WO2007034505A2

WO2007034505A2 - A starter system for a two or three wheeled vehicle

Info

Publication number: WO2007034505A2
Application number: PCT/IN2006/000236
Authority: WO
Inventors: Joseph Abraham
Original assignee: Bajaj Auto Limited
Priority date: 2005-07-05
Filing date: 2006-07-05
Publication date: 2007-03-29
Also published as: WO2007034505A3

Abstract

A starter system comprising: a starter motor; a clutch actuating means; and a starter switch circuit; wherein declutched and clutched clutch states of said clutch actuating means cause completion of respective first and second electric circuits associated with the starter switch circuit and corresponding with each clutch state.

Description

TITLE OF INVENTION

A STARTER SYSTEM FOR A TWO OR THREE WHEELED VEHICLE

FIELD OF THE INVENTION

This invention relates to a starter system suitable for a two or three wheeled vehicle.

BACKGROUND OF THE INVENTION

A typical starter system of a two or three wheeled vehicle comprises a starter switch connected to the vehicle battery and to the starter motor of the engine of the vehicle through a starter coil operated starter contact. The starter system also comprises an interlock relay comprising a movable contact and a pair of fixed contact terminals, namely, a first fixed contact terminal and a second fixed contact terminal and also a relay coil. The starter coil is connected to a neutral indicator lamp and a neutral indicator switch in series configuration through the first fixed contact terminal, the second fixed contact being grounded. The relay coil is connected to the vehicle battery and also to a clutch safety switch. The neutral indicator lamp is also connected to the vehicle battery through the neutral indicator switch. The neutral indicator switch and clutch safety switch are grounded. The interlock relay and starter coil and starter contact are mounted in the proximity of the starter motor using a mounting bracket.

A clutch lever is angularly movably pivoted in a recess formed in a clutch lever support provided on the handle bar of the vehicle and the clutch safety switch is operated by the clutch lever through a plunger located in the proximity of the clutch safety switch. The plunger, is located in the recess in the clutch lever support and is exposed.

The starter switch and clutch safety switch are normally open and the neutral indicator switch is normally closed. The movable contact of the interlock relay is normally making contact with the first fixed contact terminal. On actuating the ignition switch in the neutral or park position of the vehicle, the neutral indicator lamp starts glowing indicating that the vehicle is in the neutral position and the circuit is completed through the closed neutral indicator switch. In order to start the vehicle in the neutral position, the rider presses and closes the starter switch. The starter coil energizes and closes the starter contact to allow power from the vehicle battery to flow to the starter motor thereby cranking the engine and starting the vehicle. As the movable contact of the interlock relay is making contact with the first fixed contact terminal of the interlock relay, the circuit is completed by the starter coil connected to the ground through the first fixed contact terminal and the closed neutral indicator switch.

On releasing the starter switch, the starter coil de- energises and opens the starter contact thereby discontinuing power supply to the starter motor. On changing the vehicle position from neutral to gear, the neutral lamp stops glowing and the neutral indicator switch opens due to shifting of cam.

In the geared position, if the vehicle happens to stop inadvertently at signals or in traffic jams, in order to restart the vehicle it is required that clutch should be disengaged from transmission system to avoid jerks to the vehicle which may cause accident. The vehicle is, therefore, restarted by operating/pressing the clutch lever and closing the clutch safety switch and also by closing the starter switch. The starter coil energizes and closes the starter contact thereby allowing power to flow to the starter motor for cranking the engine. The relay coil of the interlock relay is energized because of the closing of the clutch safety switch and the movable contact of the interlock relay makes contact with the second fixed contact terminal of the interlock relay. The circuit is completed by the starter coil connected to the ground through the second fixed contact terminal of the interlock relay and by the relay coil through the closed clutch safety switch. On releasing the starter switch, the starter relay -de-energizes and the starter contact opens thereby discontinuing power supply to the starter motor. On releasing the clutch safety switch by releasing the clutch lever, the relay coil de- energizes and the movable contact of the interlock relay moves back and makes contact with the first fixed contact terminal of the interlock relay.

Instances of restarting the vehicle in geared position are invariably frequent. Because of this, the plunger and clutch safety switch are frequently operated by the clutch lever frequently. Each time the clutch lever actuates the plunger, it actually hits or strikes the plunger thereby causing frequent damage to the plunger and frequent malfunctioning of the starter system. Besides, there are chances of water entering the recess in the clutch lever support where the plunger is located and seeping to the clutch safety switch. The water not only damages the plunger but also the clutch safety switch in the proximity thereof. Frequent damage to the plunger requires replacement of the entire clutch safety switch and plunger. Damage to the plunger and clutch safety switch due to water seepage also requires replacement of the entire . clutch safety switch including the plunger. This calls for recurring expenses. If the clutch safety switch is short or corroded due to water entiy in the recess, the relay coil will remain continuously ON and get heated up and may get damaged. The relay coil also will remain ON continuously and get heated up and may get damaged if the clutch safety switch is not operated by the clutch lever along with the starter switch in the geared condition of the vehicle. Besides, the motor will start and try to crank the engine and the vehicle will jerk forward as it is in the geared condition. This may cause accident to the rider and may damage the clutch mechanism and gear of the engine. Due to space constraints in a two or three wheeled vehicle mounting of the interlock relay in the proximity of the starter motor is problematic in that the mounting bracket is required to be large enough to accommodate the interlock relay in addition to the starter coil and starter contact. The interlock relay also requires wiring to be done on the chassis of the vehicle increasing the cost.

SUMMARY OF INVENTION

An object of the invention is to provide a starter system suitable for a two or three wheeled vehicle which eliminates the interlock relay advantageously simplifying the construction of the starter system and rendering it economical and avoiding all the disadvantages associated with the interlock relay.

Another object of the invention is to provide a starter system of a two or three wheeled vehicle which reduces the size of the mounting bracket for the starter coil and starter contact correspondingly reducing the mounting space therefor.

With such objects in view, the present invention provides a starter system comprising: a starter motor; a clutch actuating means; and a starter switch circuit; wherein declutched and clutched clutch states of the clutch actuating means cause completion of respective first and second electric circuits associated with the starter circuit and corresponding with each clutch state to be completed. The circuits may be completed through a switch such as a clutch safety switch. Switches may correspond with neutral and clutched states. Energizing a circuit may also cause an indicator, such as a lamp, to be activated. For example, where the first electric circuit, corresponding to declutched or neutral state, is energized, a neutral transmission position indicator circuit which may include a warning light may also be energized.

The switch may be a contact switch or a non-contact switch such as a reed switch.

Completion of either circuit associated with clutch state may result in breakage of the other circuit. However, this is not required.

Where the switch is a contact switch, the switch may have a plurality of contacts including a movable contact; wherein the movable contact is a contact that displaces directly with displacement of the clutch actuating means. No plunger or intermediate means in required. The clutch actuating means is a conveniently a clutch lever which may be angularly movably pivoted in a clutch lever support. Displacement of the clutch lever may actuate the switch, advantageously a three pole switch, having three fixed contacts and one moveable contact.

The starter system may be used in a two or three wheeled vehicle in which the starter switch is connected to the vehicle battery and to the starter motor of the engine of the vehicle through a starter coil operated starter contact.

The switch may be located in a protective chamber to protect it from ingress of water and dust. The chamber may be formed in the clutch lever support conveniently provided on the handle bar of the vehicle. The chamber may include a closure.

The three fixed contact terminals of the three pole switch may be formed by three strips of conductive material which may be embedded in an insulating material layer provided on the inner surface of the chamber. The chamber may be an open ended slot, formed in a support, the bottom of the slot being closed with a closure which is provided with the three fixed contact terminals. Two fixed contact terminals may be provided in spaced alignment with the third fixed contact terminal being provided parallel to the said two fixed contact terminals. The movable contact of the three pole switch is disposed in the slot between the fixed contact terminals from the top thereof and located in a cut out provided in an arm extending from the pivoted end of the clutch lever.

The chamber may be provided with a vent and a hood for the vent located on an outer surface of the chamber, conveniently in the closure. This vent allows escape of any trapped water.

The starter system avoids need for interlock relay and plunger with benefits in terms of reliability. DETAILED DESCRIPTION OF PREFERRED EMBODIMENT OF THE INVENTION

The following is a detailed description of a preferred non-limiting embodiment of the invention made with reference to the accompanying drawings in which:

Fig 1 is a schematic diagram of a starter system of a two wheeled vehicle according to the prior art where the vehicle is in a neutral position;

Fig 2 is a schematic circuit diagram of a starter system of a two wheeled vehicle according to the prior art where the vehicle is in a geared position;

Fig 3 is a plan view of a clutch lever assembly comprising a clutch safety switch according to the prior art; Fig 4 is a schematic circuit diagram of a starter system of a two wheeled vehicle according to an embodiment of the invention when the vehicle is in neutral position;

Fig 5 is a schematic circuit diagram of a starter system of a two wheeled vehicle according to an embodiment of the invention when the vehicle is in geared position;

Fig 6 is bottom view of a clutch lever of the starter system of Figs 4 and 5 pivoted in a clutch lever support and showing the movable contact of the three pole switch;

Fig 7 is bottom view of the chamber of the three pole switch of the starter system of Figs 4, 5 and 6;

Fig 8 is an inner side view of the closure of the chamber of the three pole switch of the starter system of Figs 4, 5 and 6; and Fig 9 is view of the clutch lever of the starter system of Figs 4, 5 and 6.

The starter system 101, as illustrated in Figs 1 to 3 of the accompanying drawings, is a prior art system commonly used in the automotive industry and comprising a starter switch 102 connected to a vehicle batteiy (not shown) and to the starter motor 103 of the engine (not shown) of a vehicle, here a motorcycle, through a starter coil 104 operated starter contact 105 as conveniently shown in Figs 1 and 2.

The starter switch 102 is a two pole switch comprising two fixed contact terminals 112 and 113 located in a chamber 117. A movable contact 114 is connected to plunger 115 as conveniently shown in Fig 3.

hi the neutral position, the circuit completes in the following sequence. When the motorcycle rider presses the starter button 102, the starter relay coil 104 is energised and the starter motor 103 receives a battery supply through starter relay contacts 105 and the motor spins.

When the engine is in a geared condition, and clutch lever 116 is not pressed by the rider, the plunger 115 is in pressed condition (see Figs 1, 2, 3) and the movable contact 114 is away from the fixed contact. Also, during the general condition, the neutral switch 119 is not grounded, hence there is no current flow through the circuit.

When the rider presses the clutch lever 116, plunger 115 moves outwardly and the movable contact 114 fixed on the plunger 115 makes contact with fixed terminals 112 and 113 such that the interlock relay 120 is energized. Such contrast of plunger 115 with fixed terminals 112 and 113 may cause damage to terminals and plunger 115. Simultaneously, when the rider presses the starter button 102, the starter relay 104 is activated, starter motor 103 receives supply through starter relay contacts 105 and the motor spins.

The starter system 1 of the invention, as illustrated in Figs 4 to 9 of the accompanying drawings, comprises a starter switch 2 connected to the vehicle battery (not shown) and to the starter motor 3 of the engine (not shown) of the vehicle (not shown) through a starter coil 4 operated starter contact 5 (Figs 4 and 5). A three pole switch 19, being a clutch safety switch, comprises three fixed contact terminals 12, 13 and 14 and is located in a closed chamber 7 (Figs 4, 5, 6 and 8) to protect the terminals from ingress of water. The closed chamber comprises an open ended slot 8 formed in a clutch lever support 9 (Fig 6) provided on the handle bar (not shown) of the vehicle. The bottom of the slot 8 is closed with a closure 10 fitted to the bottom of the slot by screws (not shown) engaged in screw holes 10a, 10a provided in the closure and corresponding screw holes 11a, 11a provided at the bottom of the sidewall 11 of the slot.

The three fixed contact terminals 12, 13 and 14 of the three pole switch are three conductor material strips embedded in an insulating material layer 15 provided on the inner surface of the closure 10 (Fig 8). The strips may be made of conductor material such as copper or phospher bronze. Two fixed contact terminals namely 12 and 13 are relatively short and are provided in spaced alignment (Fig 8).

The third fixed contact terminal 14 is relatively long, compared to terminals 12 and 13 and is provided parallel to the two fixed contact terminals 12 and 13 (Fig 8). The starter coil 4 is connected to the first fixed contact terminal 14 (Figs 4 and 5). The second fixed contact terminal 13 is connected to a neutral indicator lamp 15 and a neutral indicator switch 16 in series configuration (Figs 4 and 5). The third fixed contact terminal 12 is grounded. The neutral indicator switch 16 is also grounded. The neutral indicator lamp is also connected to the vehicle battery. The three pole switch 19 also comprises a movable contact 17 disposed between the fixed contact terminals adapted to make and break contacts therewith. Clutch lever 18 is angularly movably pivoted in a recess 19 formed in the clutch lever support using pivot pin 20. Pivot hole on the clutch lever arm is marked 27 (Fig 9). The movable contact 17 is located in a cut out 21 provided in an arm 22 extending from, the pivoted end of the clutch lever 18 (Fig 9). The sidewall 11 of the slot is provided with an opening 23 associated with a guide wall 24 extending from one end wall of the opening (Fig 5).

The closure 10 is provided with a vent 25 and a hood 26 for the vent at the outer surface of the closure 10 (Fig 8). Sleeve 2S provides insulation for the leadwires (not shown) connected to the contact terminals of the three pole switch (Figs 6 and 7). 29 is an extension on the closure to prevent water seeping into the chamber (Figs 5 and 7).

The starter switch 2 and starter contact 5 are normally open and the neutral indicator switch 16 is normally closed. On actuating the starter switch 2 in the neutral or park position of the vehicle, the neutral indicator lamp starts glowing indicating that the vehicle is in the neutral position and a circuit is completed through the closed neutral indicator switch 16. In the neutral position of the vehicle, the clutch lever is in its non-operative position and the movable contact 17 of the three pole switch makes contact with the second and third fixed contact terminals 13 and 14 (Fig 4). In order to start the vehicle in the neutral position, the rider presses and closes the starter switch 2. The starter coil 4 energizes and closes the starter contact to allow power from the vehicle battery to the starter motor 3 thereby cranking the engine and starting the vehicle. As the movable contact 17 makes contact with the fixed contact terminals 13 and 14, a first electric circuit, corresponding with the declutched or neutral state, is completed by the starter coil 4 connected to the ground through the fixed contact terminals 13 and 14 and the closed neutral switch.

On releasing the starter switch 2, the starter coil 4 de-energises and opens the starter contact thereby discontinuing power to the starter motor.

On changing the vehicle position from a neutral to a geared position, the neutral lamp 15 stops glowing and the neutral indicator switch opens due to shifting of cam. If the vehicle happens to stop in the geared position, it is restarted by closing the starter switch 2 and by displacing the clutch lever IS angularly in the anticlockwise direction to move the movable contact 17 to make contact with the fixed contacts 12 and 14 (Fig 5) completing a second electric circuit corresponding with the clutched state. The starter coil 4 energises and closes the starter contact 5 thereby allowing power to flow to the starter motor 3 for cranking the engine. The circuit is completed by the starter coil 4 connected to the ground through the fixed contact terminals 12 and 14 as the fixed contact terminal 12 is grounded. On releasing the starter switch 2, the starter relay de-energises and the starter contact 5 opens thereby discontinuing power to the starter motor 3. The clutch lever IS is displaced horizontally angularly in the clockwise direction and the movable contact 17 is made to establish contact between the fixed contact terminals 13 and 14.

The interlock relay 120 and plunger 115 are eliminated by the three pole switch which is housed within chamber 7 in the clutch lever support 9. The clutch lever IS is horizontally angularly displaced to move the movable contact 17 of the three pole switch 19 to and fro to make and break contacts and first and second electric circuits, with the fixed contact terminals thereof. Due to elimination of the interlock relay and plunger, and use of the three pole switch in place thereof, construction of the starter system is rendered simple and cost effective. Disadvantages associated with the interlock relay and plunger also have been eliminated. During angular displacement of the clutch lever 18, the movable contact 17 of the three pole switch 19 simply moves, in linear displacement with it and engages between, and disengages from, the fixed contact terminals 12, 13 and 14. Therefore, making and breaking of contacts by operation of the clutch lever 18 is smooth and damage to the three pole switch 19 is avoided. The switching operation is also smooth.

As the three pole switch 19 is located in enclosed chamber 7, seepage of water is prevented thereby reducing damage to the three pole switch and increasing its life. Seepage of water, if any, into the chamber 7 immediately drains out through the opening in the sidewall of the chamber 7 and also through the vent 25 in the closure S of the chamber 7. The hood 26 for vent 25 also prevents water entering the chamber 7 through the vent 25. As the interlock relay has been eliminated, size and space requirement of the bracket for mounting the starter coil 4 and starter contact 5 in the proximity of the starter motor 3 is reduced. Also the wiring for the interlock relay on the vehicle chassis has been eliminated. All this makes the starter system of the invention further economical.

Modification and variations to the starter systems of the present invention may be apparent to the skilled reader of this disclosure. Such modifications and variation are deemed within the scope of the present invention.

Claims

CLAIMS:

1. A starter system comprising: a starter motor (3); a clutch actuating means (IS); and a starter switch circuit; wherein declutched and clutched clutch states of said clutch actuating means (18) cause completion of respective first and second electric circuits associated with the starter switch circuit and corresponding with each clutch state.

2. The starter system of claim 1 wherein completion of one said electric circuit corresponding to clutch state results in breakage of the other said electric circuit.

3. The starter system of claim 1 or 2 wherein said first electric circuit, corresponding to declutched state, includes a neutral transmission position indicator (15) circuit.

4. A starter system as claimed in any one of claims 1 to 3 wherein each circuit is completed through a switch (19) having a plurality of contacts (12,13,14,17) including a movable contact (17); wherein said movable contact (17) is a contact that displaces directly with displacement of the clutch actuating means (IS).

5. The starter system of claim 4 wherein said switch (19) forms one of a plurality of switches, one corresponding with declutched state and a further switch corresponding with clutched state,

6. The starter system of claim 4 wherein the contacts (12,13,14) of said switch (19) are enclosed in a protective chamber (7).

7. The starter system of any one of claims 4 to 6 wherein said switch (19) has three fixed contacts (12,13,14) and one movable contact (17).

S. The starter system of claim 6 or 7 wherein said fixed contacts (12,13,14) are strips of conductive material located on an inner surface of said chamber (7).

9. The starter system of claim 8 wherein said chamber (7) is provided with a vent (25).

10. The starter system of claim 9 wherein said vent (25) is provided with a hood (26).

11. The starter system of any one of claims 8 to 10 wherein two fixed contacts (12,13) are arranged in spaced alignment with the third fixed contact (14) arranged parallel to said two fixed contacts (12,13).

12. The starter system of any one of claims 6 to 11 wherein said chamber (7) is formed in a support (9) for a clutch lever (18) forming the clutch actuating means.

13. The starter system of claim 12 wherein said chamber (7) is formed in a handlebar of said vehicle.

14. The starter system of any one of claims 6 to 13 wherein said chamber (7) has a closure (8).

15. The starter system of claim 9 or 10 wherein said vent (25) is located in said closure (10).

16. A vehicle including the starter system of any one of the preceding claims.