This paper investigates breakdown characteristics in the bearings of variable speed electric drive trains. The analyses reveal that breakdown phenomena previously known from high-voltage technology appear to also occur in the bearing contact, though at significantly lower voltages. By loading the bearing with AC voltage of different frequencies at various mechanical load points, five states, which range from partial discharge through arc discharge to a completely conductive channel, emerge. Consistent with the concept that the magnitude of the breakdown voltage depends on the lubricant film height, the contact force, and the frequency of the AC voltage, a thicker lubricant film results in a higher breakdown voltage, analogously to a capacitor with a larger plate spacing, which requires a higher potential difference to be punctured. Furthermore, the sinusoidal frequency of the AC load correlates with the breakdown voltage. The breakdown tends to occur earlier at low frequencies, which is illustrated by the fact that at low frequencies, capacitive behaviour can only be observed at higher speeds, i.e., at a larger lubrication gap, while no voltage can be built up over the bearing at lower speeds. An increase of the contact force for the same lubricant film height lowers the breakdown voltages. The reduction of the breakdown voltage by the contact force may result from an increase of the relative permittivity of the lubricant with higher pressure and likewise of the contact area; the increased area may also increase the number of surface-roughness peaks where an increase in the electric field occurs.

In the presented work, a parametric multibody simulation model is presented that is capable of predicting the friction torque and kinematics of tapered roller bearings. For a highly accurate prediction of bearing friction, consideration of solid and lubricant friction is mandatory. For tapered roller bearings in particular, the friction in the contact between the rolling element and raceway is of importance. Friction forces in the contact between the rolling element end face and inner ring rib as well as roller cage pocket contacts are also considered in the model. A large number of tests were carried out to validate the model in terms of the simulated frictional torque. Influencing variables such as speed, axial load, radial load, and temperature were investigated. The simulation results show good agreement with the measured friction torque, which confirms that the model is well suited to predict frictional torques and therefore the kinematics of tapered roller bearings.

The effect of variable DC bearing current amplitude, bearing current polarity, mechanical force, rotation speed, bearing temperature, and number of the balls on the fluting in an axial ball bearing type 51208 is investigated under DC currents. The results are obtained from two different test setups with two different lubricants (mineral-oil-based grease and polyglycol oil). The speed varies between 100 rpm and 2000 rpm, the axial bearing force between 200 N and 2400 N, the DC current amplitude between 0.5 A and 20 A, the bearing temperature between 29 °C and 80 °C, the number of steel balls per bearing between 3 and 15, and the test duration between 6 h and 168 h. The results show that with a higher bearing current density and/or a higher bearing speed, a lower bearing force and/or a lower bearing temperature, a bigger number of roller elements, but also at a negative polarity of a DC electric bearing current, the occurring of fluting is more probable and occurs at an earlier stage of operation.