Borgwarner Inc.

Remy Technologies, LLC

Michael E Kirk

Mingshe Zhou

William P Whitlock

Kurt Wachowski

Rodney E Spangler

Randy L Andis

A starter assembly which includes a switch for energizing a solenoid. Energizing the solenoid biases a starter gear into engagement and energizes the starter motor. A thermally responsive switch is positioned to absorb heat generated by operation of the electric motor and is disposed in an electrical line controlling operation of the switch controlling the solenoid wherein opening of the thermally responsive switch results in the opening of the solenoid switch. The use of such a thermally responsive switch de-energizes the electric motor when the electric motor is subjected to elevated operating temperatures that might otherwise cause damage to the electric motor. The starter assembly may also include control circuitry that includes a microprocessor wherein the control circuitry is operably coupled with the switch controlling the solenoid. The control circuitry is programmed to de-energize the solenoid upon the satisfaction of predetermined conditions to thereby prevent damage to the electrical motor.

Vehicle starter with integrated thermal protection

An electric machine having a field coil and a rotatable armature coil. A rotatable commutator is conductively coupled with the armature coil and has a plurality of contacts. A plurality of brushes are conductively engageable with the plurality of contacts wherein rotation of commutator about the rotational axis causes the plurality of contacts to sequentially engage the plurality of brushes as the plurality of contacts rotate about the rotational axis. The plurality of brushes includes at least one positive brush and at least one negative brush, the at least one positive brush being a multi-layer brush and the negative brush being a single layer block brush. The multi-layer brush may include a high-copper layer and a low-copper layer with the low-copper layer forming the trailing edge of the brush. The single layer brush may have a copper content greater than the high-copper layer of the multi-layer brush.

Electric machine with single layer and multilayer commutator brushes

A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct 'click-no-crank' events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.

Starter system having controlling relay switch

A system for detecting operation of a motor includes a ripple voltage detector module including a ripple voltage detector unit, an input operatively connected to the ripple voltage detector unit and connectable to an alternator, and an output operatively connected to the ripple voltage detector unit and connectable to a starter motor control system. The ripple voltage detector module provides a motor operation signal to the starter motor control system upon detection of a ripple voltage produced by the alternator.

System and method for detecting an operating motor

The present disclosure teaches a system for starting an engine in which at least two starter assemblies are employed to crank a ring gear of an engine. At least one of the starter assemblies has a 'smart relay' configured with an auto-retry function that detects abutment and corrects it by powering the solenoid off and then on again. Advantageously, multiple starter assemblies can be in electrical communication with one another so that click-no-crank events in the starter assemblies can be corrected.

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Greenfield, IN, United States of America

Michael E Kirk