, the restricting members make contact at the outside diameter portions thereof. Accordingly, unpleasant noise generated during the operation of the starting apparatus is reduced by the shock absorbing member. Further, the damage to respective parts is reduced.

Starting apparatus

A starter for engines uses a leaf spring as a shaft lever for advancing a pinion gear for engagement with a ring gear. The shift lever may be constructed with a plurality of layered leaf springs having respective front ends spaced apart one another to contact a one-way clutch at different positions. The shift lever may include a lever holder which has a low heat conductive member to minimize fatigue of the leaf spring. The leaf spring is initially loaded with a spring force.

Starter having resilient shift lever for driving pinion gear

A brush of a rotary electric machine includes a brush element and a pigtail. The brush element includes a high-conduction member extending in the longitudinal direction and a low-conduction member bonded to a side of the high-conduction member. The low-conduction member is a thin layer extending in the longitudinal direction from the contact surface to the middle of the length of the brush element. The wire end is embedded in the high conduction member on the side of the low-conduction member remote from the contact surface.

Multi-layered brush of rotary electric machine and method of manufacturing the same

A shock absorber for a starter is presented. The shock absorber includes a rotary disk, a stationary disk and a disk spring. The rotary disk is pressed by the disk spring against a stationary disk to generate frictional force when the rotary disk is rotated by an excessive shock thereby absorbing the shock. The rotary disk has a plurality of press-formed rectangular dimples at a surface opposite the stationary disk, and each side of each the rectangular dimple inclines to a direction of rolling of the raw material of the rotary disk.

Shock absorber

A starter motor for cranking an internal combustion engine includes an electric motor, a planetary gear device for reducing a rotational speed of the electric motor, and a shock-absorbing device that absorbs excessive impact transmitted from the engine to the starter motor. The planetary gear device has an annular member contacting a separating plate that separates the planetary gear device from the electric motor. A depressed portion such as a circular groove is formed on an axial end surface of the annular member. Lubricant retained in the depressed portion lubricates the end surface that rotates relative to the separating plate to absorb the excessive impact transmitted from the engine, and thereby abrasion wear of the end surface is suppressed.

Starter motor having planetary gear device for reducing rotational speed of electric motor

A direct current motor includes a stator generating a magnetic field therein and a rotor having an armature and rotating inside the stator. A commutator for supplying electric current to the armature is connected to the rotor. The commutator is composed of plural commutator segments bonded together with an insulating resin material. Each commutator segment includes an anchor portion formed at a radial inside and a projecting portion extending in an axial direction, and both portions are embedded in the insulating resin. The commutator segments are firmly bonded with the insulating resin, and the bonding strength is increased without enlarging the commutator size.

Direct current motor having commutator segments firmly embedded in insulation bond

A starter for engines uses a leaf spring as a shift lever for advancing a pinion gear for engagement with a ring gear. The shift lever may be constructed with a plurality of layered leaf springs having respective front ends spaced apart one another to contact a one-way clutch at different positions. The shift lever may include a lever holder which has a low heat conductive member to minimize fatigue of the leaf spring. The leaf spring is initially loaded with a spring force.

The present invention provides an engine starting method from an idling stop condition wherein a preliminary step pushes a pinion to abut with a ring gear when a vehicle operating condition is in an idling stop condition, a starting step rotates the pinion into mesh with the ring gear by a motor upon receiving an engine start signal and thereafter an engine is started, and a restoring step is carried out after engine startup where the pinion is restored to an original position thereof. Also provided, when the engine is stopped, a pinion is meshed with a ring gear. Upon engine start-up, a pinion actuator disengages the pinion from the ring gear and a cutout portion engages an engaging piece to maintain the pinion disengaged. When the engine stops, a releasing actuator disengages the cutout portion and the engaging piece and the pinion is reset.

Engine starting method in idling stop condition

In a two-layer brush for a commutator, the plane form projected on a commutator surface is nearly similar to the plane form of the segment. A molding die used in brush fabrication has a lower punch which slides obliquely up and down along a sliding groove provided in the lower die, and an upper punch which can slide obliquely up and down in relation to the lower punch. The pressure applying face of the upper punch is formed nearly level, while the pressure receiving face of the lower punch is inclined by a predetermined angle relative to the pressure applying face of the upper punch. It is, therefore, possible to form a first brush material to a predetermined shape, and to apply a uniformly pressure to the second brush powder, to thereby form a second brush material having nearly fixed thickness.

Method of fabricating brushes

In a current supply circuit for starters, an inductance coil is connected in series or a capacitor is connected in parallel with a starter motor to slow down the rise of a current supplied to the starter motor. The current, which flows in a magnet switch upon occurrence of bouncing of the magnet switch, is lowered. Thus even if the time of occurrence of bouncing delays due to increased inductance of a pull-in coil, the magnet switch turns on and off a small current by bouncing and hence generation of noise arising from bouncing can be suppressed. Generation of arc in the magnet switch due to bouncing can be suppressed, and the reliability of the magnet switch can be increased.

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Chiryu, Japan

Masahiro Katoh