Electrical generator or motor structure – Dynamoelectric – Rotary
Reexamination Certificate
2000-01-05
2001-03-20
Mullins, Burton (Department: 2834)
Electrical generator or motor structure
Dynamoelectric
Rotary
C310S091000, C310S090000, C310S06700R, C029S596000
Reexamination Certificate
active
06204577
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to a method and an apparatus for space-saving installation of a starter-alternator, and more particularly, to a method and an apparatus for space-saving installation of a starter-alternator within a vehicle which automatically and precisely aligns the starter-alternator, and which provides an integral seal to substantially prevent the leakage of oil and/or lubricant from the vehicle's engine.
BACKGROUND OF THE INVENTION
Starter-alternators are electric machines which function as both motors and generators, and are employed within vehicles to provide electrical power and torque. Particularly, starter-alternators are typically used within hybrid-electric type vehicles, and provide a variety of functions and benefits, including but not limited to generating and providing electrical power to vehicle systems and components; starting the vehicle's engine; providing additional torque to the vehicle's engine during heavy accelerations; assisting in and/or performing the braking functions of the vehicle, thereby capturing the kinetic energy of the moving vehicle; and stopping or “shutting off” the vehicle's engine during idling and decelerating states or conditions, thereby improving the overall fuel economy of the vehicle.
Starter-alternators are typically and operatively disposed in the space or area normally occupied by a flywheel an d a clutch, in the case of manual transmission type vehicles, or by a torque converter, in the case of automatic transmission type vehicles . Starter-alternators generally include a stator, which is fixedly coupled to the vehicle's engine block, and a rotor which is coupled to the vehicle's crankshaft, and which is rotatably disposed within the stator. Particularly, the rotor is concentrically disposed with respect to the stator, and is separated from the stator by a relatively uniform, precise and minute gap or space, across which magnetic flux generated by the two assemblies traverses or travels.
One drawback associated with these starter-alternators is that the relatively uniform, precise and minute gap between the stator and the rotor is relatively difficult to create and/or form during the installation and/or assembly procedures. Another drawback associated with these starter-alternators is that they do not accommodate or compensate for axial loads which are generated by internal combustion forces of the engine, which are transferred to the electric machines by way of the crankshaft. These axial loads cause undesirable stress and/or wear to the crankshaft and to the components of the electrical machine. Additionally, oil and/or lubricant, which is contained within the engine block, may leak outside of the engine block and into the space or area occupied by the starter-alternator, thereby undesirably contacting components and/or portions of the starter-alternator.
Attempts have been made to maintain the precision and uniformity of the relatively small gap between the stator and the rotor, to reduce the axial loads imparted on the crankshaft, and to prevent the leakage of oil and/or lubricant from the engine block. For example and without limitation, attempts have been made to manually align and/or center the rotor and the stator during the installation procedure, by the use of manual alignment tools or devices. However, these types of manual alignment procedures are undesirably time-consuming and tedious. Additionally, such alignment procedures do not significantly reduce the axial loads transferred to the crankshaft by the substantially unsupported rotor. Other attempts have been made to tighten the specifications and/or tolerances of the components of the starter-alternator and/or of the crankshaft. These prior attempts have undesirably and significantly increased the overall cost of the assembly, and have not provided substantial improvement in maintaining the small and uniform gap, in reducing the stress imparted on the crankshaft, or in reducing the space required for oil retaining components.
There is therefore a need for a new and improved method and apparatus for installing a starter-alternator within a vehicle which overcomes many, if not all, of the previously delineated drawbacks of such prior methods and devices.
SUMMARY OF THE INVENTION
It is a first object of the invention to provide a method and an apparatus for installing a starter-alternator within a vehicle which overcomes at least some of the previously delineated drawbacks of prior devices, apparatuses, and methodologies.
It is a second object of the invention to provide a method and an apparatus for installing a starter-alternator within a vehicle which automatically and precisely aligns the rotor assembly and the stator assembly, thereby eliminating the need for tedious manual alignment procedures.
It is a third object of the invention to provide a method and an apparatus for installing a starter-alternator within a vehicle which substantially reduces and/or absorbs axial loads generated by the rotor assembly.
It is a fourth object of the invention to provide a method and an apparatus for installing a starter-alternator within a vehicle which substantially prevents oil and/or lubricant from leaking into t he starter-alternator from the vehicle's engine block.
It i s a fifth object of the invention to provide a method and an apparatus for installing a starter-alternator within a vehicle, which integrates oil retaining components, thereby reducing the overall space required for installation.
According to a first aspect of the present invention, an apparatus for use in combination with an assembly is provided. The assembly is of the type having an engine block and a crankshaft which extends from the engine block. The assembly also includes a rotor assembly having a hub, and a stator assembly which operatively contains said rotor assembly. The apparatus includes: a support member which is fixedly coupled to the engine block, the support member including an outer annular surface upon which the stator assembly is fixedly secured and an inner annular surface; a piloting portion, which integrally formed with the hub, and which is adapted to engage the crankshaft, the engagement being effective to axially align the rotor assembly with the crankshaft; and a bearing assembly, which is coupled to the inner annular surface of the support member and which abuttingly engages the hub, the abutting engagement being effective to center the support member and the stator assembly with respect to the rotor assembly, thereby aligning the rotor assembly within the stator assembly.
According to a second aspect of the present invention, a method for installing a electric machine within a vehicle is provided. The vehicle is of the type having an engine block and a crankshaft having an end portion which extends from the engine block, the electric machine including a stator assembly and a rotor assembly which is adapted to be separated from the stator assembly by a certain gap. The method includes the steps of:
providing a support member having a centrally disposed channel; coupling the stator assembly to the support member; providing a bearing assembly; coupling the bearing assembly to the support member and within the channel; axially aligning the channel of the support member with the end portion of the crankshaft; moving the support member from a first position in which the support member is remote from the engine block and a second position in which the support member abuts the engine block; relatively loosely coupling the support member to the engine block; peripherally disposing the rotor assembly upon a hub member; disposing an pilot upon the hub member, the pilot being effective to abuttingly engage the end portion of the crankshaft; axially aligning the hub member with the end portion of the crankshaft; and moving the hub member from a first position in which the hub member is remote from the end portion of the crankshaft and a second position in which the pilot engages the end portion of the crankshaft, the moveme
Benjamin Michael
Chottiner Jeffrey Eliot
Joachim Jon Barry
Ford Global Technologies Inc.
Mullins Burton
LandOfFree
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