Abstract: A pinion gear of a starter is engaged with a ring gear of an internal combustion engine by restricting rotation of the pinion gear while driving a motor at a low speed. After the engagement is established, the motor is driven at a full speed by supplying a full current, thereby cranking up the engine. A crank bar for transferring movement of a plunger in a magnetic switch to a pinion-rotation-restricting member is divided into two or three portions. After the divided portions are assembled to the starter, they are connected together to form a solid piece. In this manner, a process of assembling the crank bar into the starter is simplified.

Abstract: The present invention relates to a starter for an engine, capable of driving the engine at a high torque at the beginning of the starting and of driving it in a high-rotation condition at the end of the starting. An inner circumferential tapered portion of a movable cam plate is pressed against an outer circumferential portion of an outer cam of a clutch so that the outer cam and an internal gear are integrated to rotate at the same speed. Thus, on the epicycle reduction principle, in an epicycle reduction gear device, a sun gear, a planetary gear and an arm portion enter an identical-rotation condition, that is, a reduction ratio 1 condition. Moreover, an outer circumferential tapered portion of the movable cam plate is pressed against a tapered portion of a housing so that the internal gear is placed into a fixed, non-rotatable condition, thereby providing an ordinary epicycle reduction to produce a high reduction ratio.

Abstract: 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.

Abstract: A starter control system is comprised of a starter motor, a control circuit for controlling the starter motor to rotate at a preliminary rotation speed that is high enough to engage a pinion with an engine for a predetermined time and low enough to suppress a harsh noise caused when the pinion engages the engine and, thereafter, at a normal rotation speed that is high enough to start the engine, and a control circuit for changing the preliminary rotation speed according to an engine temperature. The starter control system is effective to reduce noises that are caused when the engine is started by an economy-run system.

Abstract: In a planetary gear speed reduction mechanism includes a drive gear, a driven gear, a sun gear connected to the drive gear, an internal gear disposed around the sun gear, a planetary gear meshed with the sun gear and the internal gear, a bearing for supporting the planetary gear, a carrier pin for supporting the bearing and a planet carrier connected to the carrier pin for transmitting revolving motion of the planetary gear to the driven gear, the bearing has a cylindrical inner wall forming an annular grease reservoir around the carrier pin at opposite ends thereof. The bearing can be lubricated by the grease supplied from the simple grease reservoir for long time.

Abstract: In the case of an engine automatic stop and start system in which an engine is stopped while a vehicle is stopped and the engine is started when the vehicle is started, it is necessary to shorten an engine starting time when a driver desires to move the vehicle. Further, it is desirable to efficiently compensate the electric power consumed by the starter. The vehicle contains an existing low voltage power source and a high voltage power source with an excellent charging efficiency. When the engine switches from a running condition to a stopped condition while the vehicle is stopped, a change-over switch switches and applies the voltage of the high voltage power source to a starter motor. This causes the starter motor to rotate at high speeds, thereby starting the engine very quickly. Therefore, it is possible to reduce overall energy losses and improve vehicle fuel consumption.

Abstract: 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.

Abstract: Simplifying a control system by integrating current control for an exciting coil and a main current control for a starter motor is accomplished by a current control unit for a starter motor and is constructed with a control device provided among a battery, a motor contact point and an exciting coil, and a starter ECU for driving the control device. The control device has a device capacity for allowing main current of the starter motor. The starter ECU changes a control specification for the control device before and after closing the motor contact point. That is, control-start timing of a coil current is determined by a battery voltage before closing the motor contact point. Thereafter, the coil current is restricted to a predetermined value to reduce a moving speed of a plunger. After closing the motor contact point, the main current is slowly raised.

Abstract: A rotary electric machine includes a plurality of permanent magnet main poles disposed on an inner periphery of a yoke and a plurality of auxiliary poles respectively disposed between neighboring two of the main poles via magnet fixing members and a plurality of magnet fixing members. The magnet-fixing member is comprised of a U-bent elastic metal plate having a pair of circumferentially opposite walls that provides a pole space. The opposite walls are respectively bent inward at edges thereof in circumferentially opposite directions to be opposed to each other. The bent edges have and elastic projections and are separated at the axial ends to form an elastic retaining member. The auxiliary pole is inserted into the auxiliary pole space by opening the elastic retaining member.

Abstract: In a starter, a front side bearing is provided between a one-way clutch and a pinion combined at a front end portion of a pinion tube. A housing supporting the pinion tube through the bearing has a housing small diameter portion where the inner diameter of the housing is set smaller than the outer diameter of the one-way clutch, between the bearing and a maximum advanced position of the one-way clutch. A housing front portion of the housing is formed into a cylindrical shape ahead of a attachment face which opposes to an engine side. The outer diameter of the front portion is gradually increased from the front end toward the attachment face. In this structure, the starter is installed from a transmission side without interfering the front portion of the housing with a transmission case.

Abstract: In the case of an engine automatic stop and start system in which an engine is stopped while a vehicle is stopped and the engine is started when the vehicle is started, it is necessary to shorten an engine starting time when a driver desires to move the vehicle. Further, it is desirable to efficiently compensate the electric power consumed by the starter. The vehicle contains an existing low voltage power source and a high voltage power source with an excellent charging efficiency. When the engine switches from a running condition to a stopped condition while the vehicle is stopped, a change-over switch switches and applies the voltage of the high voltage power source to a starter motor. This causes the starter motor to rotate at high speeds, thereby starting the engine very quickly. Therefore, it is possible to reduce overall energy losses and improve vehicle fuel consumption.

Abstract: A rotary electric machine includes a plurality of permanent magnet main poles disposed on an inner periphery of a yoke and a plurality of auxiliary poles respectively disposed between neighboring two of the main poles via magnet fixing members and a plurality of magnet fixing members. The magnet-fixing member is comprised of a U-bent elastic metal plate having a pair of circumferentially opposite walls that provides a pole space. The opposite walls are respectively bent inward at edges thereof in circumferentially opposite directions to be opposed to each other. The bent edges have and elastic projections and are separated at the axial ends to form an elastic retaining member. The auxiliary pole is inserted into the auxiliary pole space by opening the elastic retaining member.

Abstract: In a planetary gear speed reduction mechanism includes a drive gear, a driven gear, a sun gear connected to the drive gear, an internal gear disposed around the sun gear, a planetary gear meshed with the sun gear and the internal gear, a bearing for supporting the planetary gear, a carrier pin for supporting the bearing and a planet carrier connected to the carrier pin for transmitting revolving motion of the planetary gear to the driven gear, the bearing has a cylindrical inner wall forming an annular grease reservoir around the carrier pin at opposite ends thereof. The bearing can be lubricated by the grease supplied from the simple grease reservoir for long time.

Abstract: A starter control system is comprised of a starter motor, a control circuit for controlling the starter motor to rotate at a preliminary rotation speed that is high enough to engage a pinion with an engine for a predetermined time and low enough to suppress a harsh noise caused when the pinion engages the engine and, thereafter, at a normal rotation speed that is high enough to start the engine, and a control circuit for changing the preliminary rotation speed according to an engine temperature. The starter control system is effective to reduce noises that are caused when the engine is started by an economy-run system.

Abstract: 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.

Abstract: 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.

Abstract: A starter for an engine includes a housing. A starter motor in said housing includes a field apparatus including a tubular yoke being provided to form a part of the housing. An annular ventilation passage is provided in the starter defined along an inner periphery of the yoke and being hermetically sealed from an inside of the yoke. A first ventilation hole is defined proximate a bottom portion of the housing for interconnecting an inside of the passage to an outside of the housing. A second ventilation hole is defined proximate a top portion of the ventilation passage for interconnecting the inside of the passage to an inside of the starter motor.

Abstract: An armature coil is formed by welding upper and lower coil conductors each having a coil trunk, a pair of coil arms and a pair of coil extensions. Between an upper coil extension and a lower coil extension to be welded together, a recess is formed. This recess may be formed at the corner between a side face of an upper coil arm which is at the side of the armature core and a radially inner side face of the upper coil extension. The radially inner side face of the upper coil extension has a space against the radially outer side face of the lower coil extension only at the location where the recess is provided, while the radially inner side face except for the recess contacts the radially outer side face of the lower coil extension.

Abstract: In a starter with a planetary gear speed reduction mechanism, a first output shaft retaining member (retaining member 10, washer 20) and a second output shaft retaining member (pinion retaining ring 250) are mounted on an output shaft 220 in such a manner as to sandwich from axially front and rear directions a bearing support portion of a housing 400 which supports one end of the output shaft 220, so that a thrust load in the frontward and rearward directions of the output shaft 220 is received at the front and rear end faces of the bearing support portion of the housing 400. Therefore, the axially rearward movement of the output shaft 220 is regulated assuredly without regulating it by the rear end face of the center bracket 360 and the mortor partition wall 800, thereby preventing deformation of the center bracket.

Abstract: A starter has a housing formed with a fitting part and a flange on the outer periphery thereof. The fitting part is in circular shape when viewed in the axial direction and is press-fitted, in the socket-and-spigot joint manner, into a fitting hole of an engine-side body with the flange being in abutment with a fitting plane of the engine-side body. The outer diameter Ho of the fitting part is set larger than the axial length of the center of gravity of an armature of a starter motor from a fitting plane of the flange.