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Bearing Currents and Their Relationship To PWM Drives
Bearing Currents and Their Relationship To PWM Drives
Doyle Busse, Jay Erdman, Russel J. Kerkman, Dave Schlegel, and Gary Skibinski
Abstract - This paper examines ac motor shaft voltages and the re- traditional magnetic effects found in sine wave driven ma-
sulting bearing currents when operated under Pulse Width Modu- chines, it was shown that PWM inverters serve to excite a ca-
lation (PWM) voltage source inverters. The paper reviews the pacitive coupling between the stator and rotor. This coupling
mechanical and electrical characteristics of the bearings and mo- combined with the high frequency electrical characteristics of
tor in relation to shaft voltages and bearing currents. A brief re- the bearing allow the motor shaft voltage to instantaneously
view of previous work is addressed including the system model and
achieve potentials over 20 times that observed on sine wave
experimental results. The theory of Electric Discharge Machining
(EDM) is presented including component calculations of the sys- operation.
tem elements. The effect of system elements on shaft voltages and The current resulting from the motor shaft voltage is lim-
bearing currents are evaluated experimentally and the results ited by the bearing impedance. As motor speed increases, the
compared to theory. A design calculation is proposed that provides bearing resistance attains values in the megohm range [4].
the relative potential for EDM. Finally, the paper will present Technical literature indicates that as speed increases, the balls
quantitative results on one solution to the shaft voltage and bear- ride an oil film forming a boundary between the race and the
ing current problem. ball with the exception of instantaneous asperity point con-
tacts. An asperity is the deviation from the mean surface, usu-
I. INTRODUCTION
ally in microns.
Fig. 1 shows the surface roughness of a bearing race that
In recent years, the powering of induction motors from
demonstrates electrical fluting damage [5]. The paper investi-
Variable Frequency Drives (VFD) has become increasingly
gates the theoretical and empirical basis of bearing oil film
popular. Even though the induction motor is a very rugged
charging with PWM voltage source inverters. The dielectric
device, the bearings are now subject to additional modes of
strength of typical lubricating films is determined along with
failure due to bearing currents. Bearing currents in larger ac
an explanation of why the film can withstand rotor shaft volt-
motors have been known for many years. The cause has been
ages in the range of 10 to 30 volts peak for short periods.
understood to be induced by magnetic dissymetries in the con-
This paper explores the relevant bearing failure mecha-
struction of the motor resulting in destructive bearing
nisms in addition to the failure indicators of shaft voltage and
currents.
bearing current magnitudes. The point contact area is calcu-
Shaft voltages and their resulting currents were recognized
lated and a current density is specified to project bearing life.
by Alger [1] in the 1920's. Since then numerous investiga-
The paper presents motor and bearing capacitance character-
tions of the problem have been reported with recent contribu-
istics for a wide horsepower range and relates them to an
tions by Costello and Lawson [2,3]. In recent years, the effect
equivalent common mode motor and bearing model. A steady
of PWM drives operating ac motors has been studied. All mo-
state analysis of the full model leads to the development of a
tors have some level of shaft voltage and resulting bearing
voltage ratio, which is convenient for analyzing the potential
current. In addition, Bipolar Junction Transistor (BJT) and
for shaft voltages and bearing currents. A reduced second or-
Insulated Gate Bipolar Transistor (IGBT) inverters experience
der model is proposed for analysis purposes. Experimental
EDM currents. Two key elements are what voltage conditions
will break down the insulating grease film, and how the re-
sulting current densities affect bearing life.
This paper will focus on the mechanisms that cause these
voltages and the ability of bearings to withstand the resulting
currents. Possible mechanisms for bearing damage when op-
erating on VFD are dv/dt or electrostatically induced currents,
oil film breakdown causing EDM currents, and current caus-
ing chemical changes within the lubrication.
Recently, the authors presented their findings on EDM and
it's relationship to PWM inverter operation [4]. In contrast to Fig. 1. Surface Roughness of a Ball Bearing Race [5].
IEEE IECON Conference Orlando, FL November, 1995
breakdown for a 2 m film @ 25C with 400 V/mil mineral temperatures high enough to melt and pit the race. Applica-
oil is 32 Vpk. However, breakdown values decrease to 6-10 tions of rotating bearings with no shaft load, where the rotor
volts as the motor heats up, agreeing with film thickness the- weight alone would divide equally over 1 to 3 balls provide
ory. the smallest contact areas. Thus, bearing current density
Region B: Vsng & Csr charge Cb by capacitive divider ac- (A/mm2) is a preferred indicator of bearing life under pitting
tion. The plateau value is less than the 32 Vpk breakdown and fluting.
value, therefore no EDM occurs. Vrg is replicated by divider Accurate calculation of actual contact surface area in a ro-
action as Vsng returns to zero. The power device switching tating bearing is difficult, since it depends on surface rough-
time determines dv/dt current levels. Peak dv/dt currents of ness, "asperity contacts" and on the oil film thickness, which
IGBT drives are 200 - 500 mA while BJT drives have 50 mA itself is a function of grease viscosity, grease temperature, mo-
or less. tor speed and motor load. Fig. 4 shows an equivalent Hertzian
Region C: Vsng & Csr charge Cb by capacitive divider ellipse area under surface roughness of associated asperity
action but to a lower value than the 35 Vpk of Region A. Even contacts. A sequence of equations was used to calculate the
before Vsng modulates upward, the 10 Vpk plateau value in- contact area using Hertzian point contact theory as provided
stantaneously breaks down, indicating EDM discharge. Here, by Harris [12].
rolling asperity contacts reduce the film thickness resulting in
a Vth lower than Vth of the oil film thickness of Region A. E. Bearing Current Density vs. Life Degradation
Regions of Vrg at 0 V with Vsng at high levels are ex-
plained by asperity contacts shorting out Cb to a low resis- Bearing current density has been proposed on sine wave
tance. Inner and outer race random contact duration of driven machines to predict bearing life under the influence of
asperity contacts is 33 S and 100 S at low speed and 12 S current passing through the bearing. Haus [13] determined
and 40 S at high speed respectively. Bearing dv/dt currents 0.7 A/mm2 for 50,000 hrs bearing life while 1.4 A/mm2 short-
of 100 - 500 mA peak also occur when asperities short Cb ened life to 500 hrs. Krumpolc [14] determined 0.1 A/mm2 as
while Vsng switches. totally safe. Kulda [15] quotes 1.0 A/mm2 as tolerable, 1.4
A/mm2 as a destruction level after 500 hrs and values > 2
C. Current Magnitude as a Failure Indicator
A/mm2 causing destruction after 5 hrs. Endo [16] quotes 1.0
Establishing a maximum allowable bearing current magni- A/mm2 as a critical density value while from field experience
tude is difficult without knowing surface contact area of the 1.8 A/mm2 caused failure in 2 hours and values < 0.15
passing current and grease composition. A non-rotating bear- A/mm2 up to 0.39 A/mm2 are time proven safe values with no
ing may pass large sine wave currents without damage be- signs of fluting.
cause larger contact area occurs [8]. Also, bearing current Bearing current testing is historically based on 60 Hz, sine
magnitude failure mechanisms are sensitive to the type of wave, rms amperes with a bearing rotating at rated base speed
grease. High resistivity mineral oil greases act as capacitors and using high resistivity grease. Bearing life is therefore
with high Vth and produce EDM currents and arcing on dis- based on destructive EDM currents occurring due to ca-
charge. This failure is best analyzed using bearing current pacitive discharge breakdowns in high resistivity grease. The
density. High resistivity greases with low bearing currents do Apk
2.17 mm 2
hr] = 7, 867, 204 10
ElectricalBearingLife[ (1)
not produce arcing but may produce fritting. Fritting tempers
the steel, which lowers surface hardness. Low resistivity lith-
authors convert historical density limits to (Amp peak / mm2)
ium grease does not exhibit a Vth but acts as a resistor. Cur-
to estimate bearing life with EDM and dv/dt bearing currents
rents of 189 mA rms (267 mA peak) cause grease
under PWM operation. However, more research on pulsed
decomposition into lithium iron oxide, leading to increased
EDM life is required. Equation (1) describes electrical bearing
wear and bearing failure [9]. Values of 0.5 A rms accelerate
life using data from Fig. 5.
corrosion and fritting [9]. Thus, EDM currents and dv/dt cur-
rents should be analyzed for allowable bearing current density
and peak currents < 267 mApk for corrosive effects and frit- Area = * a * b
ting.
( Ws ) - Stator ( d ) - Dielectric
BVR = V rg / V sng = C sr / (C sr + C b + C rf ) (3)
( Rc ) - Radial
Slot Width Thickness
Clearance
s sn
Zcm ro Lo
i (t)
Vterm
Vsg Ceq Vsng
Ib
g
Iframe
Fig. 8 Reduced Order Common Mode Model
Vrg Vrg
Ib Ib
Vsng Vsng
Fig. 10. Common Mode Choke Experimental Results Fig. 12. Long Cable Length Experimental Results
unknown. However, EDM bearing current densities less than resulting dv/dt and EDM currents produce current densities in
0.6 to 0.8 Apk/mm2 probably do not degrade bearing life. Ac- line with those observed on sine wave operation.
curate life predictions are difficult due to the steepness of the
life curve, e.g., from 0.8 to 2.0 Apk/mm2 life is greatly de- VI. ACKNOWLEDGMENTS
creased.
Table I shows the ESIM proposed in [4] appears promising The authors wish to thank Dave Conrad of Dodge-Reliance,
as a solution to bearing current problems, since destructive Leonard Cox of Bearings, Inc., Steve Evon of Reliance Elec-
EDM pulse currents are eliminated and dv/dt current is re- tric, Dave Hyypio of Marathon Electric, Gary Lynk of Tor-
duced to < 50 mApk. Since dv/dt current is < 267 mApk limit rington Bearing, Jim Misch of NTN Bearing, and Dr. Joesph
for low level current corrosion and fritting, this problem is Tevaarwerk of Emerson Electric for their assistance in this
also eliminated. Thus, loaded or unloaded, bearing life ap- research project. The motor was provided by Marathon
proaching 100,000 hrs is now attainable with mechanical Electric.
limitations determining ultimate life.
VII. References
V. CONCLUSIONS
[1] Alger P., Samson H., "Shaft Currents in Electric Machines" A.I.R.E. Conf.,
Feb. 1924.
The paper presented a review of the mechanisms that cause [2] Costello, M., "Shaft Voltage and Rotating Machinery", IEEE Trans. IAS,
bearing currents. Theoretical calculation and measurement March, 1993.
verification of the equivalent circuit impedances of the electri- [3] Lawson, J. ,"Motor Bearing Fluting", CH3331-6/93/0000-0032 1993-IEEE.
cal model were presented. Shaft voltages and the resulting [4] Erdman, Jay, Kerkman, Russel J., Schlegel, Dave, and Skibinski, Gary, "Ef-
fect of PWM Inverters on AC Motor Bearing Currents and Shaft Voltages,"
bearing currents were measured and their components identi- APEC '95, Tenth Annual Applied Power Electronics Conference and Exposition,
fied. With typical lubricant dielectric strengths, rotor voltages March 5-9, 1995, Vol. 1, pp. 24-33.
in excess of 30 Vpk were measured. [5] Tallian, T., Baile, G., Dalal, H., and Gustafsson, O., "Rolling Bearing Dam-
age - A Morphological Atlas", SKF Industries, Inc., Technology Center, King of
The theory of bearing contact area calculation was pre- Prussia, PA.
sented and a current density verses life projection was made. [6] Kaufman, H., Boyd, J., "The Conduction of Current in Bearings", ASLE
Lubrication plays an important role in this issue. Further Conf, 1958.
[7] NEMA MG-1 Specification Part 31, Section IV, 1993.
work needs to be done to show the effects of different lubrica- [8] Andreason, S. "Passage of Electrical Current thru Rolling Bearings", SKF
tion materials affecting bearing currents. A search of the lit- Gothenburg.
erature indicates that currents of 0.2 to 0.5 Arms/mm2 on a [9] Murray, S., Lewis, P., "Effect of Electrical Currents on Ball Bearing Dam-
sine wave basis will result in a reasonable useful life. The age in Vacuum and Air", 22nd ALSE annual meeting May 1,1967.
[10] Tevaarwerk, J. L. and Glaeser, W. A., "Tribology", University of
author's propose the maximum bearing current density with Wisconsin-Milwaukee, College of Engineering & Applied Science, Center for
PWM drives to be < 0.8 (Apk / mm2) to insure bearing current Continuing Engineering Education, May 15-16, 1995.
does not limit the mechanical life of the bearing. [11] Komatsuzaki, Uematsu, Nakano, " Bearing Damage by Electrical Wear
Experimental results with PWM voltage source inverters and its Effect on Deterioration of Lubricating Grease", ASLE Vol. 43, 1, pp.
and typical system components demonstrated possible rotor 25-30, 1987.
[12] Harris, T., Rolling Bearing Analysis, Wiley, 3rd Edition, 1991.
voltages far in excess of the nominal 30 Vpk. The EDM cur- [13] Haus, O., "Shaft Voltage and Bearing Currents - Causes, Effects and Reme-
rents produced current densities of over 5.0 Apk/mm2. dies", ETZ -A, 1964, pp.105-112.
The data indicates that an ESIM is capable of reducing [14] Krumpolc, E., "Bearing Currents and Shaft Voltages in Electric Machines",
Electrotechnik, Vol. 45, No. 4, pp. 88-91, April, 1990.
bearing currents to a level that exhibits reasonable life. The [15] Kulda, V., "Bearing Currents in Electrical Machines", Czechtech Journal
"The -Electrical Engineer", 20, 1965, no. 11, pp. 323-326.
Table 1. Calculated Bearing Life with PWM IGBT Drives and 15 hp Motor
[16] Endo, H., "Analysis of Current Density at D.C. Motor Bearing", Shinko
Electric -Ltd., Jan. 21, 1978.
[17] Bonnet, A., "Cause and Analysis of Anti-Friction Bearing Failures in AC
Induction Motors", US Electrical Motors Inc.
[18] Hayt, William H., Engineering Electromagnetics, McGraw-Hill, 5th Edi-
tion, 1989.
[19] Prashad, H., "Theoretical Evaluation of Capacitance, Capacitive Reac-
tance, Resistance and Their Effects on Performance of Hydrodynamic Journal
Bearings," Trans. of the ASME, Oct. 1991, Vol. 113, pp. 762-767.
[20] Melsa, James L., Schultz, Donald G., Linear Control Systems, McGraw-
Hill, 1969.