Forklift Starters and Alternators

Forklift Starter and Alternator - The starter motor these days is usually either a series-parallel wound direct current electric motor which has a starter solenoid, which is similar to a relay mounted on it, or it could be a permanent-magnet composition. Once current from the starting battery is applied to the solenoid, basically through a key-operated switch, the solenoid engages a lever which pushes out the drive pinion that is situated on the driveshaft and meshes the pinion with the starter ring gear which is found on the flywheel of the engine.

The solenoid closes the high-current contacts for the starter motor, that begins to turn. After the engine starts, the key operated switch is opened and a spring inside the solenoid assembly pulls the pinion gear away from the ring gear. This particular action causes the starter motor to stop. The starter's pinion is clutched to its driveshaft by an overrunning clutch. This allows the pinion to transmit drive in just one direction. Drive is transmitted in this way via the pinion to the flywheel ring gear. The pinion remains engaged, for example as the driver did not release the key as soon as the engine starts or if the solenoid remains engaged for the reason that there is a short. This actually causes the pinion to spin independently of its driveshaft.

This above mentioned action prevents the engine from driving the starter. This is an important step for the reason that this kind of back drive would allow the starter to spin really fast that it can fly apart. Unless adjustments were made, the sprag clutch arrangement would preclude making use of the starter as a generator if it was used in the hybrid scheme discussed earlier. Typically a regular starter motor is meant for intermittent use which will stop it being used as a generator.

The electrical components are made so as to work for roughly thirty seconds so as to avoid overheating. Overheating is caused by a slow dissipation of heat is due to ohmic losses. The electrical components are designed to save weight and cost. This is the reason nearly all owner's manuals meant for vehicles recommend the driver to pause for at least ten seconds after each 10 or 15 seconds of cranking the engine, if trying to start an engine that does not turn over at once.

During the early part of the 1960s, this overrunning-clutch pinion arrangement was phased onto the market. Prior to that time, a Bendix drive was used. The Bendix system functions by placing the starter drive pinion on a helically cut driveshaft. When the starter motor begins spinning, the inertia of the drive pinion assembly allows it to ride forward on the helix, hence engaging with the ring gear. Once the engine starts, the backdrive caused from the ring gear enables the pinion to exceed the rotating speed of the starter. At this point, 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 developed in the 1930's with the overrunning-clutch design called 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 inside the body of the drive unit. This was a lot better because the typical Bendix drive utilized to be able to disengage from the ring once the engine fired, although it did not stay functioning.

The drive unit if force forward by inertia on the helical shaft as soon as the starter motor is engaged and begins turning. Next the starter motor becomes latched into the engaged position. Once the drive unit is spun at a speed higher than what is achieved by the starter motor itself, for example it is backdriven by the running engine, and then the flyweights pull outward in a radial manner. This releases the latch and allows the overdriven drive unit to become spun out of engagement, therefore unwanted starter disengagement could be prevented before a successful engine start.

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