23rd ABCM International Congress of Mechanical Engineering

December 6-11, 2015, Rio de Janeiro, RJ, Brazil

DYNAMIC SIMULATION OF AN INNOVATIVE

PERMANENTLY ENGAGED MECHANISM FOR
STARTING SYSTEMS
Authors:
Alvaro Canto Michelotti
ZEN S.A. Indstria Metalrgica, Brusque (SC), Brazil.
Alvaro.michelotti@zensa.com.br

Jonny Carlos da Silva

Universidade Federal de Santa Catarina (UFSC),
Florianpolis (SC), Brazil.
jonny.silva@ufsc.br
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Summary
1. Introduction
2. Stop-Start Vehicles
3. Mechanical Interface for Starting Systems
4. Innovative DCS concept
5. Simulation Model
6. Results

7. Conclusions & Next Steps

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Introduction - About the Author

Alvaro Michelotti, M.Eng. R&D Technical Specialist

Master degree in Mechanical Engineering Univ. Federal de Santa Catarina (UFSC)

Doctorate (on-going) in Mechanical Engineering - UFSC
Research focus in Mechanical Systems, Lumped parameter Modeling & Simulation

Since 2003 works for ZEN S.A., in R&D area since 2012
+16 years of professional experience in the automotive market

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Introduction
Automotive Market Challenge
Annual carbon emissions from passenger vehicles are projected to climb +54% by 2030

Ref. Eichlseder & Wimmer (2005)

Upcoming technologies to replace current ICE (Fuel-Cell, Plug-in Electric and Hybrid)

New Technologies - infrastructure, fuel availability and cost level Ref. Christidis (2003)

Continuity of ICE as the main propulsion system (Improved):

HCCI (Homogeneous Charge Compression Ignition), Carney (2008).
Engine Downsizing - DeCicco, et al. (2001)

Fuel Direct Injection - Leduc (2003)

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Introduction
Starting Systems Evolution
Starting system remains basically the same for over a century
New Concepts => permanent connection by means of gear set or belt system
New requirements for SSV (Stop-Start Vehicles)
Potential SSV market share: 37 Mi in 2020

Ref. Pike Research (2012)

Objective:
propose and develop a new concept in Dynamic Coupling System (DCS), based on a
permanently engaged connection between ICE and Starter Motor

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Stop Start Vehicles (SSV)

Concept Overview
- Electronic Management System
Controls automatic stop and start of the ICE
- SSV 1st Generation:

To Shutdown engine:
Vehicle is stationary
Gear in neutral
Battery has enough power for next engine start up
... Any additional strategy
To turn engine back on:
First gear engaged
Temp inside vehicle
...
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Stop Start Vehicles (SSV)

Starting System Overview
Main structure:

Electric Starter Motor

Control systems (solenoid, relay, ...)
Battery
Wiring (control circuit, battery poles +/- )

Product design evolution / Application Specific

DD Starter
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GR Starter

PLGR Starter

PMOSGR
Starter

OSGR
Starter
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Stop Start Vehicles (SSV)

Starting System Overview
Starting Engagement

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Starting failure (milling)

Stop Start Vehicles (SSV)

Dynamic Coupling System (DCS)
Mechanical components
Connecting Electric motor armature
to ICE crankshaft

Power transmission

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Stop Start Vehicles (SSV)

DCS Generic Types
Conventional Starter

Improved Starter with

Tamdem Solenoid

Permanently Engaged Starter

Patent search

Belt Starter/Alternator
(BAS)

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PES wet sprag clutch inside engine block

PES dry sprag clutch in

flywheel

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Innovative DCS Concept

New DCS Concept
Ring gear with internal or external gear teeth profile (1)
ICE flywheel (2)
Pinion gear (3) fixed in the armature shaft of the electric starter motor (4)
Permanently Engaged System between internal gear (5) and pinion (3)
Ring gear (1) has also na external ratchet or wedge profile (6)
Ratchet profile to engage to one or more pawls or mechanical diodes (7)
Pawl mounted in the flywheel subsystem (2) of the ICE crankshaft (8)
Damping system CRITICAL DESIGN VARIABLE
Patent
Application
sketch

Patent pending design in 2012 (INPI BR102012029979-8)

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Innovative DCS Concept - Subsystems / Components

Subsystems

1) OWC Carrier System ( carrier / pawl / spring / pin)

2) Damping System ( arc springs / endstops / retainer / fasteners)
3) Flywheel System (Flywheel / Ring gear / Ratchet Profile / Bearing or Bushing)

4) Starter Motor Interface (armature shaft end / pinion)

Assembly View

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Exploded View
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Innovative DCS Concept Damping System

Damping System for the Pawl-Ratchet OWC

Pawl-Ratchet OWC carrier (1) inside the flywheel (High Torque Capacity)
Damping System for noise/vibration attenuation => arc springs (1) and carrier friction (2)
Overrunning noise reduced by adjusted centrifugal effect and damping surface in pawl (3)

(2)
22

(1)

21

23 25

20
11 12
13

24

16
14

(3)

50

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17
40

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Simulation Model: Block Diagram

Input / Output

One-Way Clutch Model (simplified)

Damping system effect in OWC

Fig 3 Schematic of the Simulation Model for OWC damping performance

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Simulation Model: 1-D System

(1)

1st step: Lumped Parameter Sketch

2nd step: Mathmatical Models
Model 1: OWC w/o damping system

(2)

Model 2: OWC with damping system

Impulse = variation in quantity of movement

Pawl Force (F) from torque TS;
TS => applied during t

Maximum distance X
Te to rotate flywheel (ICE crankshaft)
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Simulation Results
3rd step: Parameter configuration
4th step: Simulation
Simulation Results:

12 kN peak
impact force

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1.5 kN peak
impact force

CONCLUSION:
with adjusted
damping system:
90% less impact
force!

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Experimental Results Prototype Construction

Engine Test Bench VW EA111 1.6l/gasoline/4 cyl
Valeo starter motor D7ES6

Proposed configuration

Current configuration

Pinion - Modified
Modified Flywheel w/ ring gear

Current starter

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starter motor proposed changes:

lever removed
solenoid plunger - removed
New positioning frame
Flywheel modification
Integrated OWC
Integrated damping system
Ring gear modification
Bearing support
External ratchet/wedge profile
Internal spur gear profile
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Experimental Results Performance

DCS Prototype installed in ICE test bench
Instrumentation (engine RPM)
Succesful engine startup:
+100 starts during preliminary testing
Noise evaluation:
DCS : 89 dB(A) max.
Conventional: 94 dB(A) max.

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Experimental Results Cycle Time

Reduced starting cycle
DCS

Conventional
~ 0.8s

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~ 0.3s

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Conclusions & Further Research

Aid of 1-D simulation to develop innovative products
Impact during engagement solved by a damping system => innovative DCS design
Experimental prototype confirmed system potential

NEXT STEPS:
Further refinement of the system Durability targets
Both technical & economical validation of the system
Further research as a potential contribution to SSV emissions reduction

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Thank you!
Alvaro Michelotti, M.Eng.
R&D Technical Specialist
ZEN S.A.
Alvaro.michelotti@zensa.com.br
Tel +55-47-3255-2899
www.zensa.com.br

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