STARTER SYSTEM HAVING CONTROLLING RELAY SWITCH

Abstract

A starter system including a motor, a solenoid assembly having a solenoid switch, a pinion rotated by the motor and moveable into an engaging position in which an engine may be cranked and the solenoid switch is closed to energize the motor from an electric power source, and relay switch regulated by a controller and closed to apply electrical power to the solenoid assembly for actuating the solenoid switch. The controller repeatedly opens and closes relay switch during a starting operation if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after electrical power is applied to the solenoid assembly, whereby electrical power applications to the solenoid assembly are automatically repeated during a starting operation to correct “click-no-crank” events and prevent prolonged power application to the solenoid assembly. A related method is also disclosed.

Claims

1. A system for starting an engine, comprising: a relay switch that is closed during a starting operation; a starter assembly comprising: a solenoid assembly including a solenoid switch adapted for connection to an electrical power source, a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position; and a controller connected to the relay switch; wherein during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.

2. The system of claim 1, wherein the controller is configured to switch electrical power to the solenoid assembly off and on by opening the relay switch, and waiting a predetermined time delay period before reclosing the relay switch, and optionally wherein the pinion does not enter a fully disengaged position prior to the controller reclosing the relay switch.

3. The system of claim 2, wherein the predetermined time delay period is a value less than 600 ms.

4. The system of claim 3, wherein the predetermined time delay period is a value less than 100 ms.

5. The system of claim 1, wherein the system is defined as a 24V starter system and the predetermined threshold level is a value less than 11.0V.

6. The system of claim 1, wherein the predetermined time period is a value no more than 150 ms.

7. The system of claim 1, wherein the relay switch is biased open and electromagnetically closed, and the system further comprises an activation coil to which voltage is applied during each starting operation, and wherein during a starting operation the controller is configured to selectively permit grounding of current through the activation coil to close the relay switch and prevent grounding of current through the activation coil to open the relay switch, and the controller is configured to regulate the relay switch through the selective grounding of the activation coil.

8. The system of claim 7, wherein the pinion is biased into its disengaged position in the absence of electrical power application to the solenoid assembly, and wherein the controller monitors sensed voltage applied to the activation coil and during a starting operation opens the relay switch when the sensed voltage applied to the activation coil rises to a threshold voltage level, whereby the pinion is automatically moved to the disengaged position upon the engine starting.

9. The system of claim 7, further comprising a momentary starter switch biased open and closed through operator actuation to commence each starting operation, wherein voltage is applied to the activation coil only when the momentary starter switch is closed.

10. The system of claim 1, wherein the system is for installation in a vehicle including the engine and a battery comprising the electrical power source, and wherein the system is operable independently of other vehicle control systems and without the controller monitoring a signal indicative of an engine speed, whereby the system defines a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.

11. The system of claim 1, wherein the controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.

12. The system of claim 1, wherein the electrical power source is a battery, and wherein the controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.

13. The system of claim 1, wherein the electrical power source is a battery, and wherein the controller monitors sensed battery voltage with the solenoid switch open and prevents the relay switch closing if the sensed battery voltage is no greater than a predetermined threshold voltage, whereby starter assembly operation is prevented if the sensed battery voltage is below the threshold voltage.

14. The system of claim 1, wherein the electrical power source is a battery, and wherein the controller monitors sensed battery voltage with the solenoid switch closed and opens the relay switch if the sensed battery voltage drops below a threshold voltage while the motor is energized, whereby the present starting attempt is aborted if battery voltage becomes lower than the threshold voltage during engine cranking.

15. The system of claim 1, wherein the controller monitors time elapsed after commencement of a starting operation, limits the maximum duration of an application of electrical power to the solenoid assembly to a first predetermined time period, and delays occurrences of consecutive starting operations by a second predetermined time period, whereby continuous cranking time and the frequency of starting operations are limited.

16. A unitary starter assembly comprising: a relay switch that is closed during a starting operation; a solenoid assembly including a solenoid switch adapted for connection to an electrical power source; a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed; a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position; and a controller connected to the relay switch; wherein during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.

17. The starter assembly of claim 16, wherein the controller is configured to limit the number of times the relay switch is opened and reclosed to switch electrical power to the solenoid assembly off and on during the starting operation.

18. The starter assembly of claim 16, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch, and the functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.

19. The starter assembly of claim 16, wherein the relay switch is biased open and electromagnetically closed, and the starter assembly further comprises an activation coil to which voltage is applied during each starting operation, and wherein during a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch, and the controller regulates the relay switch through the selective grounding of the activation coil.

20. A method for regulating a starter system, comprising: providing electrical power to a relay switch; commencing a starting operation with an operator-actuable starter switch; using a controller during the starting operation to close the relay switch for applying electrical power to a solenoid assembly; using the powered solenoid assembly to urge a pinion rotatable by an energized motor toward an engaged position in which the engine may be cranked using the starter system, and to connect the motor to an energizing electrical power source through a solenoid switch closed when the pinion is in the engaged position; and using the controller to monitor sensed motor energization voltage and for opening and reclosing the relay switch during the starting operation to switch electrical power to the solenoid assembly off and on if sensed motor energization voltage falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, whereby a “click-no-crank” event can be corrected during the starting operation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] The above-mentioned aspects of exemplary embodiments will become more apparent and will be better understood by reference to the following description of the embodiments taken in conjunction with the accompanying drawings, wherein:

[0069] FIG. 1 is a schematic of an embodiment of a prior conventional starter system;

[0070] FIG. 2 is a schematic of an embodiment of a conventional starter system according to the present disclosure;

[0071] FIG. 3 is a perspective view of an embodiment of a starter relay switch usable in the starter system of FIG. 2;

[0072] FIG. 4 is a first schematic of a controller integrated into the starter relay switch of FIG. 3;

[0073] FIG. 5 is a second schematic of the controller of FIG. 4, wherein portions of the controller circuit there shown are represented as individual functional circuits;

[0074] FIG. 6 is a table associating individual functional circuits shown in FIG. 5 with operational features of a starter system according to the present disclosure;

[0075] FIG. 7 is a control state diagram for a 24V starter system embodiment according to the present disclosure.

[0076] Corresponding reference characters indicated corresponding parts throughout the several views. Although the drawings represent embodiments of the disclosed apparatus, the drawings are not necessarily to scale or to the same scale and certain features may be exaggerated in order to better illustrate and explain the present disclosure.

DESCRIPTION

[0077] The embodiments described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may appreciate and understand the principles and practices of this disclosure.

[0078] In referring below and in the drawings to a starter system or device according to the present disclosure, its elements corresponding to elements of the prior art starter system or device discussed above are identified with a like reference numeral primed. Thus, for example, an embodiment of above-discussed starter system 20 and starter assembly 22 modified in accordance with the present disclosure is identified as starter system 20′ and starter assembly 22′. Corresponding elements of system 20′ or starter assembly 22′ that are substantially unchanged relative to above-discussed prior system 20 or starter assembly 22 are identified with common respective element numerals. FIG. 2 schematically shows one embodiment of starter system 20′ according to the present disclosure that is substantially similar to prior starter system 20 except as herein disclosed.

[0079] Starter system 20′ includes starter assembly 22′ including intelligent integral magnetic switch assembly (or iIMS) 62′ shown in FIG. 3. Like IMS 62, iIMS 62′ includes electromagnetically-closed relay switch 83, and may be included as an attached component of its starter assembly 22′. Starter system 20′ may include starter assembly 22′ and iIMS 62′ as a unitary assemblage, i.e., as a single unit comprised of the assembled parts, which are together commercialized or installed in a vehicle. Such an assemblage may also be referred to as a unitary starter assembly.

[0080] Starter relay switch 62′ has switch cover 66′ which is interchangeable with prior starter relay switch cover 66. Thus, certain embodiments of starter relay switch 62′ have switch cover 66′ mated to housing 64 of prior starter relay switch 62. Switch cover 66′ includes a plurality of screws 67 for attaching switch cover 66′ to housing 64. As in the case of depicted prior starter relay switch 62, grounding terminal 70 of the depicted embodiment of starter relay switch 62′ is connected to ground 90 through the attachment of switch housing 64 to housing/frame structure 34 of starter assembly 22′, which is also grounded. Those having ordinary skill in the relevant art will recognize, however, that grounding terminal 70 may be insulated from switch housing 64 and separately grounded.

[0081] Starter relay switch 62′ includes integrated controller 108 provided on printed circuit board (“PCB”) 110, which is mounted to the interior of switch cover 66′. PCB 110 is provided with M terminal 112, B+ terminal 114, S− terminal 116, S+ terminal 117, and ground terminal 118. Switch cover 66′ includes rivet 119 which is connected to S− terminal 116. Referring again to FIG. 2, M terminal 112 is electrically connected to input terminal 120 of switch cover 66′ for monitoring (or sensing) applied motor voltage. In the depicted embodiment, input terminal 120 is electrically connected to second solenoid switch contact 98. B+ terminal 114 is electrically connected to first switch terminal 79 of switch cover 66′ for monitoring battery voltage applied to first switch contact 78 and, with relay switch 83 closed, to second switch contact 80 and second switch terminal 81.

[0082] S− terminal 116 is electrically connected to the low or downstream current side of relay switch activation coil 72 for monitoring voltage at this location, whereas S+ terminal 117 is electrically connected to the high or upstream current side of relay switch activation coil 72 for monitoring voltage at this location and at relay switch activation terminal 68, which is electrically connected to second key switch contact 88.

[0083] Ground terminal 118 is electrically connected to grounding terminal 70, which is electrically connected to the interior metallic switch housing 64 which, as mentioned above, is connected to ground 90 through the attachment of iIMS 62′ to motor housing 34 of starter assembly 22′, which is also grounded. As also mentioned above, those having ordinary skill in the relevant art will recognize that grounding terminal 70 may instead be insulated from switch housing 64 and separately grounded. Additionally, the various grounds 121 of controller 108 are electrically connected to ground terminal 118 and starter system ground 90. At least one of screws 67 is also connected to ground 121. As discussed further below, controller 108 selectively permits or prevents current flow through relay switch activation coil 72, thereby controlling, on the basis of time and monitored conditions, the opening and closing of relay switch 83. Consequently, the operation of starter assembly 22′ is regulated by controller 108 of iIMS 62′, which may thus be understood to provide a starter system-controlling relay switch.

[0084] FIGS. 4 and 5 show related schematic views of controller 108, indicating portions of starter relay switch 62′ and other components of starter system 20′ with which it operably communicates. Where mentioned in the following discussion, resistor and capacitor first terminals are those oriented towards the top or right hand side of FIG. 4, and their second terminals are oriented towards the bottom or left hand side of that Figure. Respective exemplary values for each resistor and capacitor are shown in FIG. 4, but may be deviated from to provide desired adjustments to the operation of starter system 20′ and to accommodate different system voltages (e.g., 12V or 24V) and characteristics of various starter system components.

[0085] Controller 108 includes microcontroller unit (“MCU”) 122 which may, for example, be a model MC9S08QD4 MCU commercially available from Freescale Semiconductor headquartered in Austin, Tex., USA. This particular MCU includes 256B RAM, integrated flash memory programmable in circuit, an analogue-to-digital converter, dual 16 bit timer modules, an internal clock source module, and eight (8) terminals or pins identified as follows: pin 1 (PTA5/IRQ) 124; pin 2 (PTA4/TM2) 126; pin 3 (VDD) 128; pin 4 (VSS) 130; pin 5 (ADC1P3) 132; pin 6 (ADC1P2) 134 which in the depicted embodiment is unconnected to other circuit portions of controller 108; pin 7 (ADC1P1) 136; and pin 8 (ADC1P0) 138. As mentioned further below, MCU 122 may be flashed to provide initial or revised programmed instructions for operating starter system 20′. The operating instructions programmed into the memory of MCU 122 define a starter system operating paradigm. At least one starter system operational parameter (e.g., a voltage or current level or signal) is monitored by controller 108 and provided as an input to the paradigm, by which the paradigm determines a resultant starter system operational output. In one embodiment, the resultant starter system operational output is effected by selectively completing or interrupting controller 108 circuit(s), respectively permitting or preventing current flow through relay switch activation coil 72, and consequently closing or opening starter relay switch 62′.

[0086] S−terminal 116 is connected to the drain of first transistor Q1 140, a power MOSFET including the shown Zener diode and which may, for example, be a model VND5N07 OMNIFET II commercially available from STMicroelectronics headquartered in Geneva, Switzerland. The source of first transistor Q1 140 is connected to ground 121. The input gate of first transistor Q1 140 is attached to the first terminal of first resistor R1 142. The second terminal of first resistor R1 142 is connected to MCU pin 2 126. The first terminal of second resistor R2 144 is connected to the input gate of first transistor Q1 140 and to the first terminal of first resistor R1 142. The second terminal of second resistor R2 144 is connected to ground 121.

[0087] The anode of first diode D1 146 is connected to the drain of first transistor Q1 140 and to S− terminal 116. The cathode of first diode D1 146 is connected to S+ terminal 117 and to the first terminal of third resistor R3 148. The second terminal of third resistor R3 148 is connected to MCU pin 7 136. Connected to MCU pin 7 136 and to the second terminal of third resistor R3 148 are the first terminals of parallel-connected fourth resistor R4 150 and first capacitor C1 152. The second terminals of parallel-connected fourth resistor R4 150 and first capacitor C1 152 are connected to ground 121. The cathode of first diode D1 146 is also connected to the first terminal of fifth resistor R5 154. The second terminal of fifth resistor R5 154 is connected to MCU pin 1 124. Also connected to the second terminal of fifth resistor R5 154 and to MCU pin 1 124 is the cathode of first Zener diode Z1 156. The anode of first Zener diode Z1 156 is connected to ground 121.

[0088] The cathode of first diode D1 146 is also connected to the anode of second diode D2 158. The cathode of second diode D2 158 is connected to the first terminal of sixth resistor R6 160. Also connected to the first terminal of sixth resistor R6 160 and to the cathode of second diode D2 158 is the first terminal of second capacitor C2 162. The second terminal of second capacitor C2 162 is connected to ground 121. The second terminal of sixth resistor R6 160 is connected to the input gate of second transistor Q2 164 which may be identical to above-described first transistor Q1 140. Also connected to the second terminal of sixth resistor R6 160 and to the input gate of second transistor Q2 164 is the first terminal of seventh resistor R7 166. The second terminal of seventh resistor R7 166 is connected to ground 121. The source of second transistor Q2 164 is connected to ground 121.

[0089] B+ terminal 114 is connected to the non-inverting input of third transistor Q3 170 which may, for example, be a model MMBT5401 150V/500 mA PNP transistor commercially available from ON Semiconductor headquartered in Phoenix, Ariz., USA. Also connected to B+ terminal 114 and to the non-inverting input of third transistor Q3 170 is the first terminal of eighth resistor R8 168. The second terminal of eighth resistor R8 168 is connected to the drain of second transistor Q2 164. The collector of third transistor Q3 170 is connected to the first terminal of ninth resistor R9 172. The second terminal of ninth resistor R9 172 is connected to the second terminal of eighth resistor R8 168 and to the drain of second transistor Q2 164. The inverting output of third transistor Q3 170 is connected to the first terminal of tenth resistor R10 174. The second terminal of tenth resistor R10 174 is connected to MCU pin 3 128. Also connected to the second terminal of tenth resistor R10 174 and to MCU pin 3 128 is the cathode of second Zener diode Z2 176. The anode of second Zener diode Z2 176 is connected to ground 121. The grounded anode of second Zener diode Z2 176 is also connected to the first terminals of parallel-connected third and fourth capacitors C3 178, C4 180. The second terminals of parallel-connected third and fourth capacitors C3 178, C4 180 are connected to the cathode of second Zener diode Z2 176 and to MCU pin 3 128.

[0090] Connected to the inverting output of third transistor Q3 170 and to the first terminal of tenth resistor R10 174 is the first terminal of eleventh resistor R11 182. The second terminal of eleventh resistor R11 182 is attached to MCU pin 8 138. Also connected to both the second terminal of eleventh resistor R11 182 and MCU pin 8 138 are the first terminals of parallel-connected twelfth resistor R12 184 and fifth capacitor C5 186. The second terminals of parallel-connected twelfth resistor R12 184 and fifth capacitor C5 186 are connected to ground 121.

[0091] M terminal 112 is connected to the first terminal of thirteenth resistor R13 188. The second terminal of thirteenth resistor R13 188 is connected to MCU pin 5 132. Connected to the second terminal of thirteenth resistor R13 188 and to MCU pin 5 132 are the first terminals of parallel-connected fourteenth resistor R14 190 and sixth capacitor C6 192. The second terminals of parallel-connected fourteenth resistor R14 190 and sixth capacitor C6 192 are connected to ground 121.

[0092] Exemplary sizes of the resistors and capacitors of control 108 shown in FIG. 4 for a 24V starter system 20′ are shown below in Table 1.

TABLE-US-00001 TABLE 1 Resistor or Capacitor Reference Numeral Resistor/Capacitor Size R1  142 1.5 KΩ R2  144 30 KΩ R3  148 180 KΩ R4  150 30 KΩ R5  154 30 KΩ R6  160 2.2 MΩ R7  166 5.1 MΩ R8  168 30 KΩ R9  172 30 KΩ R10 174 820 Ω R11 182 180 KΩ R12 184 30 KΩ R13 188 180 KΩ R14 190 30 KΩ C1 152 0.1 μF C2 162 2.2 μF C3 178 0.1 μF C4 180 10 μF C5 186 0.1 μF C6 192 0.1 μF

[0093] Those having ordinary skill in the relevant art will recognize that interconnected portions of the circuit shown in FIG. 4 and described above form functional circuits of controller 108:

[0094] First and second resistors R1 142, R2 144 define gate drive circuit 194.

[0095] First transistor Q1 140 and first diode D1 146 define power driver circuit 196.

[0096] Third resistor R3 148, fourth resistor R4 150, and first capacitor C1 152 define voltage divider circuit 198.

[0097] Fifth resistor R5 154 and first Zener diode Z1 156 define level circuit 200.

[0098] Second diode D2 158, sixth resistor R6 160, second capacitor C2 162, second transistor Q2 164, seventh resistor R7 166, eighth resistor R8 168, third transistor Q3 170, ninth resistor R9 172, tenth resistor R10 174, second Zener diode Z2 176, third capacitor C3 178, and fourth capacitor C4 180 define 5V regulating circuit 202.

[0099] Eleventh resistor R11 182, twelfth resistor R12 184, and fifth capacitor C5 186 define voltage divider circuit 204.

[0100] Thirteenth resistor R13 188, fourteenth resistor R14 190, and sixth capacitor C6 192 define voltage divider circuit 206.

[0101] The enumerated pins of MCU 122 thus individually communicate with different ones of the abovementioned functional circuits, as shown in FIG. 5:

[0102] MCU pin 1 (PTA5/IRQ) 124 is connected to level circuit 200;

[0103] MCU pin 2 (PTA4/TM2) 126 is connected to gate drive circuit 194;

[0104] MCU pin 3 (VDD) 128 is connected to 5V regulating circuit 202;

[0105] MCU pin 4 (VSS) 130 is connected to ground 121;

[0106] MCU pin 5 (ADC1P3) 132 is connected to voltage divider circuit 206;

[0107] MCU pin 6 (ADC1P2) 134 is, in the depicted embodiment, unconnected;

[0108] MCU pin 7 (ADC1P1) 136 is connected to voltage divider circuit 198; and

[0109] MCU pin 8 (ADC1P0) 138 is connected to voltage divider circuit 204.

[0110] FIG. 6 shows which of these functional circuits of controller 108 are utilized with MCU 122 in starter system 20′ for controlling operational features that prevent certain failure modes. It is to be understood that some embodiments of starter system 20′ and controller 108 may provide some but not all features in various combinations, depending on design and/or performance preferences of, for example, the vehicle OEM or a particular customer. Such combinations may be effected through circuit design or by flashing MCU 122 to initially establish or alter the programming of controller 108, whereby starter relay switch 62′ may be selectively adapted to provide any or all of the features (or functions) listed in FIG. 6.

[0111] Referring to FIG. 6, starter engagement monitoring and automatic retry feature 216 corrects occurrences of “click-no-crank” events and prevents prolonging power application to the solenoid. Feature 216 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, power driver circuit 196, voltage divider circuit 198, level circuit 200, 5V regulating circuit 202, voltage divider circuit 204, and voltage divider circuit 206, to recycle power application to solenoid assembly pull-in and hold-in coils 92, 94 if, in a 24V system, motor voltage at M terminal 112 falls below 11.0V or, more preferably, 6.0V within a predetermined time period of 600 ms, and limits starter operation to three (3) consecutive retry events in the starter switch 24 closed condition, i.e., during a starting operation. In a 12V system, electrical power application to pull-in and hold-in coils 92, 94 is similarly recycled to when the monitored motor energization voltage at M terminal 112 falls below 6.0V or, more preferably, 4.0V within a predetermined time period of no more than 600 ms. For either a 24V or 12V starter system, it may be preferable to reduce the predetermined time period to no more than 150 ms to correct the “click-no-crank” occurrence as quickly as possible.

[0112] A recycle of electrical power application to the solenoid assembly entails, during a starting operation, using the controller 108 for opening relay switch 83 to cut power to solenoid assembly pull-in and hold-in coils 92, 94, waiting a predetermined time delay period, and then reclosing relay switch 83 to repeatedly provide electrical power application to the solenoid assembly pull-in and hold-in coils 92, 94. To ensure that the electrical current is not applied to the solenoid assembly pull-in and hold-in coils 92, 94 for an extended period of time, which can result in overheating the solenoid assembly, the predetermined time delay period should be a value less than 600 ms.

[0113] Moreover, the predetermined time delay period between opening relay switch 83 to cut electrical power to solenoid assembly pull-in and hold-in coils 92, 94, and reclosing relay switch 83 to reapply electrical power to these coils, to respectively deactivate and reactivate solenoid assembly 50 during a starting operation, is desirably set control the axial travel of pinion 46 from ring gear 28. It is desirable that pinion 46, once leaving axially abutting engagement with the face of ring gear 28 after deactivation of solenoid assembly 50, is optionally prevented from returning to its “home” or fully-disengaged position during the predetermined time delay period. Preventing pinion 46 from reaching the fully disengaged position during the delay period reduces the reengagement time for quicker starting since the pinion need not travel as far, and also reduces wear on the pinion and ring gear because re-contacting forces on their faces when again abutted during reactivation of the solenoid assembly are lower than would occur were pinion 46 to travel from its home position toward ring gear 28.

[0114] In some embodiments, the predetermined time delay period is so short as to prevent pinion 46 leaving abutting engagement with ring gear 28—their faces remain in contact. The time delay period may be just long enough to relax the pinion on the ring gear, and reduce compressive forces therebetween. Thus, upon reactivation of solenoid assembly 50, no re-abutment between the pinion and the ring gear occurs, which desirably reduces wear do to re-contacting forces between the pinion and the ring gear, reduces their reengagement time for quicker starting, and reduces noise because no additional “click” occurs. The predetermined time delay period in such an embodiment may be less than 100 ms, and preferable for correcting a “click-no-crank” occurrence as quickly as possible.

[0115] Rapid starter re-engagement lockout feature 208 prevents damage to the pinion and ring gear teeth. Feature 208 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, voltage divider circuit 198, level circuit 200, 5V regulating circuit 202, and voltage divider circuit 204, to provide a delay of, for example, three (3) seconds, before reactivation of starter relay switch assembly 62′, which again closes relay switch 83.

[0116] Running engine starter lockout feature 210 prevents starter engagement with the running engine, and damage to the pinion and ring gear teeth. Feature 210 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, power driver circuit 196, level circuit 200, 5V regulating circuit 202, and voltage divider circuit 204. In a 24V starter system, the running engine starter lockout feature 210 locks-out starter assembly operation if sensed battery voltage at B+ terminal 114 is greater than 26.0V, a predetermined threshold voltage indicative of the engine running and the alternator charging.

[0117] Low voltage starter lockout feature 212 prevents overcranking and solenoid chatter. Feature 212 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, power driver circuit 196, voltage divider circuit 198, level circuit 200, 5V regulating circuit 202, and voltage divider circuit 204. In a 24V starter system, the low voltage starter lockout feature 212 blocks starting attempts if open circuit voltage at B+ terminal 114 is less than or equal to 24.0V. Also, a starting attempt is aborted if voltage at B+ terminal 114 drops below 10.0V (in a 24V system) during cranking.

[0118] Time-limited starter cranking feature 214 prevents overcranking. Feature 214 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, power driver circuit 196, voltage divider circuit 198, level circuit 200, 5V regulating circuit 202, and voltage divider circuit 204, to provide a maximum continuous cranking period of 20 seconds, with a ten (10) second delay between starting attempts.

[0119] Automatic starter disengagement at engine start feature 218 prevents extended starter overrun. Feature 218 employs MCU 122 and the following functional circuits of controller 108: gate drive circuit 194, power driver circuit 196, voltage divider circuit 198, level circuit 200, 5V regulating circuit 202, and voltage divider circuit 204. Closing starter switch 24 commences a starting operation and applies voltage to activation coil 72. That voltage is sensed upstream of activation coil 72 and monitored by controller 108 via S+ terminal 117. Prior to controller 108 permitting grounding of current through activation coil 72 which will electromagnetically close relay switch 83 against the biasing force of spring 75, the sensed voltage input to S+ terminal 117 will have a nominal level approximating battery voltage (e.g., about 24.0V). Upon controller 108 permitting grounding of current through activation coil 72 and the consequent closing of relay switch 83, the sensed voltage input to S+ terminal 117 will drop below that nominal level temporarily, but rise to return (or “rebound”) to at least a predetermined 24.0V threshold level upon the engine starting as the engine-driven alternator increases battery voltage. Though the operator holds starter switch 24 closed after engine starting, automatic starter disengagement at engine start feature 218 acts to interrupt grounding of activation coil 72 when voltage sensed at S+ terminal 117 rebounds to 24.0V. Consequently, relay switch 83 of starter relay switch assembly 62′ is opened under the unopposed biasing force of spring 75, which de-energizes solenoid coils 92 and 94. Compression spring 53 thus urges pinion 46 out of its engaged position and into a disengaged position.

[0120] FIG. 7 shows a control state diagram for a 24V starter system 20′ having an embodiment of starter relay switch assembly (or iIMS) 62′.

[0121] The following is a list of embodiments according to the present disclosure:

1. A system for starting an engine, including a relay switch that is closed during a starting operation and a starter assembly. The starter assembly includes a solenoid assembly including a solenoid switch adapted for connection to an electrical power source, a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The system also includes a controller connected to the relay switch. During a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.
2. The system of preferred embodiment 1, wherein the controller is configured to switch electrical power to the solenoid assembly off and on by opening the relay switch, and waiting a predetermined time delay period before reclosing the relay switch. Optionally, the pinion does not enter a fully disengaged position prior to the controller reclosing the relay switch.
3. The system of preferred embodiment 2, wherein the predetermined time delay period is a value less than 600 ms.
4. The system of preferred embodiment 3, wherein the predetermined time delay period is a value less than 100 ms.
5. The system of preferred embodiment 1, wherein the system is defined as a 24V starter system and the predetermined threshold level is a value less than 11.0V.
6. The system of preferred embodiment 5, wherein the system is defined as a 24V starter system and the predetermined threshold level is a value less than 6.0V.
7. The system of preferred embodiment 1, wherein the system is defined as a 12V starter system and the predetermined threshold level is a value less than 6.0V.
8. The system of preferred embodiment 7, wherein the system is defined as a 12V starter system and the predetermined threshold level is a value less than 4.0V.
9. The system of preferred embodiment 1, wherein the predetermined time period is a value no more than 600 ms.
10. The system of preferred embodiment 9, wherein the predetermined time period is a value no more than 150 ms.
11. The system of preferred embodiment 1, wherein the controller limits the number of times the relay switch is opened and reclosed to switch electrical power to the solenoid assembly off and on during the starting operation.
12. The system of preferred embodiment 1, wherein the relay switch is biased open and electromagnetically closed, and the system further comprises an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch, and the controller regulates the relay switch through the selective grounding of the activation coil.
13. The system of preferred embodiment 12, wherein the pinion is biased into its disengaged position in the absence of electrical power application to the solenoid assembly. The controller monitors sensed voltage applied to the activation coil and during a starting operation opens the relay switch when the sensed voltage applied to the activation coil rises to a threshold voltage level, whereby the pinion is automatically moved to the disengaged position upon the engine starting.
14. The system of preferred embodiment 12, further including a momentary starter switch biased open and closed through operator actuation to commence each starting operation, wherein voltage is applied to the activation coil only when the momentary starter switch is closed.
15. The system of preferred embodiment 1, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch.
16. The system of preferred embodiment 15, wherein the functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.
17. The system of preferred embodiment 1, wherein the system is for installation in a vehicle including the engine and a battery comprising the electrical power source. The system is operable independently of other vehicle control systems and without the controller monitoring a signal indicative of an engine speed, whereby the system defines a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
18. The system of preferred embodiment 1, wherein the controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
19. The system of preferred embodiment 1, wherein the electrical power source is a battery. The controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
20. The system of preferred embodiment 1, wherein the electrical power source is a battery. The controller monitors sensed battery voltage with the solenoid switch open and prevents the relay switch closing if the sensed battery voltage is no greater than a predetermined threshold voltage, whereby starter assembly operation is prevented if the sensed battery voltage is below the threshold voltage.
21. The system of preferred embodiment 1, wherein the electrical power source is a battery. The controller monitors sensed battery voltage with the solenoid switch closed and opens the relay switch if the sensed battery voltage drops below a threshold voltage while the motor is energized, whereby the present starting attempt is aborted if battery voltage becomes lower than the threshold voltage during engine cranking.
22. The system of preferred embodiment 1, wherein the controller monitors time elapsed after commencement of a starting operation, limits the maximum duration of an application of electrical power to the solenoid assembly to a first predetermined time period, and delays occurrences of consecutive starting operations by a second predetermined time period, whereby continuous cranking time and the frequency of starting operations are limited.
23. The system of preferred embodiment 1, wherein the starter assembly, the relay switch and the controller define a unitary assemblage.
24. A unitary starter assembly including a relay switch that is closed during a starting operation, a solenoid assembly including a solenoid switch adapted for connection to an electrical power source, a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The starter system also includes a controller connected to the relay switch, and during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.
25. The starter assembly of preferred embodiment 24, wherein the controller limits the number of times the relay switch is opened and reclosed to switch electrical power to the solenoid assembly off and on during the starting operation.
26. The starter assembly of preferred embodiment 24, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch. The functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.
27. The starter assembly of preferred embodiment 24, wherein the relay switch is biased open and electromagnetically closed, and the starter assembly further includes an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch. The controller regulates the relay switch through the selective grounding of the activation coil.
28. The starter assembly of preferred embodiment 27, wherein the starter assembly is adapted for attachment to the engine of a vehicle having a battery that comprises the electrical power source. The starter assembly is adapted for connection to a momentary starter switch biased open and closed through operator actuation to commence each starting operation, and voltage is applied to the activation coil only when the momentary starter switch is closed. The starter assembly is operable independently of other vehicle control systems and without the controller receiving a signal indicative of an engine speed, whereby the starter assembly and the connected operator-actuable starter switch define a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
29. The starter assembly of preferred embodiment 27, wherein the controller is configured to switch electrical power to the solenoid assembly off and on by opening the relay switch, and waiting a predetermined time delay period before reclosing the relay switch. Optionally, the pinion does not enter a fully disengaged position prior to the controller reclosing the relay switch.
30. The system of preferred embodiment 29, wherein the system is defined as a 24V starter system and wherein the predetermined threshold level is a value less than 11.0V.
31. The system of preferred embodiment 29, wherein the system is defined as a 12V starter system and wherein the predetermined threshold level is a value less than 6.0V.
32. A method for regulating a starter system, including: providing electrical power to a relay switch; commencing a starting operation with an operator-actuable starter switch; using a controller during the starting operation to close the relay switch for applying electrical power to a solenoid assembly; using the powered solenoid assembly to urge a pinion rotatable by an energized motor toward an engaged position in which the engine may be cranked using the starter system, and to connect the motor to an energizing electrical power source through a solenoid switch closed when the pinion is in the engaged position; and using the controller to monitor sensed motor energization voltage and for opening and reclosing the relay switch during the starting operation to switch electrical power to the solenoid assembly off and on if sensed motor energization voltage falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, whereby a “click-no-crank” event can be corrected during the starting operation.
33. A system for starting an engine, including a relay switch that is closed during a starting operation and a starter assembly. The starter assembly includes a solenoid assembly including a solenoid switch adapted for connection to an electrical power source, a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The system also includes a controller connected to the relay switch. The controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
34. The system of preferred embodiment 33, wherein during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.
35. The system of preferred embodiment 33, wherein the relay switch is biased open and electromagnetically closed, and the system further comprises an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch, and the controller regulates the relay switch through the selective grounding of the activation coil.
36. The system of preferred embodiment 35, further including a momentary starter switch biased open and closed through operator actuation to commence each starting operation, wherein voltage is applied to the activation coil only when the momentary starter switch is closed.
37. The system of preferred embodiment 33, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch.
38. The system of preferred embodiment 37, wherein the functional circuits include a gate drive circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.
39. The system of preferred embodiment 33, wherein the system is for installation in a vehicle including the engine and a battery comprising the electrical power source. The system is operable independently of other vehicle control systems and without the controller monitoring a signal indicative of an engine speed, whereby the system defines a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
40. The system of preferred embodiment 33, wherein the electrical power source is a battery. The controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
41. The system of preferred embodiment 33, wherein the electrical power source is a battery. The controller monitors sensed battery voltage with the solenoid switch open and prevents the relay switch closing if the sensed battery voltage is no greater than a predetermined threshold voltage, whereby starter assembly operation is prevented if the sensed battery voltage is below the threshold voltage.
42. The system of preferred embodiment 33, wherein the electrical power source is a battery. The controller monitors sensed battery voltage with the solenoid switch closed and opens the relay switch if the sensed battery voltage drops below a threshold voltage while the motor is energized, whereby the present starting attempt is aborted if battery voltage becomes lower than the threshold voltage during engine cranking.
43. The system of preferred embodiment 33, wherein the controller monitors time elapsed after commencement of a starting operation, limits the maximum duration of an application of electrical power to the solenoid assembly to a first predetermined time period, and delays occurrences of consecutive starting operations by a second predetermined time period, whereby continuous cranking time and the frequency of starting operations are limited.
44. The system of preferred embodiment 1, wherein the starter assembly, the relay switch and the controller define a unitary assemblage.
45. A unitary starter assembly including a relay switch that is closed during a starting operation, a solenoid assembly including a solenoid switch adapted for connection to an electrical power source, a motor connected to the solenoid switch and energized by the electrical power source when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The starter system also includes a controller connected to the relay switch. The controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
46. The starter assembly of preferred embodiment 45, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch. The functional circuits include a gate drive circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.
47. The starter assembly of preferred embodiment 45, wherein the relay switch is biased open and electromagnetically closed, and the starter assembly further includes an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch. The controller regulates the relay switch through the selective grounding of the activation coil.
48. The starter assembly of preferred embodiment 47, wherein the starter assembly is adapted for attachment to the engine of a vehicle having a battery that comprises the electrical power source. The starter assembly is adapted for connection to a momentary starter switch biased open and closed through operator actuation to commence each starting operation, and voltage is applied to the activation coil only when the momentary starter switch is closed. The starter assembly is operable independently of other vehicle control systems and without the controller receiving a signal indicative of an engine speed, whereby the starter assembly and the connected operator-actuable starter switch define a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
49. A method for regulating a starter system, including: providing electrical power to a relay switch; commencing a starting operation with an operator-actuable starter switch; using a controller during the starting operation to close the relay switch for applying electrical power to a solenoid assembly; using the powered solenoid assembly to urge a pinion rotatable by an energized motor toward an engaged position in which the engine may be cranked using the starter system, and to connect the motor to an energizing electrical power source through a solenoid switch closed when the pinion is in the engaged position; and using the controller to monitor time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
50. A system for starting an engine, including a relay switch that is closed during a starting operation and a starter assembly. The starter assembly includes a solenoid assembly including a solenoid switch adapted for connection to a battery, a motor connected to the solenoid switch and energized by the battery when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The system also includes a controller connected to the relay switch. The controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
51. The system of preferred embodiment 50, wherein during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.
52. The system of preferred embodiment 50, wherein the relay switch is biased open and electromagnetically closed, and the system further comprises an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch, and the controller regulates the relay switch through the selective grounding of the activation coil.
53. The system of preferred embodiment 52, further including a momentary starter switch biased open and closed through operator actuation to commence each starting operation, wherein voltage is applied to the activation coil only when the momentary starter switch is closed.
54. The system of preferred embodiment 50, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch.
55. The system of preferred embodiment 54, wherein the functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a voltage divider circuit.
56. The system of preferred embodiment 50, wherein the system is for installation in a vehicle including the engine and a battery. The system is operable independently of other vehicle control systems and without the controller monitoring a signal indicative of an engine speed, whereby the system defines a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
57. The system of preferred embodiment 50, wherein the controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
58. The system of preferred embodiment 50, wherein the controller monitors sensed battery voltage with the solenoid switch open and prevents the relay switch closing if the sensed battery voltage is no greater than a predetermined threshold voltage, whereby starter assembly operation is prevented if the sensed battery voltage is below the threshold voltage.
59. The system of preferred embodiment 50, wherein the controller monitors sensed battery voltage with the solenoid switch closed and opens the relay switch if the sensed battery voltage drops below a threshold voltage while the motor is energized, whereby the present starting attempt is aborted if battery voltage becomes lower than the threshold voltage during engine cranking.
60. The system of preferred embodiment 50, wherein the controller monitors time elapsed after commencement of a starting operation, limits the maximum duration of an application of electrical power to the solenoid assembly to a first predetermined time period, and delays occurrences of consecutive starting operations by a second predetermined time period, whereby continuous cranking time and the frequency of starting operations are limited.
61. The system of preferred embodiment 1, wherein the starter assembly, the relay switch and the controller define a unitary assemblage.
62. A unitary starter assembly including a relay switch that is closed during a starting operation, a solenoid assembly including a solenoid switch adapted for connection to a battery, a motor connected to the solenoid switch and energized by the battery when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The starter system also includes a controller connected to the relay switch. The controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
63. The starter assembly of preferred embodiment 62, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch. The functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a voltage divider circuit.
64. The starter assembly of preferred embodiment 62, wherein the relay switch is biased open and electromagnetically closed, and the starter assembly further includes an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch. The controller regulates the relay switch through the selective grounding of the activation coil.
65. The starter assembly of preferred embodiment 64, wherein the starter assembly is adapted for attachment to the engine of a vehicle having the battery. The starter assembly is adapted for connection to a momentary starter switch biased open and closed through operator actuation to commence each starting operation, and voltage is applied to the activation coil only when the momentary starter switch is closed. The starter assembly is operable independently of other vehicle control systems and without the controller receiving a signal indicative of an engine speed, whereby the starter assembly and the connected operator-actuable starter switch define a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
66. A method for regulating a starter system, including: providing electrical power to a relay switch; commencing a starting operation with an operator-actuable starter switch; using a controller during the starting operation to close the relay switch for applying electrical power to a solenoid assembly; using the powered solenoid assembly to urge a pinion rotatable by an energized motor toward an engaged position in which the engine may be cranked using the starter system, and to connect the motor to an energizing battery through a solenoid switch closed when the pinion is in the engaged position; and using the controller to sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
67. A system for starting an engine, including a relay switch that is closed during a starting operation and a starter assembly. The starter assembly includes a solenoid assembly including a solenoid switch adapted for connection to a battery, a motor connected to the solenoid switch and energized by the battery when the solenoid switch is closed, and a pinion rotatably coupled to the motor and moveable between an engaged position in which the engine may be cranked by the starter assembly and a disengaged position. The system also includes a controller connected to the relay switch. The system is for installation in a vehicle including the engine and the battery. The system is operable independently of other vehicle control systems and without the controller monitoring a signal indicative of an engine speed, whereby the system defines a stand-alone starter system adapted for installation in a vehicle separately from other vehicle control systems.
68. The system of preferred embodiment 67, wherein the relay switch is biased open and electromagnetically closed, and the system further comprises an activation coil to which voltage is applied during each starting operation. During a starting operation the controller selectively permits grounding of current through the activation coil to close the relay switch and prevents grounding of current through the activation coil to open the relay switch, and the controller regulates the relay switch through the selective grounding of the activation coil.
69. The system of preferred embodiment 68, further including a momentary starter switch biased open and closed through operator actuation to commence each starting operation, wherein voltage is applied to the activation coil only when the momentary starter switch is closed.
70. The system of preferred embodiment 67, wherein during a starting operation, if sensed motor energization voltage monitored by the controller falls below a predetermined threshold level within a predetermined time period after the application of electrical power to the solenoid assembly, the controller opens and recloses the relay switch to switch electrical power to the solenoid assembly off and on, whereby a “click-no-crank” event can be corrected during the starting operation.
71. The system of preferred embodiment 67, wherein the controller includes a plurality of functional circuits selectively interconnected in accordance with a starter system paradigm for regulating the relay switch.
72. The system of preferred embodiment 71, wherein the functional circuits include a gate drive circuit, a power driver circuit, a level circuit, a regulating circuit and a plurality of voltage divider circuits.
73. The system of preferred embodiment 67, wherein the controller monitors time elapsed after commencement of a starting operation and delays permitting reclosing the relay switch, whereby rapid re-engagement of the pinion and the engine is prevented.
74. The system of preferred embodiment 67, wherein the controller monitors sensed battery voltage and prevents the relay switch closing if the sensed battery voltage is greater than a predetermined threshold voltage, whereby starter assembly operation is prevented while the engine is running.
75. The system of preferred embodiment 67, wherein the controller monitors sensed battery voltage with the solenoid switch open and prevents the relay switch closing if the sensed battery voltage is no greater than a predetermined threshold voltage, whereby starter assembly operation is prevented if the sensed battery voltage is below the threshold voltage.
76. The system of preferred embodiment 67, wherein the controller monitors sensed battery voltage with the solenoid switch closed and opens the relay switch if the sensed battery voltage drops below a threshold voltage while the motor is energized, whereby the present starting attempt is aborted if battery voltage becomes lower than the threshold voltage during engine cranking.
77. The system of preferred embodiment 67, wherein the controller monitors time elapsed after commencement of a starting operation, limits the maximum duration of an application of electrical power to the solenoid assembly to a first predetermined time period, and delays occurrences of consecutive starting operations by a second predetermined time period, whereby continuous cranking time and the frequency of starting operations are limited.
78. The system of preferred embodiment 67, wherein the starter assembly, the relay switch and the controller define a unitary assemblage.
79. A method for regulating a starter system, including: providing electrical power to a relay switch; commencing a starting operation with an operator-actuable starter switch; transitioning the relay switch from a biased-open condition to a closed condition with a controller and applying electrical power to a solenoid assembly through the relay switch in its closed condition; urging a solenoid switch connected to a battery and a motor towards a closed state in which the motor is energized by the battery during the application of electrical power to the solenoid assembly; moving a pinion rotatably coupled to the motor toward an engaging position in which the engine may be cranked using the starter system and the solenoid switch is only capable of being in the closed state; monitoring a sensed voltage with the controller; and using the controller to determine, in the absence of the controller receiving a signal indicative of an engine speed, whether the engine is running on the basis of the monitored sensed voltage relative to a predetermined threshold voltage level.

[0122] While exemplary embodiments have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of this disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.