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Case Study-Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder Setup Angles
1. 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)
2. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page ii
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 resultsonoverallstartermotorperformancesafterbrushholderscrewsposition
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 1The Latest Drawing Dimensions After Brush Holder Screws Position Modificationon 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
3. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page iii
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
4. 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:
Determinethe practical resultsonoverall startermotorperformances afterbrushholderscrews
positionmodifications.
5. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 2
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
6. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 3
3. Determine the practicalresults on overall starter motor performances after brush
holder screwspositionmodifications.
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
7. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 4
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.
8. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 5
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
9. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 6
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
10. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 7
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
11. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 8
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
12. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 9
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
13. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush Holder
Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page 10
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.
14. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
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
15. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page II
APPENDIX 2: Practical Test Results in Original Degree Angle Brush Holder
16. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page III
APPENDIX 3: Practical Test Results in Original Degree Angle Brush Holder
17. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page IV
APPENDIX 4: Practical Test Results in Original Degree Angle Brush Holder
18. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page V
APPENDIX 5: Practical Test Results in Original Degree Angle Brush Holder
19. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page VI
APPENDIX 6: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder
20. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page VII
APPENDIX 7: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder
21. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page VIII
APPENDIX 8: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder
22. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page IX
APPENDIX 9: Practical Test Results in Anti-Clockwise 10 Degree Angle Brush Holder
23. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page X
APPENDIX 10: Practical Test Results in Clockwise 10 Degree Angle Brush Holder
24. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page XI
APPENDIX 11: Practical Test Results in Clockwise 10 Degree Angle Brush Holder
25. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page XII
APPENDIX 12: Practical Test Results in Clockwise 10 Degree Angle Brush Holder
26. Assignment Relates to the Overall Performances on Starter Motor against the Different Brush
Holder Setup Angles
FA Engineer: 13071015 (Lim Zhen Xing) Page XIII
APPENDIX 13: Practical Test Results in Clockwise 10 Degree Angle Brush Holder
