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 Analysis Fundamentals of DC Operation and Repair Tips

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
bearing journal shoulder which had an inadequate ra- torsional loading. The shaft material is unknown, but
dius. 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 Analysis Fundamentals of DC Operation and Repair Tips

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
Fatigue fracture of the outer ring caused by burrs in right indicates the inner ring is misaligned relative to the
the housing bore. housing.

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

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
The bearing failed, leaving the clearance fit of the end break easily if cocked or jammed. The broken ear can be
bracket to support the shaft. Vibration sensors or bear- brazed in place; or if it is lost, attach a nut by welding.
ing 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 Analysis Fundamentals of DC Operation and Repair Tips

NOTES

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Fundamentals of DC Operation and Repair Tips Index — Section 12

12
Index

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Section 12 — Index Fundamentals of DC Operation and Repair Tips

varnish, types of, 5-14

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

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Fundamentals of DC Operation and Repair Tips Index — Section 12

steel, 5-18 Coil bracing, 5-14

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

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Section 12 — Index Fundamentals of DC Operation and Repair Tips

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
aluminum to copper conversion, 7-6
Current for low field voltage, 1-3 compensating windings, 7-10
interpoles, 7-8
D series 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
nomenclature, 1-6
Differential air pressure switches, 8-6
Frog-leg windings, 5-6, 5-26
Disassembly and inspection, 3-1
Drives and controls, troubleshooting, 10-5
G
E Generator
does not produce correct voltage, 10-7
Eddy currents in armature cores, 5-8 does not produce voltage, 10-7
Encoders
absolute, 8-6 H
optical, 8-6
Equalizers Horsepower, increasing, 5-9
armature, 5-4
troubleshooting, armature, 5-24 I
Inspection
F 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
tips for rewinding, 7-8
Fans
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 M
testing, 4-4
Magnetic field strength (flux), theory of, 2-4
Field current (amps), 1-2
Magnetic force, theory of, 2-3
Field loss relays, 8-6
Magnets, principles of, 2-2
Field strength, 1-2
Mechanical failures, photographs of, 11-20
Fields
bucking (suicide), 7-3 Motor nomenclature, 1-4

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Fundamentals of DC Operation and Repair Tips Index — Section 12

N Steel banding, see Banding

Stresses, summary of, 11-2
Nameplate
correctly interpreting the DC motor, 1-2 T
current for low field voltage, 1-3
DC field strength, 1-2 Tachometers, 8-5
field current (amps), 1-3 Temperature
resistance multiplier for temperature rise, 1-3 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
missing fans, 10-5
Nomenclature temperature rise, resistance multiplier for, 1-3
ball bearing, 1-8
Test form, DC machine drop voltage, 4-6
carbon brush and brushholder, 1-7
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
high potential test, 4-3
sleeve bearing, 1-8
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
inductive kick method, 9-8
R 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
final testing, 9-12
Root cause methodology forms, 11-5 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 load testing a DC generator using salt water rheostat
method, 9-16
tips for rewinding, 7-7
no-load testing when rated voltages are available, 9-12
Shafts no-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
speed vs. field and armature voltage, 9-13
Shunt fields, tips for rewinding, 7-4
interpoles
Slot liners, armature, 5-10 AC drop test, 4-5
current comparison (impedance test), 4-5
Soldering
surge test, 4-5
commutators
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
DC motor, 2-2
Sparking, see Brushes
interpoles, 2-6
Stabilized shunt fields, 7-2, 7-7, 9-11

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Section 12 — Index Fundamentals of DC Operation and Repair Tips

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