Analysis And Countermeasures Of DEUTZ Type Engines’ Starter Failures

Starter plays an important role in the course of engine starting, the starter includes three parts such as dc series motor, transmission mechanism and control device. Motor is introduced into current from the battery and make the gear on the starter motor produces mechanical movement; transmission mechanism will drive the gear into the flywheel ring gear, The flywheel rotated and start the engine, and the gear can automatically release after the engine start, this will ensured the starter won’t be hurt when the flywheel speed if far more away then the starter drive gear starting after the vehicle is running.Despite of different types of automobile use different form starters, but their dc series motor parts are similar, the main difference is the transmission mechanism and control devices. Starter failures is a very big quality problem for the users during they use a vehicle, my company is en engine production enterprises, in the past complains from our customers because of the starter quality and replacement requirements have been many times, the company not only made great economic losses but also effects the reputation of the company.In this thesis, through the analysis of the zero kilometers and social feedback of the starter failure modes, locking the three major quality problems affecting starter failure points, including relay failure (shown as switch failure), the armature ablation and broken of back cover. By means of the data analysis it is found that the three kinds of quality problems account for76%of the total feedback problem. So analysis of the three failure mode and fix them are extremely valuable. The fishbone diagram analysis method is used and the test data is statistically analyzed in the thesis. For each of these three types of problems I formulated the improvement measures such as the changing of the armature insulated paper level and the iron core structure, improving of the relay waterproof design, changing of the starter shaft structure and improvement scheme and the design plan.By the final experiment results and social feedback failure rate, the effect of improvement is very good, starter’s3MIS failure rate and0-h failure become lower significantly.