A Practical Introduction To Electric Discharge Machining, or "Bearing Currents" in Bearings - Wha

EDM Physics and Reality EDM Physics and Reality
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A +,actical int,-d.cti-n t- Elect,ic Discha,/e Machinin/, -,
0Bea,in/ 1.,,ents0 in Bea,in/s 2hat it is, h-2 t-
dia/n-se, a3-id and 4iti/ate.

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1-ntents
Int,-d.cti-n. EDM, PWM.
Bea,in/ c.,,ent da4a/es EDM inc,ease. PWM is the 4ain ca.se.
P,-5le4s e6ist in all 4-t-, si7es 4-,e -, less
EDM cl-se8.+
The 9-., 9ail.,e 4echanis4s
Is-lati-n, 9ilte,, sha9t /,-.ndin/, ce,a4ic 5alls :hy5,id 5ea,in/s;
EDM si/nat.,e
1ases

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The -il 9il4 in a ,-lle, -, 5all 5ea,in/ is =.ite thin .s.ally less than -ne
4ic,-n. T2- c-nditi-ns dete,4ine 5,ea>8d-2n 3-lta/e) Oil 9il4 thic>ness
and st-chastically -cc.,in/ i4+.,ities in s.,9aces and -il.
A si4+le test ci,c.it can 5e .sed t- st.dy
5,ea>8d-2n 3-lta/e. See 9i/.,e t- le9t.
Res.lts sh-2n a,e si4.lated +e,9-,4ance
and 4eas.,e4ents -n a ,eal "&%! DGBB.
Si4.lated
Real

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It is 3e,y ,a,e that y-. 9ind a 5ea,in/ 2ith a D1 3-lta/e
a++lied t- it li>e sh-2n in +,e3i-.s 9,a4e. The 3-lta/e
d-es, -9 c-.,se, c-4e 9,-4 -the, s-.,ces. B.t the D1
5,ea>8d-2n test ill.st,ates 2hat an EDM 5,ea>8d-2n is
and it is a /--d sta,tin/ +-int 9-, the 9-ll-2in/ disc.ssi-n.
The 4-st c-44-n s-.,ce -9 sha9t 3-lta/e is n-2 +a,asitic
c-.+lin/ 9,-4 the stat-, -9 PWM 9ed asynch,-n-.-s
4-t-,s. An e6a4+le -9 a PWM 3-lta/e and the ,es.ltin/
4-t-, c.,,ent is /i3en in ne6t 9,a4e.

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M-t-, c.,,ent
M-t-, 3-lta/e

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Bea,in/ da4a/es inc,ease PWM is the c.l+,it
The,e a,e a 9e2 ,eas-ns 9-, elect,ical da4a/e t- 5ea,in/s.
The 4-,e c-44-n a,e)
Elect,ic 2eldin/ 2ith c-44-n lead a++lied t- 2,-n/ s+-t
0L-c-4-ti3e /,-.ndin/0 th,-./h 5ea,in/s
1i,c.latin/ c.,,ent th,-./h sha9t and 5ea,in/s
Elect,-static discha,/e :EDM; th,-./h 5ea,in/
Inc,eased .se -9 ?@Ds 2ith PWM inc,eases EDM and
is n-2 the d-4inatin/ ,eas-n 9-, 5ea,in/ da4a/es

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B?A1 Middle Ran/e Bi/h P-2e,
T-tal n.45e,
-9 +,-5le4s
P,-5le4
9,e=.ency
P,-5le4s e6ist in all 4-t-, si7es n-t -nly la,/e -nes.

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B?A1 Middle Ran/e Bi/h P-2e,
Di99e,ent +,-5le4s in di99e,ent 4-t-, si7es
1a+aciti3e 1-.+lin/
@,a4e ?-lta/e
Ind.cti3e 1-.+lin/

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EDM 1l-se8.+
The,e a,e 9-., +,e,e=.isites 9-, EDM :Elect,ic Discha,/e
Machinin/;
1a+acitance
1ha,/e :3-lta/e ac,-ss ca+acitance;
Is-lati-n
Is-lati-n 9ail.,e
EDM can 5e a3-ided 5y eli4inatin/ -ne :-, se3e,al;
-9 these +,e,e=.isites

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EDM 1l-se8.+
Ene,/y in the a,c e3a+-,ates steel s- that a c,ate, is c,eated.
> E D.% 2hen .nits a,e F4, ? and n@

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EDM 1l-se8.+
Test 2ith 04ac,-8ene,/y0. Mic,-9a,ads and h.nd,eds -9 3-lts
+,-d.ce shall-2 c,ate,s. B.t the +,inci+le h-lds 4-,e ca+acitance
and 4-,e 3-lta/e c,eate la,/e, c,ate,s

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EDM 1l-se8.+
N-,4al ca+acitance 3al.es :% %D n@; and n-,4al 3-lta/es :# %#
?; +,-d.ce c,ate,s in the % 4ic,-n ,an/e. Th-se sh-2n t- the le9t
a,e a5-.t that si7e.
Ty+ical 2ash85-a,d +atte,n sh-2n t- the ,i/ht. The +atte,n has
n- c-nnecti-n t- in3e,te, 9,e=.ency -, s+eed a +-+.la, and
c-44-n 4is.nde,standin/

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The 9-., 9ail.,e 4echanis4s
EDM ,e=.i,es that the,e is a +-tential di99e,ence ac,-ss the
5ea,in/ in -the, 2-,dsG the,e shall 5e a 3-lta/e di99e,ence
5et2een ,-t-, and stat-,. This 3-lta/e di99e,ence can 5e
c,eated in 9-., di99e,ent 2ays)
1a+aciti3ely c-.+led
Ind.cti3ely c-.+led
@,a4e 3-lta/e d.e t- hi/h /,-.nd i4+edance
E6te,nally c-.+led ene,/y
We shall ha3e a cl-se, l--> at these in the 9-ll-2in/ 9,a4es.

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The 9-., 9ail.,e 4echanis4s %. 1a+aciti3e 1-.+lin/.
PWM 3-lta/e 9,-4 the ?@D has 3e,y stee+ ed/es.
The c-44-n 4-de 3-lta/e :le9t; is ca+aciti3ely
c-.+led 9,-4 stat-, t- ,-t-,. The ,es.ltin/ 3-lta/e
ac,-ss the 5ea,in/ ,es.lts in EDM and dest,.cti-n.

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1a+aciti3e c-.+lin/
5-th sha9t ends 4-3e
in8+hase.
Sha9t 3-lta/e is
sa4e sha+e as
c-44-n84-de
3-lta/e
The ca+aciti3e 3-lta/e
di3ide, ,ed.ces sha9t
3-lta/e t- +e,cents -9
c-44-n84-de 3-lta/e,

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One ins.lated 5ea,in/ :-, -ne hy5,id 5ea,in/; is -9 n- .se in a sit.ati-n
li>e this. The ,es.lt is that ,-t-, discha,/es in the -the, 5ea,in/.
The 5ea,in/ 2ith the l-2est 5,ea>8d-2n 3-lta/e :3a,ies st-chastically
-3e, ti4e; 5,ea>s d-2n 9i,st. I9 the,eHs -nly -ne 5ea,in/, the 0ea,liest0
5,ea>8d-2n 3-lta/e /ets hi/he,. And, since ene,/y is +,-+-,ti-nal t-
3-lta/e s=.a,ed, discha,/e ene,/y and da4a/e inc,eases.
Ins.lated 5ea,in/

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An e6a4+le -9 ca+aciti3e c-.+lin/. This is a n-n8ty+ical case in a ,athe,
la,/e 4-t-,. The 9act that 5-th sha9t ends a,e in8+hase is i4+-,tant. The
ND 5ea,in/ is ins.lated. This 4eans that the sha9t 3-lta/e d-esnHt /- t-
7e,- and stays the,e, 5.t -scillates 2ith a hi/h 9,e=.ency dete,4ined 5y
5ea,in/ ca+acitance and 0l-cal0 ind.ctance. The ,-t-, ind.ctance and
ca+acitance act as a l-2+ass 9ilte, the -scillati-ns can ha,dly 5e seen
in t,ace A.

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The 9-., 9ail.,e 4echanis4s &. Ind.cti3e 1-.+lin/.
Sha9t 3-lta/e
@l.6 a,,-2
The s.4 -9 the th,ee +hases that 4a>e .+ a PWM 3-lta/e d-es
n-t e=.al 7e,-. A ,es.ltin/ n-n87e,- st,ay c.,,ent is /-in/ 9,-4
stat-, 2indin/ 3ia ca+acitance t- /,-.nd. The st,ay c.,,ent in3->es
a 4a/netic 9ield that :c-nt,a,y t- the sine 9ield; ind.ces a 3-lta/e in
the 4-t-, sha9t. A 3-lta/e that can ,each "D ? +> -, 4-,e in la,/e
4achines. The sha9t end 3-lta/es 4-3e -.t -9 +hase.

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P-siti3e 3-lta/e
e6c.,si-n
Ne/ati3e 3-lta/e
e6c.,si-n
Sha9t 4ean 3-lta/e is 7e,-. E6c.,si-ns .s.ally /- t- tens -9
3-lts. P.lse 2idth is in 4ic,-sec-nds ,an/e. RMS 3-lta/e,
the,e9-,e, .s.ally is 5el-2 % ?. M.lti4ete,s can n-t 5e .sed t-
st.dy sha9t 3-lta/e. *se an -scill-sc-+e 2ith at least &D MB7
5and82idth.

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A ty+ical PWM EDM sit.ati-n. Le9t sha9t end /-es ne/ati3e
.ntil a 5,ea>8d-2n -cc.,s. Le9t end then 4-3es in +-siti3e
di,ecti-n t- 7e,- 3-lts. In 9act the 2h-le ,-t-, and sha9t
4-3es in +-siti3e di,ecti-n s- that the ,i/ht sha9t end /-es
e3en hi/he, than it 2as. S-4eti4es ca.sin/ a sec-nda,y
5,ea>8d-2n in that 5ea,in/.

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R-t-, ca+acitance is a >ey +a,a4ete,. E3en 2ith a c-4+letely
ins.lated ,i/ht end 5ea,in/, the 3-lta/e e6c.,si-n at the le9t end
2-.ld 5e the sa4e and als- the ,es.ltin/ 5,ea>8d-2n.
An ins.lated 5ea,in/ is .s.ally e99ecti3e -nly in the 0-ld8
9ashi-ned0 4a/netic i45alance sit.ati-n. That is n-t a 3e,y
c-44-n sit.ati-n in 4-de,n 4-t-,s 2ith t-dayHs ti/ht
4a.9act.,in/ t-le,ances.

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An ins.lated 5ea,in/ has 5een installed :yell-2 I ins.lati-n;.
As sh-2n, the le9t 5ea,in/ d-es n-t 0>n-20 that the,e is an
ins.lated 5ea,in/. The 3-lta/e e6c.,si-n is sa4e as 5e9-,e
and 5,ea>8d-2n als-. 1.,,ent is NOT ci,c.latin/ in sha9t it is
-nly a =.esti-n -9 discha,/in/ ,-t-, ca+acitance. B.t, the
ins.lati-n .s.ally +,-l-n/s se,3ice li9e -9 the ins.lated
5ea,in/. N-t the n-n8ins.lated.

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E6a4+les -9 sha9t 3-lta/es ind.cti3e c-.+lin/.
The 9act that the ends 4-3e in -++-site di,ecti-ns is a s.,e
si/n that 2e ha3e ind.cti3e c-.+lin/. The 5,ea>8d-2n in
.++e, t,ace is ,e9lected in a si4ila, 3-lta/e dec,easeJinc,ease
in l-2e, t,ace.

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The 9-., 9ail.,e 4echanis4s <. @,a4e ?-lta/e.
Si4.lati-n. PWM ed/es a,e
c-.+led 3ia &D n@ t- 4-t-,
9,a4e. PE ind.ctance :#D FB in
this case; +,-d.ces 3-lta/e
d,-+ and ,in/in/.
Bl.e I PWM.
Red I @,a4e ?-lta/e.
The TRMS 3-lt4ete, sh-2s
a 9e2 h.nd,ed 4?. The
sc-+e sh-2s t,.e 3-lta/e.
G--d /,-.ndin/ is i4+-,tant
in cases li>e this.

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The 9-., 9ail.,e 4echanis4s !. E6te,nal Ene,/y.
E6te,nal ene,/y is al4-st al2ays t,i5-elect,ic ene,/y -, static
elect,icity. T,i5-elect,icity is 2hat y-. /et 2hen ,.55in/ t2-
4ate,ials a/ainst each -the,. Thin> 1at s>in and E5-nite. Ins.latin/
-ils and s-4eti4es e3en ai, can +,-d.ce static elect,icity. Li/htnin/
is a /--d, alth-./h s-4e2hat e6a//e,ated, e6a4+le. Sit.ati-ns
that 1AN +,-d.ce t,i5-elect,icity a,e)
Belt d,i3es
P.4+s and 9ilte,s 9-, -ils. Synthetic -ils a,e c,itical.
@ast :di,ect d,i3en; 9ans.
Sit.ati-ns 2he,e dy 4ate,ial is c-n3eyed. Wi,es in +a+e, 4achine
d,ye, secti-ns is a +,actical e6a4+le.
The,e a,e indicati-ns that Wind T.,5ines 4ay ha3e this +,-5le4.

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Miti/ati-n G,-.ndin/ B,.shes
G,-.ndin/ 5,.shes c,eate a +a,allel c.,,ent +ath s- that the
5ea,in/ is sa3ed. N-t -nly that they als- +,e3ent that a cha,/e
is 9-,4ed. G,-.ndin/ 5,.shes a,e -9ten 3e,y e99ecti3e, 5.t s-4e
e6+e,tise 4ay 5e needed 2hen a++lyin/ the4 t- la,/e 4achines.
They can 5e +.,+-se85.ilt .nits li>e the R-c>2ell e6a4+le -,
si4+le ad h-c de3ices li>e the -ne t- the ,i/ht.
They need ca,e, ins+ecti-n and 4aintenance.

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Miti/ati-n G,-.ndin/ B,.shes
An inte,estin/ s-l.ti-n is a ne2 ty+e -9 sha9t /,-.ndin/ ,in/ 2ith
ca,5-n 9i5e,s. A test 2as 4ade t- see i9 they a,e as e99icient as
the 4an.9act.,e, clai4s. The 4-t-, 2as a &# BP 4-t-, 9ed 9,-4
a 2ell8>n-2n d,i3e 2ith $ >B7 ca,,ie, 9,e=.ency. This +a,tic.la,
test 2as 4ade 2ith a =.a,te, -9 a ,in/. The EDM sh-2n t- the le9t
is c-4+letely eli4inated. The ,esid.al 3-lta/e is 5el-2 & ?, 2hich
is 2ell 5el-2 EDM ince+ti-n 3-lta/e. N-te) Di99e,ent scalin/K

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Miti/ati-n Ins.lati-n
End
shield
Ins.latin/
4ate,ial
Steel
,in/
M-di9yin/ end shield s- that 5ea,in/ is ins.lated is
-ne 4eth-d that has 5een .sed. It is ,athe, c-stly, 5.t
standa,d 5ea,in/s can 5e .sed n- need t- st-c>
s+ecials.

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Miti/ati-n Ins.lati-n
S+.tte,ed Al&O<.
A /--d ins.lat-,,
5.t als- a /--d
dielect,ic.
Al&O< :Al.4ina; is a /--d ins.lat-,, 5.t als- a /--d
dielect,ic. 1a+acitance can /et ,athe, hi/h in the %D n@
,an/e 9-, a AD 44 ID 5ea,in/. P.ttin/ the ins.lati-n -n
the inne, dia4ete, has se3e,al ad3anta/es. Less
ca+acitance and als- the,4al ins.lati-n 9,-4 h-t
,-t-,Jsha9t. And 5ette, the,4al c-ntact 2ith end 5ell.
Bette, +.t
ins.lati-n he,e

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Miti/ati-n @ilte,s
React-,
Di-des and ca+acit-,s
D1 5.s5a,
Th,ee8+hase
:4-t-,; 3-lta/e
d3Jdt 9ilte,s ,ed.ce the PWM ed/eHs ,ate8-98chan/e. That e99ecti3ely
,ed.ces ca+aciti3e st,ay c.,,ents,2hich 4eans less EDM. This is a
Sie4ens ty+e 9ilte,. It is ,athe, ela5-,ate, t,ansient ene,/y is 9ed
5ac> t- the D1 lin> -9 the in3e,te, :thatHs 2hat the di-des a,e 9-,;
and ca+acit-,s 4a>e s.,e that the s+eci9ied ?JFs isnHt e6ceeded.

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Miti/ati-n @ilte,s
ABB, a4-n/ -the,s, ha3e a si4+le, 9ilte,. It needs a ca5le and
4-t-, ca+acitance t- 5e e99ecti3e. Rin/in/ is a3-ided 5y sh.ntin/
2ith ,esist-,s. This 9ilte, is 9-, a s4alle, 4achine than the Sie4ens
9ilte, sh-2n in +,e3i-.s +ict.,e.

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Miti/ati-n @ilte,s
Di99e,ent d3Jdt 9ilte,s +,-d.ce di99e,ent 2a3e89-,4s.
N- da4+in/ -nly
,eact-, and ca5le
ca+acitance
Da4+in/ ,esist-,s
Ene,/y in ,in/in/
9ed 5ac> t- D1 lin>.
Red I ?@D -.t+.t Bl.e I 4-t-, 3-lta/e

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M-t-, ca5le
A4-,+h 4a/netic t-,-id
PE shall /- -.tside t-,-id
A 1-44-n84-de 9ilte, :ABB sh-2n; c-nsists -9 a set -9 0Metal
Glass0 t-,-ids. The t-,-ids a,e hi/hly +e,4ea5le and ,e+,esent
a hi/h i4+edance t- c-44-n84-de c.,,ents. They d- s- 5y
a5s-,5in/ the stee+ ed/es -9 the PWM. That n-t -nly ,ed.ces
ca+aciti3e st,ay c.,,ents, 5.t als- 9,a4e 3-lta/e. It is an
e99ecti3e s-l.ti-n, that s-4eti4es needs t- 5e s.++le4ented
5y ins.lated 5ea,in/s.
Miti/ati-n @ilte,s

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Th,ee t-,-ids can
a5s-,5 "DD F?s
A4-,+h-.s s-9t 4a/netic 4ate,ial has 3e,y /--d 4a/netic
+,-+e,ties. That is als- t,.e 9-, s-4e i,-n +-2de, ,in/s.
@e,,ites ha3e 4.ch l-2e, +e,4ea5ility and d- n-t +e,9-,4
2ell. The te,4 0@e,,ite Rin/0 is -9ten .sed t- desc,i5e these
n-n89e,,ite t-,-ids.
Miti/ati-n @ilte,s

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D,i3e syste4 4an.9act.,e,s -9ten +,-3ide /--d ad3ice.
This is 9,-4 the R-c>2ell A.t-4ati-n site.
Miti/ati-n

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA <"
Miti/ati-n

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA <A
Miti/ati-n

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA <$
1ha,/in/
Discha,/in/
The sha9t 3-lta/e is an -9ten cha-tic 4isch84asch -9 si/nal
c-4+-nents. The EDM discha,/e stands -.t in -ne 2ay it is
the -nly si/nal that has a ,ate8-98chan/e 4-,e than #D8%DD M?Js
and that 0lands0 at 7e,- :-, cl-se t-; 3-lts.
The cha,/in/ +hase l-->s di99e,ently, de+endin/ -n 2hat
the ene,/y s-.,ce is. B.t the discha,/e is al2ays the sa4e
a stee+ 3-lta/e d,-+ /-in/ t- D ?. This is the +,-+e,ty
.sed t- 9ind and disc,i4inate EDM.
EDM Si/nat.,e

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA <C
Bl-c> dia/,a4 9-, the BEPPE
:Bea,in/ P,edict-,;. A.6ilia,y
9.ncti-ns li>e 4eas.,e4ent -9
synch,-n-.s s+eed, sli+ and
te4+e,at.,e a,e sh-2n.
EDM Si/nat.,e and Meas.,e4ent

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA !D
The,e a,e se3e,al +,-t-ty+e i4+le4entati-ns -9 the Bea,in/
P,edict-,. The dis+lay -9 an ea,ly .nit is sh-2n.
PPS I P.lses Pe, Sec-nd
B I &DD M?Js
M I %DD M?Js
L I #D M?Js

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA !%
An-the, 3e,si-n c-ntains disc,i4inat-, and c-.nte,s in a se+a,ate
.nit that c-44.nicates 2ith a P1 3ia By+e,te,4inal -, -the,
asynch,-n-.s +,-t-c-l. A +,int-.t e6a4+le is sh-2n 5el-2.
S-,,y, S2edish, 5.t h-+e9.lly .nde,standa5le.

GKE ELEKTRONIK AB, GRANBERGSDAL, SWEDEN. !" #$" %&&"" GKE'SWIPNET.SE SK(PE) SKOGSG*RRA !&
The,e is als- the 0Lill8Be++e0. A
hand8held 5atte,y8d,i3en .nit that
can 5e .sed t- detect EDM acti3ity
in 5ea,in/s. A 4a/net c-nnects t-
/,-.nd and a ca,5-n elect,-de is
.sed t- c-ntact the sha9t. ?JFs
:M?Js; is set 2ith the >n-5 and
2hen the,eHs n- acti3ity :LED 5lin>s
2hen the,e is EDM; at le3els at -,
a5-3e %DD M?Js, the,e is n- ,is>
that EDM 2ill sh-,ten the 5ea,in/Hs
li9e.

A Practical Introduction To Electric Discharge Machining, or "Bearing Currents" in Bearings - Wha

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A Practical Introduction To Electric Discharge Machining, or "Bearing Currents" in Bearings - Wha

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EDM Physics and Reality EDM Physics and Reality

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