case study-assignment relates to the overall performances on starter motor against the different...

ENGINEERING DEPARTMENT

Lim Zhen Xing (FA Engineer)

Department: BNA

Employment Code: 13071015

Case Study: Assignment Relates to the Overall Performances on Starter Motor

against the Different Brush Holder Setup Angles

Submission date: 26th NOVEMBER 2015

Mr. Teh (Quality Control Manager)

Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder Setup Angles

FA Engineer: 13071015 (Lim Zhen Xing) Page i i

TABLE OF CONTENTS

TABLE OF CONTENTS...................................................................................................................................... ii

LIST OF FIGURES............................................................................................................................................. iii

LIST OF TABLES .............................................................................................................................................. iii

1. Introduction ...............................................................................................................................................1

1.2 Aim.......................................................................................................................................................1

Determine the practical results on overall starter motor performances after brush holder screws position

modifications.................................................................................................................................................1

2. Facilities/ Equipment ...................................................................................................................................2

3. Determine the practical results on overall starter motor performances after brush holder screws position

modifications. .......................................................................................................................................................3

4. Conclusions ................................................................................................................................................ 10

APPENDICES ......................................................................................................................................................... I

APPENDIX 1 The Latest Drawing Dimensions After Brush Holder Screws Position Modification on Rear

Housing Cover ................................................................................................................................................. I

APPENDIX 2: Practical Test Results in Original Degree Angle Brush Holder .................................................... II

APPENDIX 3: Practical Test Results in Original Degree Angle Brush Holder ................................................... III

APPENDIX 4: Practical Test Results in Original Degree Angle Brush Holder ................................................... IV

APPENDIX 5: Practical Test Results in Original Degree Angle Brush Holder .................................................... V

APPENDIX 6: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder ................................... VI

APPENDIX 7: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder .................................. VII

APPENDIX 8: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder ................................. VIII

APPENDIX 9: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder ................................... IX

APPENDIX 10: Practical Test Results in Clockwise 10 Degree Angle Brush Holder.......................................... X

APPENDIX 11: Practical Test Results in Clockwise 10 Degree Angle Brush Holder ......................................... XI

APPENDIX 12: Practical Test Results in Clockwise 10 Degree Angle Brush Holder ........................................ XII


FA Engineer: 13071015 (Lim Zhen Xing) Page i i i

APPENDIX 13: Practical Test Results in Clockwise 10 Degree Angle Brush Holder ....................................... XIII

APPENDIX 14: DV Electronics Ltd. – Computerized Starter Tester ST16 Test Results on Starter Motor ....... XIV

LIST OF FIGURES

Figure 1. Front view of the modification rear housing cover starter motor in different degree angles at brush holder

screws position .....................................................................................................................................................1

Figure 2. Rear view of both of the brush holder screws positions at the starter rear housing cover is located at the

origin degree.........................................................................................................................................................3

Figure 3. Rear view of the carbon brush position against the magnetic pole shoes position after placed at the origin

degree at the brush holder screws position ..............................................................................................................4

Figure 4. Graph of the Maximum Power, Torque and Ampere against Different Brush Holder Setup Angles...............5

Figure 5. Graph of the Mean Maximum Power, Torque and Ampere against Different Mean Values Brush Holder

Setup Angles ........................................................................................................................................................5

Figure 6. Graph of the Free Run Test on Current, Speed and Voltage against Different Brush Holder Setup Angles ....6

Figure 7. Graph of the Solenoid Test on Hold Current, Pull Current and Voltage Drop against Different Brush Holder

Setup Angles ........................................................................................................................................................7

Figure 8. Graph of Starter test on Current Max. , Power Max., Ripple Current and Torque Max against Different Brush

Holder Setup Angles .............................................................................................................................................7

Figure 9. Graph of The Test Step #0 at 1000 RPM on Solenoid Voltage Drop, Starter Current, Starter Power, Starter

Torque, Starter Torque Constant and Starter Voltage against Different Brush Holder Setup Angles ............................8

Figure 10. Graph of the Test Step #0 at Maximum Power on Solenoid Voltage Drop, Starter Current, Starter Power,

Starter Speed, Starter Torque, Starter Torque Constant and Starter Voltage against Different Brush Holder Setup

Angles ..................................................................................................................................................................9

LIST OF TABLES

Table 1. Facilities/ Equipment require in this experiment .........................................................................................2

Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder

Setup Angles

FA Engineer: 13071015 (Lim Zhen Xing) Page 1

1. Introduction In the previous case study relates to the yoke assembly housing and the front housing on the position marking

lock, the author succeed to prove that there is no influence on changing each other’s position when keep the

original setup angles at brush holder screws position. On this stage, the researcher has to identify whether any

different brush holder angles installation would be affect the performances on the starter motor.

1.2 Aim

This part of the assignment relates to overall performances on the starter motor against the comparison between

different angles at the brush holder setup but without change the yoke assembly housing and the front housing

at the origin position marking lock as presented in Figure 1.

Figure 1. Front view of the modification rear housing cover starter motor in different degree angles at

brush holder screws position

Objectives

This research is focused on one main study aspect as follow:

Determine the practical results on overall starter motor performances after brush holder screws

position modifications.


Setup Angles


2. Facilities/ Equipment

This experiment is applied research in the same Starter Motor - OEM No.: 23300-EB71B. The facilities/

equipment are set out in Table 1.

Table 1. Facilities/ Equipment require in this experiment

The SolidWorks 2015 Professional executes under this modification [APPENDIX 1]. To accelerate the testing

process, the EVERSPARK’s Brand New Department (BND) sent out the latest drawing dimension paper to

build the latest modification brush holder screws position. The mould takes only 2 days on progression, the

project is under control.

Facilities/ Equipment Quantity

Latest: Brush Holder Screws Position Modification 2-Dimension

SolidWorks Drawing Reference [APPENDIX 1]

1

DV Electronics Ltd. – Computerized Starter Tester ST16

1

OEM Starter Motor (Manufacturing No. : S14 -413 & OEM No. 23300-EB71B) and Brush holder Screw Position Modification on the Rear

Housing Cover.

1

Extension Ground Copper Cable Harness at the Yoke Assembly – 25 cm 1


Setup Angles


3. Determine the practical results on overall starter motor performances after brush

holder screws position modifications.

All of the tests at here are not change the position marking lock on the yoke assembly housing and the front

housing. This experiment degree setting variance is related to the brush holder screw position at the starter rear

housing cover. To identify the reliable results, the DV Electronics Ltd. – Computerized Starter Tester ST16 has

been employed in this experiment. The researcher had simulated with Maximum Power, Maximum Torque,

Maximum Amperes, Free Run Test, Solenoid Test, Test Step #0 at 1000 RPM and Test Step #0 at Maximum

Power being altered in 3 different degree angles at the brush holder screws position, all of the results are shown

in Figure 4 till Figure 10.

To ensure that the starter motor is fully cool down in the winding and wiring harness under this test, the interval

between test 1, 2, 3 and so on are 50 minutes to 1 hour. Conversely, check the performances on starter motor

after heat up the test of i. and ii. are continuance. As shown in Figure 2, both of the brush holder screws

positions at the starter rear housing cover are located at the origin degree in the test No. 1 and 2 which is just all

of the carbon brush positions perpendicular to the magnetic pole shoes can be compared in Figure 3. The test 3

and 4 are placed on the anticlockwise 10° angle on the brush holder. When come to the test 5 and 6, the

experiment is concentrated on clockwise 10° angle at the brush holder screws position. In order to ensure that a

reliable data in this experiment, test 1 and 2 are needed in this stage which work as the reference points after

this modification.

Figure 2. Rear view of both of the brush holder screws positions at the starter rear housing cover is

located at the origin degree


Setup Angles


Figure 3. Rear view of the carbon brush position against the magnetic pole shoes position after placed at

the origin degree at the brush holder screws position

All of the tests are within the range and pass to the test, except the results of test 3 and 4 are out of the technical

specification and fail in the free run test (current) [APPENDIX 6,7,8 and 9]. The graph of this experiment

shows the maximum power, torque and ampere against different brush holder setup angles, as given in Figure 6.

The results of this experiment indicate that the values of maximum power and torque are slightly increasing

whereas maximum ampere has substantial raise up while differ from the origin angles. It is quite obvious that

the origin position angle produces the smallest maximum power, torque and ampere to fulfil the specification.

According to the equations as follow:

𝑉(𝑣𝑜𝑙𝑡𝑠) = 𝐼(𝐴𝑚𝑝𝑒𝑟𝑒) × 𝑅 (𝑂ℎ𝑚𝑠) ----------------- (1)

𝑃𝑜𝑤𝑒𝑟 (𝑤𝑎𝑡𝑡𝑠) = 𝑉 (𝑣𝑜𝑙𝑡𝑠) × 𝐼 (𝐴𝑚𝑝𝑒𝑟𝑒) ------------ (2)

𝑃𝑜𝑤𝑒𝑟 (𝑘𝑖𝑙𝑜 − 𝑤𝑎𝑡𝑡𝑠) = 𝑇𝑜𝑟𝑞𝑢𝑒 (𝑁𝑚)×𝑆𝑝𝑒𝑒𝑑 (𝑟𝑝𝑚)

9.5488 ----------- (3)

It is apparent from the Figure 4 till Figure 10 that there are small fluctuations on the results, therefore the

tightness between the connection cables from the test machine to the starter motor are under consideration.


Setup Angles


Figure 4. Graph of the Maximum Power, Torque and Ampere against Different Brush Holder Setup

Angles

Figure 5. Graph of the Mean Maximum Power, Torque and Ampere against Different Mean Values

Brush Holder Setup Angles


Setup Angles


The Figure below illustrates the Free Run Test on Current, Speed and Voltage against Different Brush Holder

Setup Angles. From the equation No.1, Free Run test (voltage) value at 0 degree provides in the middle range to

counteract resistance from the current, in that case, the current would not too close on the lower control limits

which are 89 Ampere as demonstrate at the clockwise 10° angle on Test 5 and 6 or over the upper control limits

which are 130 Ampere as shown in the anticlockwise 10° angle on Test 3 and 4. Thus, Free Run Test (Speed)

plays as the main role to generate the amount of power and torque.

Figure 6. Graph of the Free Run Test on Current, Speed and Voltage against Different Brush Holder

Setup Angles


Setup Angles


From the Figure 7 till 10, it can be seen that all of the origin degree produces the median value of a range of

values between anticlockwise 10° angle and clockwise 10° angle.

Figure 7. Graph of the Solenoid Test on Hold Current, Pull Current and Voltage Drop against Different

Brush Holder Setup Angles

Figure 8. Graph of Starter test on Current Max. , Power Max., Ripple Current and Torque Max against

Different Brush Holder Setup Angles


Setup Angles


Figure 9. Graph of The Test Step #0 at 1000 RPM on Solenoid Voltage Drop, Starter Current, Starter Power,

Starter Torque, Starter Torque Constant and Starter Voltage against Different Brush Holder Setup Angles


Setup Angles


Figure 10. Graph of the Test Step #0 at Maximum Power on Solenoid Voltage Drop, Starter Current,

Starter Power, Starter Speed, Starter Torque, Starter Torque Constant and Starter Voltage against

Different Brush Holder Setup Angles


Setup Angles


4. Conclusions

It can be demonstrated that under the condition of the yoke assembly housing and the front housing cover on the

position marking lock, the findings of this study suggest that the origin angle degree at the brush holder screws

position on rear housing cover starter motor are getting on the middle point of the data. This can be balance the

requirement data between power, torque, voltage, speed and resistance. The brush holder screws positions at the

starter rear housing cover are located at the origin degree which is just all of the carbon brush positions

perpendicular to the magnetic pole shoes, it allows the installation becomes easier and also improves the

average performances under overall results.

Due to the power equal to torque times the angular velocity (ω) from the No. 3 equation,

𝑃 = 𝑇𝜔

It works as the output of mechanical energy. If the power is constant, therefore, the torque is indirect

proportional to the speed of shaft in this principle. It can be seen from the data in Figure 10 that the 2) i. 0

degree reported significantly more 2) ii. 0 degree than the Test Step #0 at Maximum Power (Starter Speed).

Conversely, the Test Step #0 at Maximum Power (Starter Torque) on 2) i. 0 degree is lower than 2) ii. 0 degree.

Once the torque sharply increase to the carbon brush consumes faster than the service intervals while compare

with the individual model specifications. The results of this study indicate that this progress leads to the

additional wear off around the mechanical materials and shorten the lifetime of the starter motor.

Simultaneously, the power is converting from the output of mechanical energy to the input of electrical energy

so that it is equal to voltage times current.

𝐼𝑉 (𝑖𝑛𝑝𝑢𝑡 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦) = 𝑇𝜔

𝑉𝐼

𝑇= 𝜔

𝑆𝑜, 𝑇𝛼 1

𝜔 Or 𝜔𝛼

1

𝑇

The researcher found that while the current raise up, the excessive heat generates in this rapid duration can

weaken the magnetic field while converting into the electrical conductivity. The results obtained from the test

step #0 at maximum power analysis can be compared in Figure 10.

Even though those values are too close on lower limits and pass the test on clockwise 10 degree but the

maximum torque in the starter test is the highest among the others, this condition will return to rapid mechanical

frictions. Notwithstanding these limitations, the study suggests that these results are very important to determine

the location in the brush angle spotting setup.


FA Engineer: 13071015 (Lim Zhen Xing) Page I

APPENDICES APPENDIX 1 The Latest Drawing Dimensions After Brush Holder Screws Position Modification on Rear Housing Cover


FA Engineer: 13071015 (Lim Zhen Xing) Page II

APPENDIX 2: Practical Test Results in Original Degree Angle Brush Holder


FA Engineer: 13071015 (Lim Zhen Xing) Page III



FA Engineer: 13071015 (Lim Zhen Xing) Page IV



FA Engineer: 13071015 (Lim Zhen Xing) Page V



FA Engineer: 13071015 (Lim Zhen Xing) Page VI

APPENDIX 6: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder


FA Engineer: 13071015 (Lim Zhen Xing) Page VII



FA Engineer: 13071015 (Lim Zhen Xing) Page VIII



FA Engineer: 13071015 (Lim Zhen Xing) Page IX



FA Engineer: 13071015 (Lim Zhen Xing) Page X

APPENDIX 10: Practical Test Results in Clockwise 10 Degree Angle Brush Holder


FA Engineer: 13071015 (Lim Zhen Xing) Page XI



FA Engineer: 13071015 (Lim Zhen Xing) Page XII



FA Engineer: 13071015 (Lim Zhen Xing) Page XIII



FA Engineer: 13071015 (Lim Zhen Xing) Page XIV

APPENDIX 14: DV Electronics Ltd. – Computerized Starter Tester ST16 Test Results on Starter Motor

Computer Setup Test No. (*OEM No.: 23300-EB71B) 23300-EB300

Starter Type: PLGR

Starter Model: HI

Rated Power: 2.2 kW

Rated Voltage: 12 V

Battery Resistance 5 mOhms

3) i. anticlockwise 10 degree 3) ii. anticlockwise 10 degree 4) i. anticlockwise 10 degree 4) ii. anticlockwise 10 degree 1) i. 0 degree 1) ii. 0 degree 2) i. 0 degree 2) ii. 0 degree 5) i. clockwise 10 degree 5) ii. clockwise 10 degree 6) i. clockwise 10 degree 6) ii. clockwise 10 degree

Max. Power (kW) 2.41 2.43 2.36 2.46 2.33 2.24 2.39 2.38 2.67 2.65 2.77 2.7

Max. Torque (Nm) 27 27 27 27 26 25 27 27 29 29 30 30

Max. Ampere (Amp) 641 642 638 657 601 590 598 602 653 634 643 639

3) i. anticlockwise 10 degree 3) ii. anticlockwise 10 degree 4) i. anticlockwise 10 degree 4) ii. anticlockwise 10 degree 1) i. 0 degree 1) ii. 0 degree 2) i. 0 degree 2) ii. 0 degree 5) i. clockwise 10 degree 5) ii. clockwise 10 degree 6) i. clockwise 10 degree 6) ii. clockwise 10 degree

Free Run Test (Current) 140 136 137 148 125 124 120 121 111 105 113 107

Free Run Test (Speed) 3686 3892 4041 3641 3666 3615 3829 3789 3787 3906 3763 3870

Free Run Test (Voltage) 11.32 11.33 11.35 11.27 11.4 11.38 11.41 11.42 11.46 11.48 11.44 11.47

Solenoid Test (Hold Current) 17.294 16.196 15.915 17.568 17.192 15.556 15.972 15.441 17.492 15.853 16.114 15.027

Solenoid Test (Pull Current) 30.483 29.999 30.08 31.552 30.943 29.306 30.041 28.188 31.043 29.864 30.146 28.394

Solenoid Test (Voltage Drop) 0.25 0.14 0.32 0.29 0.16 0.16 0.19 0.13 0.19 0.24 0.23 0.16

Starter Test (Current Max) 641 642 638 657 601 590 598 602 653 634 643 639

Starter Test (Power Max) 2410.55 2426.37 2360.85 2457.63 2327.16 2236.96 2388.82 2384.22 2670.46 2652.77 2774.27 2698.04

Starter Test (Ripple Current) 12 12 10 13 9 8 8 8 9 8 7 8

Starter Test (Torque Max) 27.147 27.131 26.719 27.498 26.261 25.345 26.734 26.765 29.361 29.345 30.49 29.819

Test Step #0 at 1000 RPM (Solenoid Voltage Drop) 0.1908 0.1212 0.3075 0.188 0.137 0.1456 0.1586 0.1192 0.157 0.1718 0.1722 0.1322

Test Step #0 at 1000 RPM (Starter Current) 577 578 573 593 537 525 537 540 588 570 581 571

Test Step #0 at 1000 RPM (Starter Power) 2409.69 2423.52 2360.62 2455.85 2326.9 2234.54 2388.43 2384.2 2669 2651.5 2773.11 2696.01

Test Step #0 at 1000 RPM (Starter Torque) 23.082 23.199 22.616 23.518 22.252 21.369 22.882 22.815 25.549 25.359 26.551 25.794

Test Step #0 at 1000 RPM (Starter Torque Constant) 0.04 0.0401 0.0395 0.0397 0.0414 0.0407 0.0426 0.0422 0.0435 0.0445 0.0457 0.0452

Test Step #0 at 1000 RPM (Starter Voltage) 9.144 9.128 9.163 9.063 9.348 9.389 9.34 9.321 9.09 9.171 9.125 9.168

Test Step #0 at Maximum Power (Solenoid Voltage Drop) 0.1863 0.1183 0.3055 0.1778 0.1379 0.1473 0.1573 0.119 0.1545 0.1666 0.167 0.1289

Test Step #0 at Maximum Power (Starter Current) 570 566 569 584 540 535 533 539 581 563 574 562

Test Step #0 at Maximum Power (Starter Power) 2410.55 2426.37 2360.85 2457.63 2327.16 2236.96 2388.82 2384.22 2670.46 2652.77 2774.27 2698.04

Test Step #0 at Maximum Power (Starter Speed) 1017 1032 1008 1023 991 972 1009 1001 1015 1017 1015 1021

Test Step #0 at Maximum Power (Starter Torque) 22.645 22.466 22.368 22.962 22.439 21.983 22.629 22.751 25.14 24.928 26.114 25.26

Test Step #0 at Maximum Power (Starter Torque Constant) 0.0397 0.0397 0.0363 0.0393 0.0416 0.0411 0.0425 0.0422 0.0433 0.0443 0.0455 0.0449

Test Step #0 at Maximum Power (Starter Voltage) 9.179 9.187 9.182 9.108 9.333 9.34 9.36 9.326 9.125 9.206 9.159 9.213

Conversely, check the starter performance after heat up the test of i. and ii. are continuance.

To ensure that the starter motor is fully cool down in the winding and wiring harness under this test, the interval between test 1, 2, 3 and so on are 50 minutes to 1 hour.

case study-assignment relates to the overall performances on starter motor against the different...

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