Forklift Starter and Alternator

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

The solenoid closes the high-current contacts for the starter motor, that starts to turn. When 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 action causes the starter motor to stop. The starter's pinion is clutched to its driveshaft by an overrunning clutch. This permits the pinion to transmit drive in only one direction. Drive is transmitted in this particular way through the pinion to the flywheel ring gear. The pinion remains engaged, for example since the driver did not release the key once the engine starts or if the solenoid remains engaged in view of the fact that there is a short. This causes the pinion to spin independently of its driveshaft.

This aforementioned action stops the engine from driving the starter. This is an important step for the reason that this kind of back drive will enable the starter to spin so fast that it could fly apart. Unless modifications were done, the sprag clutch arrangement would prevent utilizing the starter as a generator if it was made use of in the hybrid scheme discussed prior. Usually a regular starter motor is designed for intermittent use which would prevent it being used as a generator.

Therefore, the electrical components are designed to work for just about under 30 seconds in order to avoid overheating. The overheating results from very slow dissipation of heat due to ohmic losses. The electrical components are intended to save weight and cost. This is the reason the majority of owner's handbooks utilized for vehicles recommend the operator to stop for a minimum of 10 seconds right after each 10 or 15 seconds of cranking the engine, when trying to start an engine that does not turn over right away.

During the early part of the 1960s, this overrunning-clutch pinion arrangement was phased onto the market. Before that time, a Bendix drive was utilized. The Bendix system functions by placing the starter drive pinion on a helically cut driveshaft. Once the starter motor begins spinning, the inertia of the drive pinion assembly allows it to ride forward on the helix, therefore engaging with the ring gear. As soon as the engine starts, the backdrive caused from the ring gear enables the pinion to go beyond 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.

During the 1930s, an intermediate development between the Bendix drive was developed. The overrunning-clutch design that was made and introduced in the 1960s was the Bendix Folo-Thru drive. The Folo-Thru drive consists of a latching mechanism along with a set of flyweights inside the body of the drive unit. This was better as the average Bendix drive used so as to disengage from the ring when the engine fired, though it did not stay functioning.

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. 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 afterward the flyweights pull outward in a radial manner. This releases the latch and enables the overdriven drive unit to become spun out of engagement, hence unwanted starter disengagement can be prevented before a successful engine start.

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