Development of starting and charging system tester / by Gionico A. De Asis and Jarem A. Leoncito.

Design Project (Bachelor of Industrial Technology Major in Automotive Technology) Cavite State University.

Includes bibliographical references.

College of Engineering and Information Technology (CEIT), Department of Industrial Engineering and Technology

DE ASIS, GIONICO A. and LEONCITO, JAREM A., Development of Starting and Charging System Tester, Undergraduate Design Project. Bachelor in Industrial Technology major in Automotive Technology. Cavite State University, Indang, Cavite. May 2019. Adviser: Mr. Danielito R. Escajio.

The starting system of an automotive engine starts from the crankshaft and must turn fast enough for air-fuel mixture to enter the cylinders; the starting motor does this job. It converts electrical energy from the battery into mechanical energy that rotates the crankshaft. The starting motor has two basic parts: the armature and field-frame assembly. The armature is the rotating assembly that includes the main current-carrying conductors. Field windings in the electromagnet starting motor produce a strong magnetic field when battery current flows through them. When current flows, the armature windings and field windings or magnets produce opposing magnetic fields. These forces the armature to rotate and crank the engine. The current flows in through the large terminal on the starting motor. Then, the current flows through the field windings and insulated brush to the commutator.

The purpose of the charging system is to restore the battery charge removed from cranking the engine. Also, it handles the load of the ignition, lights, radio and other electrical and electronic equipment while the engine is running. One of the major
the components of the charging system are the alternator. The alternator converts mechanical energy from the engine into electrical energy. It usually mounts beside the engine. The engine crankshaft pulley drives the alternator the alternator through a belt at two to three times crankshaft speed.

The main objective of the design project was to design, construct and develop a starting and charging system tester. The design project was developed to ease the difficulties identifying the functionality of a starter motor and alternator for instructor and students. The impact of the study is that the students will have broader knowledge on the principles on how the starting and charging system operates.

The components needed for the design project were gathered, the frame was constructed. It has a dimension of 35” x 30” x 45”. The alternator mounted in the upper part of the frame was aligned with the AC motor. The starter and the flywheel mounted at the right side of the frame. The disassembled parts of starter motor and alternator were placed in the pull-out drawers. The barbell disc was attached to the flywheel that serves as the counter weights. It also serves as a weight of crankshaft, and compression of an engine. The AC motor was mounted on the top of the plywood under the main table, the holes was drilled off same as the mounting holes of the AC motor. The brace of alternator
was mounted aligned with the AC motor. The mounting of alternator was placed above and side corner of the table. The hole was bored to the mounting of about 14mm for different alternator to be tested. It was aligned by means of tension belt to prevent wobbling of the belt. After all the components were mounted, the proponents installed the electrical wires that served as the connection of all power that comes from the battery, connections for the starting system and the connection for the cranking of the starter motor.

The starter motor was connected to the battery which is the main source of power to crank the starter in a short period. It can test the capacity of starter motor through the use of the barbell that served as the power output. The alternator serves as the charging component of the design project. The three different sockets are fixed in the design

project for replacement of 3 different alternators. The alternator gives 14.5v when charging the battery, to supply and charged the battery while it consumes or discharging by means of loads. Three batteries have initial voltage of 10v to record the reading of each alternator. The first alternator has a reading of 0.60 voltage per minute; the second alternator has a reading of 0.65 voltage per minute while the third alternator has a reading of 0.60 voltage per minute. Each alternator has the same capacity to fully charge the battery. Given a specific time for each alternator the voltage rating is determined.

Based on the design project functionality, workability, durability and safety, the evaluated average was 4.66 which correspond to outstanding degree of level. According to the results of the design project evaluation, the evaluators recommend providing an external voltage regulator for alternator tester; adjustable brace for wide variety of starter motors; provide braking mechanism for starter weights; make the tester compatible with 24v starter motor and alternator; and provide a built-in voltage meter/gauge or multitester

Submitted to the University Library 09-12-2019 DP-737