VOL. 7, NO.

7, JULY 2012 I SSN 1819- 6608

ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

AN OVERVIEW OF AUTOMOBILE STARTING SYSTEM FAULTS

AND FAULT DIAGNOSIS METHODS
Murugesan V. M.1, Chandramohan G.2, Senthil Kumar M.3, Rudramoorthy R.4, Ashok Kumar L.5, Suresh
Kumar R.1, Basha D.1 and Vishnu Murthy K.5
1
Department of Automobile Engineering, PSG College of Technology, Coimbatore, Tamil Nadu, India
2
Karpagam College of Engineering, Coimbatore, Tamil Nadu, India
3
Department of Mechanical Engineering, PSG College of Technology ,Coimbatore, Tamil Nadu, India
4
PSG College of Technology, Coimbatore, Tamil Nadu, India
5
Department of Electrical and Electronics Engineering PSG College of Technology, Coimbatore, Tamil Nadu, India
E-Mail: [email protected]

ABSTRACT
Starter motor converts electrical energy through a battery into mechanical rotating energy. These motors work
under heavy load. They produce big power in a short time and in a small volume. If the starter motor fault occurred, the
vehicle cannot be run, especially in emergency vehicles (ambulance, fire engine, etc.). Starter motor conveys its rotating
energy with a pinion to the flywheel. For initiating internal combustion engine, the rotating moment of starter motors
should be requested being greater. The starter motor must be rotating the flywheel at a minimum starting speed. It must
also continue support rotation during initial combustion to maintain momentum until the engine can sustain operation. The
starter motor turns for approximately 1s during each starting attempt. In each attempt the starter motor gear bounces out
and meshes with the flywheel attached to the engine crankshaft. During the compression cycle of each cylinder, the starter
motor torque is high, resulting in higher force on the starter gear teeth. Because of the lack of over current protection, the
traditional starter control through solenoid easily causes short circuit and bums out starter. So the starter motor and its
components are subjected to either mechanical fault like wear, fractures of moving parts or electrical faults like short
interrupted circuit and contact resistance increase etc. This paper focuses on causes for various faults and different fault
diagnosis methods and also various developments in starter motor fault control are reviewed in detail. The need of
electronic control unit based starting system with some of the safety features and online monitoring system for indicating
state of charge of battery is also discussed.

Keywords: starter motor, faults, solenoid, pinion, flywheel, pitting, electronic control unit.

INTRODUCTION the flywheel without any damage to both flywheel and

Engine start is the initial phase, and a very crucial pinion and then it has to develop high torque for starting
phase in the operation of automotive engines. The quality the engine. Pinion is fixed on the armature shaft with an
of engine start influences emission and also the drivability over running clutch. This over running clutch which has a
of the vehicle. The starter motor plays a vital role in this slipping torque of about 3 times lock torque of starter to
short transient period. The main function of the starter avoid damage to pinion and also protects armature running
system is to supply cranking torque to the crankshaft of at high speeds, over load and transmits high torque to
the I.C. engine until a sustainable RPM is achieved due to pinion.
consecutive robust engine combustion events. The torque In order to protect the starter system from damage
generated by the starter motor is amplified through two or due to high (transient) engine RPM, a roller one-way
three stages of gear reduction so as to be capable of clutch (OWC) is introduced. In older or heavy-duty
cranking the engine shaft from zero to around 200 RPM. A applications, a conventional gear reduction scheme may be
planetary gear-train is used to amplify the torque adopted instead of a planetary gear-train. As high density
generated. magnets are readily available today, the Permanent
The cranking torque provided by the starter motor Magnet motor is more common. It makes the starter
is a linear or quadratic function (depending on the stator system compact with very high torque capability [1].
winding configuration) of the current flowing through the In the coming years, the need for electrical
rotor winding of the starter motor [1]. energy in the vehicle will rise at an ever faster pace. The
If a fault occurs with the starter motor, the ICE increasing demand for electrical energy stems from the
cannot be run. Especially in emergency vehicles (such as large amount of electrical equipment which has become an
ambulance, fire engine, etc), starter motor faults causes integral part of every modern-day vehicle. This stems from
any other faults. the ECUs for electronic systems, and from all the safety,
Larger size engine will have high inertia at the comfort and convenience electronics and their
flywheel and crank shaft. It needs starter motor with components. The starter motor must at all times be ready
higher torque for starting the engine. When high torque to crank the engine, and during the course of its life must
motor was used, it is needed to be engaged the pinion with successfully complete thousands of starting operations.

812
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

Taking a passenger car which is mainly operated in town In the case of starter motors, the load of the
traffic, this can equate to about 2000 engine starts per year machine is an engine, with widely varying load torque,
for an average annual mileage of 15,000 km (10,000 which is dependent on the motor condition, external
miles) [2-3] while the latest starters and alternators environment, and multiple resonances [6]. If any fault
provide improved power generation capacity, they are also occurred on starter motor, peak current during cranking
smaller, lighter and quieter in order to improve fuel will increase. The mostly observed faults on starter motor
consumption, help reduce CO2 and improve cabin comfort. and starter system are; brush fault, battery fault, open
It is very difficult to use the starter motor circuit fault (broken connection cables, looses battery pole
effectively due to malfunctioning of solenoid switch etc.), armature fault, field (excitation) winding’ fault and
because of its damaged contact points (pitting) due to short circuit fault. Because of improper starter mounting,
arcing and prolonged cranking. This affects the battery switching or lack of maintenance etc., teeth of the starter
life, starter motor armature and pinion finally results with pinion and flywheel ring gear may not mesh properly and
vehicle idle affecting actual purpose of the vehicle. even impact each other. Due to improper mesh or violent
impact, it can induce unstable, high transient forces and
torques during starting, and therefore failures or troubles
such as gear teeth flake off, meshing harness, tightly
meshing, armature failure, drive end housing fracture etc.,
are common in application after a certain period of service
time [7].
As the starter gear applies force, a moment comes
where contact between the starter and a flywheel gear is
lost, followed by a knock when contact is reestablished.
This mechanical transient translates into speed and torque
transients and, subsequently, into a short transient of the
stator current.

Battery Fault
Automobile engine starting requires extremely
Figure-1. Performance graph of the serial wound - starter high current, in the range of 600 Amps peak for 250 ms,
motor (1 kW/12 V). then a 150 A to 300A sine wave at a reasonably stable
voltage for 0.5 to 3 seconds. Starter efficiency increases
Here the curves of revolution (rpm), power (P), with higher deliverable voltage. Batteries required for
torque (T), and voltage (V) are drawn subjects to the these applications should be capable of operation at
current. According to the values of variables, the status of temperatures ranging from -208 C to 508 C [8].
the motor is diagnosed by the help of the performance
graph. If these values are too high or too low from the
desired values, it is understood that some breakdowns
have already occurred or will occur soon in the motor [4].

STARTER MOTOR FAULTS

Starting of SI engines at low temperatures is
easier than CI engines due to sparking systems in the
combustion chamber and the fuel properties. By using the
conventional lubricating oils, fuels, etc., the SI engines can
easily be started by using the more volatile fuel having 10
per cent evaporation temperature at about 40°C.
Starting of diesel engine creates problems of cold
starting at lowest temperatures. While studying the
problem of cold starting, it was observed that four
operating factors influence the diesel engine starting: (i)
engine design, (ii) properties of lubricating oils, fuels and
coolant, (iii) battery conditions and starter motor, and (iv)
use of starting aids. Hence, cold starting of IC engines
under sub-zero temperature conditions is a delicate
operation. A little carelessness can damage the whole
Figure-2. Battery capacity as a function of discharge
engine, but if proper precautions are taken and right type
current strength.
of lubricating oil, fuel, coolant, starting aid, etc. are used
then a summer like start can be achieved [5].
In battery fault, the battery cannot provide
enough current in order to turn the flywheel. In this

813
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

condition the battery is fully discharged or there is end-of-life is reached when the output is not sufficient for
problem on charging system and therefore revolution of minimal cranking RPM of the combustion engine.
the motor will be too low. Significant losses in the starter circuit which often cause
the whole starting system malfunction.
Starter cable fault
Arcing and arc damage in an electrically
energized cable is often recognized as a result of insulation
failure of the cable and a possible cause for the ignition of
a fire. Typically, cables routed in an automobile are
protected by a combination of fusible links, circuit
breakers and fuses [7]. The exception is the starter cable,
which, due to the intrinsic nature of its application, is not
protected by circuit breakers or fuses. Cable insulation
failure can result in the energized conductor contacting the
vehicle chassis, which may then result in a high-current,
low resistance fault. An insulation failure of the starter
cable may occur due to the following reasons: Figure-4. Damaged solenoid terminal.
ƒ If the cable is routed/supported improperly, causing
damage to the insulation due to shock and vibration.
ƒ Environmental conditions may cause cable
degradation.
ƒ The starter cable may be damaged during accident.

Figure-5. Pitting in the solenoid contacts.

Corroded battery terminal Good connection of cable

Figure-3. Starter motor cable fault condition.

Open circuit fault (Connection fault)

These are the cross section reduction of
connection cable, a loose cable connection and the loose
battery pole. The cross section of connection cable for
starter motor is so essential. Decreasing the cross section
of cable results in increasing the current; however, if the
reduction is too much it causes the effect on revolution. In Figure-6. Pitting in hold-in winding contact.
the loose connection, when the contact resistance
increases, starter motor current goes up. Brush fault
In the case of brush faults, the sparks occur
Solenoid contact resistance fault between the starter motor and commutator and the brushes
The solenoid winding number N can change due due to unsmooth contact of the brushes, dirty collector of
to turn-to-turn winding fault, the drop of the instantaneous brushes, unadjusted brush pressure springs, oval shaper
current i can emerge due to increased contact resistance. collector and consumed brush life.
The draw force drops significantly in both mentioned
cases. Considering the starter reliability, the starter end-of-
life is reached when the draw force drops insofar it is
unable to equal the passive resistance and the force of the
solenoid armature pull-back spring. During the
combustion engine cranking process the starter
electromotor circuit is carrying current of hundreds A. If
the contact resistance of the power contacts increases, the
losses increase and the starter output drops. The starter

814
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

Figure-7. Brush fault in starter motor.

Figure-9. Damaged field winding.
Especially, carbon brushes for automotive starters Starter motor pinion fault and drive end housing
contain lead as an additive. The desired effect is an fracture
increase in starter performance without raising the copper During a normal starting action, the drive pinion
to current-density ratio, which is directly correlated to the of a starter is turned helically and then pushed towards the
brush wear rate. However, lead dust is toxic or may cause engine flywheel in one continuous operation. This rapid
genetic changes if incorporated, even in small quantities. operation makes teeth of the pinion mesh those of the
In addition, lead oxidizes easily in air, which leads to flywheel ring gear successfully. But in many cases,
dimensional and resistivity changes of the brushes over because of improper starter mounting, switching or lack of
time. The role of lead in the contact has been attributed to maintenance, etc., teeth of the two gears may not mesh
its ability to control the film, and lowering the temperature properly and even impact each other. Improper mesh or
by dissipating heat through phase transition [9]. violent impact can induce unstable, high transient forces
and torques during starting, therefore, failures or troubles
Armature faults such as gear teeth flake off, meshing harness, tightly
When a short circuit is occurred on armature, the meshing, clutch failure, armature failure, drive end
current drawn is getting increased. In the case of brush housing fracture, etc. are common in application after a
comes across the short circuited armature winding, the certain period of service time [10].
starter motor is not able to start the engine [4].

Figure-10. Failure in starter motor pinion component.

DISCUSSIONS
The above discussed faults can be detected and
overcome by the following fault diagnosis methods and
techniques.
Figure-8. Starter motor armature fault.
Artificial neural network (ANN) based fault detection
Field winding fault system
Field winding fault is either due to short circuit A fault diagnosis system for a serial wound
with the ground or the short circuit between own starter motor based on multilayer feed forward artificial
windings. In this case, the motor turns but there are neural network (ANN). ANN based fault detection system
fluctuations in torque due to the no existence of enough has been developed for implementation on the emergency
and smooth magnetic field. Hence the motor draws too vehicles. Information of starter motor current is acquired
much current subject to the largeness of the short circuit. It and then it is practiced on a neural network fault diagnosis
causes damage to the field winding. (NNFD) system. The multilayer feed forward neural
network structures are used. Feed forward neural network

815
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

is trained using the back propagation algorithm. NNFD Lead free carbon brushes for starter motors
system is effective in detection of starter motor faults. Materials which could possibly replace lead
NNFD system is able to diagnose the faults that can be would have to be cheap, conductive, and have a low
seen in most frequencies in starter motors. By using melting point, a soft oxide, and a low toxic potential
defective starter motor current signals, the faults are (Table-1). Aluminum has a low melting point, but is ruled
classified by feed forward neural network [2]. out because of a very hard oxide. The only true candidates
are tin and zinc. Tin and zinc both have high diffusion
Graphical user interface (GUI) software using learning rates in copper. The diffusion rate of tin, even at ambient
vector quantization (LVQ) network temperature is so high that it is impossible to put tin and
A graphical user interface software for real time copper in mechanical contact without forming an alloy
condition monitoring and fault diagnosis of serial wound within a few days. Unfortunately, these alloys have a high
starter motors has been developed using Learning Vector melting point and cannot act as a heat sink. The situation
Quantization (LVQ) neural network. The information of is not as critical with zinc; however, the diffusion has to be
voltages and currents are acquired from the starter motor inhibited during the heat treatment [9].
via data acquisition card and transferred to the program.
Using LVQ network, the faults observed in the starter Table-1. Additives to replace lead in carbon brushes [9].
motors were successfully detected and diagnosed in real
Melting Mohs Mohs
time. The GUI software makes it possible to condition
Metal point hardness of hardness of
monitoring and diagnosed the faults in starter motors
(K) metal oxide
before they occur by keeping fault records of the past
occurrences [3]. Copper 1356 3 3.7
Lead 600 1.5 2
Prognosis of gear faults in starter motors using time
frequency distribution method Aluminum 932 2.3 9
The prognosis of gear faults in starter motors Zinc 693 2.5 4.3
using time frequency distribution method which presents
Tin 505 1.7 6.7
future state prediction of the machine faults using Hidden
Markov model with limited data. The method uses
Matching Pursuit decomposition and projections of the Automobile functions control system via Bluetooth
training data on linear discriminant planes for the utility
estimation of model parameters. This method is to ensure An Intelligent - Low Cost Car Control System
operation of the starter motor and the estimation of using Bluetooth Technology enables the end-user to
remaining useful life [11]. control different functions so that it can be controlled
Prognosis method for the gear faults in dc quickly and accurately using his own cellular phone as
machines uses the time-frequency features extracted from he/she connects it with the hand free Bluetooth device.
the motor current as machine health indicators and The functions can be freely selected and each can get its
predicts the future state of fault severity using hidden own mechanism based on a microcontroller program. Up
Markov models (HMMs). Parameter training of HMMs to nine separated functions can be controlled each with
generally needs huge historical data, which are often not two switching keys, these functions include starting the
available in the case of electrical machines. Methods use engine, windows controlling in both directions, center
matching pursuit decomposition for estimating state- lock, lights and alarm system, stereo system, and any other
transition probabilities for computing state-dependent functions. The proposed system is reliable, robust and
observation probability distributions [6]. The drawback of adjustable through all its designed parts to insure the
this method is the need of huge historical data of starter maximum comfort ability of the user [12].
motor parts.
Starter motor peak current measuring techniques
A fuzzy logic based fault detection system Apparatus for measuring the ignition timing of an
A fuzzy logic based fault detection system has internal combustion engine while cranking the engine with
been developed for implementation on emergency the starter motor, and with the ignition inhibited. Starter
vehicles. Information of the current and the voltage of a motor current fluctuations are examined to determine the
starter motor is acquired and then practiced on a fuzzy times of current peaks due to compression in individual
logic fault diagnosis system (FLFDS). For this purpose, a cylinders. Means coupled to the ignition circuit determines
graphical user interface (GUI) software is developed by the times of points openings. A time difference signal
using Visual Basic 6.0 programming language. FLFDS is representing the lead or lag of the ignition relative to the
effective in detection of six types of starter motor faults. starter current peaks is generated. The lead or lag is then
The proposed system can be used in a Quality Control unit related to the time of top dad center in terms of degrees
of manufacturers and maintenance-repairing units [7]. [13].
Diagnostic apparatus, connected to probes for
sensing conditions or parameters of an internal combustion
engine during non-combustion cranking of the engine,

816
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

reads electrical conditions at times related to the crank running. The electric starter motor system comprises two
angle of the engine. Electrical tests are made at times electric circuits, one for starting the motor which may be
indicated by peaks and valleys in the starter current, the directly or indirectly connected, and the other for
average of these providing load compensated indications controlling or cutting off the first or starting motor circuit.
of true electrical parameters, to eliminate effects of battery The first circuit contains the conventional starter motor,
loading variations due to compression-induced variations current source such as a battery, and starter switch plus a
in cranking power required [14]. normally closed cut-off switch. The other and second
The current drawn by a starter motor is derived circuit for controlling the first and just mentioned starter
from measuring the compression of internal combustion motor circuit, contains the conventional ignition switch for
engine. The compression in the individual cylinders is a the ignition system of the engine, plus a normally open
determining factor for the even running of the engine and switch closed by the vacuum from the intake of the engine
thereby, for uniform stress of the crankshaft and the when the engine starts, and a self-holding electromagnetic
bearings. In the course of the life of the engine, the means such as relay or solenoid, which when energized by
compression in the individual cylinders can deteriorate the closing of the vacuum switch, opens the normally
differently; therefore there is a need of checking the closed cut-off switch in the first starter motor circuit,
variations in compression between cylinders. If a cylinder whereby the starter motor control circuit remains open
lacks compression, a current increase occurs in the until the other and second cut-off control circuit is broken
cylinder which comes next in the engine cycle, because by the opening of the ignition switch. Thus, if the engine
part of the energy contained in compressed air of the stalls, it cannot be restarted until the ignition switch is
preceding cylinder is missing. This missing energy must closed and opened again [17].
be supplied by the current source of the starter motor, In a starter control system for an engine equipped
which manifests itself in the current increase mentioned with a starter motor, starter relay, ignition switch and
[15]. electronic control unit, a circuit and method whereby the
A measuring method for vehicles equipped with ECU will deactivate the starter relay if the operator of a
an internal combustion engine, the engine including a vehicle attempts to re-start the vehicle when the current
starter battery and a driven starter motor used when an engine speed is greater than the minimum engine running
attempt is made to start the engine, is disclosed. According speed, under both initial starting and engine running
to the method, a voltage across a measuring shunt inserted conditions. By deactivating, the starter relay will prevent
in a current circuit between the battery and starter motor is engagement of the pinion gear to the ring gear of the
repeatedly measured, at a sampling rate, during each starter motor, potentially reducing wear on the starter
revolution of a crankshaft of the engine during the motor, grinding of the pinion gear to the ring gear when
activation of the starter motor. Corresponding values of a engaging the gears at a high RPM, and noise to an
current delivered from the starter battery to the starter operator of the vehicle [18].
motor are derived from measured voltage. Values of the A controller for a vehicle starter motor, the
current are registered in a memory of a measuring controller comprising means for applying power to the
computer. The registered values are used to establish a electric starter motor as a function in particular of the open
status of the combustion engine and its starting system. A or closed state of a starter switch, wherein said means
value of a derivative of a rotational speed of the include in particular Resistor Capacitor (RC) type circuit
combustion engine crankshaft is obtained from the having a charging time constant that is shorter than its
registered values. The sampling rate is sufficiently high to discharging time constant and that charges and discharges
permit obtaining the value of the derivative of the depending on whether the starter switch is closed or open,
rotational speed of the combustion engine crankshaft [16]. said control means also including means for preventing
3.8 Methods for preventing the energization of the starter power being applied to the starter motor when the voltage
motor while the engine is running. across the terminals of the capacitor means of the RC
A circuit for preventing the energization of the circuit exceeds a given threshold. This control circuit also
starter motor for an internal combustion engine while the serves to control other functions such as automatically
engine is running. A first solid state switch energizes the stopping the starter or indeed providing protection against
starter relay, and also a second solid state switch. Circuitry surge currents or against operator error such as trying to
is provided to maintain the second solid state switch start an engine that is already running. The control unit is
energized as long as the engine is running and to prevent either integrated within the starter, or else it is housed
the first solid state switch from being reenergized as long externally there to in a special box [19].
as the second solid state switch is energized. According to
one aspect of the invention time delay means is provided ECU controlled solenoid power contactor
to insure that all rotating parts can come to a stop before A motor vehicle starter system includes a
the starter motor can be reenergized [22]. contactor comprising an annular cylindrical armature and a
The circuit to control the energizing of an electric winding which actuates a movable core in axial
starter motor for an internal combustion engine having an displacement, so that the latter acts on a control rod
electric ignition system, which prevents energizing said extending through the centre of a fixed core in the form of
starter motor while the internal combustion engine is a disc. The control rod controls axial displacements of a

817
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

movable contact, and the contactor further includes a hood REFERENCES

having the general form of a cylindrical pot, with a skirt
portion which defines housing. The movable contactor is [1] QiMa Rajagopalan S.S.V, Yurkovich S. and
arranged within this housing. The starter system also Guezennec Y.G. 2005. A high fidelity starter model
includes an electronic control system for the contactor, for engine start simulations. American Control
comprising a support member such as a printed circuit Conference. 7: 4423-4427.
board, and circuit components carried by the support
member. The electronic control circuit is arranged inside [2] Bayir R and Bay O.F. 2004. Serial Wound Starter
the contactor [20]. Motor Faults Diagnosis Using Artificial Neural
A device for controlling an automobile vehicle Network. IEEE International Conference,
starter motor contactor having a power contact controlling Mechatronics. pp. 194-199.
the supply of power to the electric motor of the starter
motor and at least one coil controlling the movement of [3] Bayir R. 2008. Condition Monitoring and Fault
the said contact, one of the coils of said contactor being Diagnosis of Serial Wound Starter Motor with
connected between the power supply terminal at the Learning Vector Quantization Network. Journal of
battery voltage and the electric motor, said device Applied Sciences. pp. 3148-3156.
including a control unit for the starter motor and a
transistor controlled by said unit that controls the supply of [4] Omer Faruk Bay and Raif Bayir. 2011. A Fault
power to the coil or coils of the contactor, wherein the Diagnosis of Engine Starting System Via Starter
control unit includes means for turning off the transistor if Motors Using Fuzzy Logic Algorithm. Gazi
the voltage at a given point between the coil and the motor University Journal of Science. 24(3): 437-449.
is not greater than a predetermined threshold at the end of [5] Gupta R.B. 1987. Cold starting of IC Engines. Def.
a predetermined time period from the starter switch of the Sci J. 38(1), January 1998. pp. 77-85.
vehicle closing [21].
In a motor vehicle starter contactor, a control [6] Syed Sajjad H. Zaidi and Selin Aviyente. 2011.
plunger controls the axial displacements of a contact plate Prognosis of Gear Failures in DC Starter Motors
which is arranged in a front cover of the contactor. A fixed Using Hidden Markov Models. IEEE Transactions on
transverse core is arranged axially in front of the contactor Industrial Electronics. 58(5).
winding, and an electronic circuit is fitted inside the cover,
between the fixed core and a partition which divides the [7] W.L. Wang. 2008. FEA-based Structure Optimization
interior of the cover into two compartments. The partition, for the Drive end Housing of an Automotive Starter.
in the form of a separating plate, has a transverse wall IEEE International Workshop on Modeling,
portion and an axial bush in which the plunger slides. The Simulation and Optimization. pp. 447-450.
bush has a central bore which is open at the front
forwardly of the transverse wall portion, and open at the [8] Ram Bhardwaj and Paul Branher. 2000. Light weight
rear behind the fixed core [22]. engine start battery based on thin metal film
technology. IEEE. pp. 323-327.
CONCLUSIONS
The above discussed faults can be overcome by [9] Arwed Uecker. 2003. Lead-free carbon brushes for
use of an Electronic Control Unit (ECU) based condition automotive starters. Elsevier Science.
monitoring and fault diagnosis of starting system for
improved battery life, starter motor service life, starter [10] Wang W.L. 2008. FEA-based Structure Optimization
reliability and safety. In addition to that some of the safety for the Drive End Housing of an Automotive Starter.
features like enhanced seat belt reminders, gear neutral IEEE International Computer Society. pp. 447-450.
position, head lamp off positions, bonnet locked condition
and engine running can be checked before attempt to start [11] Syed Sajjad H. Zaidi and Selin Aviyente. 2009.
the engine to avoid damage to vehicle and passengers. The Failure Prognosis of DC Starter Motors Using Hidden
ECU based starting system has potential to be used for real Markov Models.
time condition monitoring and fault diagnosis of vehicles
with the help of industrial computers to overcome [12] Qusai Abu-Ein, Suleiman Abu-Ein, Sayel M. Fayyad
unexpected vehicle idle due to starting system faults. and Ghazi Al-Marahlehand Waleed Al-Momani.
2009. Automobile Functions Control System via
ACKNOWLEDGEMENT Bluetooth Utility. Australian Journal of Basic and
Applied Sciences. 4: 3273-3282.
Authors wishes to thank Council of Scientific and
Industrial Research (CSIR), New Delhi, India for financial [13] 1976. US patent No. 3, 968, 425. Measuring Ignition
support to this research work. Timing Using Starter Current. pp. 1-12.

818
 VOL. 7, NO. 7, JULY 2012 I SSN 1819- 6608
ARPN Journal of Engineering and Applied Sciences
© 2006- 2012 Asian Resear ch Publishing Net wor k ( ARPN) . All right s reser ved.

www.arpnjournals.com

[14] 1977. US patent No. 4, 050, 297. Measuring Electrical

Parameters of an Internal Combustion Engine during
Cranking. pp. 1-13.

[15] 1979. US patent No. 4, 144, 746. Method for

Determining a Measurement value Proportional to the
Compression of an Internal Combustion Engine. pp.
1-8.

[16] 1996. US patent No. 5, 585, 717. Method for

Measuring Starter Motor Current to Determine Engine
Status. pp. 1-5.

[17] 1951. US patent No. 2, 560, 094. Starter Motor

Control System. pp. 1-4.

[18] 1998. US patent No. 5, 742, 137. Starter Motor

Control Circuit and Method. pp.1-10.

[19] US patent No. 6, 050, 233. Controller for a Vehicle

Starter Motor. pp. 1-6.

[20] 1997. US patent No. 5, 703, 551. Starter Contactor

having an Electric Control Circuit, and a Vehicle
Starter having such a Contactor. pp. 1-8.

[21] 1999. US patent No. 6, 003, 484. Device for

Controlling an Automobile Vehicle Starter Motor
Contactor. pp. 1-6.

[22] 2001. US patent No. 6, 229, 415 B1. Contactor for a

Motor Vehicle Starter, having Improved Protection for
an Electronic Circuit of the Contactor. pp. 1-6.

819