NSK widens range of electrical erosion resistant bearings

Preventing electrical erosion is becoming increasingly difficult due to the higher output of electric motors and higher drive voltages. Here, technologies like insulating ceramic-ball bearings (hybrid bearings) are most effective way of providing electrical insulation, but are not always the optimal solution for high-volume applications such as EVs.

A good alternative is the adoption of plastic over-moulded bearings, which deliver the electrical insulation required for eAxles but at a lower cost than ceramic-ball bearings. Notably, NSK configures its over-moulded bearings to suit the application and any specific requirements. The materials and manufacturing processes would be quite different for an eAxle and those of a railway application, for example.

Another option to resist electrical erosion is the use of conductive brushes. However, trends in eAxle motors are moving towards the use of highly efficient oil-cooled systems, for which conventional conductive brushes are not suitable, especially in combination with high speeds. NSK’s new brushes differ in that they offer sufficient conductivity for a wide range of eAxle applications, even those involving cooling oil lubricated environments. As a further benefit, it is possible to incorporate the conductive brush directly into the shaft to save space.

NSK has already completed basic durability evaluations and can now provide customers with proposals for its latest anti-electrical-erosion technologies, including evaluation data, for practical applications.

In summary, the company’s anti-electrical-erosion options cover both insulating and conductive methods to meet a diverse range of design requirements that balance application and volume criteria. These technologies improve reliability and include measures that support the reduction of overall eAxle unit size. They also contribute to lower electricity consumption and longer vehicle range on a single charge.