Analysis of Automobile Starter Solenoid Switch for Improved Life

Abstract

The purpose of this paper is to present an experimental study of simple geometries representing the electrical contact in automotive connectors when current passes through them. The starting system is designed to provide the vehicle operator with a convenient, efficient and reliable means of cranking and starting the internal combustion engine used to power the vehicles and all of its accessory systems from within the safe and secure confines of the passenger compartment. The starting system consists of two separate circuits, high amperage circuit (150A–350A) and low amperage circuit (< 20A). Since foresaid circuit involves high current low voltage system, the starter motor solenoid contact will observe high current at their contacts. So this high current makes pitting effect and lead to increase in solenoid contact resistance. Due to increased contact resistance the starter motor may not produce sufficient torque and leads to overloading of battery due to successive attempts. In order to overcome this problem, a new model for solenoid switch contact has been developed using finite element modelling method ANSYS Parametric Design Language to reduce the internal resistance of the battery due to overloading because of increased contact resistance at the solenoid contact points. The obtained results are useful for finding a compromise between the electrical and mechanical aspects for a power connector and to help manufacturers to decrease the weight and the electrical contact resistance of their connectors.