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A Study on the Estimation of Bearing Life of Electric Motor Using ISO 281 and
Accelerated Life Test
Youn-Hwan Kim, Hae-Joong Kim, Jae-Won Moon Youn-Hwan Kim, Sang-Yong Jung
Rotating Machinery Center School of Electronic and Electrical Engineering
Korea Testing Certification Sungkyunkwan University
Gunpo, South Korea Suwon, South Korea
e-mail: younhwan@ktc.re.kr, motor@ktc.re.kr, e-mail: younhwan@ktc.re.kr, syjung@skku.edu
moon@ktc.re.kr
Abstract—This paper introduces the results of the study on the In general motors, failure occur mostly in bearings and
development of accelerated life test methods for the motor used windings. Bearing failure accounts for 37 to 60% of the fault
in machine tools. In recent years, as well as efficiency for of the induction motor and windings failure are reported to
motors, there is a growing need for research on life expectancy account for 16 to 37% of induction motor failure [3].
of motors. It is considered impossible to calculate the According to the literature, bearing failures account for more
acceleration coefficient by increasing the rotational load or than 80% of stepper motors [4]. Most of the failures of the
temperature load as the acceleration stress in the motor system machine tool were found to occur in the motor bearings.
because the temperature of the copper exceeds the wire In this study, we analyzed the failure mechanism of a
thermal class rating. In general, the failure of bearings in a
motor used in a machine tool and proposed a method of the
motor accounts for most of the total failure factor. This paper
bearing lifetime estimation.
describes the development of the procedure for the lifetime
estimation of the 12 kW three-phase squirrel-cage induction II. TEST METHOD DESIGN
motor. The test to predict bearing life was conducted and the
result was compared with the bearing life expectancy by ISO The motor for the test is shown in Table I below.
281. Finally, a lifetime correction coefficient was calculated. Through the Failure Mode and Effect Analysis [FMEA], the
bearings were identified as the most frequent failure and
Keywords-accelerated life test; bearing; life expectancy; critical component. As a result of analysis of the operating
lifetime correction coefficient; motor environment, the rotation speed of the shaft at the time of
drilling was 6,000 rpm and the axial load was 150 N. The
I. INTRODUCTION radial load during face milling was 150 N.
Machine tool is a machine for shaping or machining TABLE I. ELECTRIC MOTOR FOR RELIABILTY TEST
metal or other rigid materials, usually by cutting, boring,
grinding, shearing, or other forms of deformation. Item Information
Machine tools are known to be the foundation of all Motor Type Induction Motor
manufacturing. In particular, the importance of machine
tools in the automotive industry has a great impact on Output power 12 kW
component productivity and quality. Therefore, there is a Number of poles 4P
growing demand for durable machine tools in the
manufacturing industry and the importance of the reliability Voltage 380V
evaluation is increasing [1].
Base speed 6,000 rpm
In a machine tool, a motor converts electrical energy into
mechanical energy. The rotational speed of the motor shaft is Axial load 150 N
controlled by the inverter so that the machine tool functions.
Radial load 150 N
Spindle system has huge effect on performance of machine
tools and working quality as well as is required of high Bearing arrangement O arrangement
reliability. In the machine tool industry, a built-in spindle
with direct drive method is more popular than a conventional Fig. 1 shows the bearing life prediction method in motor.
belt driven spindle because of the wide range of torque and The first method is by calculation using bearing dynamic
output of direct drive motor. load rating. This method is a method of bearing lifetime
Recently, studies on the reliability and accelerated life calculation by ISO 281 (Rolling bearings: Dynamic load
test of a motor have been carried out. A study is the ratings and rating life). It is applicable when the bearing life
calculation of remaining useful life for machine tool [2]. The prediction is possible. It is necessary to check the load
load condition according to the actual operation cycle usually applied to the bearing in order to predict the life. A simple
is not taken into consideration in the life test, so that the method is to use the load distribution equation. It is difficult
actual life may be estimated differently. to apply when a concentrated load is applied to the bearing.
Cr i0.7 u C 1
Figure 3. Conceptual diagram for load distribution calculation
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Fa is calculated assuming that the axial load of the
machine tool is evenly distributed in each of the two bearings.
As a result, the L10 was analyzed as 797,711 hours. Table II
is the value of each parameter used to calculate the bearing
life.
TABLE II. THE VALUES OF BEARING LIFE CALCULATION
225
Therefore, it was predicted that there was a failure in the 1
cage. ln(ln( )) E lnt E lnK
1 F (t)
REFERENCES
[1] T. H. Lee, “A study on the failure and life assessment of high speed
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Figure 6. Bearing Faults: Discoloration and Cage Crack
2014.
[2] X. Du, “Remaining useful life assessment of machine tools based on
The lifetime correction factor measured by the test can be AHP method and euclid approach degree,” Intern. Confer. Syst.
applied to the lifetime at a load of 150N. Finally, the lifetime Reliab. and Scie. pp. 46-52, Nov. 2016.
correction factor was applied to the ISO 281 calculation [3] F. J. T. E. Ferreria, “Reliability and operation of high-efficiency
method and the lifetime of 26,894 hours was calculated. induction motors,” IEEE Trans. Ind. Appl., vol.52, no. 6, pp.4628-
4637, Nov. 2016.
V. STATISTICAL ANALYSIS [4] A. D. Nisio, “Methodology for implementing accelerated life stress
Statistical analysis of the results of the accelerated life on stepper motors,” 12th IMEKO TC 10 Workshop on Techical
Diagnostics, Jun. 2013.
test is required for life prediction. In general, Weibull
[5] L. J Liang, “Study on bearing life calculation for wind turbine
distribution is used as the life distribution of mechanical gearbox,” J.Korean Soc of Manu. Proc. Eng., 13(5), pp.21-27 Oct.
parts. The distribution function F(t) of the Weibull 2014.
distribution can be expressed as (6). [6] S. P. Lee. “Bearing life calculation by using the ISO281:2017,” KSPE
2012 Spring conference, pp. 903-904.
t
( )E [7] ISO 281:2007 Rolling bearings - Dynamic load ratings and rating life.
F (t) 1 e K
[8] W. Wang, “Size estimation for naturally occurring bearing faults
using synchronous averaging of vibration signals,” ASME J. Vib.
It can be transformed as (7) to draw a straight line on Acoust. vol. 138, pp. 051015/1-10, Oct. 2016.
Weibull probability paper. [9] D.F. Shi, “Defect detection for bearings using envelope spectra of
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