Abstract:
An electromagnetic switch for the starter of a heat engine, including a first terminal (B 1 ), a second terminal (B 2 ), a first mobile contact (C 1 ) which is movable between an inactive position and a power supply position, and at least one second mobile contact (C 2 ), which is placed between the first mobile contact (C 1 ) and the second terminal (B 2 ) and which is movable between a disconnected position and a connected position. The switch is capable of being placed in three operating states: an inactive state, an engagement state, and a power supply state.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY 
     This application is a national stage application of International Application No. PCT/FR2012/053051 filed Dec. 21, 2012, which claims priority to French Patent Application No. 1162255 filed Dec. 22, 2011, of which the disclosures are incorporated herein by reference and to which priority is claimed. 
     FIELD OF THE INVENTION 
     The invention relates to the technical field of starters for motor vehicle heat engines. 
     BACKGROUND OF THE INVENTION 
     A starter generally comprises an electric motor associated with drive means of the internal combustion engine. The drive means are most often adapted to be coupled to the movable components of the internal combustion engine during a start-up phase of said engine and to be decoupled from the internal combustion engine when said engine operates. To this end, the starter comprises an electromagnetic switch adapted, on the one hand, to control the power supply of the electric motor and, on the other hand, to control the coupling and decoupling of the drive means of the internal combustion engine. The drive means comprise a launcher, which is rotationally mobile about itself and which is movable by axial translation between a rest position and a drive position of the internal combustion engine. The launcher is then moved between its rest and drive positions by a lever operated by the electromagnetic switch. 
     More specifically, the invention relates to such an electromagnetic switch, also referred to as contactor, for a starter for a motor vehicle. 
     When implementing the starter, it is necessary to ensure that the gear of the launcher is properly engaged in the drive position before starting the electric motor. In effect, in the event of the incorrect engagement of the launcher when starting the electric motor, there is a major risk of damaging the launcher and/or the starter ring rigidly connected to the internal combustion engine. 
     For this reason, a need has arisen for an electromagnetic switch that ensures that the launcher is engaged in the drive position before the electric motor of the starter is started. 
     SUMMARY OF THE INVENTION 
     In order to achieve this objective, the invention relates to an electromagnetic switch for a starter of a heat engine, comprising:
         a first terminal;   a second terminal;   a first movable contact, which is located between the first and second terminals and which is movable between a rest position and a power supply position;   a plunger core, of a first coil, designed to activate a system for operating a launcher of the starter, controlling the displacement of the first movable contact;   a second movable contact, which is located between the first movable contact and the second terminal and which can be moved, between a disconnected position and a connected position, by a core of a second coil and by a spring.       

     According to the invention, the switch is designed to be placed, according to the power supply of the coils, in three operating states, namely:
         a rest state, wherein the first movable contact is electrically isolated from the two terminals, and in that the two terminals are isolated from each other;   an engaged state, wherein:   the first movable contact is in an engaged position between the power supply position and the rest position and is in electrical contact with the first electric terminal;   the second movable contact is in a rest position and in electrical and mechanical contact with the first movable contact;   the second terminal is electrically isolated from the movable contacts and the first terminal;   a power supply state, wherein:   the first movable contact is in a power supply position and is in electrical contact with the second terminal through the second movable contact and is in electrical contact with the first terminal; and   the second movable contact is in a connected position and is in electrical and mechanical contact with the second terminal.       

     Given the three distinct states that can be known by the starter, it is possible to control the power supply of the motor by placing the switch in its power supply state after it has been placed in its engaged state. 
     According to one feature of the invention, the second movable contact is in a connected position when the second coil is powered and is in a disconnected position when the coil is deactivated, with a spring returning the movable contact to a disconnected position. 
     According to one feature of the invention, the second movable contact is in a connected position when the second coil is powered and is in a disconnected position when the coil is deactivated, with a spring returning the movable contact to a connected position. 
     According to a variant of this feature, the first contact exerts a force on the second movable contact and passes from the disconnected position to the connected position when the first contact passes from the engaged position to the power supply position. 
     According to a further feature of the invention, the second movable contact is in a disconnected position when the second coil is powered and is in a connected position when the second coil is deactivated, and the second movable contact is held in a connected position by a spring. 
     According to one embodiment of the invention, the electromagnetic switch comprises:
         1. a third movable contact, which is located between the first movable contact and the first terminal and which is moved, between a disconnected position and a shunting position, by a core of a third coil and by a spring; and       1. a load resistor electrically mounted between the first terminal and the third movable contact;
 
wherein:
   1. in the rest state, the third movable contact is electrically isolated from the other two movable contacts;   1. in the engaged state, the first movable contact is in electrical and mechanical contact with the third movable contact, and in that the third movable contact is in a disconnected position that is mechanically isolated from the third terminal and is electrically linked to the first terminal through the load resistor;   1. in the power supply state, the first movable contact is in electrical and mechanical contact with the third movable contact, the third movable contact is in a connected position and is in electrical and mechanical contact with the first terminal shunting the resistor;
 
and wherein, the switch is capable of passing to an intermediate state, wherein:
   1. the first movable contact is in an engaged position and is in electrical and mechanical contact with the second and third movable contacts;   1. the third movable contact is in a disconnected position and is in electrical contact with the first terminal through the load resistor; and   1. the second movable contact is in a connected position and is electrically linked to the second terminal.   

     The four distinct states of the switch allow precise control of the starter integrating the switch according to the invention. In particular, this embodiment allows the use of a resistor in series with the electric motor for a short duration when the electric motor is powered. 
     According to a further feature of this embodiment, the third movable contact is in a disconnected position when the third coil is activated. 
     According to a further feature of this embodiment, the first movable contact exerts a mechanical force on the third movable contact so as to move the third movable contact toward the shunting position when the third coil is not powered, and in that a return spring applies a force to the third movable contact toward the disconnected position and is held in the disconnected position by a spring. 
     In this embodiment, the third movable contact is permanently electrically connected, via a load resistor, to the second terminal so that in the intermediate state the load resistor is powered and in the power supply state the resistor is short-circuited. This feature allows a rotation of the electric motor to be controlled in the intermediate state with less power than is available in the power supply state. 
     According to one feature of the invention, the second and/or the third coil is a micro-solenoid. 
     According to a variant of this feature, the second and/or the third movable contact is formed by a contact stirrup comprising two jaws that hold together the core of the micro-solenoid, which is also located between the two jaws. The contact stirrup is then preferably adapted to support the passage of a power current. 
     According to a further variant of this feature, the micro-solenoid comprises a shell forming part of the magnetic circuit of the micro-solenoid and forming a housing for the coil of the micro-solenoid. The shell is then preferably rigidly connected to a wall of the switch. 
     According to one embodiment, the contact stirrup is adapted to support the passage of a power current. 
     According to one embodiment, the micro-solenoid comprises a shell forming part of the magnetic circuit of the micro-solenoid and forming a housing for the coil of the micro-solenoid. 
     According to one embodiment, the shell is rigidly connected to the body of the switch. 
     The invention further relates to an electric starter for an internal combustion engine, comprising:
         a launcher, which is rotationally driven by an electric motor and which is movable by axial translation between a rest position and an engaged position with drive means of the internal combustion engine;   an electromagnetic switch as previously described adapted, on the one hand, to control the power supply of the electric motor and, on the other hand, to control the displacement of the launcher between its rest and engaged positions.       

     The invention further relates to a starter system comprising a starter as previously described, wherein the first coil comprises:
         a pull-in winding with an output terminal electrically linked to the positive terminal of the motor; and   a holding winding with an output terminal electrically linked with the negative terminal of the motor and an input terminal linked to an input terminal of the pull-in coil;   wherein said system further comprises:   an electric battery comprising a positive terminal linked to the second terminal of the switch and a negative terminal linked to a terminal of the electric motor;   a first circuit breaker electrically linked from a first terminal to the positive terminal of the battery and from a second terminal to the holding and pull-in windings;   a second circuit breaker electrically linked from a first terminal to the positive terminal of the battery and from a second terminal to the input terminal of the second coil; and   wherein the output terminal of the second coil is electrically linked to the positive terminal of the motor.       

     According to one feature of the previously described system, the output terminal of the second coil is connected to the output terminal of the pull-in winding of the first coil. 
     According to one feature of the aforementioned system, the third coil is connected between the third contact and the output terminal of the first coil. 
     Of course, the different variants and embodiments of the invention can be associated with each other according to various combinations insofar as they are not incompatible or exclusive from each other. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Furthermore, various other features of the invention will become apparent from the appended description, which is provided with reference to the drawings according to the invention. 
         FIG. 1  is a partial extracted view of a starter for a heat engine, according to the invention. 
         FIG. 2  is a schematic longitudinal section of the electromagnetic switch of the starter shown in  FIG. 1 . 
         FIG. 3  is a wiring diagram of a power supply circuit of the electric motor of the starter shown in  FIG. 1  incorporating the switch shown in  FIG. 2 . 
         FIG. 4  is a diagram of a multi-contacts assembly constituting the switch shown in  FIG. 2  in a rest state. 
         FIG. 5  is a side view of a micro-solenoid constituting a coil of a switch according to the invention. 
         FIG. 6  is an exploded view of the micro-solenoid shown in  FIG. 5 . 
         FIGS. 7 and 8  are similar diagrams to  FIGS. 3 and 4 , respectively, showing an engaged state of the switch shown in  FIG. 2 . 
         FIGS. 9 and 10  are similar diagrams to  FIGS. 3 and 4 , respectively, showing a power supply state of the switch shown in  FIG. 2 . 
         FIG. 11  is a schematic longitudinal section of a further embodiment of the electromagnetic switch of the starter shown in  FIG. 1 . 
         FIG. 12  is a wiring diagram of a power supply circuit of the electric motor of the starter shown in  FIG. 1  incorporating the switch shown in  FIG. 11 . 
         FIG. 13  is a diagram of a multi-contacts assembly constituting the switch shown in  FIG. 11  in a rest state. 
         FIGS. 14 and 15  are similar diagrams to  FIGS. 12 and 13 , respectively, showing an engaged state of the switch shown in  FIG. 11 . 
         FIGS. 16 and 17  are similar diagrams to  FIGS. 12 and 13 , respectively, showing an intermediate state of the switch shown in  FIG. 11 . 
         FIGS. 18 and 19  are similar diagrams to  FIGS. 12 and 13 , respectively, showing a power supply state of the switch shown in  FIG. 11 . 
         FIGS. 20 and 21  are similar diagrams to  FIGS. 12 and 13 , respectively, showing a further embodiment of a switch according to the invention in a rest state. 
     
    
    
     It is noteworthy that in these figures the various structural and/or functional elements common to the different variants can have the same alphanumeric references. 
     DETAILED DESCRIPTION 
     As can be seen in  FIG. 1 , a starter D, according to the invention, for a heat engine comprises a front part A comprising a reducer R 1  , on which an electric motor M is fixed that is controlled by an electromagnetic switch C that also controls a launcher L integrated into the front part A. The launcher L and the reducer R 1  together form drive means of the internal combustion engine. The embodiment of such a starter D and its constituent elements is well known to a person skilled in the art and for this reason only those features will be described that are necessary to understand the invention. For further information relating to the details for producing a starter, details of which will not be provided hereafter, please refer to the documents FR 2934933 and 1933, FR 2843427 and WO 2005/054664. 
     The electromagnetic switch C comprises, as can be seen in  FIG. 2 , a first terminal B 1  and a second terminal B 2  that extend outside of the body  1  of the switch C. The first terminal B 1  is, according to the example shown in  FIG. 3 , designed to be connected to a pole of a battery  2 , whereas the second terminal B 2  is designed to be connected to the electric motor M. The terminals B 1  and B 2  belong to a multi-contacts assembly MC constituting the switch C and shown schematically in  FIG. 4 . 
     In addition to the terminals B 1  and B 2 , the multi-contacts assembly MC comprises a first movable contact C 1 , which is located between the first and second terminals B 1  and B 2 . The first movable contact C 1  is activated by a plunger P 1  of a first coil L 1 . The plunger P 1  is also adapted to move the launcher L between rest and engaged positions. The first coil L 1  comprises two windings Em and Ea that have a common end connected to a control unit U. A first winding Em, referred to as holding winding, is also directly connected to the ground of the vehicle, whereas the other winding Ea, referred to as pull-in winding, is also connected to the second terminal B 2 . 
     The multi-contacts assembly MC further comprises a second movable contact C 2 , which is located between the first movable contact C 1  and the second terminal B 2 . The second movable contact C 2  is moved by the core P 2  of a second coil L 2  that is connected, on the one hand, to the control unit U and, on the other hand, to the second terminal B 2 . 
     According to the example shown, and as is more specifically shown in  FIGS. 5 and 6 , the second movable contact C 2  is in the form of a U-shaped stirrup comprising two parallel branches  10  and  11  connected by a core  12  substantially parallel to the second coil L 2 . The second movable contact C 2  is preferably made of a material with very good electric conductivity characteristics, such as copper, so as to support the passage of a high-intensity current without overheating. 
     The second coil L 2  is then produced in the form of a micro-solenoid  9  comprising the mobile core P 2  that is clamped by the two branches  10  and  11  of the second movable contact C 2  whilst being substantially parallel to its core  12 . The mobile core P 2  is, for example, made of soft iron so as to be able to be magnetised and have good electric conductivity characteristics. The mobile core P 2  is surrounded by the second coil L 2 , which is disposed inside a shell  14 . Furthermore, this shell  14  is linked to the body  2  so as to be translationally immobilised parallel to the axis Δ of the coil and by translation of the core P 2 . Finally, the micro-solenoid  9  comprises a spring  15  interposed between the shell  14  and the lower branch  11  of the movable contact C 2 . 
     The control unit U comprises a first circuit breaker I 1  dedicated to the power supply of the first coil L 1  and a second circuit breaker I 2  dedicated to the power supply of the second coil L 2 . 
     The output terminals of the second and first coils are electrically linked together. 
     The switch C that is formed in this way operates as follows. 
     In a rest state, with the two circuit breakers I 1  and I 2  being open and no current circulating in the coils L 1  and L 2 , the first movable contact C 1  is in the rest position R and the second movable contact C 2  is in the disconnected position D, as shown in  FIG. 3 . 
     When the engine of the vehicle incorporating the starter according to the invention needs to be started, the switch C is placed in an engaged state, more specifically shown in  FIGS. 7 and 8 . To this end, the first circuit breaker I 1  and the second circuit breaker I 2  are closed. 
     The first coil L 1  is then powered so that its plunger P 1  moves in the direction of the arrow E 1 . The plunger P 1  places the first movable contact C 1  in the engaged position E where it is found in mechanical and electrical contact with the first terminal B 1 , as well as with the second movable contact C 2 . The power supply of the second coil L 2  urges C 2  in direction E 2  and keeps the second movable contact C 2  in the disconnected position D to prevent the movable contact C 1  from moving the movable contact C 2  toward the connected position. 
     The movement of the plunger P 1  has also moved the launcher L to an engaged position with the drive means of the internal combustion engine. 
     From the engaged state, the switch C can be placed in a power supply state, as shown in  FIGS. 9 and 10 . To this end, the second circuit breaker I 2  is open so that the second coil L 2  is no longer powered, which causes a translation movement of its core P 2 , in the direction of the arrow F 3 , thus placing the second movable contact C 2  in the connected position Cx, in which it is in mechanical and electrical contact with the second terminal B 2 . The switch further comprises a retention spring W, shown in  FIG. 2  , which applies a force to the movable contact C 1  toward the powered position and which also applies a force to the movable contact C 2  through the movable contact C 1  toward the connected position. 
     In this way, the first C 1  and second C 2  movable contacts provide electrical continuity between the first B 1  and second B 2  terminals so that the electric motor M of the starter is powered and can ensure the drive for the internal combustion engine. 
     The return spring  15  exerts a force returning the movable contact to a disconnected position when the contact plate moves toward the rest position. 
     It is noteworthy that the first contact C 1  is only perfectly placed in its engaged position when the launcher L correctly meshes with the drive means of the internal combustion engine. Therefore, the electric motor M is only powered when, on the one hand, the second circuit breaker I 2  is closed and, on the other hand, the launcher L is correctly engaged. 
     It is also noteworthy that in this power supply state the pull-in winding Ea is short-circuited, whereas the second coil L 2  is not powered so that a maximum amount of electrical power is available for the electric motor M. 
     According to a further variant of an embodiment, not shown, the movable contact is arranged between the movable contact C 1  and the second terminal B 2 . The operation remains identical to the previously described mode. 
     According to a variant of an embodiment of the invention, the switch C comprises, as shown in  FIGS. 11 to 13 , a third movable contact C 3 , which is located between the first terminal B 1  and the first movable contact C 1 . This third movable contact C 3  is activated by the core P 3  of a third coil B 3  produced in the same way as the second coil B 2  in the form of a micro-solenoid, as shown in  FIGS. 5 and 6 , and for this reason its constitution does not need to be described in further detail. 
     According to a variant of an embodiment, the second movable contact C 2  is also permanently connected to the second terminal B 2  by a flexible braid T incorporating a current load resistor R. 
     As shown in  FIG. 12 , the third coil L 3  is connected, on the one hand, to the second coil L 2  and, on the other hand, to the first circuit breaker I 1  of the control unit U, whereas the second coil L 2  is connected to the second terminal B 2  via the load resistor R. The second circuit breaker I 2  of the control unit U is also connected to the line linking the second coil L 2  to the third coil L 3 . In this embodiment, the second movable contact moves from a disconnected position to a shunting position, also referred to as short-circuited position, corresponding to the embodiment previously described for the connected position. In the shunting position, the resistor R is short-circuited. 
     The switch C that is formed in this way operates as follows. 
     In the rest state, as shown in  FIGS. 12 and 13 , with the circuit breakers I 1  and I 2  being open, the first movable contact C 1  is in the rest position, whereas the second and third movable contacts C 2 , C 3  are in the disconnected position, through the return spring  15  shown in  FIG. 6 . The movable contacts C 1  to C 3  and the terminals B 1  and B 2  are then electrically isolated from each other. The resistor R electrically links the movable contact C 3  to the positive terminal of the electric motor. 
     When the engine of the vehicle incorporating the starter according to this variant needs to be started, the switch C is placed in an engaged state, more specifically shown in  FIGS. 14 and 15 . To this end, the first circuit breaker I 1  is closed, with the second circuit breaker I 2  remaining open. 
     The first coil L 1  is then powered so that its plunger P 1  moves in the direction of the arrow F 1 . The plunger P 1  places the first movable contact C 1  in the engaged position E, in which it is found in mechanical and electrical contact with the second movable contact C 2  and the third movable contact C 3 . The second coil L 2  and the third coil L 3  are also powered, which keeps the second movable contact C 2  and the third movable contact C 3  in the disconnected position through a magnetic force, shown by the arrow F 2 . The movement of the plunger P 1  has also placed the launcher L in an engaged position with the drive means of the internal combustion engine. 
     From the engaged state, the switch C can be placed in an intermediate state, as shown in  FIGS. 16 and 17 . To this end, the second circuit breaker I 2  is closed so that the third coil L 3  is short-circuited and therefore is no longer powered. The power supply fault of the third coil L 3  causes a translation movement of its core P 3 , in the direction of the arrow F 4 , thus placing the third movable contact C 3  in the connected position Cx, in which it is in mechanical and electrical contact with the first terminal B 1 . The second coil L 2  is parallel to the pull-in winding Ea and thus remains powered so as to keep the second movable contact in the disconnected position. 
     In this intermediate state, the electric motor M is powered via the load resistor R so that it runs at reduced speed and power. 
     From the intermediate state, the switch C can be placed in a power supply state, as shown in  FIGS. 18 and 19 . To this end, the second circuit breaker I 2  is open so that the power supply of at least the pull-in winding Ea of the first coil L 1 , as well as the power supply of the second and third coils B 2  and B 3 , is cut so as to no longer hold the movable contact C 2  and so that said movable contact moves under the action of the retention spring W, which applies a force F 5  toward the connected position Cx through the movable contact C 1 . The second movable contact C 2  in the connected position Cx is therefore in mechanical and electrical contact with the second terminal B 2 . 
     Therefore, in this power supply state, the first C 1 , second C 2  and third C 3  movable contacts provide an electrical continuity between the first B 1  and second B 2  terminals so that the electric motor M of the starter is fully powered and can ensure the drive for the internal combustion engine. 
     In this power supply state, it is sufficient, in order to interrupt the power supply of the electric motor M, for the first circuit breaker to be opened. In effect, the power supply to the holding winding is removed causing the return of the plunger P 1  through one or more return springs and thus causing the second C 2  and third C 3  movable contacts to return to the disconnected position by means of their reciprocal return springs  15 . 
     The second movable contact C 2  is permanently linked to the second terminal by a braid T comprising the resistor R. 
     However, such a permanent link is not required for the invention. According to a further embodiment, not shown, the output of the second coil L 2  and the input of the third coil L 3  (or vice versa) are not electrically connected together. In this embodiment, a third circuit breaker is required to control the third movable contact. Therefore, the advantage of the embodiment described is that it saves volume as it only uses two movable contacts. 
     Of course, various other modifications can be added to the invention within the scope of the appended claims.