Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

APPEARANCE OF THE MOST COMMON SHAFT FAILURES

BEACH MARKS (CLAMSHELL, CONCHOIDAL)

Beach marks indicate successive positions of the ad-

vancing crack front. The marks usually have a smoother
texture near the origin and become rougher as the crack
grows.

RATCHET MARKS (RADIAL STEPS)

Ratchet marks are the telltale sign of several individual

cracks that ultimately merge to form a single crack.
Ratchet marks are present between the crack origins.

CHEVRON MARKS

Chevrons, or arrows, point to the origin of the crack.

Rotational bending fatigue failures occur when each part
of the shaft is subject to alternating compression and
tension under load. A crack can start at any point on the
surface where there is a stress riser.

HELICAL (TORSIONAL)

Torsional failures are identified by the “twisted” appear-

ance on the shaft. The appearance of the failure
depends on the amount of torsional loading and whether
the material is ductile or brittle. This shaft shows some
twisting before failure. If the shaft material is ductile, it
will twist more before failing; if the shaft is more brittle,
or subject to extreme torsion, the fracture will have a
rougher appearance.

BRITTLE FRACTURE (TORSIONAL)

A brittle failure due to a sudden torsional load results in a

diagonal break with a rough surface. Possible causes include
an equipment jam, high-impact loading or a voltage
transient.

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Section 11 — Failure Fundamentals of DC Operation and Repair

SHAFT FAILURES

This shaft failed due to high-impact loading. The mate- rial

is 1045 carbon steel, which has good ductility.

This armature rub could have resulted from a bent shaft, a

loose pole dropping down onto the armature, or a broken
shaft within the armature core. In this case, the shaft broke
behind the bearing shoulder. The ratchet marks offer
evidence of why the shaft broke.

Excessive radial load. The inner race is from an NU roller

bearing, indicating it was used in a belted application. The
service center should check belt tension and pulley profile.

This is a 1040 carbon steel motor shaft that failed due to

rotational bending fatigue. The point of failure was at the
This shaft failed due to fatigue created by reversed torsional
bearing journal shoulder which had an inadequate ra- dius.
loading. The shaft material is unknown, but may possibly
be 4100 high-tensile steel alloy.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

SHAFT FAILURES

Excessive torque and an excessively-long keyway were the

cause of failure for this shaft.

This pump shaft, made of 4140 alloy steel, failed due to

rotational bending fatigue, initiated in the root of the shaft
keyway. The most likely cause was a combination of
misalignment and vibration. The coupling may also have
been a contributing factor. There were a number of beach
marks present.

This turbine shaft, made of 1051 carbon steel, failed due to

rotational bending fatigue. There were also signs of minor
torsional fatigue. Cracks initiated at the root of a coupling
weld. This material has poor welding character- istics.
There were also signs of misalignment.
This is an example of extreme corrosion, wear and
cracking on a pump shaft.

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Section 11 — Failure Fundamentals of DC Operation and Repair

BEARING FAILURES

Fluting due to shaft currents on a ball bearing.

The spacing of the fluting marks depends on rpm, diam- eter,

radial load and magnitude of the shaft voltage.

The arcing on this ball was caused by welding done near the
motor. Dirt in the roller path imbeds in the raceway, decreasing
bearing life.

Fretting corrosion caused by loose fit and vibration.

Smear marks on roller caused by debris.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

BEARING FAILURES

The damage shown here corresponds to the spacing of the

rolling elements. This damage started as non-rotating
vibration. This can result from shipping (rail, rough roads) or
vibration from nearby equipment.

Heavy shock loads can cause unusual fractures of the outer

race and/or balls.

The upper thrust bearing of a vertical motor was damaged by

shock load. This type of damage may be caused by
cavitation (momentary up thrust with high impact when the
thrust load is restored) or shipping damage.

Early stage of spalling caused by excessive preload.

Color variation due to excess temperature.

The load zone of the bearing on the left, shown as a

shadowed path, indicates that the outer ring is mis- aligned
to the shaft. The load zone of the bearing on the right indicates
Fatigue fracture of the outer ring caused by burrs in the the inner ring is misaligned relative to the housing.
housing bore.

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Section 11 — Failure Fundamentals of DC Operation and Repair

MECHANICAL FAILURES

Lip seals are sometimes added to retain grease and/or

exclude dirt or moisture.

This bushing did not have enough shaft clearance. The use
of aluminum or brass for the bushing will prevent shaft
damage during future failures.

Inspect the coupling if it is available.

Avoid using impact wrenches when tightening bearing caps.

Most bearing retainers are brittle cast iron and break easily if
The bearing failed, leaving the clearance fit of the end cocked or jammed. The broken ear can be brazed in place; or
bracket to support the shaft. Vibration sensors or bear- ing if it is lost, attach a nut by welding.
RTDs would have prevented this damage.

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Fundamentals of DC Operation and Repair Tips Failure Analysis — Section 11

MECHANICAL FAILURES

For safety, fully seat shouldered eyebolts. A lateral pull on

an eyebolt will result in broken eyebolts and dropped
motors.

When the original lifting device broke, the damage to the

motor was extensive (middle and bottom). The original
lifting device is shown beside a much more substantial
replacement (above).

Lifting swivel-eye bolts are commercially available, and

should be used when standing an armature on end or laying
it down.

Use homemade lifting devices with caution. Consider

liability, as well as safety.

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Section 11 — Failure Fundamentals of DC Operation and Repair

NOTES

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Fundamentals of DC Operation and Repair Index — Section

12
Index

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 Section 12 — Fundamentals of DC Operation and Repair

Index varnish, types of, 5-14

wedges, 5-14
split-pitch coils, frog-leg windings, 5-29
tests
A growler test, 4-2
high-frequency bar-to-bar test, 4-3
Accessories high potential test, 4-3
brush monitoring systems, 8-7 low-resistance bar-to-bar test, 4-2
differential air pressure switches, 8-6 megohmmeter test, 4-2
encoders surge comparison test, 4-3
absolute, 8-6 troubleshooting tips
optical, 8-6 equalizers, 5-24
field loss relays, 8-6 locating a grounded coil, 5-23
resolvers, 8-6 locating a shorted coil, 5-23 only
space heaters, 8-4 one bar off, 5-22
use of growler, hacksaw blade, 5-23
tachometers, 8-5
wave windings, 5-5
ventilation, 8-2
winding terms
Armature commutator pitch, 5-6
balancing, 5-21 equalizers, 5-4
banding frog-leg windings, 5-6, 5-26
fiberglass, 5-18 lap windings, 5-3
calculating centrifugal force, 5-19 converting wave windings, 5-5
steel banding to, 5-18 estimating weight of Assembly and testing
coil extensions, 5-19 procedure, 5-19
after assembly, 9-6
tensile strength, 5-18
brush neutral, 9-8
finishing the armature, 5-21
AC method, 9-8
steel, 5-18
clockwise rpm vs. counterclockwise rpm, 9-9
tips, 5-21
inductive kick method, 9-8
commutator observation, 9-9
soldering commutators, 5-15 permanent magnet machines, 9-9
inspection of soldered joint, 5-16 brush seating, 9-6
production soldering, 5-16 brush spacing adjustment of double brush-per-post de- signs, 9-
TIG-welded commutator connections, 5-16 10
tips, 5-15 brushholder spacing, 9-9 commutator
connections (joints), checking with infrared, 5-24 film, establishing, 9-8 compound
data, 5-8 field polarity, 9-11 interpole polarity,
DC machine data sheet, 5-25 9-11
eddy currents in armature cores, 5-8 before assembly, 9-3
failures, photographs of, 11-8 verify brush grade and size, 9-4 verify
frog-leg windings, 5-6, 5-26 field and interpole polarity, 9-4
lap-windings, 5-3 during assembly, 9-5
brushholder alignment, 9-6
nomenclature, 1-6
insulated bearing housing or shaft, 9-5
rewinding cautions
changing wire size, 5-9
increasing horsepower, 5-9
odd turns, 5-8 B
stripping, 5-9
rewinding tips Balancing, armature, 5-21
coil bracing, 5-14 Banding
coil insertion, 5-11
fiberglass, 5-18, 6-4
coils, 5-11
calculating centrifugal force, 5-19 converting
fitting the coils, 5-12
steel banding to, 5-18 estimating weight of
preparing the core for rewind, 5-10
coil extensions, 5-19 procedure, 5-19
slot liners, 5-10
tensile strength, 5-18
soldering commutators, 5-15
TIG-welded commutator connections, 5-16 finishing the armature, 5-21
protective, 6-8

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 Fundamentals of DC Operation and Repair Index — Section

steel, 5-18
Coil bracing, 5-14
string, 6-7
Teflon, 6-8 Coils
tips, 5-21 armature, 5-11
fitting, 5-12
Bearings condition,
insertion, 5-11
3-12
locating grounded armature coil, 5-23
failures, photographs of, 11-18
locating shorted armature coil, 5-23
nomenclature
ball bearing, 1-8 Commutator
sleeve bearing, 1-8 appearance, guide to, 11-10
Blowers, 3-3, 10-4 banding replacement, 6-7
basics, 6-2
Bracing, coil, 5-14 condition, 3-4
Brushes connections, TIG-welded, 5-16
brush grade and size, 9-4 designs, 6-2
brush life, 3-11 dimensions, original and minimum
brush neutral ABB, 6-10
adjusting Baldor, 6-10
AC method, 9-8 General Electric, 6-10
clockwise rpm vs. counterclockwise rpm, 9-9 P&H (Harnischfeger), 6-13
inductive kick method, 9-8 Reliance, 6-13
observation, 9-9 Toshiba, 6-13
permanent magnet machines, 9-9 WEG, 6-14
theory of, 2-5 Westinghouse, 6-14
brush pressure and spring tension, 3-8 failures, photographs of, 11-11
disassembly and inspection, 3-8 failures, film, establishing, 9-8
photographs of, 11-12 monitoring systems, mechanical condition, 3-5
8-7 nomenclature, 1-5
nomenclature, 1-7 pitch, 5-6
seating, 9-6 riser repairs, 6-8
spacing adjustment of double brush-per-post designs, 9-10 soldering, 5-15
sparking inspection of soldered joint, 5-16
arcing increases with load, 10-4 production soldering, 5-16
assessing, 9-13 tips, 5-15
causes and cures, 10-6 testing, 4-4, 6-8
Brushholders torque values, 6-3 turn
alignment, 9-6 and undercut, 6-5 V-
connections, 3-9 rings
protective banding, 6-8
disassembly and inspection, 3-8
replacing, 6-3
failures, photographs of, 11-12
string band, 6-7
nomenclature, 1-7 Teflon band, 6-8
spacing, 9-9 wear patterns, 3-5, 11-10
Bucking (suicide) fields, 7-3 Compensating windings failures,
photographs of, 11-14 theory of,
C 2-7
tips for rewinding, 7-10
Carbon brushes, see Brushes
Compound fields
Cautions polarity, 9-11
armature rewinding changing theory of, 2-5
wire size, 5-9 increasing
horsepower, 5-9 Connections
odd turns, 5-8 brushholder, 3-9
stripping, 5-9 commutator, as received template for 2-, 4-, and 6-pole DC machines, 3-14
never dip, 6-5

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 Section 12 — Fundamentals of DC Operation and Repair

Covers
compound
blowers, 3-3, 8-3, 10-4 general, 7-2
gaskets, 10-5 theory of, 2-5
internal fans, 3-4, 8-2 strength, 1-2
ventilation, 3-2 tips for rewinding
Current for low field voltage, 1-3 aluminum to copper conversion, 7-6
compensating windings, 7-10
interpoles, 7-8 series
D field coils, 7-7 shunt
field coils, 7-4
Data sheet, DC machine, 5-25
Flux, magnetic field strength, 2-4
DC field strength, 1-2
Frames
DC motor theory, 2-2 introduction, 7-2
Differential air pressure switches, 8-6 nomenclature, 1-6
Disassembly and inspection, 3-1 Frog-leg windings, 5-6, 5-26
Drives and controls, troubleshooting, 10-5
G
E
Generator
Eddy currents in armature cores, 5-8 does not produce correct voltage, 10-7
does not produce voltage, 10-7
Encoders
absolute, 8-6
optical, 8-6
H
Equalizers Horsepower, increasing, 5-9
armature, 5-4
troubleshooting, armature, 5-24 I
F Inspection disassembly
and, 3-1
Failures, photographs of report, 3-13
armatures, 11-8
Interpoles
bearings, 11-18
failures, photographs of, 11-13
brush and brushholders, 11-12
polarity, 9-4, 9-11
commutators, 11-11
testing
compensating windings, 11-14 AC drop test, 4-5
field coils, series and interpoles, 11-13 current comparison (impedance test), 4-5
mechanical, 11-20 surge test, 4-5
shafts, 11-15 theory of, 2-6
Fans tips for rewinding, 7-8
internal, 3-4, 8-2
missing, 10-5 L
Fiberglass banding, see Banding
Lap windings, armature, 5-3
Field coils
failures, photographs of, 11-13 testing, M
4-4
Field current (amps), 1-2 Magnetic field strength (flux), theory of, 2-4

Field loss relays, 8-6 Field Magnetic force, theory of, 2-3

strength, 1-2 Magnets, principles of, 2-2

Fields Mechanical failures, photographs of, 11-20

bucking (suicide), 7-3 Motor nomenclature, 1-4

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 Fundamentals of DC Operation and Repair Index — Section

N Steel banding, see Banding

Stresses, summary of, 11-2
Nameplate
correctly interpreting the DC motor, 1-2
current for low field voltage, 1-3
T
DC field strength, 1-2
Tachometers, 8-5
field current (amps), 1-3
resistance multiplier for temperature rise, 1-3 Temperature
motor runs over temperature, 10-4
Neutral
blower, 10-4
brush pencil, 9-17 covers and gaskets, 10-5
working, 2-8 drives and controls, 10-5
Nomenclature ball missing fans, 10-5
bearing, 1-8 temperature rise, resistance multiplier for, 1-3
carbon brush and brushholder, 1-7 Test form, DC machine drop voltage, 4-6
commutator, 1-5 Testing
DC armature, 1-6 armatures
DC frame, 1-6 growler test, 4-2
DC motor, 1-4 high-frequency bar-to-bar test, 4-3
sleeve bearing, 1-8 high potential test, 4-3
low-resistance bar-to-bar test, 4-2
megohmmeter test, 4-2
O surge comparison test, 4-3
brush neutral
Odd turns, armature, 5-8
AC method, 9-8
Overload relay trips, 10-3 brush pencil neutral, 9-17
clockwise rpm vs. counterclockwise rpm, 9-9
R inductive kick method, 9-8
observation, 9-9
permanent magnet machines, 9-9
Resistance multiplier for temperature rise, 1-3
commutator, 4-4, 6-8
Resolvers, 8-6 DC test panels, 9-20
Root cause methodology, 11-3 field coils, 4-4
Root cause methodology forms, 11-5 final testing, 9-12
assessing brush sparking, 9-13
back-to-back “closed loop” (Kapp test), 9-16
S black band, 9-18
brush pencil neutral, 9-17
Series field coils dynamometer, 9-15
failures, photographs of, 11-13 tips load testing a DC generator using salt water rheostat
for rewinding, 7-7 method, 9-16
no-load testing when rated voltages are available, 9-12 no-
Shafts load testing when rated voltages are not available,
appearance of most common failures, 11-15 9-13
failures, photographs of, 11-16 series motor no-load, 9-12
Shunt fields, tips for rewinding, 7-4 speed vs. field and armature voltage, 9-13
interpoles
Slot liners, armature, 5-10 AC drop test, 4-5
Soldering current comparison (impedance test), 4-5
commutators surge test, 4-5
inspection of soldered joint, 5-16 Theory
production soldering, 5-16 brush neutral, 2-5
tips, 5-15
compensating windings, 2-7
Space heaters, 8-4 compound fields, 2-5
Sparking, see Brushes DC motor, 2-2
interpoles, 2-6
Stabilized shunt fields, 7-2, 7-7, 9-11

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 Section 12 — Fundamentals of DC Operation and Repair

magnetic field strength (flux), 2-4

Wire
magnetic force, 2-3
changing size, 5-9
magnets, principles of, 2-2
converting from aluminum to copper, 7-6
TIG welding
Working neutral, 2-8
commutator connections, 5-16
equipment, 5-17
joint preparation, 5-17
operator skill and proper welding procedures, 5-17
summary of, 5-17
Troubleshooting
generators
does not produce correct voltage, 10-7
does not produce voltage, 10-7
machines that have been in service
motor runs faster than rated speed, 10-5
motor runs slower than rated speed, 10-5
sparking at the brushes, 10-5
newly-installed motors
brushes spark and arcing increases with load, 10-4 does
not start or does not run properly, 10-3
overload relay trips or fuses blow when motor is ener-
gized, 10-3
runs backwards, 10-4
runs faster than rated speed, 10-5
runs over temperature, 10-4
blower, 10-4
covers and gaskets, 10-5
drives and controls, 10-5
missing fans, 10-5
will not start, 10-3
sparking causes and cures, 10-6

V
V-rings
protective banding, 6-8
replacing, 6-3
string band, 6-7
Teflon band, 6-8
Varnish, types of, 5-14
Ventilation
blowers, 3-3, 8-2, 10-4
covers, 3-2, 8-3
DC motor, 8-2
gaskets, 8-3
improvement tips, 8-3
internal fans, 3-4, 8-2

W
Wave windings, armature, 5-5
Wear patterns, commutator, 3-5
Wedges, armature, 5-14

12 - Copyright © 2003-2005, Electrical Apparatus Service Association, Inc. (Version 503CI-405)