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The wheels of industry turn on bearings, so why do the wheels often vibrate, clatter, squeak, drag, and overheat? Bearings can fail for lots of reasons. Most failures are related to lubrication and contamination, but myths and misconceptions handed from one generation of maintenance engineers to the next help perpetuate many easily avoidable problems. These myths fall into three general areas of bearing use: installation, misapplication, and lubrication.

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Isolation improves communication by breaking ground loops and reduces noise when there are large differences in ground potential between ports. These devices allow for robust communication up to 500kbps (MAXM22510) and 25Mbps (MAXM22511).

Fit tolerance

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Table 1 also shows that the tolerance band generally widens as bearings get larger, and that the journal fit is always interference (shaft journal is larger than bearing ID), while the bore fit is always line-to-line (housing bore is the same dimension as bearing OD) to loose (housing bore is larger than bearing OD).

H8 tolerance

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The MAXM22510/MAXM22511 evaluation kit (EV kit) is a fully assembled and tested PCB that demonstrates the functionality of the MAXM22510/MAXM22511 isolated RS-485/RS-422 transceiver module. The EV kit operates from a single 3.3V supply.

The same principles apply to bearing housing bores. If the fit is too tight, the bearing can be damaged during an aggressive assembly attempt (i.e., a large mallet). If it is too loose, there may not be enough friction between the outer race and the bearing housing bore to prevent movement ranging from micromotion to the bearing spinning in the housing. It is also possible for the fit to be within tolerance at ambient temperature but expand at operating temperature, allowing the bearing outer race to move, especially with aluminum housings.

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Fans and blowers are simple pieces of equipment, yet require a lot of maintenance, particularly for bearings. The higher the speed, the more problematic they become. This article details how to avoid common problems caused by the improper selection of pillow block housings, seals, bearings, lubricant and lubrication systems.

Figure 1 illustrates the importance of precise measurement for the journal fit of a 6210 bearing for which the acceptable limits are 1.9686 in. to 1.9690 in. (50.002 mm to 50.013 mm). For example, if a machinist measures 1.9687 in. (50.004 mm), the measurement appears to be acceptable. However, if the machinist is only able to measure to within ± 2 tenths (± 5.1 μm), the confidence factor that the measurement is in tolerance decreases to 75% of the capability, because only 3 of 4 tenths will fall within tolerance-i.e., everything from -1 tenths to +2 tenths will be in tolerance while -1 to – 2 will not. For example, 1.9687 in. to 0.0002 in. = 1.9685 in. and would be out of tolerance.

The MAXM22510 and MAXM22511 isolated RS-485/RS-422, full-duplex, transceiver modules provide 2500VRMS (60s) of galvanic isolation between the cableside (RS-485/RS-422 driver/receiver side) and the UART-side of the device. An integrated DC-DC powers the cable-side of the module. No external components are required. Isolation improves communication by breaking ground loops and reduces noise when there are large differences in ground potential between ports. These devices allow for robust communication up to 500kbps (MAXM22510) and 25Mbps (MAXM22511). The MAXM22510/MAXM22511 operate from a single 3.3V supply on the UART-side. An integrated DC-DC converter generates the 3.3V operating voltage for the cable-side of the module. The devices include one drive channel and one receive channel. The receiver is 1/4-unit load, allowing up to 128 transceivers on a common bus. Integrated true fail-safe circuitry ensures a logic-high on the receiver output when inputs are shorted or open. Undervoltage lockout disables the driver when cable-side or UART-side power supplies are below functional levels. The driver outputs and receiver inputs are protected from ±35kV electrostatic discharge (ESD) to GNDB on the cable-side, as specified by the Human Body Model (HBM). The MAXM22510/MAXM22511 are available in an LGA 44-pin package and operate over the -40°C to +105°C temperature range.ApplicationsBuilding AutomationHVACIndustrial AutomationPower MetersProgrammable Logic Controllers

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Interference fits and loose fits are expressed in “tenths” (a unit equal to 0.0001 in. or 2.54 microns; μm), a level of precision that requires extreme care to measure accurately. A recent study involving 16 machinists in nine service centers found that experienced machinists with calibrated, well-maintained micrometers should have no problem measuring journals within ±2 or 3 tenths (±5.1 μm to 7.6 μm). The same study, however, found that 25% of the measurements of certified master rings of known dimensions were off by 10 tenths to 20 tenths [0.0010 in. to 0.0020 in. (25 μm to 51 μm)], in most cases due to lapsed calibration intervals and improper use of machinists’ standards.

Integrated true fail-safe circuitry ensures a logic-high on the receiver output when inputs are shorted or open. Undervoltage lockout disables the driver when cable-side or UART-side power supplies are below functional levels.

Micromotion causes fretting (mechanical wear at the surface), which will appear as small rusty patches on the bearing inner or outer race, or on the housing or shaft (see Figure 2). Because the oxidized areas are usually harder than the bearing surfaces, fretting can accelerate mechanical wear. Under the right circumstances, fretting can occur on either fit. Bearing fits are critical to the reliability of rotating equipment. Application conditions including the type of driven load, the connection to that load (direct coupled or belted), and the proper bearing for the application are all factors to be considered in achieving the correct fit.

It is of utmost importance, however, that machinists use properly calibrated measuring tools and the correct techniques to ensure accurate measurement of these precision tolerances. Not only must the gage be calibrated according to the appropriate schedule, but also it should be compared to the standard regularly—at least daily.

A tight (interference) fit is usually recommended for motor bearing journals. Standard fits for radial ball bearing journals range from j5 to m5; the standard housing fit is H6 (see Table 1). These are the “standard” fits and may be different depending on the machine designer’s understanding of the application.

The MAXM22510/MAXM22511 evaluation kit (EV kit) is a fully assembled and tested PCB that demonstrates the functionality of the MAXM22510/MAXM22511 isolated RS-485/RS-422 transceiver module. The EV kit operates from a single 3.3V supply.ApplicationsBuilding AutomationHVACIndustrial AutomationPower MetersProgrammable Logic Controllers

If these measures are taken and fretting still is a problem, several anti-fretting compounds are available on the market. Talk to your bearing vendor.

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The MAXM22510 and MAXM22511 isolated RS-485/RS-422, full-duplex, transceiver modules provide 2500VRMS (60s) of galvanic isolation between the cableside (RS-485/RS-422 driver/receiver side) and the UART-side of the device. An integrated DC-DC powers the cable-side of the module. No external components are required.

Radial load tends to inhibit micromotion, and a strong, consistent radial force can “pin” the bearing race to the bore. But the weaker the force, the greater the likelihood that the micromotion will occur (e.g., a perfectly aligned, direct-coupled application theoretically would have no radial load).

A journal fit that is too tight will preload the bearing (reduce its internal clearance), which will increase the friction and temperature and lead to premature bearing failure. It is also important not to exceed the tolerance in the other direction. If the fit is too loose, it will allow movement ranging from micromotion to the bearing spinning on the shaft. The latter usually results from the combination of a loose fit and an increase in the internal friction of the bearing.

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A note: Typical calibration intervals are 1 year; determine what is appropriate for your facility or the service center you use. There should also be written calibration procedures to follow. The best machinists compare each tool to the standard gauge each time they use a different one. Good practice indicates checking each tool at least once each day it is used. Proper technique is the other part of the equation. This method verifies both the tool and the user.

Bearinghousing tolerance

Increased internal friction may have several causes including poor or degraded lubrication, bearing race damage, and excessive preload. If this type of damage occurs, the bearing eventually will spin even if the fit was originally in tolerance.

The MAXM22510/MAXM22511 evaluation kit (EV kit) is a fully assembled and tested PCB that demonstrates the functionality of the MAXM22510/MAXM22511 isolated RS-485/RS-422 transceiver module. The EV kit operates from a single 3.3V supply.ApplicationsBuilding AutomationHVACIndustrial AutomationPower MetersProgrammable Logic Controllers

The devices include one drive channel and one receive channel. The receiver is 1/4-unit load, allowing up to 128 transceivers on a common bus.

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Contamination can dramatically shorten bearing life and lead to costly downtime. Maintenance professionals should be knowledgeable about the effects of contamination and well-trained in the procedures to prevent it. There are five basic ways to maintain bearings and reduce the number of failures caused by contamination.

Interference fit

ADI has always placed the highest emphasis on delivering products that meet the maximum levels of quality and reliability. We achieve this by incorporating quality and reliability checks in every scope of product and process design, and in the manufacturing process as well. "Zero defects" for shipped products is always our goal. View our quality and reliability program and certifications for more information.

The driver outputs and receiver inputs are protected from ±35kV electrostatic discharge (ESD) to GNDB on the cable-side, as specified by the Human Body Model (HBM).

The MAXM22510/MAXM22511 operate from a single 3.3V supply on the UART-side. An integrated DC-DC converter generates the 3.3V operating voltage for the cable-side of the module.

The MAXM22510/MAXM22511 evaluation kit (EV kit) is a fully assembled and tested PCB that demonstrates the functionality of the MAXM22510/MAXM22511 isolated RS-485/RS-422 transceiver module. The EV kit operates from a single 3.3V supply.

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Jim Bryan is a technical support specialist at the Electrical Apparatus Service Association (EASA), St. Louis. A CFE Media content partner, EASA is an international trade association of more than 1,900 firms in 62 countries that sell and service electrical, electronic, and mechanical apparatus.

Much has been said and done to produce the “perfect” fit for rolling element bearings in motors and other rotating equipment. Assembly of these machines requires that either the inner fit to the shaft (journal) or the outer fit to the housing (bore) is able to slide; so if one fit is tight, the other must be loose. While “tight” and “loose” are relative terms that must be defined in the quest for the perfect fit, any fit that’s too loose or too tight can lead to early bearing failure and costly downtime.

Micromotion occurs when a variable load is applied and there is room to move. Though limited to an extent by the fit tolerance band, it can still happen under the right conditions because the housing bore is loose by design.