Starting system

STARTING SYSTEM AND MOTOR DESIGN

• DC MOTOR PRINCIPLES
• DC MOTOR FIELD WINDINGS
• STARTER DRIVES
• CRANKING MOTOR CIRCUITS
• AC MOTOR PRINCIPLES
• INTERGRATED STARTER GENERATOR
 ENGINE STARTING REQUIREMENTS

• Combustion mixture
• Compression stroke
• A form of ignition
• The minimum starting speed of (about
100rpm)
• In order to achieved the first three, the
minimum starting speed must be achieved
• This is where the electric motor starter is
applied.
• The motor is a direct current motor which we
be discussed in detail.
 Factors influencing minimum speed

The ability to reach this minimum speed is

dependent on the following factors
• Rated voltage of the starting system
• Lowest possible temperature at which it must
be possible to start the engine.(starting limit
temperature)
• Engine cranking resistance .“torque required”
• Battery capacity
• Battery capacity
• Voltage drop between the battery and the
starter
• Start-to-ring gear ratio
• Characteristics of the starter
• Minimum cranking speed of the engine at the
starting limit temperature.
 DC MOTOR PRINCIPLES
• The direct current (dc) machine can be used as a
motor or as a generator.
• DC Machine is most often used for a motor.
• The major advantages of dc machines are the easy
speed and torque regulation.
• However, their application is limited to mills, mines
and trains. As examples, trolleys and underground
subway cars may use dc motors.
• In the past, automobiles were equipped with dc
dynamos to charge their batteries.

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 DC Motor
• Even today the starter is a series dc motor
• However, the recent development of power
electronics has reduced the use of dc motors and
generators.
• The electronically controlled ac drives are gradually
replacing the dc motor drives in factories.
• Nevertheless, a large number of dc motors are still
used by industry and several thousand are sold
annually.

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 DC Motor Construction

Figure 8.1 General arrangement of a dc machine

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• The stator of the dc motor has
poles, which are excited by dc
current to produce magnetic fields.
• In the neutral zone, in the middle
between the poles, commutating
poles are placed to reduce
sparking of the commutator. The
commutating poles are supplied by
dc current.
• Compensating windings are
mounted on the main poles. These
short-circuited windings damp
rotor oscillations. .

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• The poles are mounted on an
iron core that provides a closed
magnetic circuit.
• The motor housing supports
the iron core, the brushes and
the bearings.
• The rotor has a ring-shaped
laminated iron core with slots.
• Coils with several turns are
placed in the slots. The
distance between the two legs
of the coil is about 180 electric
degrees.

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• The coils are connected in series
through the commutator
segments.
• The ends of each coil are
connected to a commutator
segment.
• The commutator consists of
insulated copper segments
mounted on an insulated tube.
• Two brushes are pressed to the
commutator to permit current
flow.
• The brushes are placed in the
neutral zone, where the magnetic
field is close to zero, to reduce
arcing.

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 • The rotor has a ring-shaped
laminated iron core with slots.
• The commutator consists of
insulated copper segments
mounted on an insulated tube.
• Two brushes are pressed to the
commutator to permit current
flow.
• The brushes are placed in the
neutral zone, where the
magnetic field is close to zero,
to reduce arcing.

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• The commutator switches the
current from one rotor coil to
the adjacent coil,
• The switching requires the
interruption of the coil current.
• The sudden interruption of an
inductive current generates
high voltages .
• The high voltage produces
flashover and arcing between
the commutator segment and
the brush.

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 Figure 8.3 Details of the commutator of a dc motor.
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 Figure 8.5 Rotor of a dc motor.
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 Figure 8.4 DC motor stator with poles visible.
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 DC MOTOR FIELD WINDINGS

• Series-Wound Motors
• Shunt wound motors
• compound wound motor
• permanent magnet motor
 Series-Wound Motors

• Most starter motors are series-wound with

current flowing first to the field windings, then
to the brushes, through the commutator and
the armature winding contacting the brushes
at that time, then through the grounded
brushes back to the battery source. This
design permits all of the current that passes
through the field coils to also pass through the
armature
 series-wound
A series-wound motor will develop
its maximum torque output at the
time of initial start. As the motor
speed increases, the torque
output of the motor will decrease
 Shunt wound motors
• Electric motors, or shunt motors, have the field
windings wired in parallel across the armature. Shunt
means there is more than one path for current to flow.
A shunt-wound field is used to limit the speed that the
motor can turn. A shunt motor does not decrease in its
torque output as speeds increase
• Due to a shunt motor’s inability to produce high
torque, it is not typically used as a starter motor.
• However, shunt motors may be found as wiper motors,
power window motors, power seat motors, and so on.
Shunt wound
 compound wound motor
• In a compound motor most of the field coils
are connected to the armature in series and
one field coil is connected in parallel with the
battery and the armature. This configuration
allows the compound motor to develop good
starting torque and constant operating
speeds. The field coil that is shunt wound is
used to limit the speed of the starter motor.
 permanent magnet motor
• A permanent magnet motor has only an armature circuit, as the
field is created by strong permanent magnets.
• Most newer vehicles have starter motors that use permanent
magnets in place of the field coils.
• These motors are also used in many different applications. When a
permanent magnet is used instead of coils, there is no field circuit
in the motor.
• By eliminating this circuit, potential electrical problems are also
eliminated, such as field-to-housing shorts.
• Another advantage to using permanent magnets is weight savings;
the weight of a typical starter motor is reduced by 50%. Most
permanent magnet starters are gear-reduction-type starters.
permanent magnet motor
 DC Motor Operation

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 Recap
• Faraday law of induction
• Flemings’ left hand rule
• A simple electromagnet-style starter motor is shown
above . The inside windings are called the armature.
• The armature is the moveable component of the
motor that consists of a conductor wound around a
laminated iron core.
• It is used to create a magnetic field. The armature
rotates within the stationary outside windings, called
the field coils, which has windings coiled around pole
shoes.
• Field coils are heavy copper wire wrapped around an
iron core to form an electromagnet. Pole shoes are
made of high-magnetic permeability material to help
concentrate and direct the lines of force in the field
assembly.
 DC Motor Operation
• In a dc motor, the stator
poles are supplied by dc Rotation
Ir_dc/2
Ir_dc/2 Ir_dc
excitation current, which Brush Pole
winding
produces a dc magnetic Shaft

field. |

• The rotor is supplied by dc

1
2
8

current through the N 7

6
3
S
brushes, commutator and 5
4

coils.
• The interaction of the Insulation
Rotor
Copper
segment
Ir_dc
magnetic field and rotor Winding

current generates a force

that drives the motor

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 DC Motor Operation
v B
• The magnetic field lines enter a

into the rotor from the north S 1

N
pole (N) and exit toward the 30 Vdc
2
south pole (S). b
• The poles generate a v
magnetic field that is Ir_dc
perpendicular to the current (a) Rotor current flow from segment 1 to 2 (slot a to b)
carrying conductors.
• The interaction between the B

field and the current produces a

a Lorentz force, S
v 30
2
v
N Vdc
• The force is perpendicular to 1

both the magnetic field and b

conductor Ir_dc

(b) Rotor current flow from segment 2 to 1 (slot b to a)

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 DC Motor Operation
v B
• The generated force turns the rotor a

until the coil reaches the neutral

S 1
N Vdc
point between the poles. 30
2
• At this point, the magnetic field
b
becomes practically zero together v
with the force. Ir_dc
• However, inertia drives the motor
(a) Rotor current flow from segment 1 to 2 (slot a to b)
beyond the neutral zone where the
direction of the magnetic field B
reverses. a

• To avoid the reversal of the force

S 2 N Vdc
direction, the commutator changes v
1
30 v
the current direction, which b
maintains the counterclockwise
rotation. . Ir_dc

(b) Rotor current flow from segment 2 to 1 (slot b to a)

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 DC Motor Operation
• Before reaching the neutral zone, v
a
B
the current enters in segment 1 and
exits from segment 2, S 1
30
N Vdc
• Therefore, current enters the coil
2

end at slot a and exits from slot b b

during this stage. v

Ir_dc
• After passing the neutral zone, the
current enters segment 2 and exits (a) Rotor current flow from segment 1 to 2 (slot a to b)
from segment 1, B
• This reverses the current direction a

through the rotor coil, when the

S 2 N Vdc
coil passes the neutral zone. v
1
30 v

• The result of this current reversal is b

the maintenance of the rotation.

Ir_dc

(b) Rotor current flow from segment 2 to 1 (slot b to a)

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 Starting system
• The starting system is a combination of
mechanical and electrical parts that work
together to start the engine.
• The starting system is designed to change
the electrical energy, which is being stored in
the battery, into mechanical energy.
• To accomplish this conversion, a starter or
cranking motor is used.
The starting system includes the following
components:
• Battery.
• Cable and wires.
• Ignition switch.
• Starter solenoid or relay.
• Starter motor.
• Starter drive and flywheel ring gear.
• Starter safety switch.
Starter and solenoid components
Simple starting system
Equivalent circuit for Starter system
Starter system layout
 Starter drivers
• The starter drive is the part of the starter
motor that engages the armature to the
engine fly-wheel ring gear. A starter drive
includes a pinion gear set that meshes with
the flywheel ring gear on the engine’s
crankshaft.
 Cranking Motor Designs
The most common type of starter motor used
today incorporates the overrunning clutch
starter drive instead of the old inertia-
engagement bendix drive. There are four basic
groups of starter motors:
• Direct drive.
• Gear reduction.
• Positive-engagement (moveable pole).
• Permanent magnet.
 Task
• Review the four basic groups of starter
motors.
 AC motors
• Like the DC motor, the AC motor uses a stator
(field winding) and a rotor. Common types of AC
motors are the synchronous motor and the
induction motor.
• In both motor types, the stator comprises
individual electromagnets that are either
electrically connected to each other or connected
in groups.
• The difference is in the rotor designs. AC motors
can use either single-phase or three-phase AC
current
• As in a DC motor, the movement of the
rotor is the result of the repulsion and
attraction of the magnetic poles. However,
the way this works in an AC motor is very
different. Because the current is
alternating, the polarity in the windings
constantly changes.
 Construction
• The stator is similar in construction that of a induction motor

• The rotor can be Salient or Non-Salient (cylindrical rotor)

• Field excitation is provided on the rotor by either permanent or

• electromagnets with number of poles equal to the poles of the
• RMF caused by stator

• Non-excited rotors are also possible as in case of reluctance

motors
Synchronous Machine
Construction

synchronousmachine
 principle of operation
• The principle of operation for all three-phase
motors is the rotating magnetic field. The
rotor turns because it is pulled along by a
rotating magnetic field in the stator.
The stator is stationary and does not physically
move. However, the magnetic field does move
from pole to pole. There are three factors that
cause the magnetic field to rotate.
• the voltages in a three-phase system are 120
degree out of phase with each other.
• the three voltages change polarity at regular
intervals.
• the arrangement of the stator windings
around the inside of the motor.
 Task
Note the similarities and differences between
Synchronous Motors and Induction Motors
 Integrated Starter Generator
• One of the newest technologies to emerge
is the integrated starter generator (ISG).
Although this system can be used in
conventional engine-powered vehicles,
one of the key contributors to the Hybrid’s
fuel efficiency is its ability to automatically
stop and restart the engine under different
operating conditions
• The ISG performs many functions such as fast,
quiet starting, automatic engine stops/starts to
conserve fuel, recharges the vehicle batteries,
smoothes driveline surges, and provide
regenerative braking.
• The ISG can also convert kinetic energy from AC
to DC voltage. When the vehicle is traveling
downhill and there is zero load on the engine,
the wheels can transfer energy through the
transmission and engine to the ISG. The ISG then
sends this energy to the HV battery for storage
• An ISG can be mounted
externally to the engine and
connected to the crankshaft
with a drive belt. This design is
called a belt alternator starter
(BAS). In these applications, the
unit can function as the engine’s
starter motor as well as a
generator driven by the engine.
• Both the BAS and the ISG use
the same principle to start the
engine.