Name: starter motor
Model: Tvs king gs
Quality: A Plus
Delivery: 30 days
Warranty: 3 months
Components of starter motor and quality control
The core components of a motor and their quality control are the key to ensuring the performance, reliability and life of the motor. The following is a summary of the main components of a motor and their quality control points:
1. Main components
(1) Stator, composed of stator core, stator winding, insulation material and other accessories. The main function is to generate a rotating magnetic field and drive the rotor to rotate.
Quality control points:
Core lamination quality: Ensure that the silicon steel sheets are tightly laminated to avoid loosening or deformation, and reduce eddy current loss8.
Winding insulation: Use high temperature and corrosion resistant insulation materials, and perform voltage resistance tests to prevent short circuits or breakdown2.
Coaxiality: The coaxiality between the inner circle of the stator and the stop of the base must be strictly controlled to ensure uniform air gap8.
(2) Rotor
Function: Rotate under the action of the magnetic field and output mechanical energy.
Key points for quality control:
Dynamic balancing test: avoid vibration or noise caused by uneven mass distribution28.
Fit between core and shaft: ensure interference fit accuracy to prevent looseness or eccentricity8.
Surface roughness: bearing and core positions need to be precisely machined to reduce friction loss8.
(3) Bearing system
Composition: bearing, end cover bearing chamber, inner and outer bearing covers.
Function: support rotor rotation and reduce friction.
Key points for quality control:
Bearing fit tolerance: avoid overtightening (causing heat) or overloosening (causing running circles)8.
End cover bearing chamber accuracy: ensure that the fit with the outer ring of the bearing meets the standard to prevent vibration or abnormal wear8.
Lubrication management: select appropriate grease and perform regular maintenance9.
(4) Shaft
Function: transmit torque and support rotor rotation.
Key points for quality control:
Coaxiality and circular runout: key parts such as bearing and core positions need to be machined with high precision8.
Material strength: Use high-strength alloy steel and perform heat treatment to improve wear resistance8.
(5) Frame & End Shield
Function: Support and protect the internal structure of the motor.
Key points for quality control:
Speed coaxiality: The coaxiality between the spigots at both ends of the frame and the core position must be strictly controlled8.
End shield rigidity: Avoid deformation of thin-walled structures during processing or assembly8.
(6) Collector ring and commutator (applicable to wound-rotor motors)
Function: Transmit current to the rotor winding.
Key points for quality control:
Surface finish: Reduce brush wear and sparks8.
Installation accuracy: Ensure coaxiality with the rotor to avoid runout or poor contact8.
2. Key quality control methods
Process control (SPC)
Use statistical process control (SPC) to monitor key dimensions (such as coaxiality and circular runout)6.
First-article inspection and patrol inspection
The first piece of each batch needs to be fully inspected, and regular sampling is carried out during the production process2.
Assembly verification
After assembly, test parameters such as no-load current, vibration, and noise2.
Material and supplier management
Strictly review raw material suppliers to ensure that silicon steel sheets, copper wires, etc. meet standards3.
ISO 9001 quality management system
Establish a total quality management (TQM) system covering the entire process of design, production, and inspection10.
3. Common quality problems and improvement measures
Problem Cause Improvement measures
Uneven air gap Deformation of the base, assembly error Improve the base processing accuracy and optimize the assembly process8
Bearing overheating Too tight/loose fit, poor lubrication Optimize tolerance design and strengthen lubrication management8
Winding short circuit Poor insulation, process defects Strengthen insulation testing and improve winding process2
Vibration and noise Poor dynamic balance, bearing wear Strictly implement dynamic balance test and replace bearings regularly8
Conclusion
The quality control of the core components of the motor (stator, rotor, bearing, shaft, etc.) directly affects the performance and life of the motor. Through strict processing accuracy management, process control (SPC), material screening and ISO quality management system, the reliability of motors can be effectively improved. In the future, intelligent detection (such as AI visual detection) and green manufacturing (low-loss materials) will become industry trends.
Common faults and cause analysis and solutions of the starter motor
The starter motor is the core component of the internal combustion engine starting system of automobiles, construction machinery, etc. Its reliability directly affects the starting performance of the engine. The following are common faults, cause analysis and solutions of the starter motor:
1. The starter motor does not work (no response)
Possible causes:
Battery problem: insufficient power, corrosion or loose terminal.
Starter relay/electromagnetic switch failure: contact burnout, coil open circuit.
Internal motor open circuit: brush wear, excitation coil or armature winding open circuit.
Ignition switch failure: signal is not transmitted to the starter relay.
Solution:
Check the battery voltage (≥12V) and clean the electrode connector.
Short-circuit the two main contacts of the electromagnetic switch. If the motor runs, replace the relay.
Disassemble the motor and check the brushes, commutator and winding on and off.
2. The starter motor is idling (not driving the engine)
Possible causes:
One-way clutch (overrunning clutch) slips: roller or spring damage.
Drive gear is worn: cannot mesh with flywheel gear ring.
Electromagnetic switch fork is broken or stuck: cannot push drive gear.
Solution:
Replace one-way clutch assembly.
Check if drive gear and flywheel gear ring are worn (replace if necessary).
Lubricate or replace electromagnetic switch fork mechanism.
3. Starter motor is weak
Possible causes:
Battery is low: difficult to start when voltage is lower than 9.6V.
Poor line contact: ground wire is loose or main cable resistance is too large.
Problems inside motor:
Brush wear (poor contact).
Commutator burns (causing spark increase).
Armature winding short circuit (abnormal current).
Solution:
Charge or replace battery, check cable resistance (≤0.5Ω).
Disassemble motor, replace brushes, grind or turn commutator.
Use multimeter to check if armature winding is short circuit.
4. Abnormal noise during startup (tooth knocking, metal friction)
Possible causes:
Poor meshing between the drive gear and the flywheel gear ring: gear wear or misalignment.
Loose motor fixing bolts: resulting in gear meshing angle deviation.
Wear of bearings or bushings: excessive radial runout of the armature shaft.
Solution:
Check whether the flywheel gear ring is missing teeth or chamfer wear.
Tighten the motor mounting bolts and adjust the gasket to ensure meshing clearance.
Replace the motor bearing or bushing (copper sleeve).
5. The motor does not stop turning after starting
Possible causes:
The electromagnetic switch contacts are sticky: the current cannot be cut off.
Ignition switch return failure: continuous power supply.
Relay stuck: unable to disconnect the circuit.
Solution:
Immediately disconnect the negative pole of the battery to prevent burning of the motor.
Replace the electromagnetic switch or relay.
Check whether the ignition switch signal is normal.
6. Other common problems
Fault phenomenon Possible cause Solution
Severe motor heating Long start, internal short circuit Avoid continuous start > 5 seconds, check winding insulation
Leakage or smoke Insulation aging, coil burnt Replace motor assembly
Intermittent failure Line connection, poor brush contact Check line, replace brush
Preventive maintenance suggestions
Check the battery regularly: keep the battery fully charged and clean the electrodes.
Avoid long start: start for no more than 5 seconds each time, with an interval of more than 30 seconds.
Listen carefully to the start sound: repair in time if abnormal sound is found.
Replacement cycle: It is recommended to check/replace the starter motor every 100,000 kilometers for commercial vehicles.
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