Solving Bearing Currents Without Teardown: Volsun Split Shaft Grounding Ring Solution for a Paper Mill

In heavy industries like paper manufacturing, electric motors are the beating heart of production lines. However, variable frequency drives (VFDs) often induce destructive shaft voltages, leading to premature bearing failure and costly downtime. In August, Volsun successfully delivered a tailored shaft grounding solution to help a major paper mill protect its large industrial motors without the hassle of equipment disassembly.

The Challenge: 24/7 Operations and No-Teardown Constraints

The client operates a massive paper mill where production lines run 24 hours a day, 7 days a week. The specific motor driving their heavy-duty equipment features high power, low speed, and operates within a weaker electrical environment.

When the client reached out to Volsun, the main hurdle was clear: the heavy machinery and motor were already fully assembled. Dismantling the equipment for maintenance or installing standard, solid-ring grounding devices was simply out of the question due to prohibitive downtime and labor costs. They needed an alternative solution that could be easily retrofitted onto an existing shaft while guaranteeing continuous, reliable protection.

The Volsun Solution: Custom-Engineered Split Shaft Grounding Rings

Understanding the urgency and technical constraints, Volsun’s engineering team stepped in. After multiple rounds of in-depth online communication and technical discussions with the client's plant equipment engineers, we designed a customized split-type carbon fiber shaft grounding ring.

Key highlights of the solution include:

● Split Design for Easy Retrofit: The two-piece split construction allowed the ring to be effortlessly wrapped around the already-assembled motor shaft without requiring any shaft extraction or major teardown.

● Direct-Contact Carbon Fiber Technology: Equipped with high-density conductive carbon fiber strands, the ring maintains constant, direct contact with the rotating shaft surface, safely diverting harmful shaft currents away from the bearings.

● Complete Mounting Kit: We provided tailor-made adjustable mounting brackets and secure bolts, ensuring the grounding ring could be firmly bolted onto the motor housing and precisely aligned with the shaft.

Current Status and Customer Feedback

The custom sample order has been successfully manufactured, delivered, and installed directly on the customer's site (as shown in our on-site installation setup).

The client has expressed high appreciation and satisfaction with Volsun, specifically praising our:

● Rapid Response Time: Quick turnaround from initial inquiry to engineering proposal.

● Technical Professionalism: Deep understanding of VFD-induced bearing currents and practical field limitations.

● Reliable Delivery & Service: Punctual sample shipping and cooperative engineering support.

Currently, the custom shaft grounding ring is undergoing live testing on the paper mill's heavy-duty motor, and we are eagerly anticipating the final performance feedback. Based on the successful installation and initial cooperation, the client has already indicated strong intentions for bulk orders following the trial phase.

At Volsun, we continue to bridge complex electrical challenges with flexible, high-performance manufacturing solutions. If your facility faces similar bearing current issues without the luxury of equipment teardowns, contact our engineering team today to find out how our split shaft grounding rings can keep your operations running smoothly around the clock.