Starter Solenoid Manufacturing and Production Standard
This Starter Solenoid Manufacturing Standard is issued by Chinese Ministry of Industry and Information Technology. The standard reference code is QC/T 810-2009.
This guide is designed to help Chinese starter solenoid manufacturers manage their production of car starter solenoid switch. The test methods and inspection ways in this guide are not only beneficial for the manufacturers’ production management, it also can be useful for people who need to source starter solenoid.
Through this guide, you will be very knowledgeable on the car starter solenoid inspection and do better than 90% of the other buyers who intend to sourcing starter solenoid from China.
This standard specified the test methods, inspection way, standards, and packaging for transport and storage.
This standard applies to the car starter motor solenoid switch.
2. Reference document
The following documents contain provisions which, through reference to this standard constitute provisions of this standard.
QC/T413-2002 Basic Technical Specifications for Automotive Electrical Equipment
QC/T731-2005 Basic Technical specifications for Car Starter Motor
GB/T 4942.1-2006 Protection Degree(IP Code) of the Rotating Electrical.
GB/T 2828.1 Sampling Procedures
3.1 General Requirement
Starter solenoid switch must conform to the requirements of this standard and manufacturing drawings and technical documents approved by the rulemaking.
The solenoid materials should be consistent with the corresponding material standards and customer requirements, the material shall not contain asbestos and cadmium metal, mercury, lead, hexavalent chromium.
3.3 Single and double-wire
single wire method is generally used in the solenoid, negative ground. For special needs, the double-wire method can also be applied after consulting with the manufacturer.
3.4 Operating Condition
The solenoid should be able to work under the following conditions:
Operating temperature: -40°C ~ + 105°C
Operating humidity: over 96%
3.5 Shape and Install dimension
The solenoid shape and install dimension shall meet the product technical requirements.
3.6 Rated Operating Time
The solenoid is the short-time duty, rated operating time is 30 seconds.
3.7 Surface protection performance & Assembly quality
3.7.1 The solenoid surface protection performance shall meet the requirement 3.15 of QC/T 413-2002.
3.7.2 The fasteners of the solenoid cannot be loosened after assembling. Tightening torque of the threaded fasteners shall conform to related requirements QC/T 731-2005 in or according to the customers’ requirements.
3.8 Cutoff and Release voltage
3.8.1 At the ambient temperature of 23°C ± 5°C, the solenoid switch is closed and the voltage shall comply with the requirements of Table 1.
|Cutoff voltage (V)||≤8.4||≤16.8|
|Release voltage (V)||≤4.8||≤9.6|
3.8.2 At the ambient temperature of 105, the closing voltage of the solenoid switch shall be in accordance with Table 2.
|Cutoff voltage (V)||≤10.8||≤21.6|
3.9 Degree of protection
The starter solenoid’s degree of protection is the IP54 that specified in GB / T 4942.1 – 2006. And its performance shall meet the requirements of 3.8.1 of this standard after the protection grade test.
3.10 Vibration resistance
The starter solenoid should be subjected to the vibration test in three directions of X, Y, and Z. The severity of the vibration test shall comply with the requirements of Table 3, “Installation on the engine” in QC / T 413-2002. After the testing, the solenoid should be no damage, torque changes of fastener tightening should not exceed 50%, the performance should be consistent with the provisions of this standard 3.8.1.
3.11 Low-temperature endurance
The low-temperature endurance test of the starter solenoid shall conform to the provisions of 3.10.1 in QC / T 413-2002 and the lowest storage temperature is -40 °C. After the low-temperature endurance test, the starter solenoid performance should meet the requirements of 3.8.1 in this standard.
3.12 High-temperature endurance
Starter solenoid high-temperature endurance test should be consistent with the provisions of 3.10.2 in QC / T413-2002. The highest storage temperature is 130°C. After the high-temperature endurance test, the starter solenoid performance shall meet the requirements of 3.8.1 in this standard.
3.13 Thermal Shock Resistance
Thermal Shock Test of the starter solenoid shall conform to the provisions of 4.13 in QC / T 731-2005. After the test, the performance shall meet the requirements of 3.8.1 of this standard.
3.14 Temperature & Humidity Resistance
Starter solenoid temperature and humidity test should be consistent with the provisions of 3.11 in QC / T413-2002. After the test, the performance should be consistent with the provisions of this standard 3.8.1.
3.15 Corrosion resistance
Starter solenoid should be able to withstand 96h salt spray test. The performance after the test shall comply with the requirements of 3.8.1 in this standard.
3.16 Dielectric voltage withstand performance
Starter solenoid dielectric voltage withstands performance should be consistent with the provisions of 4.16 in QC / T731-2005. The value of leakage current should be less than 10mA.
For the starter solenoid that have the extra gastight requirements, its airtight performance should meet the customer’s product technical requirements.
3.18 Contact resistance
When 200A current flow through the main contact of the starter solenoid, the resistance value of two main contacts should be less than 1mΩ.
3.19 Additional Stroke
When the main contacts of the solenoid are closed, there should be additional stroke provisions, which should meet the technical requirements.
3.20 suction Force
The suction force of the starter solenoid should meet the technical requirements of the product.
3.21 Power outage performance
The starter solenoid should have the ability to power off.
3.22 Roughness of core surface
The roughness of the solenoid iron core surface should meet the requirements of the drawing. When the solenoid switch work, the core should be able to move flexibly and no any stuck.
The durability of the starter solenoid should meet the technical requirements of the starter.
4. Test Method
4.1 General testing condition
A The accuracy class of voltmeter and ammeter that used to test the solenoid shall not be lower than Class 0.5, the measuring instrument should not be lower than class 1.0. Unless there is specified provision, the test ambient temperature should be 23°C ± 5°C
4.2 Installation dimensions inspection
The solenoid installation dimensions should be checked by the measuring tool that meets the accuracy requirements of the pattern.
4.3 Rated operating time
Install the starter solenoid to the matching starter, test it according to the provisions of 5.2 in QC / T731-2005.
4.4 Surface protection and assembly quality inspection
4.4.1 Starter solenoid surface protection performance should be checked according to the provisions of 4.15 in QC / T413-2002.
4.4.2 Assembly quality of the solenoid should be checked with a dedicated measuring instrument.
4.5. Cutoff voltage test
4.51. Check the solenoid with the starter together according to provisions 5.20.1 in QC / T731-2005.
4.5.2. The starter solenoid closed voltage inspection should be carried out on a dedicated test bench. Allows the starter solenoid coils in series a series resistor(simulate the resistance of the starter), measure the voltage value of the solenoid, while it makes the suction force under the specified air gap.
4.6 Release voltage test
4.6.1 Check the solenoid with the starter together according to provisions 5.20.2 in QC / T731-2005.
4.6.2 The starter solenoid released voltage inspection should be carried out on a dedicated test bench. After the cutoff voltage test, reduce(starting from the cutoff voltage) the power supply voltage gradually until the solenoid switch main contact points are disconnected. At this point, the voltage value is the release voltage.
4.7 High-temperature cutoff voltage test.
At the ambient temperature of 105, the test shall be carried out in accordance with Provision 4.5 in this standard.
4.8 Ingress protection rating test
Ingress protection rating test should be carried out in accordance with provision GB/T492.1-2006.
4.9 Vibration resistance
The vibration resistance test should be carried out according to the provisions 4.12 in QC / T 413-2002.
4.10 Low-Temperature Endurance Test
The low-temperature endurance test should be carried out according to the provisions 4.10.1 in the QC/T413-2002.
4.11 High-Temperature Endurance Test
The High-temperature endurance test should be carried out according to the provisions 4.10.2 in the QC/T413-2002.
4.12 Temperature Shock Test
The temperature shock test should be carried out according to the provisions 5.11 in the QC/T731-2005.
4.13 Temperature & Humidity Resistance
The solenoid temperature and humidity test should be carried out according to the provisions of 4.11 in QC / T413-2002.
4.14 Salt Spray Test
Salt Spray Test should be carried out according to the provisions of 4.13 in QC / T413-2002.
4.15 Dielectric voltage withstand test
Dielectric voltage withstands test should be carried out according to the provisions 5.13 in QC / T731-2005. And the test should be performed before welding the solenoid coil ground wire.
Sealing the starter solenoid from the bottom and adding specified air pressure. Then put the solenoid switch in the water, in the customers can also request a dedicated bed. Check whether there are bubbles in the water in the specified time. Also, the test can be performed in the dedicated test bench if the customer requested. The specified air pressure and test time should be in accordance with the product specifications.
4.17 Contact resistance value test.
The Test should be carried out according to the provisions of 4.13 in QC / T413-2002.
4.18 Additional stroke test
Tests should be carried out on a dedicated test bench. Measure the distance from the start of the main contact cutoff to the movable iron core to the extreme position.
4.19 Suction force test
Tests should be carried out on a dedicated test bench. Under the specified air gap, apply the specified voltage in the starter solenoid, and hang on the counterweight on the movable iron core, to check the suction force.
4.20 Power outage test.
Tests should be carried out on a dedicated test bench. With the matching starter braking current value through the starter solenoid main contact, disconnect the starter solenoid voltage, the main contact should be able to immediately disconnect.
4.21 Roughness of core surface Check
Check with roughness tester or compare with the sample.
4.22 Durability test
Install the starter solenoid in the matching starter, test the solenoid according to provision 5.17,5.15,5.19 in the QC/T 731-2005.
5.1 Quality assurance should be carried out according to provision 3.7/3.8.1/3.19. The product can only not leave the manufacturer until it passed all the quality test and should be attached with Product certification.
5.2 The client should perform the acceptance test as required in GB/T 2828.1. Inspection items, defect classification and acceptance quality are as shown in Table 3.
- General Inspection level: secondary
- sampling plans: Single Sampling Plan
|sequence||acceptance test||Major Defect||minor defect||acceptable quality limit (AQL)|
|1||Surface protection performance & Assembly quality||–||√||4.0|
|2||Shape and Install dimension||√||–||0.4|
|3||Cutoff and Release voltage||√||–||0.4|
5.3 Formal test should be carried out according to the provision 5.5 in QC/T413-2002.
Test group and sequence are shown in Table 4.
|Testing Items & sequence||requirement||Test method||1||2||3||4||5||6||7||8||9||10||11||12|
|Shape and Install dimension||3.5||4.2||√||√||√||√||√||√||√||√||√||√||√||√|
|Surface protection performance & Assembly quality||3.7||4.4||√
|Cutoff and Release voltage ?23??||3.8.1||4.5?4.6||√||√||√||√||√||√||√||√||√||√||√||√|
|Cutoff and Release voltage(105?)||3.8.2||4.7||–||–||–||√||√||√||–||–||–||–||–||–|
|Power outage performance||3.21||4.20||–||–||–||√||√||√||–||–||–||–||–||–|
|Thermal Shock Resistance||3.13||4.12||–||–||–||√||√||√||–||–||–||–||–||–|
|Rated Operating Time||3.6||4.3||–||–||–||√||√||–||–||–||–||–||–||–|
|Degree of protection||3.9||4.8||–||–||–||–||–||–||√||√||√||–||–||–|
|Temperature & Humidity Resistance||3.14||4.13||–||–||–||–||–||–||√||√||√||–||–||–|
|Dielectric voltage withstand performance||3.16||4.15||–||–||–||–||–||–||–||–||–||–||–||√|
6. Marking, Packaging, Transportation, Storage
Logo, packaging, transport, and storage should conform to the provisions of chapter 6 in QC/T413-2002.