Introduction to How Bearings Work

The bearing makes many of the machines we use every day possible. Without bearings, we would be constantly replacing parts that wore out from friction. In this article, we'll learn how bearings work, look at some different kinds of bearings and explain their common uses, and explore some other interesting uses of bearings. The Basics The concept behind a bearing is very simple: Things roll better than they slide. The wheels on your car are like big bearings. If you had something like skis instead of wheels, your car would be a lot more difficult to push down the road. That is because when things slide, the friction between them causes a force that tends to slow them down. But if the two surfaces can roll over each other, the friction is greatly reduced. Bearings reduce friction by providing smooth metal balls or rollers, and a smooth inner and outer metal surface for the balls to roll against. These balls or rollers "bear" the load, allowing the device to spin smoothly Ball bearing motor A ball bearing motor is an unusual electric motor that consists of two ball-bearing-type bearings, with the inner races mounted on a common conductive shaft, and the outer races connected to a high current, low voltage power supply. An alternative construction fits the outer races inside a metal tube, while the inner races are mounted on a shaft with a non-conductive section (e.g. two sleeves on an insulating rod). Extend Motor Life with Improved Bearing Care Bearing failures are the root cause for the great majority of electric motor downtime, repair and replacement costs. Bearing and motor manufacturers are aware of the situation. Motor repair shops can attribute much of their business to bearing failures. And motor users see bearing failure as the fundamental cause of virtually every electric motor repair expense. Studies conducted by the Electrical Apparatus Service Association also demonstrate that bearing failures are by far the most common cause of motor failures. Knowing that shaft bearings are the Achilles heel of industrial electric motors is not a new idea in maintenance departments, but what is new is recognizing that something can be done to prevent most motor bearing failures.

Factors Affecting Bearing Life Electric motors actually present a relatively easy duty for shaft bearings. The motor rotor is lightweight, yet because of its large shaft diameter, the bearings are large. For example, the bearings supporting the 140 lb. Rotor for a typical 40 hp. 1800 rpm industrial motor are so large that they have an L-10 minimum design fatigue life of 3000 years, or 10 percent of the bearings are statistically expected to fail from fatigue after 3000 years of operation. Plant operating experience, however, strongly contradicts such optimistic estimates of motor bearing life. In actual industrial environments, bearing failure is rarely caused by fatigue; it is caused by less-than-ideal lubrication. Because of contaminated lubrication, bearings fail well before they serve their theoretical fatigue life. There are many reasons for less than-ideal bearing lubrication. Lubricants can leak out; chemical attacks or thermal conditions can decompose or break down lubricants; lubricants can become contaminated with non-lubricants such as water, dust, or rust from the bearings themselves. These lubrication problems can be eliminated. Motor bearings can last virtually forever by simply providing an ideal contamination-free, well-lubricated bearing environment. Conventional wisdom teaches that such an ideal motor bearing environment can be provided by using a dry-running lip seal or using sealed (lubricated-for-life) bearings. Indeed, for many light-duty applications, such bearing protection techniques are often sufficient to allow bearings to last as long as the equipment itself. However, these bearing protection methods have not significantly reduced the rate of bearing failure in severe-duty industrial motors. Bearings in industrial applications continue to fail because of inadequate lubrication caused by lubricant loss, contamination, and decomposition and break-down. Lip seals invariably wear out well before the bearing fails, and sealed bearings inherently foreshorten the life of a bearing to the service life of the contained grease (usually only about 3,000 to 5,000 hours for most industrial services). Maintenance professionals may find the following suggestions on how to forestall motor hearing failure obvious, but some new techniques and technologies are available. Lubricate Bearing at Correct Intervals Despite years of warnings from bearing manufacturers, over lubrication continues to plague many motor bearings. Too much grease can cause overheating of the bearings. The lubrication instructions supplied by the motor manufacturer will specify the quantity and frequency of lubrication. Generally, two-pole motors should be greased twice a year, four-pole and slower motors only once a year.

Other Suggestions Improved bearing protection and lubrication will reduce downtime and the maintenance costs of electric motors, but other important motor design features contribute to long service life, including over-sized high quality bearings, high-tech winding insulation, superior fan design, high-performance paint (such as epoxy) and a strong, rigid cast iron frame. These features, usually standard or readily available, are found in most industrial-grade severe-duty electric motors. However, are not universally accepted as essential for long motor life. Specifying permanent bearing protection for new motors, or retrofitting isolators onto existing equipment, usually requires initiative on the part of the users maintenance or engineering staff. Permanent, absolute bearing protection has a greater effect on motor life than any other decisions made in specifying, equipping, and caring for electric motors. Keeping bearings lubricated with the right amount of clean, uncontaminated, high-quality lubricant allows bearings in most industrial motors to outlast all other motor components.