Abstract: A power module is connected to the starter, and generator of a motor vehicle. The power module is housed in a casing made of an insulative material. The power module includes a capacitor and an isolation circuit. The capacitor is connected to the starter when the ignition switch is closed to provide cranking current to the starter. The isolation circuit allows current to flow from the battery to the capacitor, but prevents current flow in the opposite direction. The capacitor is quickly recharged when the engine reaches an increased speed. Therefore, the capacitor is available to provide cranking current to a vehicle even when the vehicle repeatedly stops and starts over a short period of time.

Abstract: A drive shaft assembly for an electromechanical apparatus is disclosed that possesses increased and long-lasting torque strength. The drive shaft assembly comprises a drive shaft that is inserted into an aperture in a plate via a cold staking process such that the outer surface of the drive shaft is in contact with an inner edge of the plate to form a frictional engagement. The drive shaft is then joined to the inner edge of the plate by laser welding, which serves to produce a rigid connection.

Abstract: Systems and methods of the invention may utilize integrated starter-alternator (ISA) electronics to drive a conventional DC starter coupled to a start-stop ISA system providing a voltage higher than that at which the starter is rated. The DC starter may cold crank an internal combustion engine, while a poly-phase starter alternator warn cranks the engine and converts mechanical energy to an AC current. The AC current may be converted to a DC current to provide charging functions. A reduced average voltage is provided to the DC starter and an adjustable-frequency alternating current may be provided to the starter alternator.

Abstract: Systems and methods of the invention may utilize integrated starter-alternator (ISA) electronics to drive a conventional DC starter coupled to a start-stop ISA system providing a voltage higher than that at which the starter is rated. The DC starter may cold crank an internal combustion engine, while a poly-phase starter alternator warm cranks the engine and converts mechanical energy to an AC current. The AC current may be converted to a DC current to provide charging functions. A reduced average voltage is provided to the DC starter and an adjustable-frequency alternating current may be provided to the starter alternator.

Abstract: A coaxial starter motor assembly that includes a housing. An electrical motor is provided in the housing that has a rotatable armature shaft that is linked with a drive shaft. A pinion assembly is provided that is engageable at one end with the drive shaft and includes a pinion at the other end engageable with a flywheel of an engine. A solenoid assembly is provided for selectively energizing the electrical motor. The solenoid assembly is coaxial with the drive shaft. The solenoid assembly includes a plunger having a bore. The plunger is engageable with the pinion assembly to move the pinion assembly including the pinion into engagement with the flywheel. The plunger is also engageable with a moveable contact to move the moveable contact to electrically connect with a pair of fixed contacts. A return spring is provided that is positioned at least in part within the bore of the plunger of the solenoid assembly for moving the pinion assembly including the pinion away from engagement with the flywheel.

Abstract: A starter motor assembly is provided. A motor housing encloses an electrical motor having a rotatable armature shaft. A rotatable drive shaft is provided that is engageably linked with the armature shaft. A pinion assembly is also provided, which includes a pinion that is engageable with the drive shaft for turning a flywheel of an engine. A solenoid assembly is provided, which includes a plunger. The plunger, when the solenoid assembly is energized, is moved in an axial direction to close electrical contacts to start the electrical motor and to move the pinion into-engagement with the engine flywheel. Once the engine is cranked and the solenoid is deenergized, a return spring moves the pinion away from engagement with the engine flywheel. The return spring of the present invention moves the pinion without utilizing contact between the spring and the pinion (or any pinion shaft) to move the pinion away from engagement.

Abstract: A starter motor assembly is provided. A motor housing encloses an electrical motor having a rotatable armature shaft. A rotatable drive shaft is provided that is engageably linked with the armature shaft. A pinion assembly is also provided, which includes a pinion that is engageable with the drive shaft for turning a flywheel of an engine. A solenoid assembly is provided, which includes a plunger. The plunger, when the solenoid assembly is energized, is moved in an axial direction to close electrical contacts to start the electrical motor and to move the pinion into engagement with the engine flywheel. Once the engine is cranked and the solenoid is deenergized, a return spring moves the pinion away from engagement with the engine flywheel. The return spring of the present invention moves the pinion without utilizing contact between the spring and the pinion (or any pinion shaft) to move the pinion away from engagement.

Abstract: A coaxial starter motor assembly that includes a housing. An electrical motor is provided in the housing that has a rotatable armature shaft that is linked with a drive shaft. A pinion assembly is provided that is engageable at one end with the drive shaft and includes a pinion at the other end engageable with a flywheel of an engine. A solenoid assembly is provided for selectively energizing the electrical motor. The solenoid assembly is coaxial with the drive shaft. The solenoid assembly includes a plunger having a bore. The plunger is engageable with the pinion assembly to move the pinion assembly including the pinion into engagement with the flywheel. The plunger is also engageable with a moveable contact to move the moveable contact to electrically connect with a pair of fixed contacts. A return spring is provided that is positioned at least in part within the bore of the plunger of the solenoid assembly for moving the pinion assembly including the pinion away from engagement with the flywheel.

Abstract: A semi-solid link solenoid 10 comprises windings 22 held within a housing 20, and a spring biased plunger 24 which is free to slide axially within the windings. The plunger 24 slideably engages a contact rod 26 having an end knob 58. The end knob 58 of the contact rod 26 is contained within a center chamber 46 of the plunger 24 between a shoulder 47 and an abutment pin 50. A contact disc 28 is fixed to an opposite end of the contact rod 26. When the windings are energized and the plunger is pulled completely into the windings, the contact disc 28 is forced into contact with the terminals 30a and 30b. After electric current is removed from the windings, the plunger returns to its non-energized position. When returning to this position, the shoulder 47 slams against the end knob 58 with a large amount of force to pull the contact rod 26 and contact disc 28 away from the terminals 30a and 30b. In this manner, the force to disengage the contact disc 28 from the terminals 30a and 30b is significantly increased.

Abstract: The method of the present invention involves setting a penetration threshold as well as a maximum weld time when hot staking armature conductors to the slots of a commutator. To perform each weld, an electrode is forcibly contacted with the top conductor in one of the slots of the commutator. Next, electric current is delivered to the electrode, causing the conductor to heat and begin to deform within the slot. During this time, the electrode moves further into the slot. If the electrode reaches the penetration threshold in the commutator slot before the maximum weld time is reached, current to the electrode is terminated. After terminating current to the electrode, the electrode remains in contact with and applies force to the conductor until the maximum weld time is reached. After the maximum weld time is reached, the electrode is removed from contact with welded conductor.

Abstract: Systems, methods, and apparatus, consistent with principles of the present invention, allow an unmodified device, for example, a dc starter motor, that normally operates at a first voltage to function in an electrical system providing a second voltage, which is different from the first voltage, and received from the power source. A device actuator, such as a solenoid, is controlled using the second voltage. The first voltage is produced and supplied to the device in response to a first action of the actuator, for example, upon solenoid depression. This voltage is then inhibited from being provided to the device in response to a second action of the actuator, for example, upon solenoid retraction after engine cranking.

Abstract: A starter motor assembly is provided having a solenoid assembly that includes a pull-in coil that is comprised of a plurality of coils connected in parallel. The plurality of coils may comprise three coils that are formed from a single wire cut and connected to form the pull-in coil. Also provided is a method of making a pull-in coil for a solenoid assembly for a starter motor assembly. The method includes the step of winding a wire down a length of a solenoid coil holder and then back up the length of the solenoid coil holder a plurality of times. Then, the wire is cut at points to form separate coils, each coil then having a first lead and a second lead opposite the first lead. The first leads of the coils are electrically connected together and the second leads of the coils are electrically connected together to form the pull-in coil comprised of multiple coils.

Abstract: The present invention provides an apparatus for reducing the allowed output current from an electrical device such as a high output capacity vehicle alternator in response to a sensed over temperature condition. In one embodiment, a thermistor is attached to the housing of an alternator to provide temperature sensing capability. As temperature exceeds a temperature set point established by a resistor bridge, op-amps, in combination with a power FET in series with the alternator field windings, act to reduce the allowed current output from the alternator in proportion to the extent the set point temperature has been exceeded. As the alternator temperature returns to below the set point, the output current restriction is reduced such that the allowed current flow is maximized without exceeding the temperature set point.

Abstract: A marine integrated starter alternator troller device (ISAT) includes a stator portion and a rotor portion connected to a drive shaft. The ISAT is incorporated into an engine assembly power train which includes an internal combustion engine having a crankshaft connected to an electric clutch. The electric clutch is operable to connect or disconnect the drive shaft and the crankshaft. Thus, the ISAT may be connected to or disconnected from the crankshaft of the internal combustion engine. When connected to the engine by the electric clutch, the ISAT device is operable to receive electrical power from a battery and act as a cranking motor to provide starting torque to the internal combustion engine. The ISAT may also be driven by the internal combustion engine and act as a generator to provide power to re-charge the battery or drive other electrical devices.

Abstract: An alternator having a sensorless power angle control includes a three phase stator winding and three stator winding outputs connected to a controlled full wave rectifier bridge with a dc output. The controlled full wave rectifier bridge includes upper MOSFET switches and lower MOSFET switches with body diodes. Operation of the alternator results in a three phase back EMF generated in the stator windings and phase voltages across each of the stator windings. The output of the alternator is increased by introducing a phase shift between the back EMF and the phase voltages, resulting in an optimized power angle. In order to provide a reference for the phase of the back EMF, a zero crossing detector is provided which monitors the zero voltage crossings across the body diodes of the lower MOSFET switches. The negative to positive zero voltage crossings across the body diodes of the lower MOSFET devices correspond to the negative to positive zero crossings of the three phase back EMF.

Abstract: A heat shield for shielding the solenoid of an engine starter from heat generated by an internal combustion engine. The shield is formed of metal and has a front pair of deflectable spring arms and a rear pair of deflectable spring arms for securing the heat shield to a solenoid of an engine starter. The arms have arcuate portions that are adapted to engage the case of the solenoid and the arms are deflected apart when the shield is assembled to the solenoid. The arms then spring back toward each other to tightly grip the solenoid. The front pair of deflectable spring arms are equipped with ribs extending from the arcuate portions and bending around one end of the solenoid to prevent axial movement of the heat shield relative to the solenoid. The heat shield has a collar to engage another end of the solenoid and prevent axial movement of the heat shield relative to the solenoid. The heat shield has a spring finger that prevents the shield from moving beyond a proper assembled position.

Abstract: An electric starter for an internal combustion engine has a coaxial pinion drive mechanism for urging the pinion gear into a positively fully meshed arrangement with the flywheel of the internal combustion engine prior to full power application to the cranking motor. The pinion drive mechanism is incompressible throughout its motion. The drive solenoid has a solid plunger which is limited in its stroke corresponding to the fully meshed position of the pinion gear by a pair of electrical contacts which are shorted at full stroke by the plunger functioning as a contact therebetween. The cranking motor is operated at a slow rotation at all times prior to full meshing of the pinion gear to aid in meshing thus reducing tooth wear and gear lash.