Design and Validation of Segmented CFRP Lamella-Based Composite End Shield for Bearing Current Mitigation

This study addresses the premature failure of electric motor bearings caused by inverter-induced parasitic currents. We propose a novel segmented end shield design utilizing 24 carbon fiber-reinforced polymer (CFRP) lamellae to provide both structural support and galvanic isolation. The “main working” of the design relies on a segmented architecture where the lamellae are adhesively bonded between a central bearing housing and an outer mounting flange, creating a high-impedance path that interrupts circulating currents. Experimental validation focused on both mechanical stability and dielectric performance. Results indicate that the assembly maintains rotor positional integrity under nominal loads while providing an insulation resistance > 1 GΩ at 1 kV and a structural capacitance of 2.47 nF. These parameters effectively mitigate low-frequency circulating currents. Data analysis, derived from the mean values of repeated test cycles, confirms that the composite architecture serves as a viable, mechanically robust alternative to conventional metallic end shields.