SUGAR INFO
S
DC
Dept/ Name, phone, e-mail
Date
Page
D456/ Bo Ljung, +46 660 87047, [Link]@[Link]
04-02-25
1(4)
Procedure on how to weld on machines
Background
Always when welding on machines, precautions have to be taken in order not to
damage sensitive parts. Many times if careless connections are done, vagabond
currents can occur which may affect reliability on bearings of any type.
The reason for this is the possible high current density that can create unforeseen
and undesired spot welds, later on provoking higher wear rate. Bearings of roller
element type are extra sensitive to this type of damage because the small contact
surfaces and thereby likely higher current density.
A Hgglunds hydraulic motor in this context has to be considered as a roller element
bearing showing some sensitivity to welding.
Damages in roller bearings those results from faulty procedures at welding shows up
on the roller elements and/or on the race ways with different appearance depending
on under which conditions they developed. These damages are known as FUSION
failures.
In the adjacent figures two typical cases are shown and explained. Regardless if the
damaged is of one type or the other they both initiates cracks in the raceway
resulting in premature failures i.e. reduced service life.
Figure 1: Current damage due to welding under motion
Figure 2: Current damage due to welding at rest
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SUGAR INFO
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D456/ Bo Ljung, +46 660 87047, [Link]@[Link]
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Avoiding damages at welding.
The general idea when welding is to create a closed current loop between the
electrode and the object that do not use the hydraulic motor as part of a conductor.
This requirement demands that the welding machine is on a floating potential and not
connected to the earth. The adjacent figure 3 shows the principal connection of a
correct machine.
Figure 3: Welding machine connection
When connecting to the machine the object, the basic rule is to connect as close to
the welding position as possible:
1. If welding is to be done on the structure the earthing conductor should be
connected on the same part as were the welding is to be carried out.
2. If welding is to be done on the rotating shaft the earthing conductor should in the
first case if accessible, be connected to the free end of the shaft.
3. If welding is to be done on the rotating shaft the earthing conductor should as a
second option be connected to:
a) Earthing brushes, which could be used sliding on the shaft in an appropriate
position. Installation of such brushes has to be decided on case by case. An
example of clamps showing earthing brushes are shown in the figure 4.
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D456/ Bo Ljung, +46 660 87047, [Link]@[Link]
04-02-25
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Figure 4: Typical earthing clamp
b) A slip ring device, which could be installed at the end of the hydraulic motor or
at the shaft end. A slip ring device available from ESAB is shown in figure 5.
Figure 5: Slip ring device available from ESAB.
A very simple example of a frequently used slip ring device is shown in figure 6.
Using this device there is a preferred solution to adjust the spring in a way that the
cable it self could take the friction torque from the sliding. If a separate reaction
rod is required for the device it has unconditional to be manufactured from a
insulating material like bakelite, non conducting glass fibre bar or similar.
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04-02-25
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Figure 6: Slip ring device.
Insulation of the motor
In order to give the motor maximum protection against damages at welding, the
motors shall be completely insulated from the ground. This is done by the use of
insulated torque arm and non conductive elements in the pipe system.
The drive system in sugar mills are normally delivered with insulated torque arm and
insulated pipe system.
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