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The Electric Self-Starter: Kettering's Motor-Generator
Volt

Created by

Volt

27. September 2026SE
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The Electric Self-Starter: Kettering's Motor-Generator

Early cars were started by hand with a crank handle — hard, and dangerous when an engine kicked back. Charles F. Kettering, at the Dayton Engineering Laboratories Company (Delco), filed in 1911 for a system in which one electric machine starts the engine as a motor and then, driven by it, runs as a generator to recharge the battery and power the lights and ignition. Cadillac fitted it from 1912. His specification gives the trick that made a small machine do both jobs: batteries switched *"in series to give twenty-four volts"* for starting, and six volts when the machine runs as a generator. This rung works out the current a starter draws, runs a hobby motor as both motor and generator, and switches a heavy load with a relay the way a starter solenoid does.
Intermediate
About 3 hours

Instructions

1

The starting sequence

Blockly Workspace

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2

Cranking current

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3

One machine, motor and generator

Connect a hobby motor to the bench supply and read the current as it runs free, then as you load its shaft with your fingers: current rises with load. That is the motor half. Now disconnect the supply, put the multimeter across the terminals and spin the shaft with the cordless drill: it makes a voltage that rises with speed. That is the generator half. Kettering's machine did both, with separate windings arranged so it worked well in each role.

Materials for this step:

Hobby Motor - GearHobby Motor - Gear1 piece
Jumper WiresJumper Wires1 set

Tools needed:

DC Power SupplyDC Power Supply
MultimeterMultimeter
Cordless DrillCordless Drill
Digital TachometerDigital Tachometer
4

The overrunning clutch that protects the starter

Once the engine fires it spins far faster than the starter can. An overrunning (one-way) clutch in the drive lets the pinion free-wheel so the engine cannot drag the motor to destruction. The embedded blueprint covers how a one-way clutch grips in one direction and slips in the other.
5

Switch a heavy load the way a solenoid does

A starter switch cannot carry hundreds of amps; it carries a few, to a solenoid that closes the heavy contacts. Wire a relay so that a push-button and a small current from the 12 V battery energise its coil, and its contacts switch a 10 W power resistor across the battery. Read the coil current and the load current with the clamp meter: a small current controls a large one. Fuse the load circuit, keep the leads short, and never short a lead-acid battery: it can deliver hundreds of amps and melt a spanner.

Materials for this step:

SPDT RelaySPDT Relay1 piece
Power Resistor Kit - 10W (25 pack)Power Resistor Kit - 10W (25 pack)1 pack
Jumper WiresJumper Wires1 set

Tools needed:

12V Deep Cycle Battery12V Deep Cycle Battery
Current Clamp Meter AC/DC 600ACurrent Clamp Meter AC/DC 600A
MultimeterMultimeter
Clear Safety GlassesClear Safety Glasses
6

History and context

**US 1,171,055, 'Engine Starting, Lighting, and Ignition System', Charles F. Kettering; filed 11 April 1911, granted 8 February 1916**, and the companion **US 1,150,523, 'Engine Starting Device', filed 15 June 1911, granted 17 August 1915**, assigned to the Dayton Engineering Laboratories Company. Cadillac made the electric starter standard from 1912, and the hand crank disappeared from cars within a decade. **Honest limits.** A starter is short-duty: cranking for long overheats it. A weak or cold battery cannot deliver the current. And the large currents need heavy cables and sound connections — a corroded terminal is the commonest 'starter fault'.

Materials

4

Tools Required

7
Estimated Total
What the maker bought. Materials shown without a price are sourced wherever you buy them.
$8.17

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