Bearings & Drives-Rockwell

Bearings and Drives
Bearings and Drives

Ron Brook - Rockwell Automation
presented at
Vibration Institute
Delaware Valley Chapter
January 27, 2000
Enteract Home
The Problem
The Problem
Historical Damage ( Utility Power )

Historical Damage ( Utility Power )
PWN ( Pulse Width Nodulation )

PWN ( Pulse Width Nodulation )
!GBT ( !nsulated Gate

!GBT ( !nsulated Gate
Bi
Bi
-Polar Transistor )
-Polar Transistor )
What Can You Do ?

What Can You Do ?
Brook Beginning Enteract Home
Lubrication Decomposition
Damage Due To
Damage Due To
EDN
EDN
( Electric Discharge Nachining )
( Electric Discharge Nachining )
Bearing "Fluting
Bearing "Fluting
Long-Term EDN
Long-Term EDN
!nverter Technology Transition
!nverter Technology Transition
I I
Six Step Technology
Six Step Technology
-
-
Six switching states per fundamental cycle
Six switching states per fundamental cycle
-
-
60 Hertz = 360 steps per second ( full wave )
60 Hertz = 360 steps per second ( full wave )
-
-
variable bus voltage to motor
variable bus voltage to motor
I I
PWN Technology
PWN Technology
-
-
Carrier frequency - 2,000 to 12,000 steps per sec.
Carrier frequency - 2,000 to 12,000 steps per sec.
-
-
Full bus voltage applied to motor (6S0
Full bus voltage applied to motor (6S0
vdc
vdc
)
)
Historical Electromagnetic !nduced Path
Historical Electromagnetic !nduced Path
I I
Problem caused by Electric Asymmetries
Problem caused by Electric Asymmetries
I I
Circulating Current - Insulate ODE Bearing
Circulating Current - Insulate ODE Bearing
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
New Electrostatic !nduced Path
New Electrostatic !nduced Path
I I
Electrostatic Coupling
Stator Windings
Rotor
Bearing
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Return to source
Electrical Notor Capacitance Nodel
Electrical Notor Capacitance Nodel
Rotor
Csr
Csr
Csr
Stator
Winding
Frame
Csf
Crf
Crf
Crf
Crf
Csf
Csf
Crf Cb
Csr
+
BVR =
Csr
+
Shaft voltage
Stator neutral voltage
BVR =
BVR - Bearing Voltage Ratio
Electrostatic Coupling - Electrical Nodel
Electrostatic Coupling - Electrical Nodel
Rot or St at or
Zer o Sequence
Sour ce
Dri ve
Csf
Crf
Csr
Cb
Rb
Z
Li ne t o Neut ral
Sour ces
Electrical Bearing Nodel
Electrical Bearing Nodel
Capacitance Variables
Load
Speed
Temperature
Lubricant
Viscosity
Additives
Oil Film Thickness
Dielectric Properties
Non Linearity Variables
Asperity Contact Area
Randomness
Mechanical
Electrical Cb
Rb
Z
l
Rotor
Frame
PWN Zero Sequence is not Zero
PWN Zero Sequence is not Zero
I I
Sinusoidal Power has a
Sinusoidal Power has a
true Zero Neutral
true Zero Neutral
I I
PWN Zero Sequence
PWN Zero Sequence
reaches DC Bus voltage
reaches DC Bus voltage
I I
Frequency is equal to
Frequency is equal to
inverter switching
inverter switching
frequency
frequency
Three Breakdown Nechanisms
Three Breakdown Nechanisms
I I Chemical Chemical
I I Nechanical Nechanical
- - Asperity contact Asperity contact
between balls and between balls and
races races
I I Electrical Electrical
- - EDN - oil film EDN - oil film
dielectric breakdown dielectric breakdown
- - dv dvfdt - induced by fdt - induced by
the switching the switching
transitions of PWN transitions of PWN
inverter inverter
Bearing Current Density - 60 Hz
Bearing Current Density - 60 Hz
Current Density (A/mm
2
)
Trouble-Shooting Procedure
Trouble-Shooting Procedure
I I
Shaft-to-ground voltage taken with
Shaft-to-ground voltage taken with
oscilloscope and pick-up brush
oscilloscope and pick-up brush
I I
!dentify voltage spikes
!dentify voltage spikes
Motor Frame
Rotor
Stator Laminations
Motor Frame
Stator Laminations
Outer
Race
Inner
Race
Inner
Race
Outer
Race
Insulating Spacer
Insulating Spacer
Carbon
Brush
Current
Probe
Grounding
Strap
Voltage Path
Oscilloscope
Neasurement Techniques to
Neasurement Techniques to
Address Grounding !ssues
Address Grounding !ssues
I I
Air cored current sensor
Air cored current sensor
I I
Oscilloscope
Oscilloscope
I I
Nultiple readings, current and voltage
Nultiple readings, current and voltage
I I
Shaft readings taken with brush; ground brush
Shaft readings taken with brush; ground brush
to motor frame for current reading
to motor frame for current reading
Current Return Path to vFD
Current Return Path to vFD
I I
Shield
Shield
I I
Notor ground
Notor ground
wires
wires
I I
Steel
Steel
baseplate
baseplate
ground (anybody
ground (anybody
use these ?)
use these ?)
I I
Auxiliary motor
Auxiliary motor
ground
ground
Neasurements
Neasurements
I I
Current (Common Node Current)
Current (Common Node Current)
-
-
all three vFD output phases inside cabinet
all three vFD output phases inside cabinet
-
-
all three phase leads, grounds, shields, armor,
all three phase leads, grounds, shields, armor,
etc
etc
. outside of the vFD cabinet
. outside of the vFD cabinet
-
-
outside the motor terminal box
outside the motor terminal box
-
-
inside the motor terminal box
inside the motor terminal box
-
-
auxiliary ground
auxiliary ground
-
-
shaft current
shaft current
Three ma]or components of CNC
Three ma]or components of CNC
I I
10-100 Hz - Due to motor cable asymmetry
10-100 Hz - Due to motor cable asymmetry
I I
800-3S00 Hz - Nost returns to inverter via
800-3S00 Hz - Nost returns to inverter via
cable shielding, not through bearings
cable shielding, not through bearings
I I
S0KHz - 1 NHz - Due to
S0KHz - 1 NHz - Due to
dv
dv
f
f
dt
dt
of switching.
of switching.
-
-
Nost damaging to bearings
Nost damaging to bearings
Neasurement Points for Current
Neasurement Points for Current
All 3 phases inside !nverter All 3 phases inside !nverter
Total conduit and ground Total conduit and ground
]ust outside cabinet ]ust outside cabinet
Total conduit and grounds Total conduit and grounds
]ust outside motor terminal ]ust outside motor terminal
box box
All 3 phases and grounds All 3 phases and grounds
inside motor terminal box inside motor terminal box
Shaft of driven unit Shaft of driven unit
Auxiliary grounds Auxiliary grounds
Shaft AND grounding brush Shaft AND grounding brush
of motor of motor
Neasurements
Neasurements
Cont'd
Cont'd
I I
Current reading inside vFD cabinet
Current reading inside vFD cabinet
establishes total common mode current
establishes total common mode current
I I
Reading outside vFD cabinet represents
Reading outside vFD cabinet represents
current flowing indirectly back through the
current flowing indirectly back through the
motor shaft, and auxiliary grounds
motor shaft, and auxiliary grounds
I I
Reading outside vFD cabinet and motor
Reading outside vFD cabinet and motor
terminal box should be zero
terminal box should be zero
I I
Reading inside motor terminal box will
Reading inside motor terminal box will
include indirect and direct current routes
include indirect and direct current routes
Neasurement !ssues
Neasurement !ssues
I I
Shaft voltage & bearing current out to S NHz
Shaft voltage & bearing current out to S NHz
I I
Bearing currents not easily measured
Bearing currents not easily measured
- - Estimate current by measuring shaft voltage to frame Estimate current by measuring shaft voltage to frame
I I
Use brush and holder to provide shaft contact
Use brush and holder to provide shaft contact
Rotor Shaft Voltage Spikes
Inverter Drive Carrier Frequency set to 2 KHz
Motor Operating at 100 Hertz
Rotor Shaft Voltage Spikes
Inverter Drive Carrier Frequency set to 14 KHz
Motor Operating at 25 Hz
Conclusions From Neasurements
Conclusions From Neasurements
I I
very difficult to predict bearing current susceptibility
very difficult to predict bearing current susceptibility
I I
Tracking bearing life most effective
Tracking bearing life most effective
I I
Shaft voltage readings can verify initiation of
Shaft voltage readings can verify initiation of
electrical damage
electrical damage
I I
Pre-failure bearing fault analysis extremely valuable
Pre-failure bearing fault analysis extremely valuable
I I
Select best approach to alleviate problem
Select best approach to alleviate problem
Conclusions
Conclusions
Cont'd
Cont'd
I I
Higher carrier frequencies cause a higher
Higher carrier frequencies cause a higher
incidence of voltage spiking
incidence of voltage spiking
I I
Spiking indicative of unpredictable frequency
Spiking indicative of unpredictable frequency
of
of
capacitive
capacitive
breakdown
breakdown
Potential Solutions
Potential Solutions
1.
1.
Eliminate problem at
Eliminate problem at
source.
source.
2
2
. Notor Faraday shield
. Notor Faraday shield
3.
3.
Ground shaft - bypassing
Ground shaft - bypassing
bearing
bearing
+.
+.
!solate shaftfbearing
!solate shaftfbearing
S.
S.
verify grounding
verify grounding
Eliminate at Source
Eliminate at Source
Reduce Drive voltage
Reduce Drive voltage
-
-
Pros:
Pros:
I I
Common solution to other !GBT-related issues
Common solution to other !GBT-related issues
I I
No additional equipment required
-
-
Cons:
Cons:
I I
Larger capacity (current) drive required
Larger capacity (current) drive required
I I
Will reduce potential, but not eliminate
Eliminate at Source
Eliminate at Source
Reduce Drive Switching Frequency
Reduce Drive Switching Frequency
-
-
Pros:
Pros:
I I
I I
Not the cause of harmonic distortion as
Not the cause of harmonic distortion as
believed by many
believed by many
-
-
Cons:
Cons:
I I
Eliminate at Source
Eliminate at Source
Drive Output FilterfChoke
Drive Output FilterfChoke
-
-
Pros:
Pros:
I I
Common solution for other Drive -related
Common solution for other Drive -related
issues
issues
I I
Retrofitable
Retrofitable
-
-
Cons:
Cons:
I I
Cost and space required
Cost and space required
I I
Reduces, but doesn't eliminate problem
Reduces, but doesn't eliminate problem
Electrostatic !nduced Path
Electrostatic !nduced Path
I I
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Return
to
Source
Shaft Grounding
Shaft Grounding
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Grounding the Shaft
Grounding the Shaft
Shaft Grounding
Shaft Grounding
-
-
Pros:
Pros:
I I
Ease of !mplementation
Ease of !mplementation
-
-
Cons:
Cons:
I I
Poor Life Experienced in high-speed operation
Poor Life Experienced in high-speed operation
> +,000 rpm
> +,000 rpm
I I
Nechanical Naintenance
Nechanical Naintenance
I I
Nechanical fit-up on retrofits
Nechanical fit-up on retrofits
Grounding the Shaft
Grounding the Shaft
Conductive Grease
Conductive Grease
-
-
Pros:
Pros:
I I
Low cost and ease of implementation
Low cost and ease of implementation
I I
Retrofitable
Retrofitable
-
-
Cons:
Cons:
I I
Separation at higher speeds reduces
Separation at higher speeds reduces
conductivity effectiveness.
conductivity effectiveness.
I I
Negatively impacts the grease lubricating
Negatively impacts the grease lubricating
properties
properties
Bearing !solation
Bearing !solation
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Frame
!solate Shaft
!solate Shaft
!nsulate Bearings
!nsulate Bearings
-
-
Pros:
Pros:
I I
Retrofitable
Retrofitable
except for potential sleeve problems
except for potential sleeve problems
I I
Off-the-shelf fix
Off-the-shelf fix
-
-
Cons:
Cons:
I I
Does not protect directly-connected equipment
Does not protect directly-connected equipment
I I
Coated Bearings do not prevent capacitive coupling of
Coated Bearings do not prevent capacitive coupling of
high frequency currents.
high frequency currents.
I I
Bearing sleeve - downtime and expense of bearing
Bearing sleeve - downtime and expense of bearing
housing modification.
housing modification.
Ceramic Balls
Ceramic Balls
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Frame
!solate Shaft
!solate Shaft
Hybrid Ceramic Bearing
Hybrid Ceramic Bearing
I I
Pros:
Pros:
-
-
Direct replacement for standard bearing-
Direct replacement for standard bearing-
minimum downtime.
minimum downtime.
-
-
Longer inherent bearing life
Longer inherent bearing life
I I
Cons:
Cons:
-
-
!nitial expense and potential long delivery.
!nitial expense and potential long delivery.
Shielded Stator
Shielded Stator
Motor
Frame
Motor
Frame
Motor
Frame
Motor
Frame
Frame
Rotor
Stator Winding
Stator Winding
Frame
Faraday Notor Shield
Faraday Notor Shield
-
-
Pros:
Pros:
I I
Permanent internal modification to motor.
Permanent internal modification to motor.
-
-
Cons:
Cons:
I I
Difficult (impossible ? ) and expensive to
Difficult (impossible ? ) and expensive to
retrofit.
retrofit.
I I
Not readily available
Not readily available
Conclusions &
Conclusions &
Recommendations
Recommendations
I I
Bearing current damage is more prevalent on
Bearing current damage is more prevalent on
motors driven by !GBT based PWN drives.
motors driven by !GBT based PWN drives.
I I
Different causes and solutions than traditional
Different causes and solutions than traditional
bearing current damage.
bearing current damage.
I I
End result of electrically initiated damage is
End result of electrically initiated damage is
lubrication andfor mechanical failure
lubrication andfor mechanical failure
Conclusions &
Conclusions &
Recommendations
Recommendations
I I
EDN damage is difficult to predict and measure.
EDN damage is difficult to predict and measure.
I I
Problem is REAL and usually assumed to be
Problem is REAL and usually assumed to be
unavoidable
unavoidable
I I
Several solution methods
Several solution methods
I I
Selecting the most effective solution will depend
Selecting the most effective solution will depend
upon several applications and technical issues.
upon several applications and technical issues.
I I
Grounding issues are critical to minimizing problem
Grounding issues are critical to minimizing problem
Case History 41
Case History 41
I I
Generator Bearing
Generator Bearing
I I
Nultiple Failures
Nultiple Failures
I I
!nsulated Outboard
!nsulated Outboard
Bearing
Bearing
Time Waveform Analysis
Time Waveform Analysis
I I
Peaks in excess o
Peaks in excess of
6 G's
6 G's
I I
!ncrease occurred
!ncrease occurred
over 3 months
over 3 months
I I
Third bearing
Third bearing
change in less
change in less
than 2 years
than 2 years
Spectral Analysis
Spectral Analysis
I I
Low level G's in
Low level G's in
spectrum
spectrum
I I
Non-synchronous
Non-synchronous
vibration
vibration
I I
Higher frequency
Higher frequency
peaks not related
peaks not related
to bearing
to bearing
frequencies
frequencies
Root Cause Failure Analysis
Root Cause Failure Analysis
I I
Outboard bearing insulation insufficient due to
Outboard bearing insulation insufficient due to
design of spoke - hub support
design of spoke - hub support
I I
0.010 insulation "peeled back during bearing
0.010 insulation "peeled back during bearing
installation
installation
I I
New bracket designed to provide sufficient hub
New bracket designed to provide sufficient hub
thickness
thickness
I I
New insulation ring over 0.S thick
New insulation ring over 0.S thick
Generator Outboard Bearing Hub
Generator Outboard Bearing Hub
I I
Thin wall supports
Thin wall supports
outer race
outer race
I I
Grounding brush would
Grounding brush would
also work to solve this
also work to solve this
problem
problem
Case History 42
Case History 42
Notor-Fan !nstallation
Notor-Fan !nstallation
I I
Typical
Typical
!nstallation
!nstallation
of Direct
of Direct
Drive Fans
Drive Fans
Electrical Fluting of Bearing
Electrical Fluting of Bearing
I I
Problem Occurring on Two of Eight Notors
Problem Occurring on Two of Eight Notors
I I
Outboard Bearing !nsulated
Outboard Bearing !nsulated
I I
!nboard Bearing Damaged
!nboard Bearing Damaged
I I
!GBT Nedium voltage Drives ( +60v )
!GBT Nedium voltage Drives ( +60v )
I I
SCR Driven Heaters in Notor
SCR Driven Heaters in Notor
I I
Coupling !nsulated - Required by Process
Coupling !nsulated - Required by Process
vibration of Suspect Bearing
vibration of Suspect Bearing
+.10 Nodulation = BPFO harmonics
+.10 Nodulation = BPFO harmonics
Notors 43, 4+, 4S, and 46
Notors 43, 4+, 4S, and 46
Acceleration Spectra
Acceleration Spectra
Notors 43,4+,4S, and 46
Notors 43,4+,4S, and 46
Acceleration Time Waveform
Acceleration Time Waveform
Shaft voltage
Shaft voltage
Current on Case Ground
vs
vs
Notor Ground
Notor Ground
Lead on 4S Fan Notor
Lead on 4S Fan Notor
vs
vs
Notor Ground on 43 Fan Notor
Notor Ground on 43 Fan Notor
Grounding - Right or Wrong ?
I I
Cable size good
Cable size good
I I
Connection point
Connection point
good
good
I I
Connection
Connection
continuity (?)
continuity (?)
I I
Cable weight
Cable weight
identical to
identical to
motor
motor
connection (?)
connection (?)
I I
Connection
Connection
continuity (?)
continuity (?)
I I
Connected to Plant
Connected to Plant
Ground Grid (?)
Ground Grid (?)
I I
Large difference
Large difference
between 43 and 4S
between 43 and 4S
measurements
measurements
Solution to the Problem
Solution to the Problem
I I
!nsulate both bearings
!nsulate both bearings
I I
Place grounding brush on motor shaft
Place grounding brush on motor shaft
I I
An !nvestigation into grounding issue is
An !nvestigation into grounding issue is
pending
pending
Case History 43
Case History 43
I I
Bearing fluting
Bearing fluting
I I
Belt-driven fans
Belt-driven fans
I I
!GBT drives
!GBT drives
I I
Nultiple failures
Nultiple failures
I I
Drives mounted within 1S feet of motors
Drives mounted within 1S feet of motors
Notors in Service -Good or Bad?
Notors in Service -Good or Bad?
I I
Evaluate motors
Evaluate motors
in service
in service
I I
All motors have
All motors have
outboard bearing
outboard bearing
insulated
insulated
Notors in Service - Good or Bad ?
Notors in Service - Good or Bad ?
I I
Fluting evident above
Fluting evident above
2KHz on three motors
2KHz on three motors
I I
Not all motors
Not all motors
experiencing problems
experiencing problems
!dentification of Bad Bearing
!dentification of Bad Bearing
I I
Bearing
Bearing
modulation
modulation
centered above
centered above
2kHz
2kHz
I I
Sideband
Sideband
modulation
modulation
occurring at +.21
occurring at +.21
orders (BPFO)
orders (BPFO)
Recommendations
Recommendations
I I
Replace motors with new
Replace motors with new
farraday
farraday
shield
shield
motors
motors
I I
!nvestigate grounding (motor ad]ustable
!nvestigate grounding (motor ad]ustable
base made of high impact plastic). Only
base made of high impact plastic). Only
ground on the motor is conduit
ground on the motor is conduit
References
References
I I
Busse
Busse
,
,
Erdman
Erdman
,
,
Kerkman
Kerkman
,
,
Schlegel
Schlegel
,
,
Skibinski
Skibinski
,
,
"Bearing Currents and Their Relationship to
"Bearing Currents and Their Relationship to
PWN Drives !ECON, Nov. 9S
PWN Drives !ECON, Nov. 9S
I I
Link,Ninimizing Electric Bearing Currents in
Link,Ninimizing Electric Bearing Currents in
Ad]ustable Speed Drive Systems!EEE, 1998
Ad]ustable Speed Drive Systems!EEE, 1998
I I
Bell,
Bell,
Epperly
Epperly
,
,
Cookson
Cookson
,
,
Fischer
Fischer
,
,
Skibinski
Skibinski
,Cope,
,Cope,
Schlegel
Schlegel
Experience with variable Frequency
Experience with variable Frequency
Drives and Notor Bearing Reliability !EEE,
Drives and Notor Bearing Reliability !EEE,
1998
1998

Bearings & Drives-Rockwell

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Bearings and Drives

Bearings and Drives

Historical Damage ( Utility Power )

PWN ( Pulse Width Nodulation )

!GBT ( !nsulated Gate

What Can You Do ?

Vous aimerez peut-être aussi

Bearings &amp; Drives-Rockwell

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Bearings &amp; Drives-Rockwell

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Bearings and Drives

Bearings and Drives

Historical Damage ( Utility Power )

PWN ( Pulse Width Nodulation )

!GBT ( !nsulated Gate

What Can You Do ?

Vous aimerez peut-être aussi

Bearings & Drives-Rockwell

Bearings & Drives-Rockwell