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Automotive Starting Motor
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RNM is a Industrial Engineer, Engineering Manager, Product Engineer with world-class expertise in project management, product development, market development, technology based products, hybrid vehicle motors, distributed energy system PM generators, light and heavy duty vehicle electric systems.
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This case study covers the product development program for a new lightweight starter for passenger cars that this consultant was assigned to as program manager. The program had two primary goals – reduce weight by 25% and reduce cost by 20%. In addition, management wanted to build the new starter in a greenfield location to take advantage of new labor concepts.
A new team was put together to design, build and test the motor. The program was successful in every respect, achieving all goals on weight and cost. The design for manufacturing concepts facilitated new methods in the plant that achieved record levels of efficiency.
The cost and weight goals were met by new design concepts in insulation systems, materials, material handling, and improved manufacturing methods, and material handling systems. Some of the new concepts were:
- Pre-insulated armature conductor. The wire suppliers applied the insulation paper and overcoated it with b-stage epoxy. The supplier also shipped the wire in large 3500 lb. containers which would last a full shift before needing a new reel.
- The field coil conductor was wrapped with Nomex insulation in our plant and ultra-sonic welded to form a seam. The field coils were then joined together via sonic welding.
- The motor frame was compacted from powdered iron and sintered in a precisely controlled atmosphere. The sintered frame was pressed into an outer tube.
- The powdered metal frame and aluminum field coils were the primary contributors to the weight savings we achieved
This starter, the 5MT, was built in Meridian MS for about 20 years and became the high-volume profit leader for Delco Remy starting motors.
Read other articles by this KKAI Associate:
Electric Propulsion System Team
Materials Engineering - Cost Savings
| Industrial Engineer, Engineering Manager, Product Engineer, project management, product development, market development, technology based products, hybrid vehicle motors, distributed energy system PM generators, light and heavy duty vehicle electric systems. | |
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Kevin Kennedy & Associates, Inc.
Rapid Response Engineering® Solutions
3905 Vincennes Road, Suite 320
Indianapolis, Indiana 46268
(317) 536-7000 voice
(317) 536-7220 fax