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Abstract - This paper investigates AC induction motor shaft voltage in magnitude, results in a high circulating current thru both
problems, current flow thru motor bearings and electric discharge motor bearings since the impedance of the circulating path is
current problems within bearings when operated under both pure low. Modern day induction motors less than 250 horsepower
sinewave and Pulse Width Modulated (PWM) inverter sources.
have grounded bearings but have minimized steady state shaft
Recent experience suggests that PWM voltage sources with steep
wavefronts especially increase the magnitude of the above electrical voltage to extremely small values. However, during transient
problems, leading to motor bearing material erosion and early start and stop conditions across the AC line, magnetic
mechanical failure. Previous literature suggests that shaft voltage - dissymmetries appear as increased shaft voltage, resulting in
bearing current problems under 60 Hz sinewave operation are bearing current flow and reduced life [4]. This transient
predominantly electromagnetically induced. It is proposed that bearing current flow for line started motors was
under PWM operation these same problems are now experimentally verified. The traditional electromagnetic
predominantly an electrostatic phenomenon. A system model to
solution to induced shaft voltage on larger frames is to insulate
describe this phenomenon is characterized and developed.
Construction and test of a new Electrostatic Shielded Induction the non drive end bearing. This does not mitigate shaft
Motor (ESIM) verifies this model and is also a possible solution to voltage but rather the resulting bearing current.
the bearing current problem under PWM operation. Electrostatic induced shaft voltage may be present in any
situation where rotor charge accumulation can occur.
Examples are belt driven couplings, ionized air passing over
I. Introduction
rotor fan blades or high velocity air passing over rotor fan
Bearing currents and shaft voltages under 60 Hz sinewave blades as in steam turbine [6]. The electrostatic solution is to
operation has been a recognized problem since 1924 [1-3]. keep the shaft and frame at the same potential by installing a
The bearing impedance characteristic largely determines the shaft grounding brush to reduce electrostatic build up and
resulting bearing current that will flow for a given shaft reduce shaft voltage to 70 - 400 mV. This value is not enough
voltage magnitude and waveform present. A number of to cause damaging bearing current to flow.
surveys have indicated that 30 % of all motor failures operated Electrostatic coupled shaft voltage from external rotor
with 60 Hz sinewave voltage are due to bearing current sources, such as a static exciter in a turbine generator, is
damage [4]. All rotating machines potentially have a bearing possible and historically solved with the application of a shaft
current problem whether it is DC or AC, and either large or grounding brush [6]. Electrostatic coupled shaft voltage from
small horsepower in size. These rotating machines have three external stator sources, such as a PWM inverter, is
basic sources of shaft voltage - electromagnetic induction, investigated in this paper.
electrostatic coupled from internal sources or electrostatic
coupled from external sources. A. Present Theory of Bearing Current with AC Line
Electromagnetic induction from the stator winding to the
rotor shaft was recognized by Alger [1] and is more prevalent The shaft voltage magnitude measured is commonly used
in long axial machines. The shaft voltage is due to small as an indicator of the possible bearing current that results. It is
dissymmetries of the magnetic field in the air gap that are the magnitude and passage of electrical current thru the
inherent in a practical machine design. Most induction bearing that results in ultimate mechanical damage [7].
motors are designed to have a maximum shaft voltage to frame Bearing damage caused by electrical current is characterized
ground of < 1 Vrms with recommended practice limits stated by the appearance of either pits or transverse flutes burnt into
in [5]. The induced shaft voltages cause bearing current flow the bearing race. Electrical pitting continues until the bearing
in a circulating path from the shaft, thru side A grounded loses its coefficient of friction, further increasing the losses
bearing, thru the stator frame, thru side B grounded bearing and breaking up bearing surface. Typical fluting results in a
and back to the shaft. The induced shaft voltage, although low washboard like formation that appears on the race as shown in
IEEE APEC Conference Dallas. TX March, 1995
c) Perfect Bearing
Fig. 5 Percent Film vs. Gamma for a Bearing [8] Fig. 6 EDM Capacitive Charging Characteristics
bearing [8]. Percent film is the time percentage during which of Fig. 1 are formed from the microscopic pits that soften
the "contacting " surfaces are fully separated by an oil or under repetitive heating of the race to its melting temperature.
lubricant film while Gamma is the relationship of lubricant Several authors suggest that shaft voltage < 0.3 volts is
film thickness to rms value of contacting surface roughness. safe, while 0.5 - 1.0 volts may develop harmful bearing
Most bearing applications operate in the Gamma = 1 to 2 currents, and shaft voltages > 2 volts may destroy the bearing.
region. This implies that high quality bearings look like a high The rotating bearing breakover threshold voltage (when
resistive impedance 80 % of the time with the oil film acting bearing current starts to flow) was measured under DC source
as a capacitor ready to charge to breakdown potential. A voltage to be 700 mv peak.
lower quality bearing will have low resistance metal to metal
contact a majority of the time and in the presence of high B. Proposed Theory of Bearing Current with PWM Inverters
resistivity lubricant acts as a race to ball junction capacitor
that may charge only randomly during non contact peak to The preceding analysis was based on steady state, low
valley points. frequency and low dv/dt shaft voltage sources. However, PWM
The magnitude of the shaft voltage will determine the inverter modulation causes high frequency step-like voltage
bearing current present in lower quality bearings having source waveforms and high dv/dt's to be impressed across the
asperity contacts the majority of the time or high quality stator neutral to frame ground. It is shown that a portion of
bearings that use low resistivity lubricants. A high shaft this waveform is also present as rotor shaft voltage to ground
voltage causes increased current and pits or craters to form due to capacitor divider action. The preceding sinewave
since bearing current flows thru a number of points. Heating analysis applies to PWM operation but with the change that
can occur at point contact to such a degree that the material the experimental static breakdown threshold voltage on the
melts creating craters, thus liberating wearing metal particles rotor shaft increases to 8-15 volts ( Fig. 6) vs. 700 mv for the
into the lubricant. A low shaft voltage has lower current same bearing monitored under 60 Hz sinewave operation (Fig.
amplitudes but has been found to still cause corrosive type of 10). This increase is explained using dielectric breakdown
pitting due to grease decomposition. theory for pulsed sources [9]. Fig. 7 shows that the impulse
In high quality bearings with high resistance grease, the breakdown strength of hexane (1.1 106 v/m) increases
junction bearing capacitor may discharge into a low dramatically over the static value for short step-like pulse
impedance circuit when the electric field exceeds the durations. The bearing voltage breakdown threshold also
breakdown strength in the lubricant asperity points . The increases as a function of shaft voltage rate of change [10].
bearing breakdown voltage threshold is 0.4 volts since mineral This increased breakdown level under PWM operation is
oil field strength is 106 v/m, a typical oil film is 0.2 microns undesirable since during bearing discharge the resulting EDM
and there are two films in series. On occasion the bearing bearing currents are much higher than with sinewave
capacitor voltage, charged by the shaft voltage present, operation. Fig. 8 shows that rough surfaces typically seen in
becomes high enough ( > 0.4 volts) to break down the grease bearings will have a statistical time lag of 3 us prior to
and a short (nanoseconds) high current impulse flows from the breakdown, which agrees with measured value of Fig 6.
charged oil film capacitor within the bearing as shown in Fig. It is theorized that the high quality bearings of Fig. 5
6. This discharge current pulse, if it occurs, is a prime source (Gamma = 2 ) give long mechanical life when used under
of bearing erosion and is commonly referred to as fluting or sinewave operation but may lead to premature bearing current
Electric Discharge Machining (EDM ). The washboard craters
IEEE APEC Conference Dallas. TX March, 1995
AC Line L2
AC Drive
460 Volt
L3
GND U V W
Earth Ground
16
10 Voltage
8 Shaft
50 X Differential Probe
Voltage
Shaft
4 Current
Neutral GND U V W
Carbon
Brush
2
AC Motor
0 Grounding
Strap
Rough Smooth Rough
Cathode Cathode Cathode Current Probe
MOTOR FRAME
Carbon Brush
C ball,i Cb Z
Inner n Balls C gap,i R
Race in Parallel ball,i Z ,i
Outer
Race
Per Ball Model Reduced Model
Grounding
Strap Insulating Sleeve Stator Laminations
Crf
Csr
Csf Line to Neutral
Sources
Zero Csr Rb
Csr Sequence
Csf Crf
Rotor Source
Cb Z
Stator Winding
Crf
between the stator and rotor connects the stator and rotor zero
sequence networks. Finally, the rotor to frame capacitance
and bearing provide the paths to ground from the rotor shaft,
here represented by the neutral of the rotor.
Calculated Measured
Csr 100 pF 100 pF
Csf ----- 11 nF
Crf 1 nF 1.1 nF
Cb 200 pF 200 pF
Fig. 16 Rotor - Frame Capacitance - Calculated
IEEE APEC Conference Dallas. TX March, 1995
Experimental
Simulation
Fig. 18 AC Drive Operation - Open Bearings
For simulation and analysis purposes, the model of Fig. 15 One area where the simulation fails to predict the observed
was reduced to a zero sequence approximation, which is the response occurs in the transient response of the dv/dt and
shaded portion of Fig. 15. A simulation was developed with EDM currents. Close examination of the experimental results
the parameters of Table 1 for the bearing model. The shows a 12.5 MHz oscillation in the measured current;
simulation provided an analytical tool for examining the however, the oscillation does not appear in the simulation
effects of PWM waveforms, verifying the system model and results. One explanation for this discrepancy is the
parameters by correlating simulation results with experimental measurement technique. Inserting a grounding strap modifies
data, and for evaluating various solutions to EDM. Fig. 19 the system impedance. The characteristic impedance of the
shows an expanded portion of Fig. 11 and a simulation grounding strap alters the natural frequency and establishes an
employing the zero sequence model. The forcing function for oscillation in the dv/dt and EDM currents.
the simulation was the stator neutral to ground voltage from
the experimental results. The outputs include the rotor voltage IV. The Electrostatic Shielded Induction Motor:
and probe current as shown. A Solution to EDM Bearing Currents
Comparing the simulation results to the experimental
results shows good agreement. The dv/dt and EDM currents The previous section's experimental results suggest
are representative of experimental results. The rapid rise in electrical discharge as a principal contributor to bearing
rotor voltage at the point of EDM discharge is in very good roughness. A bearing model was developed and interfaced
agreement with the data. To obtain this accuracy, an estimate with the model for the electrical source and interconnecting
of the nature of Zl is necessary. For the results presented network. The model reflects the observed electrical behavior,
above, Zl was modeled as a diac (Fig. 2); high impedance until which suggests the source of PWM induced bearing roughness
the voltage threshold is met; thereafter it is voltage limited. is the common mode or zero sequence voltage.
The threshold voltage was experimentally determined. The Using the model developed above, the task of proposing
value of the impedance while voltage tracking, determined solutions to EDM discharge becomes simply one of disrupting
from the rate at which the experimental rotor voltage of Fig. the discharge either through the source voltage,
19 decayed, was found to be in good agreement with the interconnecting impedance, or the bearing design. Thus three
results of Fig. 2. design areas are available for investigation.
IEEE APEC Conference Dallas. TX March, 1995
Fig. 20 Stator Shield - Open Bearing Fig. 22 Full Shield - Open Bearings
Because of the capacitive coupling from stator to rotor, the extending the Faraday shield to enclose the stator end
most likely candidate is the coupling mechanism from stator to windings and duplicating the tests above, a near complete
rotor - the Csr in Fig. 15. If an electrostatic shield is inserted shielding of the rotor voltage was observed. As results of Fig.
between the stator and rotor, the coupling capacitance from 22 show, the rotor voltage with grounding strap open is
stator to rotor is defeated; thus reducing the dv/dt and reduced 98% when compared to the unshielded case.
preventing voltage tracking by the rotor. Because the Connecting the grounding strap (Fig. 23), virtually zero dv/dt
induction machine generates torque through magnetic current was measured and no EDM current detected.
induction, the presence of the shield will not affect motor The experimental results presented above confirm bearing
output ratings. A shield was constructed by inserting 1 inch currents, both dv/dt and EDM, are induced primarily by
adhesive backed copper foil tape strips to cover the stator slot electrostatic coupling. The stator to rotor capacitance couples
area. The shield was grounded to the motor frame. the zero sequence or common mode source from stator to
Fig. 20 shows the stator neutral to ground and shaft voltage rotor. The bearing provides a return path for the common
for an identical operating condition as shown in Fig. 18. With mode source, thus allowing dv/dt and EDM discharge
the shield in place, a rotor voltage of 18 volts peak exists when currents.
the outer race grounding strap is open circuited - a 56%
reduction when compared to the 40 volts peak of Fig. 18. V. Conclusions
With the strap grounded (Fig. 21), the dv/dt currents were
reduced from 500 ma to 50 ma. No EDM currents were The paper presented a review of electrically induced bearing
detected. roughness for AC machines under low frequency sine wave
Employing the copper foil strips as indicated above reduced operation. A theory was proposed for lubricant dielectric
the rotor exposure to the stator windings in the precise breakdown under PWM excitation. Electrostatic coupled
proportion by which the rotor voltage is reduced. By discharge or displacement (dv/dt) and electric discharge
Fig. 21 Stator Shield - Sleeve Shorted Fig. 23 Full Shield - Sleeve Shorted
IEEE APEC Conference Dallas. TX March, 1995
machining (EDM) currents were identified and experimentally [3] Lawson, J. ,"Motor Bearing Fluting",
measured. Electrical models were developed and CH3331-6/93/0000-0032 1993-IEEE
experimentally verified for the source voltage, coupling [4] Prashad, H., "Theoretical Analysis of Capacitive Effect of
network, and bearing. An electrostatic shielded induction Roller Bearings on Repeated Starts and Stops of a Machine
motor was described and experimentally demonstrated as a Under the Influence of Shaft Voltages", Journal of Tribology,
solution to the bearing current problem. Jan. 1991
The technical literature and experience show unloaded [5] NEMA MG-1 Specification Part 31, Section IV , 1993
motors at high speed provide the worst case scenario for [6] Ammann, C. , Reichert,K., Joho, R., Posedel, Z., "Shaft
bearing currents. In addition, applications with coupled loads Voltages in Generators with Static Excitation Systems-
tend not to exhibit the problem because of parallel paths for Problems and Solutions", 1987 IEEE Power Eng. Society
electrostatic discharge. Summer Mtg.
[7] Andreason, S. "Passage of Electrical Current thru Rolling
ACKNOWLEDGMENT Bearings", SKF Gothenburg
[8] Harris,T. Rolling Bearing Analysis, Wiley, 1984
The authors wish to thank Mr. Steve Stretz for his research [9] Alston,L., High Voltage Technology, Oxford Press ,1968
assistance in the bearing current phenomenon from a motor [10] Prashad, H., "Theoretical Evaluation of Capacitance,
design point of view. Resistanace and their Effects on Performance of
Hydrodynamic Journal Bearings , Journal of Tribology, Oct.
REFERENCES 1990
[11] Prashad, H. "Theoretical Analysis of the Effects of
[1] Alger P., Samson H., "Shaft Currents in Electric Instantaneous Charge Leakage On Roller Bearings Lubricated
Machines" A.I.R.E. Conf. , Feb 1924 with High Resistivity Lubricants under the Influence of
[2] Costello, M., "Shaft Voltage and Rotating Machinery", Electric Current", Journal of Tribology Jan.1990.
IEEE Trans. IAS, March 1993