Forklift Starter and Alternator

Forklift Starters and Alternators - The starter motor nowadays is normally either a series-parallel wound direct current electric motor that has a starter solenoid, which is similar to a relay mounted on it, or it can be a permanent-magnet composition. As soon as current from the starting battery is applied to the solenoid, basically through a key-operated switch, the solenoid engages a lever that pushes out the drive pinion which is positioned on the driveshaft and meshes the pinion utilizing the starter ring gear which is seen on the flywheel of the engine.

The solenoid closes the high-current contacts for the starter motor, that starts to turn. After the engine starts, the key operated switch is opened and a spring within the solenoid assembly pulls the pinion gear away from the ring gear. This action causes the starter motor to stop. The starter's pinion is clutched to its driveshaft by means of an overrunning clutch. This allows the pinion to transmit drive in just a single direction. Drive is transmitted in this method via the pinion to the flywheel ring gear. The pinion continuous to be engaged, like for example since the driver fails to release the key as soon as the engine starts or if there is a short and the solenoid remains engaged. This actually causes the pinion to spin separately of its driveshaft.

This aforementioned action prevents the engine from driving the starter. This is an important step as this type of back drive would enable the starter to spin really fast that it can fly apart. Unless modifications were made, the sprag clutch arrangement would preclude making use of the starter as a generator if it was utilized in the hybrid scheme mentioned earlier. Normally a standard starter motor is meant for intermittent use that would prevent it being used as a generator.

Hence, the electrical parts are meant to work for approximately less than 30 seconds in order to avoid overheating. The overheating results from very slow dissipation of heat because of ohmic losses. The electrical parts are intended to save weight and cost. This is actually the reason nearly all owner's instruction manuals utilized for automobiles suggest the operator to stop for a minimum of ten seconds right after each and every ten or fifteen seconds of cranking the engine, whenever trying to start an engine that does not turn over at once.

During the early 1960s, this overrunning-clutch pinion arrangement was phased onto the market. Previous to that time, a Bendix drive was used. The Bendix system operates by placing the starter drive pinion on a helically cut driveshaft. Once the starter motor starts spinning, the inertia of the drive pinion assembly enables it to ride forward on the helix, hence engaging with the ring gear. Once the engine starts, the backdrive caused from the ring gear allows the pinion to go beyond the rotating speed of the starter. At this moment, the drive pinion is forced back down the helical shaft and thus out of mesh with the ring gear.

The development of Bendix drive was made in the 1930's with the overrunning-clutch design known as the Bendix Folo-Thru drive, developed and introduced in the 1960s. The Folo-Thru drive has a latching mechanism along with a set of flyweights in the body of the drive unit. This was better since the standard Bendix drive used to be able to disengage from the ring once the engine fired, even though it did not stay running.

The drive unit if force forward by inertia on the helical shaft once the starter motor is engaged and starts turning. Next the starter motor becomes latched into the engaged position. When the drive unit is spun at a speed higher than what is achieved by the starter motor itself, for instance it is backdriven by the running engine, and afterward the flyweights pull outward in a radial manner. This releases the latch and permits the overdriven drive unit to become spun out of engagement, hence unwanted starter disengagement could be avoided previous to a successful engine start.

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