The problem of estimation the friction torque in operating miniature ball bearings lubricated with oil or grease is a complex one. Generally, in an angular contact ball bearing (ACBB), various types of losses can appear including losses caused by kinematics in ball-race contacts (rolling, sliding and pivoting), losses between the cage and the balls and between the cage and the guiding race and losses generated by lubricant, especially at high speeds. In the miniature ACBB, the applied loads have generally low values, and some losses can be ignored. In these circumstances, the most important contribution to the increase in the losses in miniature ACBB is the presence of the lubricant. In normal rolling bearings, the lubricant has an important contribution to decrease the losses and increase the reliability in miniature ball bearing; the lubricant (oil or grease) leads to the increase in the losses compared to the dry or limit lubrication conditions. The catalogues of various rolling bearing companies have not provided more details referring to the friction losses in miniature ball bearings. In order to evaluate the total friction torque in the rolling bearings, some empirical complex relations are presented via the SKF methodology, which can be applied only to moderate and high loads applied to the rolling bearings. Other empirical relations are presented by the Schaeffler catalogue. Based on previous experiments, the authors determined the friction torque in a 7000C ACBB with the spin-down method. The experimental results were correlated with the results obtained via the theoretical model developed by Houpert for IVR lubrication conditions. The theoretical results evidenced that the hydrodynamic rolling resistance generated by the lubricant is the most important component of the friction torque for 7000C ACBB. The experimental and theoretical results were compared to the results obtained according to the SKF and Schaeffler relations. The experimental results and the results obtained with the Houpert model generally had higher values compared to the results obtained with the SKF and Schaeffler relations.

To the film thicknesses of grease-lubricated ball bearings, the viscosity of the base oil is considered in the Elastohydrodynamic Lubrication (EHL) equations. For very low speeds, the grease film thickness is much larger than the calculated base oil film thickness. Initially, the grease film thickness decreases with speed to a minimum value, followed by an increase, thus generating a “V-shape pattern”. To evidence this behavior of grease film in a ball bearing, the authors used the method of measuring electrical resistance. Using an oil with a viscosity close to a grease base oil viscosity, a relationship was obtained between the electrical resistance of the ball bearing and the average film thickness in the ball–race contacts. Based on this relationship, the variation in the grease film thickness was obtained by measuring electrical resistance at a bearing speed between 1 and 500 rpm for short running periods of 60 s. A “V-shape pattern” was evidenced with a minimum value of grease film thickness at around 10 rpm. Additionally, the electrical resistance methodology was considered, evidencing the good stability of the film thickness for long operation time at speeds between 200 rpm and 1500 rpm. After 8 running hours, minor fragmentation of the soap filaments was observed under the scanning electron microscope compared to the fresh grease structure, without affecting the thickness of the grease film.

In this paper, the authors have analytically and experimentally investigated the friction torque in an angular contact ball bearing (ACBB) considering the following configurations: (i) a modified ball bearing with three equidistantly positioned balls without a cage and (ii) three modified ball bearings having four, six and eight balls with a phenolic cage. The experimental tests were realised at a low axial load and a rotational speed between 100 and 500 rpm under lubricated conditions. The test results for the ACBB with three balls without a cage showed that the friction torque is generated only by the rolling contacts between the balls and the two raceways in lubricated conditions. Considering the low axial load, the influence of the hydrodynamic rolling resistance was the dominant source of the frictional torque. The cage presence added supplementary friction, causing the friction torque to increase up to 60–65% compared to the cage-less configuration. Also, an additional increase in the frictional torque by 35–40% was observed for every two additional balls. The friction torque component that is generated by the cage presence does not depend on the number of balls added but rather on the rotational speed. All the tests were performed using the spin-down methodology, and the resulting friction torques (T_exp) were determined by integrating the dynamic equation during the deceleration process using Python-based software (Python version 3.10). The input and output parameters are presented for each test. Logarithmic diagrams revealing the dependence between the experimental friction torque and angular speed were obtained and fitted, and the relations have been determined for all tests. The analytical results of the friction torque were obtained based on Houpert’s model for all modified ball bearing configurations.

Eddy-current braking is increasingly considered a promising complementary technology to conventional hydraulic braking systems in next-generation automotive platforms, particularly in electric and autonomous vehicles. Unlike traditional friction-based systems, eddy-current braking enables the contactless generation of braking torque and can reduce mechanical wear while potentially providing rapid and controllable torque modulation and facilitating integration with intelligent vehicle-control architectures. However, a consistent vehicle-level response-time advantage over conventional braking systems has not yet been established through quantitative comparative testing. This paper presents a critical review of electromagnetic braking systems intended for automotive applications. This review analyzes the integration of electromagnetic braking technologies with embedded electronic control architectures, with particular emphasis on their potential role in future Brake-by-Wire systems. This study examines the operating principles of contactless braking, control strategies, actuator behavior, and system performance under variable operating conditions. In addition, key challenges related to energy efficiency, thermal management, fail-safe operation, and cybersecurity vulnerabilities of electronically controlled braking systems are discussed. The reviewed literature demonstrates the potential of contactless eddy-current braking technologies to support the development of advanced Brake-by-Wire architectures with reduced maintenance requirements and enhanced vehicle dynamics control. However, current evidence supports their use primarily as complementary actuators within hybrid architectures combining electromagnetic, regenerative, and conventional friction braking, rather than as stand-alone replacements for conventional brakes. This review provides a foundation for future research and development of intelligent contactless braking systems for modern automotive applications.