Bearing current and shaft voltage measurement in electrical motors

Abstract: Due to the fast-rising voltage pulses of pulse width modulated drives, the generated shaft voltage of electrical motors causes electrical discharge currents in bearings. These discharges can cause bearing failure leading to costly maintenance and unexpected production stops. To eliminate the raised shaft voltage, several techniques are used such as shaft grounding brushes, insulated bearings and conductive grease. The possibility to measure discharge activity on a PWM driven induction motor offers a tool for researchers to test different bearings in electric motors. In order to measure the shaft voltages and bearing currents, modifications of an induction motor are made firstly using 3D software and then on the physical motor. By insulating the bearing from the frame and attaching a copper ring to the bearings outer race bearing currents can be measured. The combined measurements of shaft voltage, bearing currents and frame currents shows the bearings conductive states at low speed, and insulated state at higher speed. Electrical discharge activity (DA) is observed as shaft voltage raises, resulting in a bearing current spike and shaft voltage drops rapidly while stator current is unaffected. Experimental tests were performed with a sample bearing at different operating conditions, such as operating speed, temperature, motor load, etc., to determine the effect of the common mode voltages on bearing currents and shaft voltages. At low temperatures between 23-26 ˚C and motor speeds above 1000 rpm EDM currents were observed. On temperatures above 40 ˚C no major EDM currents were observed regardless of rpm due to the bearing remaining in an ohmic conductive state. The modifications of the motor have shown to give reliable bearing current and shaft voltage measurements that can help in future research in this area.