BY JOHN MALINOWSKI & DANIEL R.

SNYDER

CHOOSING
AN ANTIFRICTION
BEARING
© DIGITAL STOCK

Selection of electric motor bearings

for coupled and belted loads

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HE DECISION BETWEEN WHICH able for heavy belted loads (i.e., roller bearing), and the

T antifriction bearing type to specify on

National Electrical Manufacturers Associa-
tion (NEMA) motors is not always easy or
obvious. From an end user’s perspective, it would be sim-
plest if each motor would only have one bearing configu-
ration available and have that bearing configuration be
suitable for both direct-connected and belted loads. Unfor-
tunately, that is currently not the case. This is particularly
true on the larger higher-speed motors (larger than 125 hp
and faster than 1,200 r/min). If a bearing is selected that is
optimized for direct connection (i.e., deep groove
ball bearing), and it is belted, the bear-
ing may prematurely fail due
to a mechanical overload
condition. On the other
hand, if a bearing is
selected that is suit-
1077-2618/06/$20.00©2006 IEEE
motor is directly connected, the bearing may prematurely
fail due to a lack of maintaining the required minimum
radial load. Often, less than optimal bearing selection can
work if special attention is given towards cleanliness, relu-
brication, alignments, etc. This article discusses the rela-
tionships between these various factors and bearing
selection and helps the reader understand the tradeoffs
involved in the various applications of antifriction bear-
ings and suggests alternate solutions.
History
Within the pulp and paper industry, an electric motor
may be connected to the driven load by two methods:
coupled and belted. Some variations in this exist, such as
inserting a quill shaft into a gearbox or using a vertical
pump motor that requires special analysis of radial and
49
axial loads; these will not be addressed in this article.

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 A coupled load is where the motor shaft is usually
connected by a flexible coupling to the driven load. This
type of load presents no axial or radial load to the motor
bearings except for the weight of the motor’s rotor and
shaft assembly (misalignment from mounting errors
can, however, add radial load). Antifriction (ball) or
hydrodynamic (sleeve) bearings are commonly used suc-
cessfully for a coupled load.
The most common type of belted load is when a V-
groove pulley is mounted on the motor shaft and is con-
nected to another pulley on the driven load by means of
one or more belts held in tension. This type of load can
generate high radial loads on the motor shaft, mostly at
the drive-end bearing because it is closest to the applied
external loading. Depending on the magnitude of radial
load, antifriction bearings (either ball or roller) are used
for belted loads.
On smaller motors (through about 100 hp in NEMA
404-5T frames), under normal conditions, a ball bear-
ing may be used for either coupled or belted loads
(many times bearing L10 life is the key—typically a
minimum of 50,000 h for belted loads). If the mini-
mum load requirements are met for the rolling bear-
ings, then the bearing life is often limited by the grease
lubrication life. As motors get larger than 100 hp, ball
bearings may still be used on coupled loads, but belted
loads should be evaluated for load on the bearing shaft
and a roller bearing with higher load capacity and pos-
sible misalignment capability selected, if required.
Roller bearings, however, require higher minimum
loading for operation than do ball bearings.
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Motor Construction
A requirement for two types of motors for different load-
ing conditions often causes problems in mills. If a 100+
hp motor with ball bearings is used on a heavy belted
load, the drive end bearing could fail after a short time
from overloading. If a motor designed for heavy belting
is used on a coupled load, there may not be enough radial
loading to cause the rolling elements to roll. They will
skate or skid on the race, causing high temperatures and
sometimes rapid and traumatic failure. Underloading of
a roller bearing, even with a belted load, can result in
premature failure from the same skidding phenomena.
This presents the challenge for a pulp and paper mill:
two motor designs are required depending on the
method of coupling to the load. Often these motors are
mixed in spare inventory, resulting in improper use and
early failure. A new toroidal roller bearing design does
offer some flexibility. These bearings may be capable of
operation under either a coupled or belted load, meet
minimum load requirements, and provide adequate life,
but they are not directly dimensionally interchangeable
with traditional bearings used in motors.
Ball Bearing Configurations
The motor is built with the bearings mounted directly to
the shaft of the motor with an interference fit. There is a
shoulder machined on the shaft, and the inner race of the
bearing is positioned directly against this shoulder. The
50
bearings are mounted in an interference (or “press”) fit,
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meaning that clearances are 0.0001–0.0015 in tight. The
endplates of the motor have bearing bores machined to
provide clearance or a “loose fit” with the bearing outside
diameter. It is usually 0.0000–0.0023 in loose. Most
often, the drive end bearing is held captive in the end-
plate, and the opposite drive bearing is allowed some
axial movement in that endplate to allow for thermal
growth or the shaft and rotor assembly. Often a spring
supplies an axial preload to the bearings to minimize
noise and keep the balls loaded.
Since radial loads are relatively low on coupled loads,
shaft material selection can be of normal strength steel
such as AISI or SAE Grade 1137. Primarily torsional loads
are present.
Roller Bearing Configurations
Like the motor with two ball bearings, the roller bear-
ing motor is built with a ball bearing and a cylindrical
roller or two self-aligning spherical roller bearings
mounted directly to the shaft of the motor. There is a
shoulder machined on the shaft, and the inner race of
the bearing is positioned directly against this shoulder.
The roller bearings are mounted in a “press fit,” mean-
ing that clearances are 0.0005–0.0019 in tight. The
endplates of the motor have bearing bores machined to
provide clearance or “loose fits” with the outer ring of
the bearing giving 0.0000–0.0023 in loose as well.
Since roller bearings accommodate limited axial loads,
the opposite bearing to the drive end bearing is held
captive in the endplate, and the drive bearing provides
some axial movement to allow for thermal growth or the
shaft and rotor assembly. In the case of cylindrical roller
bearings, this axial movement is accommodated within
the bearing as opposed to the housing bores. Because
roller bearings require higher minimum loads to func-
tion than ball bearings, they are normally only used for
belted or overhung loadings.
Motors requiring roller bearings with high overhung
loads require higher-strength shaft steel. Depending on
calculated radial shaft loads, the motor designer may select
grades such as AISI/SAE 1045 or 4140.
Toroidal Roller Bearing Configuration
A toroidal roller bearing provides self-aligning capabili-
ties and axial movement within the bearing, and it
requires lower minimum loading than other roller bear-
ings. The toroidal bearing mounts directly to the shaft
with an interference or tight fit of 0.0005–0.0022 in.
The outer ring is mounted to the endplate with a clear-
ance or loose fit of 0.0000–0.0023 in. It can provide
large axial movements within the bearing and, therefore,
is a nonaxial load carrying bearing and must be mounted
with a captive (or held) bearing capable of handling some
thrust loading.
Motors using a toroidal roller bearing offer advantages
in that they may be used on either a coupled or heavy belt-
ed load. The shaft material selection must be for the
worst-case condition of a heavy overhung load requiring
higher-strength shaft steel. Depending on calculated radial
shaft loads, the motor designer may select AISI or SAE
grades such as 1045 or 4140.
 The added width of a toroidal roller bearing may pre-
sent challenges to the motor designer attempting to uti-
lize existing endplate tooling to prevent the bearing from
protruding inside the motor where it is unsupported. The
loads from the bearing need to be directed to the strongest
part of the endplate.
Also, due to the additional heat produced when used
with heavy belted loads, a cooling fan mounted on the
shaft may be used. This may result in a non-NEMA “BA”
dimension (shaft shoulder to foot mount holes).
Table 1 illustrates a comparison of ISO radial capacity,
required minimum loads, misalignment capabilities, and
boundary dimensions for commonly used motor bearings.
Bearing Loads
The type of coupling connector used between the drive
and driven unit will influence the loads on the motor
bearings. There are two kinds of coupling drives: flexible
and rigid. Good alignment is important in both cases;
otherwise, additional forces may be induced into the
bearing system to reduce service life.
Proper alignment is particularly important with a rigid
coupling, where there are typically three bearings on a
shaft. When rigid couplings are aligned
very accurately, by using laser aligning
equipment, the drive end bearing might TABLE 1. BEARING CHARACTERISTC COMPARISON FOR A 95-MM
become relatively unloaded, the load SHAFT 449T FRAME, TEFC, 250-HP MOTOR AT 1,785 R/MIN.
being taken by the bearings on the non-
drive end and the coupling shaft. In this
case, a deep groove ball bearing is nor-
mally recommended at the drive end. Deep groove
selection. Most motor manufacturers can supply a work-
sheet that may be used to define the data required for the
analysis.
Bearing Selection
The purpose of using rolling bearings in electric
machines is to support and locate the rotor, to keep the
air gap small and consistent, and to transfer loads from
the shaft to the motor frame. The bearings should
enable high- and low-speed operation, minimize fric-
tion, and save power. The designer must consider many
different parameters when selecting the bearing type
and arrangement to meet the requirements of any par-
ticular motor application. The orientation of the motor
and the drive coupling can have a significant impact on
the final selection.
Electric motors and generators use a wide variety of
bearing types, including deep groove ball bearings, angu-
lar contact ball bearings, cylindrical roller bearings, taper
roller bearings, spherical roller bearings, toroidal roller
bearings, and spherical roller thrust bearings. The differ-
ent bearing types are shown in Figure 1. In small horizon-
tal machines, the most common arrangement consists of
Bearing ISO Minimum Allowable
Width Capacity Load Misalignment
45 mm 35,730 lb 100 lb 2–10 min

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A belt or gear drive will often load the ball bearing
motor bearings more heavily than a cou- Angular contact 45 mm 40,450 lb 230 lb 2–10 min
pling drive. Belt and gear drives therefore ball bearing
often use cylindrical roller bearings at the
drive end. In applications where there are Cylindrical roller 45 mm 87,640 lb 585 lb 4 min
bearing
heavy loads and a possibility of misalign-
ment and/or shaft deflection, a self-align- Spherical roller 45 mm 95,500 lb 1,100 lb 120 min
ing roller bearing should be considered. bearing
Any time a belted load is used on a large Toroidal roller 67 mm 137,000 lb 630 lb 30 min
motor, the pulley data should be analyzed bearing
to determine the appropriate bearing

Angular Cylindrical Spherical

Deep Groove Ball Taper Roller Spherical Toroidal Roller
Contact Ball Roller Roller Thrust
Bearing Bearing Roller Bearing Bearing
Bearing Bearing Bearing

1
Bearing types.
51

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 two deep groove ball bearings. In larg-
er or heavier loaded machines, roller
bearings are typically used. In vertical
machines, deep groove ball bearings,
angular contact ball bearings, or spher-
ical roller thrust bearings are typically
used, depending on the loads, speeds,
temperature, and environment of the
application.
In many cases, however, several fac-
tors must be considered and weighed
against each other when selecting a
bearing type, so that no general rules
can be given. The most important fac-
tors to be considered when selecting a
standard bearing type and an appropri-
ate choice are:
■ boundary dimensions
■ magnitude and direction of loads
■ speed: fixed, variable, or high
■ required precision
■ shaft and housing material
■ coupling, belt, or gear drive
■ horizontal or vertical mounting
■ environment
■ vibration level
■ noise level
■ temperature
■ required bearing life
■ lubrication: grease versus oil, integral seals.
A general overview of the standard bearing types, their bearing for axial loads. For combined loads, single- and
IEEE INDUSTRY APPLICATIONS MAGAZINE • NOV|DEC 2006 • WWW.IEEE.ORG/IAS
speeds, bearing internal clearance or
ROLLING preload, lubrication, and sealing.
The magnitude of the load is one of
BEARINGS IN the factors that usually determines the
size of the bearing to be used. General-
ELECTRIC ly, roller bearings are able to support
heavier loads than similar-sized ball
MACHINES bearings. Ball bearings are mostly used
where loads are light or moderate. For
SUPPORT AND heavy loads and where shaft diameters
are large, roller bearings are usually the
LOCATE THE more appropriate choice.
ROTOR, KEEP Cylindrical roller bearings, needle
roller bearings, and toroidal roller bear-
THE AIR GAP ings can only support pure radial loads,
while other radial bearings can accom-
SMALL AND modate some axial loads in addition to
radial loads.
CONSISTENT, Angular contact ball bearings can
support moderate axial loads at rela-
AND TRANSFER tively high speeds. For moderate and
heavy axial loads acting in one direc-
LOADS FROM tion, spherical roller thrust bearings
THE SHAFT TO THE can be used.
A combined load comprises a radial
MOTOR FRAME. and an axial load acting simultaneously.
The ability of a bearing to carry an
axial load is determined by the angle of
contact or load action internal to the
bearing—the greater the angle, the more suitable the

design characteristics, and their suitability for the demands double-row angular contact ball bearings and single-row
in motor applications is shown in the matrix in Table 2. taper roller bearings are most commonly used, although
Other important bearing-specific criteria must be con- deep groove ball bearings and spherical roller bearings
sidered when designing a bearing arrangement, including may also be suitable depending on the ratio of axial to
load carrying capacity and life, friction, permissible radial loading.

TABLE 2. BEARING PERFORMANCE CHARACTERISTICS.

Availability
Speed Radial Axial Combined of Shields
Bearing Type Noise Capability Loading Loading Loading Misalignment and Seals
Deep groove 5 5 3 3 3 2 5
ball bearing
Angular contact 5 5 3 4 4 2 2
ball bearing
Cylindrical 5 5 5 2 2 1 1
roller bearing
Tapered 3 3 4 4 4 1 1
roller bearing
Spherical roller 3 3 5 2 3 5 3
bearing
Toroidal roller 4 4 5 1 2 5 4
bearing
Spherical roller 3 3 2 5 4 5 1
thrust bearing
The numbers represent a relative scale from 1 to 5 with 1 being poor and 5 being excellent.
52

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 Single-row angular contact ball All ball bearings with integral
bearings and tapered roller bearings can seals on both sides are filled with a
only accommodate axial loads acting in BEARINGS grease of an appropriate quality and
one direction. For axial loads of alter- SHOULD ENABLE quantity based on the anticipated
nating direction, these bearings must operating conditions and required
be combined with a second bearing. HIGH- AND service life. Because of this, the bear-
When a load acts eccentrically on a ings are not designed to be relubri-
bearing, such as from an overhung LOW-SPEED cated in operation.
sheave or pulley, a tilting moment will
occur. Double-row bearings (e.g., deep OPERATION, Calculation of Bearing Load
groove or angular contact ball bear- The loads acting on the bearing can
ings) can accommodate tilting MINIMIZE be calculated according to the laws
moments, but paired single-row angu- FRICTION, AND of mechanics if the external forces
lar contact ball bearings or taper roller (forces from power transmission,
bearings are more suitable. SAVE POWER. work forces, or inertia forces) are
Angular misalignments may occur known or can be calculated. When
between the shaft and housing. Exam- calculating the load components for
ples are when the shaft bends (flexes) a single bearing, the shaft is assumed
under the operating load, when the bearing seating in the to be a beam resting on rigid, moment-free supports
housing is not machined to the same height, or when for the sake of simplification.
shafts are supported by bearings in separate housings that Radial bearings are often subjected to simultaneous-
are too far apart. ly acting radial and axial loads. If the resultant load is
Rigid bearings (i.e., deep groove ball bearings and cylin- constant in magnitude and direction, the equivalent
drical roller bearings) cannot accommodate any misalign- dynamic bearing load can be obtained from the general
ment or can only accommodate very minor misalignments, equation:
unless by force. Self-aligning bearings (i.e., spherical roller
bearings, toroidal roller bearings, and spherical roller thrust P = XFr + YFa,
bearings) can accommodate misalignment produced under
operating loads and also compensate for initial errors of mis- where P = equivalent dynamic bearing load, Fr = actual
alignment resulting from machining or mounting errors. radial bearing load, F a = actual axial bearing load, X =
The permissible bearing operating temperature in the radial load factor for the bearing, and Y = axial load fac-

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application limits the speed at which rolling bearings can tor for the bearing.
be operated. Bearing types with low friction and corre- X and Y load factors can be obtained in bearing manu-
spondingly low heat generation inside the bearing are facturers’ catalogs. Except for vertical applications, bear-
therefore the most suitable for high-speed operation. The ings in electric motors are subjected to little if any axial
highest speeds can be achieved with deep groove ball bear- loading, hence P = Fr.
ings when loads are purely radial and with angular contact
ball bearings for combined loads. This is particularly true Requisite Minimum Load
of angular contact ball bearings or deep groove ball bear- If a bearing is to operate satisfactorily, it must always be
ings with ceramic rolling elements. subjected to a given minimum load. This minimum
Locating and nonlocating bearings generally support load ensures proper rolling element rotation, i.e., no
shafts or other rotating machine components. Locating skidding, and enhances lubricant film formation in the
bearings provide axial location for the machine component rolling contact areas. A general “rule of thumb” indi-
in both directions. The most suitable bearings for this are cates that loads corresponding to 0.02 times the dynamic
those that can accommodate combined loads or can pro- radial load rating should be imposed on roller bearings
vide axial guidance in combination with a second bearing. and loads corresponding to 0.01 times the dynamic
Nonlocating bearings must permit shaft movement in radial load rating on ball bearings. The importance of
the axial direction so that the bearings are not overloaded imposing this load increases where accelerations in the
when, for example, thermal expansion of the shaft and bearing are high and where speeds are in the region of
rotor assembly occurs. The most suitable bearings for the 75% of the permissible speed ratings quoted in the
nonlocating position include cylindrical roller bearings. In bearing manufacturers’ catalogs.
applications where the required axial displacement is rela-
tively large and the shaft also may be misaligned, the Bearing Life
toroidal roller bearing is the ideal nonlocating bearing. The bearing type and size to be used in a motor applica-
The selection of an integral seal can be of vital impor- tion can be initially selected on the basis of its load rat-
tance to the proper performance of the bearing. A large ings in relation to the applied loads and the
number of types and sizes are available for requirements regarding service life and reliability. The
■ deep groove ball bearings basic dynamic load rating C is used for calculations
■ angular contact ball bearings involving dynamically stressed bearings, for example,
■ spherical roller bearings when selecting a bearing, which is to rotate under load.
53
■ toroidal roller bearings. It expresses the bearing load, which will give an ISO

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 281:1990 and ABMA Standards 9 comments in parenthesis in the fol-
and 11(1990) basic rating life of 1 lowing NEMA MG 1 and IEEE 841
million revolutions.
FOR HEAVY standards.
The simplest method of life calcula- LOADS AND
tion is to use the ISO or ABMA equation NEMA MG 1
for basic nonadjusted rating life, which is WHERE SHAFT NEMA MG 1 defines maximum

P allowable radial overhung load for
L10 =
C
, DIAMETERS ARE horizontal motors with antifriction
P ball bearings in NEMA MG 1 Table
LARGE, ROLLER 14-1A.
where L10 = basic rating life, millions ■ The limits are given and should
of revolutions; C = basic dynamic BEARINGS ARE not be exceeded. Bearing and shaft
load rating; P = dynamic bearing USUALLY THE failure constitute a safety hazard,
load; and p = exponent of the life and safeguards suitable to each
equation. MORE application should be taken.
For ball bearings, p = 3. For roller The figures in the NEMA table
bearings, p = 10/3. APPROPRIATE show limits for loads applied at the
For bearings operating at constant center of the N-W dimension and a
speed it may be more convenient to CHOICE. reduction factor for loads applied at
deal with a basic rating life expressed the end of the shaft. NEMA MG 1-
in operating hours using the equation 14.7.1 provides information on the

P mounting of sheaves (pulleys).
1,000,000 C ■ In general, the closer pulleys, sheaves, sprockets,
L10h = × ,
60n P or gears are mounted to the bearing on the motor
shaft, the greater the load on the closest bearing.
where L10h = basic rating, operating hours; and n = (The loading will be higher but the misalign-
rotational speed, r/min. ment less from shaft deflection). This will give
ISO 281:1990/Amendment 2:2000 also makes pro- greater assurance of trouble-free service.
visions for bearing manufacturers to recommend a suit- ■ The center of the belt, or system of V-belts, should
able method for calculating the life modification factor not be beyond the end of the motor shaft (for ade-
to be applied to a bearing based on operating condi- quate support for the sheave).
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tions. The ISO life modification factor aXYZ applies ■ The inner edge of the sheave or pulley rim should
the concept of a fatigue load limit analogous to that not be closer to the bearing than the shoulder on the
used when calculating other machine components. shaft but should be as close to this point as possible.
Furthermore, the life modification factor aXYZ makes ■ The outer edge of a chain sprocket or gear should not
use of the lubrication conditions, a factor for contami- extend beyond the end of the motor shaft.
nation level to reflect the application’s operating con- ■ NEMA MG 1-14.7.2 further discusses the mini-
ditions and performance level. mum pitch diameter for drives other than a V-belt.
■ To obtain the minimum pitch diameters for flat-
L10m = a1 aXYZ L10 , belt, timing-belt, chain, and gear drives, the mul-
tiplier given in Table 3 should be applied to the
where L10m = adjusted rating life (at ∼10% reliability), narrow V-belt sheave pitch diameters in 14.41 for
millions of revolutions; and aXYZ = life modification factor. alternating-current (ac) general-purpose motors or
to the V-belt sheave pitch diameters as deter-
Standards Defining Bearing Performance mined from NEMA 14.67 for industrial direct
To better clarify certain points, the authors have made current motors:
(The multipliers do not improve or worsen L10 life. The
TABLE 3. LOAD TYPE MULTIPLIERS.
tension in the belt will, but the size of the pulley diameter
has little influence in the bearing loading, as the location
Drive Multiplier of the load on the shaft is the same).
*
Flat belt 1.33
**
IEEE 841
Timing belt 0.9
IEEE Standard 841-2001 addresses both bearing life
Chain sprocket 0.7 and loading. Section 6 of that standard addresses
Spur gear 0.75 mechanical features of the motor, namely that horizontal
and vertical ball bearing and roller bearing manufactur-
Helical gear 0.85 ing tolerance limits shall be in accordance with Table 4
*
The above multiplier is intended for use with conventional single-ply belts. When of ABMA 20-1996. In addition, ball bearings used in
other then single-ply belts are used, the use of a larger multiplier is recommended.
**
horizontal motors shall have ABMA C/3 clearances.
It is often necessary to install timing belts with a snug fit. However, tension should
be no more than necessary to avoid belt slap or tooth jumping.
■ Bearings are to be selected to provide an L10 life of
54
26,280 h minimum per ABMA 9-1990 or ABMA

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 11-1990, as applicable. L10 life
calculations for vertical motors
and horizontal motors mounted
in a vertical position shall con-
sider applicable thrust loading.
L 10 life calculations shall be
based on external side loads for
NEMA belted application lim-
its, in accordance with Section
14.42 of NEMA MG 1-2003,
and internal loads defined by
the manufacturer. For NEMA
frame sizes above 445T, mini-
mum sheave sizes in centime-
ters shall be defined by (1) or
(2) and shall be applied per
NEMA requirements for nar-
row width belts:
Sheave diameter = 70.0 (P/NR )1/3 ,
where P is rated is rated motor power (kW) and NR
is rated motor speed (r/min).
Sheave diameter = 63.5 (P/NR )1/3 ,
where P is rated motor power (hp) and NR is rated
motor speed (r/min).
Note that the two-pole belted applications are not
recommended for motors above 19 kW (25 hp).
■ Antifriction bearings are acceptable where the dN
factor is less than 300,000. (The dN factor is the
product of bearing size (bore) in millimeters and the
rated speed in r/min).
■ When direct coupled, the stabilized bearing temper-
ature rise at rated load shall not exceed 45 ◦ C (50 ◦ C
on two-pole motors) as measured by a thermometer
or thermocouple on the surface of the bearing hous-
ing as close to the outer race as possible.
■ Bearings shall be suitable for, and supplied with,
rust-inhibiting grease compatible with polyurea-
thickened grease.
■ Some modifications to motors may be required to
accommodate oil mist lubrication. The manufactur-
er shall be consulted for oil mist lubrication.
IEEE 841–2001 requires some additional bearing sys-
tem mechanical construction requirements:
■ Bearings shall be regreasable without disassembly
of the fan or fan covers and shall contain a reservoir
equipped with outlet plugs that extend beyond the
fan cover for elimination of purged grease.
■ Inner bearing caps shall be provided so that the entry
of oil or grease into the motor interior is minimized.
■ Bearing and grease reservoirs shall be protected from
entry of contaminants. Most end users request that
replaceable rotating noncontact labyrinth seals be
used for this.
In section 3.2 of IEEE Standard 841-2001, abnormal
axial or side thrust is defined as an unusual service condi-
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tion that must be defined by the users
for analysis by the motor manufacturer.
THE SELECTION
Lubrication: Grease or Oil
OF AN INTEGRAL If rolling bearings are to operate reli-
ably and realize their full service life
SEAL CAN BE they must be adequately lubricated.
The function of the lubricant is to
OF VITAL form a protective oil film that sepa-
rates the bearing components and pre-
IMPORTANCE vent metal-to-metal contact. The
TO THE PROPER lubricant also protects the bearing and
related components against corrosion.
PERFORMANCE When grease is used as a lubricant, it
can also help protect the bearing
OF THE BEARING. against contaminants like dirt, dust,
and water. Some important properties
of a lubricant include viscosity, film
forming ability, and consistency (for
grease). The most important determi-
(1) nants of the film thickness are
■ rotational speed
■ bearing temperature
■ load
■ base oil viscosity
■ NLGI grade number or consistency for grease.
(2) The choice between grease lubrication and oil lubrica-
tion is chiefly determined by the following factors:
■ grease should be used in applications where the fol-
lowing requirements apply:
– simplified maintenance
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– improved cleanliness (fewer leaks)
– better protection against contaminants
■ oil lubrication should be used in applications where
normal operating temperatures are high as a result
of an external heat source or excess heat generated by
the machine or its bearings at high speed.
Note that the friction in the bearing is generally lower
with grease than with an oil bath, provided that the
appropriate type and amount of grease is used and that it
is supplied to the bearing in a suitable manner. The oper-
ating temperatures will be similar, however, since heat is
not removed with grease. Oil lubrication should be used
when the relubrication interval for grease is too short.
Using the best and most suitable lubricant related to
specific operating conditions is of crucial importance in
obtaining appropriate motor performance and reliability.
Areas of consideration should include the following:
■ bearing type and size
■ operating temperature
■ load
■ speed range
■ operating conditions e.g., vibration levels, orienta-
tion of the shaft (horizontal or vertical)
■ cooling
■ sealing efficiency
■ environment.
Grease Lubrication
Under normal speed and temperature conditions, the
55
bearings in electric motors are usually lubricated with
 grease. Grease has a number of ing prevent damaging electric cur-
advantages when compared to oil. It BEARING rents—sometimes seen when using a
allows simpler, more cost-effective motor with a PWM (pulse width mod-
housing and sealing designs while SELECTION ulated or inverter) ac drive—from pass-
offering better adhesion of the lubri- ing through the bearing. This is one of
cant to critical surfaces and protec- REMAINS A the main reasons for using hybrid bear-
tion against contaminants. ings in electric motors and generators.
For small- and medium-sized ball CONSIDERATION High-speed electric motors use hybrid
bearings where the grease life is bearings because they provide substan-
longer than the expected service life ON LARGER tially longer service life due to lower
of the bearings, one single filling of NEMA FRAME operating temperatures and longer
grease is sufficient. The grease must grease life as well as lower friction than
then be retained in the bearings and MOTORS OF 125 traditional all-steel bearings.
prevented from escaping. Polyurea-
and urea-based greases are typically HP AND ABOVE. Conclusions
furnished by most manufacturers of Bearing selection remains a considera-
industrial motors. Lithium-based tion on larger NEMA frame motors of
greases or oil are normally used for 125 hp and above. Different bearing
roller bearings on larger motors. arrangements and solutions may be necessary depending
The life expectancy of grease depends on several factors on the operating conditions. Bearing load capacity, mini-
including the type of bearing, the type of grease, the ori- mum loads, and lubrication methods all can influence
entation and speed of the motor, and the operating tem- the proper choice. In addition, the external loading from
perature of the bearings. For instance, roller bearings have pulleys or sheaves can lead to additional loadings as well
shorter relubrication intervals than ball bearings. Other as misalignments within the bearing, thereby limiting
factors must be considered, including the sealing arrange- life. A new toroidal roller bearing design may offer some
ment, operating environment, and contamination. For advantages, but endplate modifications may be required.
small ball bearings in standard motors, since normal The toroidal roller bearing is a self-aligning roller bear-
grease life usually exceeds the expected service life of the ing that combines the features of a cylindrical roller
motor, these bearings are usually fitted with seals or bearing (internally adjusts for axial movements), the nee-
shields and lubricated for life. At the end of the bearings’ dle roller bearing (long rollers to maximize load capacity)
life, they are simply replaced. and the spherical roller bearing (raceways based on
IEEE INDUSTRY APPLICATIONS MAGAZINE • NOV|DEC 2006 • WWW.IEEE.ORG/IAS

Severe duty and IEEE 841 motors are often supplied spheres to accommodate misalignments). The user
with open bearings and provision for regreasing regardless should evaluate the connection to the load and consult
of the motor size. However, if the grease life is shorter with the motor manufacturer on belted loads to achieve
than the expected bearing life, the bearings need to be an optimized solution. By utilizing this new toroidal
relubricated while the grease is still performing satisfacto- bearing, it may now be possible for mills to stock one
rily. This is usually the case on motors above 20 hp. When motor that is suitable for either coupled or belted loads.
using high-performance greases, a longer relubrication
interval and grease life may be possible.

Oil Lubrication References

Oil is typically selected as a lubricant when rotational
speeds or operating temperatures make it impractical or
impossible to use grease. In applications where there are
high operating temperatures, recirculating oil systems
are used to dissipate heat. Recirculating systems can also
be used to remove and filter out contaminants. Oil lubri-
cation requires more sophisticated seals and there could
be a risk of leakage. In general, only large electric motors
(above NEMA sizes) and high-thrust vertical pump
motors are oil lubricated.
Alternate Bearing Materials
Hybrid bearings have rings made from bearing steel and
rolling elements made from bearing-grade silicon nitride.
Silicon-nitride is a low-density, high-strength ceramic
material that has a high degree of toughness and hardness
with excellent insulating properties as well. When used as
an insulator, the ceramic rolling elements in a hybrid bear-
56
[1] Motors and Generators, NEMA Standard MG 1-2003.
[2] IEEE Standard for Petroleum and Chemical Industry—Severe Duty Totally
Enclosed Fan-Cooled (TEFC) Squirrel Cage induction Motors—Up to and
including 370 kW (500 hp), IEEE Standard 841-2001.
[3] Rolling Bearings—Dynamic Load Ratings and Rating Life, ISO Standard
281:1990.
[4] Load Ratings and Fatigue Life for Ball Bearings, ABMA Standard 9-
1990.
[5] Load Ratings and Fatigue Life for Roller Bearings, ABMA Standard 11-
1999.
(6) Rolling Bearings—Dynamic Load Ratings and Rating Life, Amendment 2:
Life modification factor axyz ,, ISO Standard 281:1990, Amendment
2:2000.
John Malinowski (JMalinowski@ieee.org) is with Baldor
Electric Company in Fort Smith, Arkansas. Daniel R.
Snyder is with SKF USA Inc., Kulpsville, Pennsylvania.
This article first appeared in its original form at the 2005
IEEE Pulp & Paper Industry Conference.

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