FORM NO.

F/ TL / 024
Rev.00 Date 20.03.2020

DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

A PROJECT REPORT SUBMITTED FOR THE ETL SUBJECT

BEE18ET2 - DESIGN OF ELECTRICAL MACHINES @
PROJECT TITLE: DC STARTER MOTOR

NAME REG. NO

XYZ 191091101HJI
B.Tech. - EEE / III Year / V Sem.

NOVEMBER 2023
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DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that this bonafide Project Design work entitled, “DC
Starter Motor” done by Mr. XYZ, Reg.No.19109110HGT of III-Year,
V Sem., B.Tech.-EEE in the ETL subject BEE18ET2-Design of Electrical
Machines@ during the academic year 2023-2024.

Signature of ETL in charge Signature of Head of the Department

Submitted for the Internal Examination held on

Internal Examiner External Examiner

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Project report format guidelines (both for UG/PG)

Sequence of topics to be maintained in Project Report:
 Title Page
 Bonafide Certificate(University format)Bonafide from the place where the work is
carried out, on their letter head
 Contents with Page numbers
 List of Abbreviations, if applicable
 List of figure, list of tables, if applicable
 Abstract of the work
 Chapter 1 ,Introduction
 Chapter 2, Literature Survey
 Chapter 3, Aim and scope of present investigation
 Chapter 4, Experimental or material and method ; algorithm used
 Chapter 5, Results and discussion, Performance Analysis
 Chapter 6, Summary and Conclusion
 Bibliography/References /Appendix
-for Journals – name of authors, journal name, year of publication, , volume number ,page
number, starting and ending.
-For Books- name of author, title, name of editor, publisher, year, page number
-Valid internet articles
 Sub chapters should be numbered as follows
Eg. Subject chapter of Chapter 1 should be numbered as 1.1, 1.2…
Further sub chapter should be numbered as 1.1.1, 1.1.2. …

 Letter Font and line spacing to be followed throughout the project work.
Line space: 1.5, Font size: 12, Font type: Arial, Margin space: Left 3cm, Right 2.5cm, Top
2cm, Bottom 1.7cm.
 Major Headings all Caps, Font size:14
 Sub-headings- headings in caps, Font size 12.
 Further Subheadings- 12 Font size, Bold, Italics.
 Still Further sub- headings- 12 Font Size, Italics.
 Legend for figures and labels-
Figure – Fig: 1: Self descriptive title, 12 Font size, Italics, Bold (should be given below
the figure).
Table- Table1: self descriptive title, 12 Font size, Bold (should be given above the
table).
 Page Numbers should be centered at the bottom of each page, starting from
Introduction chapter onwards.
For Contents, Abstract, List of Abbreviations, List of figures, and list of tables – the page numbers
should be in the format (i), (ii), (iii)….. And centered at the bottom of the page.

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TABLE OF CONTENTS
CHAPTER NO CONTENT PAGE NO
DECLARATION ii
ACKNOWLEDGEMENT iii
TABLE OF CONTENT iv
LIST OF FIGURES v
LIST OF ABBREVIATIONS vi
ABSTRACT vii

1 INTRODUCTION
1.1Overview 4
1.2 Fault detection 6
1.3 Application of fault detection 8
1.4 Future scope 10

2 LITERATURE SURVEY
2.1 Mobile damping robot for OH Lines 11
2.2 Hybrid transmission line inspection robot 12
2.3 Line Follower and fault detection robot 13
2.4 Three arm inspection robot for OH Lines 14
2.5 A Hybrid power line inspection robot 15
3 METHODOLOGY
3.1 Block diagram 16
3.2 Power distribution panel 18
3.3 Flight controller overview 21
3.4 FPV Transmitter principle 23
4 ALGORITHM AND SIMULATION
4.1 Feature detection and description 25
4.2 Flow chart 27
4.3 Source Code of prototype 28
4.4 Simulation 29

5 RESULTS 30

6 CONCLUSION 31
REFERENCES

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LIST OF FIGURES

FIGURE NO DESCRIPTION PAGE NO

1.1 Overview of project 5

1.2 Fault detection 6

3.1 Block Diagram of prototype 10

3.2 PDB 11

3.3 Flight controller 12

3.4 FPV Transmitter 15

4.1 Detection of Fault 17

4.1.a Fault Detection through drone 18

4.2 Flow Chart 18

4.2.a Fault detected on insulator 20

4.3 Source Code of algorithm 33

5.1 Prototype model 34

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LIST OF ABBREVIATIONS

IR INFRARED SENSOR

PDB POWER DISTRIBUTION PANEL

FPV FIRST PERSON VIEW

LRF LASER RANGE FINDER

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LIST OF CONTENTS

S.NO. CONTENT PAGE

1.1 What is dc motor 2
1.2 Dc motor principle 2
1.3 Dc motor working 3
2.1 Motor Parts and how they work 4
2.2 Yoke, poles, field winding, armature, 4
brushes and commutator
3 Parts of stator and function 6
3.1 Design of yoke 6
3.2 Calculation of no of poles 6
4 Solenoid and function 7
4.1 Design of solenoid 7
4.2 Calculation of solenoid 8
5 Armature and function 9
Armature core, winding, shaft, 10
torque and design of it
Dimension of slots 11
6 Spring and its function 14
7 Dc motor brush size 15
8 Plunger, function calculation 15
9 Battery terminal and function 16
10 Pinion gear and function 17
10.1 Calculation of gear 17
11 Advantage, disadvantage application 18
12 Reference 19

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LIST OF FIGURES
S.no Figure page
1.1 Dc motor 6
1.2 Working of dc motor 7
3.1 Yoke 9
4.1 Solenoid 10
4.2 Magnetic flux 12
5.1 Armature 13
6.1 Dc motor spring 19
8.1 Plunger 20
10.1 Pinion gear 21

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DC STARTER MOTOR
ABSTRACT

The aim of the report is to study the Dc 12-volt motor mechanism

Provides a rotating magnetic field that drives the armature to rotate. A
simple DC motor uses a stationary set of magnets in the stator, and A
coil of wire which a current running through it to generate an
Electromagnetic field aligned with the center of the coil.
The report explains the in depth mechanism of the parts of 12 volts
DC MOTOR like a stator, a rotar, a yoke, poles, armature winding,
commutator and the brushes it also explains the design mechanism of
it.

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1.1 WHAT IS DC MOTOR?

A DC motor is an electrical machine that converts electrical energy into mechanical
energy.
The working of DC motor is based on the principle that when a current carrying conductor is
placed in a magnetic field, it experiences a mechanical force.
The direction of the mechanical force is given by Fleming’s Left-hand Rule and its
magnitude is given by F = BIL Newton.
The working of the AC motor (Induction motor and Synchronous Motor) is different from the
DC motor.

There is no basic difference in the construction of a DC generator and a DC motor. In fact,

the same DC machine can be used interchangeably as a generator or as a motor.
Like generators, there are different types of DC motors which are also classified into shunt-
wound, series-wound and compound-wound dc motors.

1.2
DC Motor Principle
A machine that converts DC electrical power into mechanical power is known as a Direct
Current motor.
DC motor working is based on the principle that when a current carrying conductor is
placed in a magnetic field, the conductor experiences a mechanical force.
The direction of this force is given by Fleming’s left-hand rule and magnitude is given by;

F = BIL Newtons
According to Fleming’s left-hand rule when an electric current pass through a coil in a
magnetic field, the magnetic force produces a torque that turns the DC motor.

The direction of this force is perpendicular to both the wire and the magnetic field.

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Fig 1.1 DC Motor

1.3
Working of DC Motor
Consider a part of a multipolar DC motor as shown in the figure below. When the terminals
of the motor are connected to an external source of DC supply:
the field magnets are excited developing alternate North and South poles
 the armature conductors carry currents.

Fig 1.2 Working of DC motor

All conductors under North-pole carry currents in one direction while all the conductors
under South-pole carry currents in the opposite direction.
The armature conductors under N-pole carry currents into the plane of the paper (denoted
as ⊗ in the figure). And the conductors under S-pole carry currents out of the plane of the
paper (denoted as ⨀ in the figure).
Since each armature conductor is carrying current and is placed in the magnetic field,
a mechanical force acts on it.

On applying Fleming’s left-hand rule, it is clear that force on each conductor is tending to
rotate the armature in the anticlockwise direction. All these forces add together to produce
a driving torque which sets the armature rotates.

When the conductor moves from one side of a brush to the other, the current in that conductor
is reversed. At the same time, it comes under the influence of the next pole which is of
opposite polarity. Consequently, the direction of the force on the conductor remains the
same.

It should be noted that the function of a commutator in the motor is the same
as in a generator. By reversing current in each conductor as it passes from one
pole to another, it helps to develop a continuous and unidirectional torque.

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2.1 What are DC Motor Parts and how they work?

A DC motor contains different parts that understanding each one can assist to know deeply
these parts cooperate with each other and in the end how DCs work. These components are: a
stator, a rotor, a yoke, poles, armature windings, field windings, commutator, and brushes.
Many of its parts are the same as parts of AC motor, but with a little change.

2.2Yoke, poles, field winding, armature, brushes and commutator

STATORA stator is one of the DC motor parts that is, as the name suggests, a static unit
containing the field windings. The stator is the DC Motor part that receives the supply.

ROTOR
The dynamic part of a DC motor is the rotor that creates the mechanical rotations of the unit.

YOKE
Another unit of the DC motor parts is the Yoke. A Yoke is a magnetic frame made of cast
iron or sometimes steel, which works as a protector. This protective cover keeps the inner
parts of the motor safe and sound and also supports the armature. Yoke also houses the
magnetic poles and field windings of anES

DC motor has magnetic poles that fit into the inner wall of the Yoke with the help of screws
to tighten them up. Poles have two parts: The Pole Core and the Pole Shoe. These two parts
are fixed together by hydraulic pressure and are attached to the Yoke. Each part of the Poles
has a specific task based on its design. The core holds the Pole Shoe over the Yoke while the
Pole Shoe is structured to both carry slots for the field winding and spread the produced flux
by the field windings into the air gap between the rotor and stator. It helps to reduce the loss
caused by reluctance.

FIELD WINDING
Made with Copper wire (field coils), the Field Windings circle around the slots carried by the
Pole Shoes. The field windings form an electromagnet capable of producing field flux. The
motor armature rotates inside the field flux, resulting in the effective flux cutting. DCmotor
to help supporting the field system.

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POL

ARMATURE WINDING Another DC motor parts is armature winding. The armature

winding of the DC motor has two constructions: Lap Winding and Wave Winding. Their
difference is in the number of parallel paths. Armature Winding is attached to the rotor and
alters the magnetic field in the path that it rotates. The result of this procedure is magnetic
losses. Designers try to reduce the magnetic losses by making the armature core with some
low-hysteresis silicon steel lamination. Then, the laminated steel sheets will be piled up
together, creating the cylindrical structure of the armature core. There are slots designed
inside the armature core with the same material.

DC MOTOR COMMUTATOR
The commutator is a split ring made up of Copper segments, Commutator is another DC
motor part. The operating system of a DCs is based on the interaction of the two magnetic
fields of rotating armature and a fixed stator. As the north pole of the armature is attracted to
the south pole of the stator and south pole of armature is attracted to the north pole of the
stator, a force is produced on the armature which makes it to turn. the process in which the
field in the armature windings is switched to produce constant torque in one direction is
called Commutation. the commutator is a device connected to the armature enabling this
switching of current. Different segments of its cylindrical structure are insulated from each
other by Mica. The commutator is designed to commute the supply current to the armature
winding from the mains. The commutator passes through the brushes of the DC motor.

The basic purpose of commutation is to certify that the torque acting on the armature is
always in the same direction. Naturally, the generated voltage in the armature is alternating,
the commutator converts it to the direct current. To control the direction the electromagnetic
fields are pointing to, the commutator turns the coils on and off. On one side of the coil, the
electricity should always flow away, and on the other side, electricity should always flow
towards. This ensures that the torque is always produced in the same direction.

BRUSHES
The last item on the DC motor parts list is Brushes that are made of Carbon or Graphite
structures. Brushes with the commutator, are working as a bridge to connect the static
electrical circuit to the rotor. Brushes are in contact with the commutator and relay the
produced current to the commutator from an external circuit. The current then moves into the
armature winding.

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3PARTS OF STARTER MOTOR AND ITS FUNCTION

3.1 DESIGN OF YOKE

Fig 3.1 Yoke

The magnetic frame or the yoke of DC motor made up of cast iron or steel and forms an
integral part of the stator or the static part of the motor. Its main function is to form a
protective covering over the sophisticated inner parts of the motor and provide support to the
armature

FUNCTION

A starter motor converts the electrical energy stored in the battery into mechanical energy to
crank the engine for starting. A simple electric motor includes a horseshoe-shaped soft-iron
yoke with field windings wound around each of the two pole-pieces

DESIGN OF A YOKE

stator pole shapes and yoke structures in switched reluctance motors (SRMs) on the
mechanical behaviour caused by the electromagnetic force. The stator part in SRM produces
most vibration. The geometric design of the stator is therefore necessary to reduce the
vibration. Based on electromagnetic and structural finite element method (FEM), the free and
forced vibrations for the various structures of SRM with 6/4 poles are analysed. Then a less
vibration stator structure is proposed

3.2 CALCULATION FOR NO OF POLES

Factors affecting the number of poles: 1. Frequency: As the number of poles increases,
frequency of the induced emf f = 120/PN increases, core loss in the armature increases and
therefore efficiency of the machine decreases. and hence the weight of iron used for the yoke
reduces.

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4 SOLENOID

Fig 4.1 Solenoid

A starter solenoid is an electromagnet which is actuated to engage the starter motor of an

internal combustion engine. It is normally attached directly to the starter motor which it
controls......All modern cars also use the starter solenoid to move the starter pinion into
engagement with the ring gear of the engine.

FUNCTION

A solenoid is a type of electromagnet, the purpose of which is to generate a controlled

magnetic field through a coil wound into a tightly packed helix. The coil can be arranged
to produce a uniform magnetic field in a volume of space when an electric current is passed
through it.

4.1 Understanding Solenoid Design & Function

Electromagnetic control

Fig no. 4.2 Magnetic Flux

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Solenoid valves are actuated with the aid of a solenoid. This is basically an electric coil with
a moveable core in the centre that is made from a ferromagnetic material. The core is often
referred to as plunger. When current flows through the coil, a magnetic field is created
around the coil. The strength of this field depends on the current, the number of windings and
the material of the core. As a result of the magnetic field, the solenoid core is pulled towards
the centre of the coil. As long as current is flowing, the core remains pulled towards the
centre. As soon as the flow of current stops, the magnetic field disappears and the core
(usually) is pushed down by a spring to its initial position.

The core, or plunger, should:

 have good magnetic properties

 have a low magnetic memory effect
 be wear resistant
 suitable to machine

4.2 CALCULATION ON SOLENOID

The basic principle of a solenoid valve is a force balance of the the magnetic
force of the solenoid on one side, and the pressure of the medium and force of
the spring on the other side. The required magnetic force for a direct operated
solenoid valve can be calculated with the following formula:

Fs=p•A-
Fspring
Where:

 Fs = solenoid force (N)

 p = pressure (Pa) (105 Pa = 1 bar)
 A = orifice (m2)
 Fspring = spring force (N)

Example

 A given solenoid provides a force of 15N. To use this solenoid to control

a 10 bar pressure differential, the maximum orifice diameter can be
calculated.

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 Fs=p•A → 15=
10=
A 6
•A1.5•10-5
m = 1/4•π•d2 → d = 4.4
A 2

mm
 Indirect operated solenoid valves have a smaller orifice and use the pressure of the
medium to switch. This formula cannot be used for indirect operated valves.

Solenoid valves for direct and alternating current

Direct current

The power of the coil can be calculated with the following formula:

P= where
U /R
2

 P= electric power (W)

 U= voltage (V)
 R= electrical resistance (I)
The properties of a coil for direct current are:

 No humming noise high solenoid force in lifted position

 Equal lifting force in initial and lifted position
 Energy consumption and magnetic force are dependent on temperature
 Less sensitive to dirt
 The coil has more windings than a coil for alternating current

5 STARTER MOTOR ARMATURE

Fig no.5.1 Armature

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An armature in a starter motor is the part that rotates. It consists of windings, an iron core
supported on a shaft, and a commutator. You cannot see the armature without disassembling
the motor. However, you can feel its working when the motor spins to crank your car’s
engine.
The armature is one of the main starter motor parts- and an important one for that matter. It
contains the parts that move to set the starter drive gears or any other mechanism in motion.
That way, it forms an essential part of the process to start an engine.

FUNCTION

Function of Armature in a Starter Motor

Vehicle starter motors contain a moving coil and another stationary one. The stationary coil is
often technically called a stator and comprises either an electromagnet or permanent magnet.
Most modern starters use permanent magnet motors, which are stronger and energy-efficient.

The moving or turning coil is the starter motor armature. It only becomes a magnet when the
motor receives an electric current. The armature assembly, being the moving part, provides
the force to spin the motor’s shaft. This constitutes the motor rotation that does useful work
to start the engine.

We can, therefore, define the starter motor armature as the part that converts electric current
into the needed rotary motion. It enables the motor to overcome external force and crank the
engine.
Starter Motor Armature Parts and their Functions
Looking at a starter armature assembly, one can easily pick out four parts: a cylindrical
slotted section, wire windings, a segmented ring, and a central shaft.

Starter Armature Core

The core of the starter motor armature is its largest part. It consists of thin circular and slotted
layers of iron, also called laminations. The pieces are insulated from each other to reduce
eddy currents. If it were a continuous block of metal, eddy currents would occur and waste
electrical energy in the form of heat.

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Starter motor armature core

Iron is used for the armature core due to its excellent magnetic properties. It produces a
strong magnet, which is necessary for the amount of torque required to start an engine. All
around the core are slots to secure the coil windings. The slots run the length of the armature
assembly.

Starter Armature Coil Windings

Looped around the core are the starter motor armature windings. These are fairly thick copper
wires that conduct current with the least resistance. To prevent shorting and other problems,
the starter armature coil wires feature a thin layer of insulation
The coil windings of a starter motor armature end in the commutator where they attach to
specific segments. This enables the changing of electrical connections with the windings. It
also allows the reversal of polarity and, therefore, the continuity of armature rotation.

Starter armature coil winding

As we have seen, the coils, together with the iron core, have to produce a strong rotational
force. For that reason, several different loops are used, which can be as many as 30 in a single
core. Each coil also features many turns of the wire to help increase the strength of the
magnetic field and, therefore, torque.

Starter Armature Commutator

The commutator is found in the back of the motor’s housing and forms part of the armature
assembly. Usually round and segmented, its main function is to transfer current to the
armature in the required sequence. That is made possible by the segments or copper bars on
which the motor brushes slide.
Each segment or bar on the commutator conveys current to a particular coil. To enhance
efficiency, the contact surfaces are made from a conductive material, usually copper. The
bars are also separated from each other using a non-conductive material such as mica. This
helps prevent shorting.

Armature Commutator
Brushes supply current to the commutator. The brushes are spring-loaded, ensuring constant
contact with the commutator and minimizing the possibility of failure. The arrangement of
the brushes may vary from one motor to another. In some motors, they are on the sides of the
shaft, and the end-plate in others.

Starter Armature Shaft

This is the central rod that runs through the starter motor armature assembly. It holds the
parts that make the armature, from the core, windings, to the commutator. Bearings at either
end support the shaft, allowing it to rotate freely.

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Armature shaft
To start the engine, the shaft spins the starter drive mechanism either directly or indirectly. It
can be a pinion gear at the end of the shaft or a set of reduction gears and other parts. For
strength, the shaft is usually steel. It is normally insulated from the commutator copper bars.

Starter Motor Armature Torque

The starter armature assembly converts electrical energy into rotary motion. The force of
rotation must be large enough for the engine to come to life. To ensure that, several design
characteristics are necessary. These include increasing the number of armature or field
windings, using permanent magnets, and utilizing a specific wiring pattern.
Most starter motor armatures contain as many as 30 coil segments. That is usually high
enough to ensure smooth rotation and high torque. Many motors also employ permanent
magnets, which can be multiple to improve torque further. Electromagnets depend on the
battery for current. Apart from draining the battery, that also means reduced power.
Another way to increase torque is by using specific coil configurations. For the
circuity or starter armature windings, different patterns can be used. Each has its up and
downsides. The next part is a description of each, including the benefits and disadvantages.

ARMATURE CORE DESIGN

The armature of a dc machine consists of core and winding.

The armature core is cylindrical in shape with slots on the outer periphery of the armature.

The core is formed with circular laminations of thickness 0.5 mm.

The winding is placed on the slots in the armature core.

The design of armature core involves the design ofmain dimensionsD & L,number of slots,
slot dimensions and depth of core

Number of armature slots

The factors to be considered for selection of number of armature slots
Are slot width (or pitch) cooling of armature conductors flux pulsations commutation cost

A large number of slots results in smaller slot pitch andso the width of tooth is also small.
This may lead to difficulty in construction.

But large number of slots will lead to less number of conductors per slot and

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so the cooling of armature conductors is better. If the airgap reluctance per pair ofpoleis
constant then the fluxrepulsionsand oscillations can be avoided.

It can be proved that the airgap reluctance is constant if the slots per pole is
an integer plus 1/2.For sparkles commutation the flux pulsations andoscillations under
theinterpose must be avoided.

This canbe achieved with large number of slots perpole.In fact, the number of slots in
the region between the tips of two adjacent
poles should be at least 3.

The slots per pole should be greater than or equal to 9, for better com
mutation. When large number of slots are used the cost of lamination and the cost of
insulation will be high. Guiding factors for number of armature slots
The slot pitchshould lie between 25 to 35 mm. For small machines it can be
20 mm or even less than20 mm.

The slot loading should not exceed 1500 ampere conductors.

Slot loading = Number of conductors in the slot x Current per conductor.
To reduce flux pulsation losses the slots per pole should be an integer plus 1/2
for lap winding and slots per pole arc should be an integer plus 1/2 for wave winding.

To avoid sparking the number of slots per pole should have a minimum value of 9. The slots
per pole varies from 9 to 1 6. In case of small machines, it can be. The number of slots
selected should be suitable for the type of winding. In case of simplex lap winding the
number of slots should be a multiple of pole pair In case of wave winding the number of slots
should not be a multiple of pole to avoid dummy coils

SLOT DIMENSION
The dimensions of the slot are slot width and depth. Usually the slot area is estimated from
the knowledge of conductor area andslot space factor.
The slot space factor lies in the range of 0.25 to 0.4 and the value depends on
the thickness of insulation.
Slot area= Conductor area/

Slot space factor

After deciding the slot area, the depth of slot is assumed based on the diameter
of the armature

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6 SPRING

Fig no. 6.1 DC Motor Spring

The starter solenoid return spring is attached to the plunger, which restores the plunger to its
original rest position.

When the driver turns the key, the solenoid is energized and the plunger is pulled due to
electromagnetism to move the pinion gear to turn the flywheel.

Conversely, when the driver releases the key and the solenoid de-energizes, so the plunger
remains in the pulling position if the return spring would not present.

With the help of the return spring, the plunger pulls back to its original rest position.

Function of Return Spring

The function of the return spring is to bring back the plunger to its original rest position after
the end of the starter solenoid operation.

DC motor carbon brush sizes

 Motor Copper Carbon Brush; Carbon Brush Size: 10 x 32 x 50mm/ 25/64" x 1 1/4" x 1
31/32"(L*W*T)
 Total Length (approx.) : 200mm/ 7.9";Mount Hole Size : 13 x 6.4mm/0.5"x 0.3"(L*W)
20
 Material : Carbon, Copper, Metal.
 Weight : 86g.
 Package Content : 1 x Motor Copper Carbon Brush.

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7 DC MOTOR BRUSH SIZE

Motor diameter
Sizing a brush DC motor to a specific application begins with matching the motor's diameter
to the available space. In general, larger frame size motors deliver more torque. Motor
diameter ranges from 8 mm to 35 mm.

Length
Various lengths are available, ranging from 16.6 mm to 67.2 mm, to best fit the application
package requirements.

Commutation type
Precious metal brushes are well adapted to low current density applications, providing low
friction and high efficiency, whereas high continuous or peak current applications will
require graphite-copper brushes.

Bearing type
Several bearing combinations have been designed, from simple sleeve bearing construction to
preloaded ball bearings systems for high axial or radial load applications.

Magnet and commutation type

Adapt your motor selection to the power and current needs of your application: NdFeB
magnets provide higher output torque than Alnico, at a higher cost. The commutation system
(type and size of the commutators) is also reflected in this coding.

Winding
Various winding options are proposed to best match with the application requirements –
voltage, resistance and torque constant are the basic parameters for selection.

Execution code
Used to specify standard and customizations.

8 PLUNGER
When the ignition switch is turned on, a small electric current is sent through the starter
solenoid......When the solenoid is energized, it operates a plunger or lever which forces
the pinion into mesh with the ring gear.

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Fig no.8.1 Plunger

FUNCTION
The plunger works by using the connected vehicle battery and the solenoid to push the
plunger forward, which engages the pinion.

When the solenoid is energized, it operates a plunger or lever which forces the pinion into
mesh with the ring gear. The pinion incorporates a one way clutch so that when the engine
starts and runs it will not attempt to drive the starter motor at excessive RPM.

CALCULATION OF SOLENOID PLUNGER

The force is F=A *B^2/2*mu_knot. For a traditional solenoid, a common expression for
magnetic field is: B=Bsol=mu_knot*N*I/g, where g = gap. Then, F=mu_knot*A*(NI/g)^2/2
[same as your equation, without NdFeB.] For your situation with permanent magnet core, you
must determine the total field, B=Btot = Bsol + BPM.

9 BATTERY TERMINAL IN STARTER MOTOR

Typically, a starter-mounted solenoid has three terminals with three connections: The “B” or
“battery” terminal: The terminal that connects the solenoid directly to the positive battery

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cable. The “S” or “start” terminal: The terminal that receives power from the ignition
switch.

FUNCTION

The negative (ground) cable connects the negative "-" battery terminal to the engine
cylinder block, or transmission, close to the starter. The positive cable connects the positive
"+" battery terminal to the starter solenoid

10 PINION GEAR

Fig no. 10.1 Pinion Gear

The pinion on a pre-engaged starter motor fully engages with the ring-gear before rotating at
high-speed.....When the starter motor is activated the pinion moves along the shaft until it
comes into contact with the toothed ring-gear. The pinion interlocks with the ring-gear before
rotating to crank the engine.

FUNCTION

Starter ring gears are attached to either the flywheel or the flex plate of an engine. The teeth
of the ring gear are driven by the smaller gear (known as the pinion) of the starter motor. The

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pinion engages the starter ring only during starting and once the engine is running the
pinion withdraws.

10.1 CALCULATION OF PINION GEAR

Root Diameter (df) is the diameter of the root circle; its value is: df = m (z – 2.5) or df = de –
2h. Center Distance (dc) is the distance between the shafts of the gear and the pinion; its
value is: dc = (D + d) / 2, where “D” corresponds to the pitch diameter of the gear and “d” to
the pitch diameter of the pinion.

11 ADVANTAGES
1. Starting torque very high up to 500%.
2. Maximum momentary operating torque up to 400%.
3. Speed regulation- widely variable, very high at no load.
4. Sped control can be done by series resistance.
5. The efficiency increases rapidly in the beginning, reaches its maximum value and
then decreases.
DISADVANTAGES
1. Speed falls rapidly with the increase in load, so it is not suitable for constant speed
application.
2. When started at no load, it achieves a very high speed with can damage the motor.
3. With decrease in speed, torque of the motor decreases sharply.

APPLICATION

 It used automobiles to start the engine

 DC motors are suitable for many applications – including conveyors, turntables and
others for which adjustable speed and constant or low-speed torque are required. They
also work well in dynamic braking and reversing applications, which are common in
many industrial machines.
 Their quick acceleration, stopping and reversing – along with their linear-speed torque
curve – make the DC motor a popular choice in many new designs, particularly for
fractional hp applications.

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REFERENCES

https://www.motioncontroltips.com/faq-why-are-starters-used-with-dc-motors.com

https://cusp.umn.edu/electric-machine-design-videos

https://ieeexplore.ieee.org/document

https://tameson.com/solenoid.html

https://eomys.com/e-nvh/technical-notes-on-electromagnetically-excited-noise-and-
vibrations/article/noise-mitigation-techniques-of-electrical-machines?lang=en/

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