Claims:We claim:
1. A compact starter motor for automobiles with plurality of slots and multilayer wave wound technology comprising:
a. an armature (101) having eleven slots of lamination pack (113) with double layer wave wound design, wherein the armature (101) is configured to provide twisting forces to drive gear or idler gear for generating torque and speed, wherein the armature (101) comprises an armature coil (102) with winding pattern which includes at least two layers of winding to provide optimum current density;
b. a brush box assembly (104) having four brushes, wherein the brushes are mounted on the Commutator-End (CE) bracket (103) by screws and;
c. a yoke assembly (109) having a higher grade of thinner magnets (108), wherein the higher grade of thinner magnet (108) is arranged on the inner part of the yoke assembly (109).
2. The device as claimed in claim 1, wherein the lamination has at least 32 mm length and 48 mm diameter
3. The device as claimed in claim 1, wherein the armature coil (102) winding pattern has double layer wave wound with at least four turns.
4. The device as claimed in claim 1, wherein the yoke assembly (109) has at least 4 magnets configured to generate the magnetic flux when combined with the electromagnetic flux which tends to rotate the armature assembly.
5. The device as claimed in claim 1, wherein the brush box assembly (104) comprises a plurality of brushes which are configured to provide optimum current flow in the two parallel path which reduce the current consumption by the starter motor device (100) through operating conditions.
6. The device as claimed in claim 1, wherein the armature (101) is mounted by bearing in a DE bracket (112) and CE bracket (103).

7. The device as claimed in claim 1, wherein a spigot (110) is used to mount the starter motor device (100) in the engine which is the part of DE bracket (112) assembly with bearing.
8. The device as claimed in claim 1, wherein the armature (101) having at least an eleven slots of lamination pack (113) with single layer wave wound design.
, Description:PREAMBLE TO THE DESCRIPTION:
[0001] The following specification particularly describes the invention and the manner in which it is to be performed:
DESCRIPTION OF THE INVENTION:
Technical field of the invention
[0001] The present invention relates to a compact starter motor for automobiles with plurality of slots and multilayer wave wound technology. More particularly, the invention relates to starter motor having an armature assembly provided with a plurality of slots and windings pattern using lamination pack for producing optimum current density.

Background of the invention
[0002] The starter motor is an electrical device that is used to start the engine on its own power. The device provides initial torque and speed to the engine to rotate the crankshaft of the vehicle. This is because the engine needs to attain some speed to work. The starter motor device helps the engine to attain the intended speed to run the automobile. After the engine start, the starter is no longer useful and thus turns off.
[0003] The starter motor device uses power which is acquired from the automobile battery. When the starter switch is turned ON, the current is passed to the starter relay. The starter relay switches the circuit and provides power to the starter motor device. The starter motor device uses the power to start the engine of the vehicle.
[0004] The limitation of the starter motor device is that it has large size and has high-power consumption. The starter motor device is used to provide the initial start to the engine. The device is powered by the battery which is connected in the automobile but the device consumes more power from the battery to provide initial start of the engine. Moreover, the starter motor for high capacity engine has more volume which makes it difficult to accommodate the device in the engine layout for automobiles. Consequently, many attempts have been made to provide a device which consumes less power, high speed torque ratio & easy to accommodate in the engine layout.
[0005] For instance, U.S. patent US4862027A discloses a coaxial starter motor. The coaxial starter motor comprises a D.C motor, an overrunning clutch, an output sleeve and a solenoid switch. The height of the starter motor is relatively small and requires a small space for installation. Also, the number of components of the starter motor is reduced, making assembly easy. However, the coaxial starter motor disclosed herein consumes more power, and has lesser speed to torque ratio.
[0006] Another U.S. patent US5118960A discloses a starter device. The starter device comprises an electric motor, a cylindrical membrane and a return spring. The cylindrical member is connected to the movable core for displacing the pinion gear and there is no magnetic flux passing through the movable core. The stationary core leaks into the cylindrical member and the magnetic flux generated by the magnetic coil is utilized. Therefore, the number of turns of the electromagnetic coil and the size of the entire starter device is reduced. However, the invention disclosed herein has more volume and accommodating the device in the engine layout is more difficult during the engine layout design for automobiles.
[0007] Hence, there exists a need of a compact starter motor for automobile with plurality of slots and wave wound technology that consumes less volume and provides a compact device which may be easily accommodated in engine layout of automobiles.
Summary of the invention:
[0008] The present invention overcomes the drawbacks in the prior art and provides a compact starter motor for automobile with plurality of slots and wave wound technology.
[0009] The compact starter motor comprises an armature with at least eleven slots of lamination pack with wave wound design. The armature is used to provide twisting forces to drive gear or idler gear for generating torque and speed. The armature has a coil winding pattern which includes at least two layers of winding to provide optimum current density. The outer part of the armature assembly has at least one yoke assembly. The higher grade of thinner magnets (4 No’s) are arranged in the inner part of the yoke assembly. The yoke assembly is used to generate the magnetic flux when combined with electromagnetic flux which tends to rotate the armature assembly. A plurality of brushes is used to provide optimum current flow in the two-parallel paths in the armature which reduces the current consumption by the starter motor device through operating condition.
[0010] The present invention provides a compact starter motor device with reduced starter motor device weight to power ratio and reduced volume. The device is easy to accommodate in engine layout for automobiles.
Brief description of the drawings:
[0011] The foregoing and other features of embodiments will become more apparent from the following detailed description of embodiments when read in conjunction with the accompanying drawings. In the drawings, like reference numerals refer to like elements.
[0012] Figure 1 shows a block diagram of compact starter motor for automobile, according to one embodiment of the invention.
[0013] Figure 2 shows a block diagram of lamination pack, according to one embodiment of the invention.
[0014] Figure 3 shows a block diagram of CE bracket and brush box assembly, according to one embodiment of the invention.
Detailed description of the invention:
[0015] Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in figures. Each example is provided to explain the subject matter and not a limitation. Various changes and modifications obvious to one skilled in the art to which the invention pertains are deemed to be within the spirit, scope and contemplation of the invention.
[0016] The present invention overcomes the drawbacks of the technology available in the state of the art by providing a compact starter motor for automobiles. The starter motor device comprises of eleven slots of lamination, two-layer wave winding, four brush construction and higher grade thinner magnets design. The combination is configured to provide 64 mm frame size starter motor device. The combination makes ease of fitment in automobiles.
[0017] Figure 1 shows a block diagram of a compact starter motor for automobiles with plurality of slots and multilayer wave wound technology, according to one embodiment of the invention. In an embodiment of the invention, the device comprises an armature assembly which has an armature shaft (111), armature winding, armature stack and commutator. The armature (101) is the rotational part of the starter motor device and comprises an eleven slots lamination pack (113) with double layer wave wound design. An armature coil (102) has winding pattern which includes at least two layers of winding to provide optimum current density. The armature coil (102) is configured to provide a strong magnetic field when the current is passed through it. The armature coil (102) is located around the lamination pack (113) and works as a magnetic field generator that reacts with permanent magnetic field for rotation of starter motor device (100). The armature coil (102) has a tubular shape. Further, the armature (101) is used to provide twisting forces to the drive gear or idler gear for generating torque and speed.
[0018] The armature (101) is mounted by bearing in a Drive end (DE) bracket (112) and a Commutator end (CE) bracket (103). The Spigot (110) is used to mount the starter motor device in the engine. The air gap between the yoke assembly (109) and the armature assembly is maintained by the bearing. The CE bracket (103) is configured to hold the brush box assembly (104). The supply of electric power to the positive terminal flows into armature (101) through commutator which tends to generate an electromagnetic flux.
[0019] A magnetic field portion is fixed to the inner wall of the yoke assembly (109). The armature (101) which is freely rotatably mounted within the yoke (109). The armature (101) has a winding which is configured by winding a wire in eleven slots formed on the outer peripheral surface of a core and extend in the axial direction. Further, a commutator is provided which is fixed to an end portion of the armature shaft (111). The brushes box assembly (104) is in contact with the commutator, which extends through the armature assembly (101).
[0020] The DE (112) bracket and CE bracket (103) are mounted at the outer portion of the yoke assembly (109) and also support the armature assembly (101). The higher grades of thinner magnets (108) are arranged on the inner part of the yoke assembly (109). The yoke assembly (109) with permanent magnet arrangement generates the magnetic flux and when combined with electromagnetic flux generate by armature assembly (101) which tends to have rotation motion at the armature shaft (111).
[0021] The starter motor device (100) includes a brush box assembly (104) for supporting electric brush which is mounted on the CE bracket (103) by screws. The brush box assembly (104) is configured to hold the positive and negative brushes through the brush holder (107) and the insulate plate (105). The brush holder (107) is provided with a spring, these spring load are used to keep the brushes in the contact with the commutator (114). The insulate plate (105) is used for positive brush insulation from the body of the motor. The brush box assembly (104) comprises a plurality of brushes. The brushes are electrically conductive, usually made of copper and graphite. The plurality of brushes is configured to provide optimum current flow in two-parallel path in the armature (101) which reduces the current consumption by the starter motor device (100) through operating condition.
[0022] The armature shaft (111) is configured to transmit the output which is generated in the starter motor device (100). The armature shaft (111) is supported on the two bearings at each end of the starter motor device (100) to allow free rotation.
[0023] Figure 2 shows a block diagram of lamination pack, according to one embodiment of the invention. In an embodiment of the invention, the starter motor device (100) consists of eleven slot lamination pack (113) with wave wound design. The lamination has at least 32 mm length and 48 mm diameter. Further, the lamination pack (113) is used in starter motor device (100) for producing optimum current density.
[0024] Figure 3 shows a block diagram of CE bracket and brush box assembly, according to one embodiment of the invention. The CE bracket (103) is configured to hold the brush box assembly (104). The DE (112) bracket and CE bracket (103) are mounted at the outer portion of the yoke assembly (109)
[0025] Thus, the present invention provides a compact starter motor for automobile with plurality of slots and wave wound technology. The starter motor consists of eleven slot lamination pack with wave wound design. The two layers of windings are used in the starter motor device to have optimum current density. The starter motor device provides four brush constructions to share the current flow in two parallel paths. The current flow in two parallel paths which reduces the current consumption by the starter motor during operating condition.
[0026] The combination of eleven slot, two layer, four brushes, higher grade thinner magnets and wave wound design is the first of its kind in 64 mm frame size starter motor device.
[0027] The description of the present system has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated.