Preventing harmonics and (motor) problems when controlling motors with frequency control

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14h45 Welcome on the webinar platform

15h00 Start of the webinar

15h05 Presentation: How to prevent bearings failure from shaft voltage

15h25 Presentation: Preventing unplanned Shut-Downs due to Uncontrolled Electrical Discharge through Rolling Element Bearings !

15h45 Presentation: Preventing harmonics and (motor) problems when controlling motors with frequency control

16h00 Q&A and conclusion

1. How to prevent bearings failure from shaft voltage

In motor control, particularly with frequency control, asset owners often encounter a critical yet frequently overlooked issue: shaft voltage and its detrimental impact on bearings. The failure of bearings due to shaft voltage not only disrupts operations but also incurs significant maintenance costs. Understanding the root causes of shaft voltage and implementing effective mitigation strategies are essential steps towards ensuring the reliability and longevity of motor-driven systems.

Content of the presentation

• Root causes of shaft voltage
• Impact on the bearings
• Possibilities to proof
• Mitigation strategies
• AEGIS® Shaft Grounding Rings
• Electrical Ground System
• Best Practice
• Application examples

Learning Takeaways

• Gain insight into the origins of shaft voltage and its correlation with bearing failures.
• Understand the mechanisms of electrical discharge machining and its implications on motor reliability.
• Acquire knowledge of proven mitigation strategies, including the utilization of AEGIS® Shaft Grounding Rings.
• Learn best practices for establishing an effective electrical grounding system to prevent shaft voltage-induced issues.
• Explore practical application examples showcasing successful implementation of prevention measures in motor-driven systems.

2. Preventing unplanned Shut-Downs due to Uncontrolled Electrical Discharge through Rolling Element Bearings
 

The presentation will give an overview of bearing failures attributed to uncontrolled discharge currents, including phenomena such as electrical erosion, fluting of raceways, lubricant aging and white etching cracks. Additionally, the presentation will explore the risk of electromagnetic interference resulting from these discharge currents on bearing performances is discussed.

As preventive countermeasure, Schaeffler developed solutions to mitigate electrical damage, including hybrid bearings and current insulated coatings (e.g. InsutectTM). These innovative industrial solutions allow to divert current away from potential or strategic damage sites and is particularly useful in high-speed motors and generators exposed to these electromagnetic interferences. Structures, materials and characteristics of these dedicated Schaeffler’s components will be described in details focusing on their performances and associated costs. Industrial example of balance benefit will be given.

You will gain comprehensive insights into the challenges of preventing bearing damage from stray currents and learn about Schaeffler's innovative insulation solutions developed to address these challenges effectively while minimizing costs and maintaining mechanical performance.

Content of the presentation

• Various bearing failures due to uncontrolled discharge currents discussed: electrical erosion, raceway fluting, lubricant aging, white etching cracks.
• Countermeasures in bearing development examined: current shunt, current insulation techniques.
• Schaeffler's innovative high-speed motor bearings with integrated shunt elements presented.

Learning Takeaways:

• Understanding of phenomenology and diverse bearing failures caused by stray currents.
• Insight into the risk of electromagnetic interference and its implications on bearing performance.
• Knowledge of innovative countermeasures and insulation techniques, including Schaeffler's developments, to mitigate electrical damage and enhance bearing durability.

3. Preventing harmonics and (motor) problems when controlling motors with frequency control

In the current industrial environment, asset owners are tasked with the dual objectives of maximizing the efficiency and extending the service life of motor-driven systems. Variable Frequency Drives (VFDs) have revolutionized the management of motor operations by offering precise control over the motor's speed and torque. However, this advancement comes with its own set of challenges. One such complication is the occurrence of bearing damage resulting from electrical discharges, a phenomenon that can degrade performance and substantially curtail the longevity of essential machinery components. Asset owners are thus faced with a complex decision-making process: leveraging the immediate advantages provided by VFD technology while being cognizant of its potential to induce long-term operational issues.

Addressing the challenges associated with high frequencies and electrical discharges in motor systems necessitates a deep understanding of their underlying causes. This understanding is achieved through a systematic approach that begins with a comprehensive schematic representation of the issue, followed by thorough visual inspections and indirect measurements. Such an approach is instrumental in identifying the origins of current leakages and devising effective strategies to channel these currents back to the Variable Frequency Drive (VFD) with minimal resistance. ORBITS employs this meticulous step-by-step methodology to not just identify, but also to rectify the root causes of these electrical disturbances, ensuring enhanced performance and longevity of the motor-driven systems.

Content of the presentation

• Exploration of motor issues caused by Variable Frequency Drives (VFDs), with a specific focus on bearing currents.
• Dissection of the mechanics of pulse width modulation (PWM) and its potential unintended consequences.
• Discussion on various tactics for alleviating these complications, including:
• Deployment of filters.
• Importance of adhering to correct installation procedures.
• Utilization of specialized components.
• Demonstration of success through real-world scenarios and case studies.
• Provision of practical guidance on integrating strategies effectively to enhance VFD advantages while ensuring motor system durability.

Learning Takeaways:

• In-depth understanding of the challenges posed by Variable Frequency Drives (VFDs) to motor systems.
• Detailed, step-by-step guide to effectively address and resolve these issues.

• Free for employees of companies that are a member of  BEMAS
• Free for invitees of the speakers (request your discount code via the speakers)
• € 35,- per person excl. VAT  for non-members