Abstract: A starter to start an engine mounted on a vehicle provides an electromagnetic solenoid to push a pinion gear towards a ring gear side, an electromagnetic switch to open and close a motor contact point. The electromagnetic solenoid and the electromagnetic switch are individually controlled by an Electronic Control Unit i.e., ECU. When an idle-stop is triggered, the ECU controls a starter relay to be closed during the ring gear is rotating whereby the pinion gear together with a clutch are pushed out to counter-motor direction by the electromagnetic solenoid. As a result, the pinion gear meshes with the ring gear that is rotating at lower rotational speed. Therefore, the inertial mass of the starter is added to the ring gear so that swinging of the engine can be suppressed.

Abstract: A starter includes an electromagnetic solenoid that generates force for pushing a pinion gear 6 to a ring gear side, and an electromagnetic switch that opens and closes a motor contact point. When idle-stop is performed, an ECU energizes a solenoid coil of the electromagnetic solenoid during inertial rotation until the ring gear stops rotating. After rotation of an engine is stopped, the ECU stops energizing the solenoid coil. As a result, in the starter, the pinion gear can mesh with the ring gear that is rotating by inertia without use of the rotational force of a motor. The meshed state can be maintained even after energization of the solenoid coil is stopped.

Abstract: In a system, an angle sensor outputs a pulse each time an output shaft of an internal combustion engine rotates by a preset angle, and a calculator calculates speed-change information indicative of a change in a speed of rotation of the output shaft based on the pulses outputted from the angle sensor. A determiner determines, based on the speed-change information, whether at least one of the pulses outputted from the angle sensor represents a proper timing for a preset of a pinion of a starter with a ring gear mounted on the output shaft. A pinion engaging unit shifts the pinion toward the ring gear so that the pinion is engaged with the ring gear when it is determined that the at least one of the pulses outputted from the angle sensor represents the proper timing for the preset of the pinion with the ring gear.

Abstract: In a system for cranking a crankshaft of an internal combustion engine, a starter is provided with a motor working to, when energized, rotatably drive an output shaft with a pinion and an actuator working to, when energized, shift the pinion toward the ring gear to be engaged with the ring gear. A power supply is electrically connected to the motor and operative to output electrical power. A first mechanical relay is electrically connected between the power supply and the motor, and works to turn on and off a supply of a current based on the electrical power to the motor for rotating the pinion. A switching element is electrically connected across the first mechanical relay, and works to turn on and off the supply of the current to the motor for rotating the pinion.

Abstract: An engine start system which may be employed in automotive idle stop systems. The engine start system includes a pinion gear to be pushed to a ring gear coupled to an engine for achieving meshing engagement with the ring gear. After the pinion gear engages the ring gear, the engine start system starts to rotate the pinion gear using a starter motor to crank the engine. Specifically, when an engine restart request is made following an engine stop request, the engine start system waits until after the speed of the engine drops below a preselected gear engageble speed and then moves the pinion gear toward the ring gear without rotating the pinion gear. This minimizes the consumption of fuel in the vehicle in supplying electric power to the starter motor and a maximum level of mechanical noise arising from the engagement of the pinion gear with the ring gear.

Abstract: In a system, a starter includes a motor for rotatably driving an output shaft with a pinion and an actuator that shifts the pinion toward a ring gear to be engaged with the ring gear. A monitor unit monitors a rotational speed of the internal combustion engine. The rotational speed of the internal combustion engine drops after an automatic control for stop of the engine. When an engine restart request occurs with the rotational speed being within a preset range during the rotational speed of the internal combustion engine dropping by the automatic control for stop of the engine, a drive unit drives the actuator to shift the pinion toward the ring gear to be engaged with the ring gear. The drive unit rotatably drives the motor with the pinion being engaged with the ring gear to thereby crank the crankshaft.

Abstract: An electromagnetic switch is provided which is equipped with a built-in electronic control circuit working to control energization of an exciting coil. The electronic control circuit is disposed within a chamber defined by a magnetic plate to be separate from a contact chamber. In other words, the electronic control circuit is disposed between the magnetic plate and the exciting coil, thereby avoiding the adhesion of conductive dusts, as arising from the wear of contacts, to the surface of the electronic control circuit. This results in decreases in electric insulation and short-circuit of the electronic control circuit and also eliminates the need for additional special parts to electrically insulate and shield the electronic control circuit, thus permitting the electromagnetic switch to be reduced in size and produced at a decreased const.

Abstract: An electromagnetic switch unit comprises a solenoid device that pushes out a pinion gear to a ring gear side of an engine, and an electromagnetic switch that opens and closes a main point of contact of a motor circuit. The solenoid device and the electromagnetic switch are arranged in series in an axial direction, while a magnetic plate that forms a part of magnetic circuit between a first coil used for the solenoid device and a second coil used for the electromagnetic switch is shared by the solenoid device and the electromagnetic switch.

Abstract: In a rotary electric machine having a field winding wound on field magnet iron cores, and an armature with an armature winding connected in series with the field winding through a pair of brushes and a corresponding pair of connecting leads that are electrically connected to the brushes, a balance winding for equalizing the magnetic field strengths of the field poles is wound around successive field magnet iron cores and thereby retained, and has one end thereof fixedly attached to and electrically connected to one of the connecting leads and the other end electrically connected to and fixedly attached to the other connecting lead.

Abstract: In a solenoid switch according to the invention, a magnetic plate is disposed on one side of a solenoid coil in an axial direction of the solenoid coil. A contact cover is arranged with the magnetic plate interposed between the contact cover and the solenoid coil in the axial direction. First and second fixed contacts are received in the contact cover and respectively electrically connected to first and second terminals that are to be electrically connected to an electric circuit. A resistor is electrically connected between the first and second terminals to limit current flowing through the electric circuit when the first and second fixed contacts are electrically disconnected by a movable contact. The resistor is received in the contact cover and interposed between the magnetic plate and the first and second fixed contacts in the axial direction.

Abstract: An electromagnetic switch is disclosed as having an electromagnetic switch, operative to open or close a main contact of a motor circuit, and a solenoid having a function to push a pinion gear to a position away from a motor. The electromagnetic switch and the solenoid are placed in series in a unitary structure such that the electromagnetic switch and the solenoid have a switch case and a solenoid case both of which are integrally formed with each other to be contiguous in an axial direction. Further, a stationary core for the electromagnet and a stationary core for the solenoid are integrally formed and an operational direction of a plunger for the electromagnet and an operational direction of a plunger for the solenoid are set to be opposite in direction.

Abstract: A carbon brush composed of a brush body and a lead wire is used for supplying electric current to a rotor of a rotary electric machine. The lead wire is made by twisting many thin wire elements each having a diameter smaller than 0.05 mm. A cross-section of the lead wire is made larger than 3 mm2 to give the lead wire a sufficient current capacity. Strength of the lead wire against vibration is improved by using a large number of thin wire elements without sacrificing flexibility. Preferably, a margin length between both ends of the lead wire is provided to allow the lead wire to smoothly follow movements of the brush body slidably contacting a commutator. An amount of a flexure of the lead wire due to the margin length is predetermined so that a stress applied to the wire element does not exceed its permissible fatigue limit.

Abstract: The speed reduction type starter for engines comprises the engaging part 34 arranged in the perimeter of two internal gears 25 and 29 used for a set of speed reducers coaxially, the magnetic coil 35 that drives the engaging part 34 to the direction of the anti-motor side, and the return spring 37 that pushes the engaging part 34 to the direction of the motor side When the magnetic coil 35 is in the OFF state, the engaging part 34 is pushed to the motor side by the return spring 37 to engage with the 1st internal gear 25 mechanically, so that the rotation of the 1st internal gear 25 is regulated and the 1st reduction ratio is selected. On the other hand, when the magnetic coil 35 is in the state of ON, the engaging part 34 is moved to the anti-motor side to engage with the 2nd internal gear 29, so that the rotation of the 2nd internal gear 29 is regulated and the 2nd reduction ratio is selected.

Abstract: A starter for cranking an internal combustion engine is composed of an electric motor, an output shaft driven by the electric motor, a pinion gear unit helical-spline-coupled to the output shaft, and a magnetic switch for supplying electric power to the electric motor in an ON-and-OFF fashion and for engaging or disengaging the pinion gear unit with a ring gear of the engine. The pinion gear unit is made by fixedly connecting a pinion gear, a rotation-restricting ring and a bearing member together. These components are separately formed from one another and then assembled to a unitary body of the pinion gear unit. Therefore, they can be forged with simple dies, or may be manufactured by other methods such as machining.

Abstract: An armature of a rotary electric machine composed of an armature core, an armature winding and a shaft is manufactured in the following manner. A conductor bar including plural conductors connected in line is formed, and each conductor is cut out from the conductor bar. The conductor in a straight shape is inserted into each slot of the armature core, and then both side portions of the conductor are bent at substantially right angle so that the side portions are positioned along axial end surfaces of the armature core. The side portions are further skewed and electrically connected to form the armature winding. An outer surface of the side portions circularly arranged on the axial end surface of the armature core is used as a commutator surface.

Abstract: A brush body 4 of a metal-graphite brush 2 is composed of a commutator side portion 6 which contains graphite, copper and a metal sulfide solid lubricant, and a lead side portion 8 which contains graphite and copper but does not contain any metal sulfide solid lubricant. A lead wire 10 is attached to the lead side portion 8 containing no metal sulfide solid lubricant.

Abstract: In a method of manufacturing a rotor of a rotary electric machine, a rotor core is formed by preparing a material sheet in a form of a belt. The material sheet has teeth extending from a first side of a middle portion of the material sheet and projections projecting from a second side of the middle portion in a direction opposite to the teeth. The projections define recesses therebetween. Each projection and each recess has substantially the same dimension with respect to a centerline between a first line passing through tops of the projections and a second line passing through bottoms of the recesses. The material sheet is helically wound so that the projections are located on an inner diameter side of a rotor core.

Abstract: The brush holding device includes a brush holder having a brush-housing chamber, and a holder plate to which the brush holder is attached. The holder plate is formed with a center hole at a center portion thereof, the center hole having a size allowing a commutator to path therethrough, and a pair of elongated holes opposing to each other with respect to the opening portion, the elongated holes defining bridge portions with the opening hole. The brush holder has a thick-wall portion integral with a bottom wall of the brush-housing chamber, the thick-wall portion being formed with fitting grooves at lateral sides thereof. The bridge portions are inserted into the fitting grooves so that the brush holder is fitted to the holding plate in such a state that the thick-wall portion is caught between the bridge portions.

Abstract: In a rotary electric machine having a field winding wound on field magnet iron cores, and an armature with an armature winding connected in series with the field winding through a pair of brushes and a corresponding pair of connecting leads that are electrically connected to the brushes, a balance winding for equalizing the magnetic field strengths of the field poles is wound around successive field magnet iron cores and thereby retained, and has one end thereof fixedly attached to and electrically connected to one of the connecting leads and the other end electrically connected to and fixedly attached to the other connecting lead.

Abstract: 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.