FAULT DETECTION OF PM SYNCHRONOUS

MOTOR VIA MODULATING FUNCTIONS

A. Balestrino, P. Bolognesi, A. Landi, L. Sani

Dipartimento di Sistemi Elettrici e Automazione
Universit di Pisa, Via Diotisalvi 2, 56126 PISA, Italy. Tel. +39
0502217300; Fax +39 0502217333; Email{author}@dsea.unipi.it


Abstract
This paper describes a model-based approach to detect electrical parameter changes
in a brushless dc motor, controlled by a PWM inverter. A continuous identification
method, based on the so-called modulating functions, is developed for estimating the
parameters of the mathematical model of the motor from only input-output data. A
real-time algorithm approach is developed for a recursive implementation of the
method. A comparison of the on-line estimated coefficients of the model with
nominal values constitutes a basis for a fault detecting method: the severity of the
fault is then classified, depending on the magnitude of the parameter changes.


1. - INTRODUCTION



Permanent magnet synchronous motors (PMSM) are
widely used in high performance drives: their popularity
is justified by several advantages over commonly used
motors. The absence of the rotor windings eliminates
losses on the rotor and makes PMSMs highly efficient,
along with their intrinsic brush less structure.
Maintenance is greatly reduced. Moreover a further
relevant advantage of PMSMs is the rapid dynamic
responses, due to their high torqueto-inertia ratio.
Nevertheless a brushless dc motor can also fail: for
example overload and overheating can damage the stator
coils. Therefore it is desirable to detect an incipient fault
as soon as possible for maintenance activities, before a
serious failure of the device occurs. The fault detection
procedure proposed in this paper belongs to the model-
based class [1], [2]. A typical approach for estimating
system parameters can be subdivided into three main
steps: the first one transforms the continuous-time
differential equation describing the model of the motor
into a discrete-time difference equation. The second step
applies a parameter estimation algorithm, such as least-
square method, to estimate parameters of the discrete-
time system, and finally the last one transforms the
discrete-time system parameters back into continuous-
time system parameters. Because of the two
transformations such approach requires long
computation time and causes degradation of estimation
accuracy. Therefore, it may be advantageous to use
suitable algorithms directly for estimating parameters
of continuous-time systems. In this paper the
modulating function approach [3], [4], [5], [6] is
adopted. By using only measured input and output data
(voltage, currents and angular speed) the physical
parameters of the three-stator coils, i.e., resistance and
inductances can be estimated. Comparing the estimated
coefficients with the nominal values, faults can be
detected and their severity can be classified, based on
the magnitude of the parameter changes.
Section 2 gives a brief introduction of the basic theory
of the modulating functions approach and its recursive
implementation. A mathematical model of a brushless
dc motor and the implementation of the fault algorithm
SPEEDAM 2004 June 16th - 18th, CAPRI (Italy)
833

are then shown in Section 3. Identification results and
final remarks are presented in Section 4 and in the
Conclusions, respectively.

2. RECURSIVE ALGORITHM OF
IDENTIFICATION

The modulating function approach has been widely used
for the identification of process parameters using only
measured input and output signals. A continuous process
can be modelled by a differential equation:

( ) ( )
( )
( )
( )
( ) ( )
( ) 1
1 0
n m
n m t t t t t
y a y a y b u b u + + + = + + " "
(1)

With the input u(t) and output y(t) data, and
( )
( )
( )
n n n
t t
y d y dt =
.

The vector of the unknown parameters is:

| |
,
i i
b a = q
(2)

Choose a set of smooth functions
i
, whose derivatives

i
(j)
are known in analytical form. Such functions,
denoted as modulating functions, have the following
properties:

a) ( )
( ) | | 0,
0
t t T
t
else

=

b)
n
C (n-time differentiable)
c)
( ) ( )
(0) ( )
0 0,1,... 1
i i
T
i n = = =

The modulating procedure starts by multiplying (1) with
the modulating function and integrating over the interval
T. Solving by part and using property (c), equation (1)
becomes:

( )
( )
( )
( )
( )
( )
( )
( )
1 1
0 0
1 1
t T t T
n m
i j
i i
i i t t t t
i i
t t
a y dt b u dt
+ +
+ +
= =
=



(3)

The modulated equation (3) is an algebraic equation and
it has the same mathematical form as the original model
equation (1).
In order to determine all unknown 2i parameters {a
i
, b
i
}
at least 2i linearly independent modulated equations
must be generated. This is possible, by discretely shifting
the same modulating function , along the input-output
measured time signals.

= Aq c (4)

Least-squares methods can be used to estimate q and
obtain:

( )
1

T T

= q A A A c (5)

The advantage of this approach is that it involves the
known derivatives of the modulating function instead
of the derivatives of the usually noisy output data y(t).

In order to implement the method online with a low
cost microcontroller a recursive formulation is given.
The flowchart of the algorithm is shown in figure 1.



Figure 1. Flowchart of the recursive identification .

The number of the rows of the matrix A is m and it is
kept constant.

Starting from a previous estimate q
k-1
(given
for instance by a batch procedure) consider
SPEEDAM 2004 June 16th - 18th, CAPRI (Italy)
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the new modulating interval [(k-1)T, kT] (step
k). Input and output signals are acquired.
At the end of step k a new row {A
k
, c
k
} of the
algebraic system (4) is computed by using (3).
The algebraic system is updated, appending the
new row and deleting the first row. By
considering a sliding window we take into
account only the more recent data, deleting the
oldest data.
The new vector q
k
is determined by using the
pseudo inverse procedure (5) if and only if
1 k k k
A q c

<
, with a fixed positive
threshold. In this case some coefficients are
changed during the last modulating interval.
Otherwise the previous solution is hold and
1 k k
q q

= . The implemented technique avoids
the compute of the pseudo inverse at each step,
reducing the computing time.

When some parameters of the model changes, the
identification algorithm gives a new correct estimate of
the vector q after m steps, because of the whole matrix A
must be upgraded.
Robustness of the monitoring with respect to
measurement noises depends on the number of rows of
the matrix A and on the window length of the considered
data. If the number of rows or the window length (T) is
increased (decreased) the identification procedure
becomes more accurate, but slower (less accurate, but
faster).


3. FAULT DETECTION PROCEDURE FOR A
BRUSHLESS DC MOTOR

In this section the dynamic model of a brushless dc
motor is first introduced. The recursive identification
algorithm is applied to estimate the model parameters.
By comparing the estimate parameters with the reference
values, fault detection can be performed on line.
In order to detect all electric parameters of the motor (i.e.
resistance and inductances of the stator coils and the
rotor flux), a detailed electrical and mechanical model
was derived. In the case of a PMSM with a nonsalient
rotor (airgap constant) the electric subsystem can be
modelled as:

r
T m
m
r
d
p
dt
P
T p

= + +

= =

I
V RI M
I

(6)

where:

1 1 1
2 2 2
3 3 3
1 12 13
12 2 23
13 23 3
0 0
; 0 0 ;
0 0
cos
2
; cos
3
4
cos
3
r
r
r
V R i
V R i
V R i
p
L M M
M L M p
M M L
p

( ( (
( ( (
= = =
( ( (
( ( (

(
(
(
(
(
| | (
= =
( |
(
\ .
(
(

(
| |

(
|
\ .
V R I
M
(7)

The mechanical differential equation is:

r
m L
d
T T J
dt

= (8)

Using the recursive modulating functions approach, all
electrical parameters of the motor can be estimated.
The vector of unknown parameters is:

| |
1 2 3 1 2 3 12 23 31
R R R L L L M M M = q (9)

The first equation of system (6) can be rewritten as:

= q V (9)

where:

3 1 2
1 1
3 2 1
2 2
3 2 1
3 3
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
r
r
r
di di di
i p
dt dt dt
di di di
i p
dt dt dt
di di di
i p
dt dt dt



(

(
(
(
=
(
(
(

(

M

By modulating each differential equation of the above
system, we get the following algebraic system:

= q V

(11)


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835

INVERTER
PSMS
ALGORITHM OF
IDENTIFICATION
i
1
i
2 i
3
-
-

r
V
1
V
2
V
3


Figure 2. Block diagram of the proposed algorithm.


with:

| |
( ) ( ) ( ) ( )
( ) ( ) ( ) ( )
( ) ( ) ( ) ( )
1 2 3
0 1 1 1
1 1 2 3 0
0 1 1 1
2 2 1 3 1
0 1 1 1
3 3 2 1 2
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
T
v v v
i i i i
i i i i
i i i i
(

(
= (
(

(

V =

and


t T
i i
t
v V dt
+
=

( )
( )
( )
1
t T
k
k k
i i
t
i i dt
+
=

2
cos
3
t T
i r r
t
p p i dt
+
| |
=
|
\ .

In order to get the algebraic system (11) the stator
currents i
i
, the supply voltage V
i
, and the angular velocity
of the rotor
r
are measured. For each modulating
interval, three row of the data matrix A of (4) are
updated.

5. SIMULATION RESULTS

The performance of the fault detection procedure via the
recursive modulating function approach is evaluated by
using MATLAB/Simulink package. Consider a PMSM
with the nominal parameters listed in Table I.

Stator 3 phase, Y connected
Pair of poles (p) 4
Rated Power (Pn) 1.1 kW
Rated supply voltage 220 V
Rated Speed 3000 rpm
Stator phase resistance (R
i
) 2.875
Stator phase inductance (L
i
) 0.0125 H
Mutual inductance (M
ij
) 0.004 H
Rotor flux () 0.175 Wb
Rotor inertia (J) 0.08 kgm
2


Table 1. Nominal parameters.

The motor test diagram is depicted in figure 2. The
motor is closed-loop current controlled. Since a PWM
inverter feeds the brushless motor, then a persisting
excitation of the system is guaranteed. Moreover, as
the stator coils have a star connection, only two stator
currents and two-supply voltages are measured.
As a first step of the recursive identification procedure,
the parameters of the motor in the nominal case (fault-
free) are estimated. Then, different faults are simulated
and the parameters of the model are continuously
monitored.
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836

As a first example, since t = 10 s, each stator resistance
increased by 10% with different time constant,
simulating an increasing of the stator temperature. In this
case only phase resistances change meaningfully. Figure
3 and 4 show estimated stator resistance R
1
and
inductance, respectively. As a second example, the
resistance of the phase B was decreased by 20%,
simulating a short circuit. In this case several electric
parameters change. This is shown in figure 5 and 6.
Obviously the identified parameters are correct if only if
the mathematical model of the machine doesnt change
as a result of occurs fault. Anyway, also in case of a
variation of the model, the estimated parameter
variations are representing a meaningful warning about
an incipient fault. Complete results of estimated motor
parameters are listed in Table II.


Estimated Parameters
Nominal Fault-free Fault 1 Fault 2
R
1
() 2.875 2.877 3.167 2.879
R
2
() 2.875 2.876 3.164 2.315
R
3
() 2.875 2.878 3.170 2.875
L
1
(H) 0.0125 0.0126 0.0127 0.0126
L
2
(H) 0.0125 0.0126 0.0126 0.0103
L
3
(H) 0.0125 0.0124 0.0127 0.0126
M
12
(H) 0.004 0.004 0.0038 0.0033
M
23
(H) 0.004 0.0039 0.0041 0.0030
M
31
(H) 0.004 0.0042 0.0042 0.0042
(Wb) 0.175 0.176 0.176 0.176

Table 2. Simulation results.

CONCLUSIONS

In this paper a new fault detection procedure for
brushless dc motor has been proposed. It is based on the
recursive modulating function approach. This continuous
identification method is able to determine the unknown
parameters of the model from input-output data. The
algorithm proposed offers the following advantages:
a) the diagnostic algorithm is very fast;
b) only standard sensors for measuring current, voltage
and angular speed are required.
The algorithm has been validated by extensive
simulation tests: preliminary experimental results
confirm the effectiveness of the technique. Work is in
progress to extend the results to different motor and to
evaluate the potentiality of such a technique for
detecting faults into the whole drive.

10 15 20 25
2.8
2.9
3
3.1
3.2
3.3
Time (s)
R
1

R
1
'

()

Figura 3. Case 1. Comparison between the real
value (continuous line) and the estimated one
(dotted line) of the resistance R
1
during an
increasing of the stator temperature.

0 5 10 15 20 25 30 35
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
Time (s)
( H
)
M
ij

L
i

Figura 4. Case 1. Estimated auto (L
i
) and mutual
(M
ij
) inductances of the stator.

ACKNOWLEDGMENTS

The authors wish to thank Dr. S. Di Nitto for his help in
the implementation of the fault detection algorithm.

LIST OF SYMBOLS

V
i
stator phase voltages;
R
i
stator phase resistance
i
i
stator phase currents;

s
inverter frequency;
SPEEDAM 2004 June 16th - 18th, CAPRI (Italy)
837

L
i
stator phase inductance;

r
rotor position;
M
ij
mutual inductance between phase i and j

r
rotor speed;
rotor flux;
T
L
load torque;
T
m
electromagnetic torque;
J inertia of the rotor;
p number pair poles.

12 13 14 15 16 17 18 19 20 21
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
Time (s)
()
R
2

R
3

R
1


Figura 5. Case 2. Estimated phase stator resistances
(dot = R
1
; continuous = R
2
; dash = R
3
) when a fault
occurs.

14 15 16 17 18 19 20 21
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
Time (s)
(H) L
2

L
1
and L
3
M
1 3

M
1 2
and M
2 3


Figura 6. Case 2. Estimated auto and mutual stator
inductances when a fault occurs.

BIBLIOGRAPHY

[1] P.M Frank. Fault diagnosis in dynamic systems
using analytical and knowledge-based redundancy.
Automatica, vol. 26, pp. 459-474, 1990.
[2] O. Moseler, R. Isermann. Application of Model-
Based Fault Detection to a Brushless DC Motor.
IEEE Transaction on Industrial Electronics, vol.
47, pp. 1015-1020, 2000.
[3] M. Shinbrot. On the analysis of linear and non
linear systems. Trans. ASME, vol. 79, 1957, pp.
547-552.
[4] A. Balestrino, A.Landi, L. Sani. Parameter
identification of continuous systems with multiple
input time delays via modulating functions. IEE
Proceedings on Control Theory & Applications,
vol.147, n.1, 2000, pp.19-27.
[5] A. Balestrino, O. Bruno, A. Landi, L. Sani.
Average PWM model of the Boost converter via
modulating functions. SPEEDAM 2000, Ischia,
2000.
[6] A. Landi, L. Sani. Modulating functions for testing
the performance of switch mode converters.
Proceedings of the IEEE SDEMPED Conference,
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