Experimental Study: Bearing Degradation Caused by Electrical Currents and Voltages at Low Speeds

In electric vehicles (EVs), bearings in traction motors are increasingly prone to electrical damage under operational currents and voltages, leading to accelerated wear and reduced lifespan. This study examines the extent of bearing damage under low-speed, electrically charged conditions to understand wear behavior at boundary lubrication better. Bearings were driven at low speed by a motor, with inner and outer rings connected to a pulsed power supply’s positive and negative terminals, simulating real-world shaft voltage conditions. The applied electrical parameters included voltages from 5 V to 240 V and frequencies of 10 kHz, leading to voltages at the bearing peaking between 0.1 and 12 V measured by an oscilloscope and multimeter. The tested bearings were disassembled, and scanning electron microscopy (SEM) was used to assess the damage associated with varying electrical stresses. The results revealed distinct wear patterns and degradation effects when the shaft current and peak voltage reached 2.5 A and 12 V, emphasizing the critical need for protective strategies. Future work will focus on evaluating the impact of higher rotational speeds and controlled power supply conditions to analyze the effects of increased power supply settings and compare outcomes to low-speed scenarios.