Beruflich Dokumente
Kultur Dokumente
Phase 2
Module 2
Unit 5
Starter Motor /
Circuit
Produced by
FS Learning Innovation Unit
In cooperation with
&
CDX Global
FENC - Further Education National Consortium
Contents
1.0 Starter Motors 1
1.1 Health and Safety 1
1.2 Starting System 1
1.3 Starter Motor Principles 3
1.4 Flemings Left Hand Rule 4
1.5 Motor Principles (Magnets) 5
1.6 Commutation 6
1.7 Starter Motor Construction 7
1.8 Starter Motor Engagement 8
1.9 Switching 10
1.10 Basic Schematic Diagram 12
1.11 Starter System DIN Numbers 13
1.12 Checking a Starting System 13
Learning Outcome
By the end of this unit each apprentice will be able to:
Describe the basic operation of a permanent magnet DC
motor
Describe the function and basic operation of the pre-engaged
starter motor
Draw a basic schematic block diagram of the starter circuit,
(no internal solenoid/motor details)
State the average current requirements for the starter motor
of a 12V petrol/diesel automobile
Remove a pre-engaged starter motor, dismantle, examine and
report on the condition of the brushes, reassemble, bench
test (run motor before refitting) and refit
Use a multimeter to test the starter circuit of an operational
vehicle
Basic Configuration
The modern starter motor is an electric motor with a solenoid
switch, similar to a relay, bolted to its side. When low-current
power from the lead-acid battery is applied to the solenoid (the
thin grey wire in the image), usually through a key switch, it pulls
out a small pinion gear on the starter motors shaft and meshes it
with the ring gear on the flywheel of the engine. The solenoid also
closes high-current contacts for the starter motor and it starts to
run.
If the engine starts the key switch is released, the solenoid pulls the
small gear back off the starter gear and the starter motor stops
running. Modern starter motors have a special pinion gear and
free-wheel assembly that enables the pinion gear to automatically
disengage from the ring gear when the engine starts.
Principle of Operation
The starting system consists of the battery, cables, starter motor,
flywheel ring-gear, and the ignition switch.
During starting, two actions occur. The pinion of the starter
motor engages with the flywheel ring gear, and the starter motor
then operates to crank the engine.
The starter motor is an electric motor mounted on the engine block,
and operated from the battery. It is designed to have high turning
effort at low speeds.
The starter cables are the thickest on the vehicle, as a high
current must be delivered to the starter motor, to turn the
crankshaft from rest, and keep it turning until the engine fires, and
runs on its own.
Basic Functionality
The starter motor converts electrical energy from the battery
to mechanical energy. It is mounted on the cylinder block in a
position to engage a ring gear on the engine flywheel. A solenoid
switch actuated by the terminal 50 of the ignition switch as an
electromagnetic relay switch to switch on and off the large
quantity of current; this solenoid also acts as a device to get the
pinion of the motor into contact with the ring gear as required.
During engine cranking excessive current draw will lead to the
cables becoming hot and the drop in battery voltage.
Current Requirements
The typical quantity of current required to crank over an
automobile engine is approx. 80 100 amps. Current requirements
differ between petrol and diesel engines. This is because of the
different compression ratios also the ambient temperature has
an effect on the amount of current draw especially on the diesel
engine as it may require the use of heater plugs.
A little practice will show how easy this rule is to apply, but it must
be carried out using the left hand and applies only to the motor
effect.
Exercises Using Flemings Left Hand Rule
Figure 1A and B
Figure 2 illustrates the combined flux of the magnet and the
conductor carrying a current. At side A the magnetic field lines of
the magnet and the conductor are in the same direction and so
reinforce one another. At B the magnetic field lines of the magnet
and the conductor are in opposite directions, so they tend to cancel
each other out. The result is a sort of catapult effect, which
propels the conductor in the direction of the arrow.
Figure 2
It is often important to know the direction of the force on a
conductor when it carries a current of given direction in a magnetic
field of given polarity. One method is to draw out the magnetic
field as shown above, but there is a rule which links the directions
of the current, magnetic field and movement of the conductor,
and which enables us to find the third unknown if the directions
of the other tow are known.
1.6 Commutation
When current flows in a conductor, an electromagnetic field is
generated around it. If the conductor is placed so that it cuts across
a stationary magnetic field, the conductor will be forced out of the
stationary field. This happens because the lines of force of the
stationary field are distorted by the electro-magnetic field around
the conductor and try to return to a straight line condition.
Reversing the direction of current flow in the conductor will cause
the conductor to move in the opposite direction. This is known
as the motor effect and is greatest when the current carrying
conductor and the stationary magnetic field are at right angles to
each other.
A conductor loop which can freely rotate within the magnetic field
is the most efficient design. In this position, when current flows
through the loop the stationary magnetic field is distorted and the
lines of force try to straighten. This forces one side of the loop up
and the other side of the loop down. The motor effect causes the
loop to rotate until it is at ninety degrees to the magnetic field. To
continue rotation, the direction of current flow in the conductor
must be reversed at this static neutral point. A commutator is used
for this purpose.
An example commutator consists of two semi-circular segments
which are connected to the two ends of the loop and are insulated
from each other. Carbon impregnated brushes provide a sliding
connection to the commutator to complete the circuit and allow
current to flow through the loop. Rotation commences with both
sides of the conductor loop cutting the stationary field. When the
loop passes the point where the field is no longer being cut, the
momentum of rotation carries the loop and the commutator
segments over so that the brushes maintain current flow in the
same direction in each side of the loop relative to the stationary
field.
This action reverses the magnetic field around the windings. The
constant changing electrical connection at the windings keeps the
motor spinning.
The commutator end frame carries the copper-impregnated
carbon brushes which conduct current through the armature when
it is being rotated in operation. The brushes are mounted in brush
holders and are kept in contact with the commutator by tensioned
spiral springs.
Half of the brushes are connected directly to the end-frame
and via the ground return of the vehicle frame to the battery
negative terminal. The other half are insulated from the end-frame and
connected to the positive battery terminal via the main starter
solenoid input terminal.
This can be a direct connection in the case of a permanent magnet
type starter or indirectly via the electro-magnetic field poles of a
series wound motor.
1.9 Switching
The starter motor is usually brought into operation by activating a
starter switch as part of ignition key operation.
This remote control operates a starter mounted solenoid which has
two functions:
It acts as a solenoid to engage the pinion with the flywheel
ring gear.
It acts as a relay to bridge the main starting terminals.
In the control circuit, the ignition lock start switch has a positive
connection from the battery and a connection to two windings in
the starter solenoid. One of these is a pull-in winding which has
a low resistance value and the other is a hold-in winding which
has a high resistance.
The pull-in winding is connected to the main starter terminal
leading to the field and armature windings and its circuit will be
completed through the armature to ground on the starter casing
and by frame return to the negative battery terminal.
The hold-in winding is connected to ground on the starter casing.
With the ignition key in the START position, current passes from
the positive battery terminal through the start switch and through
both windings. The high current flow through the low resistance
pull-in winding creates a strong magnetic field which attracts the
solenoid plunger towards the main terminals. Plunger movement
also operates the shift fork lever engaging the pinion with the ring
gear.
Further Reading
Advanced Automotive Diagnosis. Tom Denton. ISBN 0340741236
Automobile Electrical and Electronic Systems (3rd Edition). Tom Denton. ISBN
0750662190
Automotive Mechanics (10th Edition). William H. Crouse and Donald L. Anglin.
ISBN 0028009436
Automotive Technology: A Systems Approach (3rd Edition). Jack Erjavec. ISBN
0766806731
Bosch Automotive Electrics Automotive Electronics: Systems and Components
(4th Edition). Robert Bosch. ISBN 0837610508
Bosch Automotive Handbook (6th Edition). Robert Bosch. ISBN 1860584748
Bosch Automotive Technology Technical Instruction booklet series (numerous
titles)
Bosch Diesel Engine Management: Systems and Components (3rd Edition).
Robert Bosch. ISBN 0837610516
Bosch Gasoline Engine Management: Systems and Components (2nd Edition).
Robert Bosch. ISBN 0837610524
Engines, Electronics and Related Systems (Vehicle Maintenance and Repair Se-
ries: Level 3) (3rd Edition). Jack Hirst and Roy Brooks. ISBN 1861528051
Hilliers Fundamentals of Automotive Electronics (2nd Edition). V.A.W. Hillier.
ISBN 0748726950
Hilliers Fundamentals of Motor Vehicle Technology: Book One (5th Edition).
V.A.W. Hillier and Peter Coombes. ISBN 0748780823
Hilliers Fundamentals of Motor Vehicle Technology: Book Two (5th Edition).
V.A.W. Hillier and Peter Coombes. ISBN 0748780998
Introduction to Motor Vehicle Craft. Jack Hirst and John Whipp. ISBN
0333361865
Light and Heavy Vehicle Technology (3rd Edition). M.J. Nunney. ISBN
0750638273
Modern Automotive Technology. James E. Duffy. ISBN 1566376106
Motor Vehicle Craft Studies - Principles. F.K. Sully. ISBN 040800133X
Motor Vehicle Engineering: NVQ Level Two. Tom Denton. ISBN 1861528922
Motor Vehicle Engineering: NVQ Level Three. Tom Denton. ISBN 1861527446
Motor Vehicle Studies for NVQ. V.A. W. Hillier. ISBN 0748720111
National Car Test (NCT) Manual (Department of Transport, Vehicle Testers
Manual - DoT VTM). Department of Transport
Transmission, Chassis and Related Systems (Vehicle Maintenance and Repair
Series: Level 3) (3rd Edition) John Whipp and Roy Brooks. ISBN 186152806X
Vehicle and Engine Technology (2nd Edition). Heinz Heisler. ISBN 0340691867