Provident Engineering: Compressor Clutch Failure Analysis

I got this GPD compressor from RockAuto.com. The clutch lasted only a few minutes before it failed open circuit. The wires were jiggling around while it was running, so I thought something was loose. So I'll do a little failure analysis to try and find the reason behind the failure.

First, I removed the center bolt holding the clutch face on. Then I removed the clutch face by just pulling it off.

Next, I removed the snap ring and pulled the pulley off.

Here's what the inside of the pulley looked like. There was a bunch of goo from the melted electromagnet.

Here's the melted electromagnet, still on the compressor. Do you notice anything missing?

See that groove at the base? That's where a snap ring is supposed to go. The top groove holds the pulley on, while the bottom groove holds the electromagnet on, well, if it had a snap ring installed. It seems somebody at GPD forgot to install it.

How does a loose electromagnet cause it to overheat? I think there was enough room for it to rub against the pulley and create heat from friction. There was a little noise coming from the compressor while it was running.

How could they have detected this at the factory? A test run using a thermal imaging camera, taking note of the temperature during operation would have been helpful. Noise measurements may have detected it. Following assembly procedure would have helped. Making sure the parts weren't loose before sending it out the door would also have helped. I can only assume their factory didn't have any of those controls in place.

What effect does one employee's carelessness have? You can lose a customer for every mistake you make. This wasn't the same exact type of compressor that was on the car, but it fit. So I can't use the old electromagnet on this one. I didn't buy an expansion valve, so I guess if I return this I won't get any credit. Oh, well, it made for a good blog post.

Not only did GPD fail quality, they failed customer service too. Here's my attempt to buy a clutch from them:

John Andrews providentengineering@gmail.com

Aug 31, 2018, 12:53 PM (23 hours ago)

I need a clutch for a compressor: GPD part number 6511491.

Can you sell me the clutch?

The one I got from rockauto didn't have the snap ring installed, so the electromagnet rubbed on the pulley, causing the clutch to overheat and fail within minutes.

Thanks,

John Andrews

Albert Brown abrown@globalpartsdist.com

Aug 31, 2018, 1:52 PM (22 hours ago)

Good Day Mr. John,

GPD does not offer the clutch for the 6511491. The clutch is only sold with a new compressor assembly.

Kind Regards,

Albert Brown

Inside Sales

Global Parts Distributors, llc

3279 Avondale Mill Road

Macon, Georgia 31216
Ph: 1 800 722 5089 ext 6329

Direct: 478 785 6329

Fax: 478 781 6006

From: John Andrews <providentengineering@gmail.com>
Sent: Friday, August 31, 2018 2:53 PM
To: CATALOG <CATALOG@globalpartsdist.com>
Subject: Need AC clutch

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