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Abstract—A cascaded H-bridge multilevel inverter is an in- systems owing to their high-quality voltage output using
dispensable part of high-power industrial drives. The multilevel switches having lesser ratings. A cascaded H-bridge (CHB)
inverters have an increased chance of switch fault as a conse- MLI, which is popular among MLIs, is a prospective component
quence of a considerably large number of semiconductor switches
associated in the power conversion. A quick and precise fault in high-power medium-voltage industrial and large automotive
detection–isolation strategy improves the system reliability as well drives due to its modularity and fault ride-through capabil-
as reduces the shutdown time of the drive. This article presents ity [1]. Since MLIs incorporate a large number of semicon-
a novel generalized open-switch fault-diagnostic approach for an ductor switches to derive high-quality output power, the cen-
N -level cascaded H-bridge multilevel inverter. In this detection tral dilemma with them is the elevated probability of switch
technique, half-cycle mean values of bridge voltages, which are
calculated for positive and negative half cycles individually, are failure [2], and it was reported that these switch faults are
used as fault identification features. These means under open- responsible for nearly one-third of total failures in converter
switch fault are predicted from the reference half-cycle means and systems [3]. The switch faults, in general, can be classified
compared with those measured values to locate the open-switch as open-switch fault (OSF) and short-switch fault (SSF). The
fault. This quick detection scheme can identify the faulty switch former one does not always lead to the complete halt of the
within one fundamental period of output voltage for the cascaded
inverters having different number of voltage levels. The computa- drive, and not so critical as SSF, mostly these faults remain in
tion requirement is minimum, since this approach does not need the system undetected for a long time and may cause secondary
complex calculations or domain transformations. This strategy faults and complete shutdown of the system [4]. The downtime of
can efficiently locate the faulty switch of the cascaded inverter crucial drive systems must be avoided to improve plant reliability
working with various level-shifted pulsewidth modulation schemes, and to minimize the maintenance and production cost. Hence, a
different loading conditions, modulation indexes, and switching
frequencies. The potency of the fault classification algorithm is dedicated switch fault diagnostic system, which can quickly and
verified through simulation and experimentation. efficiently identify the location of switch fault, is a mandatory
Index Terms—Cascaded H-bridge multilevel inverter (CHB element in MLI-fed drives [3]. This fault detection system
MLI), fault detection, half-cycle mean voltage (HCMV), level- can assure continuous functioning of the drive by avoiding the
shifted pulse width modulation (LS PWM), open-switch fault. unwanted operating conditions, which arise due to the presence
I. INTRODUCTION of switch faults.
Many techniques for condition monitoring and switch fault
ULTILEVEL inverters (MLIs) have now become
M a favorite choice in high-power dc–ac conversion
classification of MLI have been proposed in recent years.
Different classifier algorithms, heuristic methods, and statisti-
cal feature optimization techniques, which are developed for
Manuscript received June 5, 2019; revised September 1, 2019 and October
22, 2019; accepted November 18, 2019. Date of publication December 12, other applications, were utilized for switch fault detection in
2019; date of current version March 17, 2020. Paper 2019-IPCC-0618.R2, the CHB MLI [5]–[9]. These methods have larger compu-
presented at the 2018 IEEE Power Electronics, Drives and Energy Systems
Conference, Chennai, India, Dec. 18–21, and approved for publication in the
tational complexity and need intensive training requirements
IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS by the Industrial Power for the classifier, which leads to larger detection time. The
Converter Committee of the IEEE Industry Applications Society. This work hardware implementation of these schemes demands advanced
was supported by Technical Enhancement of R&D and Institutional Consul-
tancy Activities of TEQIP phase II at National Institute of Technology Calicut
processors. In [9], an OSF diagnosis in the CHB MLI us-
(NITC/TEQIP-II/R&D/2014 dated 16-08-2016). (Corresponding author: Anjali ing fast Fourier transform–principal component rearrangement–
Anand.) backpropagation neural network is suggested. This scheme re-
A. Anand, A. Vinayak B, Jagadanand G, and S. George are with the De-
partment of Electrical Engineering, National Institute of Technology Calicut,
quires nearly two fundamental periods to detect the fault due to
Kozhikode 673601, India (e-mail: anjalianandk89@gmail.com; vinayakakhil@ its intensive computation steps involving complex matrix oper-
gmail.com; jagadanand@nitc.ac.in; saly@nitc.ac.in). ations. An artificial-neural-network-based detection scheme for
N. Raj was with the Department of Electrical Engineering, National Institute
of Technology Calicut, Kozhikode 673601, India. He is now with L&T Tech-
an asymmetric CHB MLI using the output voltage is discussed
nology Services, Bangalore 560001, India (e-mail: nithinrmu@gmail.com). in [10]. This method is not suitable for the symmetric CHB MLI,
Color versions of one or more of the figures in this article are available online since it fails to accurately separate the location of the OSF within
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIA.2019.2959540
a bridge for the symmetric inverter.
0093-9994 © 2019 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See https://www.ieee.org/publications/rights/index.html for more information.
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1564 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
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ANAND et al.: GENERALIZED SWITCH FAULT DIAGNOSIS FOR CASCADED H-BRIDGE MLIs USING MEAN VOLTAGE PREDICTION 1565
TABLE I
SWITCHING STATES FOR FIVE-, SEVEN-, AND NINE-LEVEL CASCADED INVERTERS
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1566 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
TABLE II
COEFFICIENTS FOR HCMV REFERENCE CALCULATION
TABLE III
COMPARISON OF MEASURED AND PREDETERMINED REFERENCE HCMV
VALUES FOR A FIVE-LEVEL CHB MLI AT VARIOUS MIS
Fig. 3. Voltages and current of a seven-level CHB MLI under the OSF at
(a) SR31 , (b) SR32 , (c) SR33 , and (d) SR34 .
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ANAND et al.: GENERALIZED SWITCH FAULT DIAGNOSIS FOR CASCADED H-BRIDGE MLIs USING MEAN VOLTAGE PREDICTION 1567
TABLE IV
COMPARISON OF MEASURED AND PREDETERMINED REFERENCE HCMV VALUES FOR A NINE-LEVEL CHB MLI AT VARIOUS MIS
Fig. 4. HCMVs under a healthy operation of the CHB MLI with various levels
of output voltage (MI = 1, fs = 10 kHz, load R = 100 Ω, and L = 20 mH).
Fig. 5. Schematic diagram of opened switches and affected HCMV of an
N -level CHB MLI.
are given in Table IV. The comparison of values from this TABLE V
table shows that the error between these reference values is AFFECTED OUTPUT VOLTAGE LEVELS UNDER OSF AT Spx1 /Spx4 FOR AN
negligible for a nine-level CHB MLI with different MIs. Mx(ref) N -LEVEL CHB MLI WITH m BRIDGES
and Mx(ref)c are plotted in Fig. 4 for a different number of
output voltage levels, and these values are found to be in close
correlation. Since bridge voltages are independent of loading of
the inverter under healthy condition, the reference values will not
change with the variation in the applied load. Hence, Mx(ref)c
are valid for different loading conditions of the CHB MLI. These
predicted HCMV references are independent of fs used for the
inverter.
A three-phase N -level symmetric CHB MLI with input dc
sources of magnitude Vdc generates the rated output voltage
under unity MI. When the magnitude of dc sources is varied to
Vdc1 , the new reference HCMV values, Mx(ref)c1 , can be derived the HCMV value (MaP or MaN ) under the OSF is zero for a
from Mx(ref)c values using pair of switches in this particular bridge. Hence, for this bridge,
Vdc1 the switch fault position can only be identified as pairs, i.e.,
Mx(ref)c1 = Mx(ref)c × . (4) Spa1 /Spa4 and Spa2 /Spa3 . For a CHB MLI controlled by the
Vdc
switching states as in Table I, the mth bridge (HB-m) has the
In a general CHB MLI working with LS PWM, the input maximum dc source utilization, i.e., a = m. The OSF at lower
source utilization is unequal, and the bridge with highest conduc- switches Spx4 or Spx3 (x = a) reflects as a change in magnitude
tion time (or dc source power utilization) under normal operation and sign of MxP and MxN , respectively. The schematic diagram
is denoted as HB-a in this article. Under normal operation, MxP of the failed switches and the corresponding affected HCMV
and MxN are positive and negative values, respectively. The values is shown in Fig. 5. The switches that conduct for a positive
OSF at upper switches Spx1 or Spx2 of HB-x in an N -level half cycle are marked in red, and those conduct in a negative half
CHB MLI is indicated by a nearly zero value for MxP and cycle are drawn in blue.
MxN , respectively. The OSF at HB-a results in a similar output Table V shows the affected output voltage levels when a
voltage pattern for the diagonally opposite switch positions, and particular switch, which conducts for a positive half-cycle,
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1568 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
fails. The detailed analysis indicates that for the mth H-bridge,
which has the maximum conduction time, the OSF at Spm1 and
Spm4 affects similarly except that the OSF at Spm4 produces
an additional distortion at 0Vdc . The distortion at zero voltage
will not be visible in the output bridge voltage. Hence, the OSF
at Spm1 and Spm4 results in similar distortions at the bridge
voltage Vm . Except this bridge, bridge voltages under the OSF
at all other positive conducting switches are visibly different.
This observation can be justified with in Figs. 2 and 3. A faulty
switch is located accurately for the remaining bridges from HB-1
to HB-(m-1), while the opened switch in HB-m is detected as
pairs.
The value of affected HCMV (MxP and MxN ) under OSF
at lower switches for HB-x can be predetermined from the no-
fault HCMV values, and these predicted HCMV under OSF
for positive and negative half cycles are denoted as MxP,e , and
MxN,e , respectively,
MxP,e = MxP (ref) − MaP (ref) (5)
MxN,e = MxN (ref) − MaN (ref) (6)
where MaP (ref) and MaN (ref) are HCMVs under normal op-
eration of HB-a. MxP (ref) and MxN (ref) can be replaced by
Mx(ref)c and -Mx(ref)c , respectively, without compromising the
detection accuracy, since the error between Mx(ref)c and Mx(ref)
is negligibly small.
The proposed detection strategy is detailed as a flowchart
in Fig. 6. MxP and MxN are calculated from measured
bridge voltages of the CHB MLI, and these values are equal
to the corresponding references MxP (ref) (or Mx(ref)c ) and
MxN (ref) (or −Mx(ref)c ), respectively, under normal operation.
A nearly zero value of the HCMV is expected for OSF at upper
switches; hence, a comparison between the normalized mea-
sured HCMV (MxP % /MxN % ) in percentage and the low-value
threshold (Mth ) is used for fault identification in upper switches.
The OSF at Spx1 (Spx2 ) is indicated by MxP % (MxN % ) value,
which is less than Mth .
The fault at Spm4 /Spm3 is identified when MmP % /MmN % is
smaller than Mth . The error between expected and measured
HCMVs under the OSF is determined for locating the fault
at lower switches with x = 1, 2, 3, . . .(m − 1). This error for
the positive and negative half cycles is calculated as δMxP Fig. 6. Proposed fault diagnosis strategy for an N -level CHB MLI.
and δMxN , respectively, using (7) and (8). δMxP and δMxN
are compared with a threshold value (δMth ) to identify the
fault at Spx3 and Spx4 respectively. When δMxP (δMxN ) is IV. RESULTS AND DISCUSSION
less than δMth , an OSF at Spx4 (Spx3 ) is detected. δMth is
A three-phase CHB MLI with a different number of levels
usually smaller than Mth , since the error between predicted and
at the output voltage, which is controlled by LS PWM control
measured HCMV values is negligibly small. The OSF can be
schemes, is considered for the analysis. The OSF is introduced to
traced up to the individual switch in all bridges using HCMV
the system by disabling the gate pulses, and the dc input voltage
except for a single-bridge HB-a, where the fault positions are
is kept constant at a magnitude, which generates the rated phase
identified as pairs of switches
voltage of 230 Vrms at the output of a healthy N -level CHB MLI
δMxP = MxP,e − MxP (7) under unity MI. The behavior of five-, seven-, and nine-level
CHB MLIs with various RL loads working under different MIs
δMxN = MxN,e − MxN (8)
with the OSF is studied with simulation and experimentation.
where MxP,e and MxN,e are the predicted HCMVs from ref- The experimental setup of a three-phase CHB MLI used in this
erence values, and MxP and MxN are the calculated HCMVs article is shown in Fig. 7. The inverter is controlled using field-
from the real-time acquisition of bridge voltages under the OSF. programmable gate array (FPGA) XC6SLX25, and H-bridges
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ANAND et al.: GENERALIZED SWITCH FAULT DIAGNOSIS FOR CASCADED H-BRIDGE MLIs USING MEAN VOLTAGE PREDICTION 1569
Fig. 8. Output voltages and half-cycle pulse of a five-level CHB MLI under Fig. 9. HCMVs of the five-level CHB MLI with RL load (200 Ω and 50 mH)
healthy operation (MI = 0.8, fs = 2 kHz, load R = 200 Ω, and L = 5 mH and under the OSF from (a) simulation and (b) hardware (fs = 2 kHz, MI = 1, POD
PD PWM). PWM).
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1570 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
TABLE VI
SIMULATION RESULTS: MEASURED AND EXPECTED HCMVS OF A SEVEN-LEVEL CHB MLI UNDER OSF (fs = 2 kHz, LOAD R = 100 Ω, AND
L = 20 mH, PD PWM)
TABLE VII
HARDWARE RESULTS: MEASURED AND EXPECTED HCMVS OF A SEVEN-LEVEL CHB MLI UNDER OSF (fs = 2 kHz, LOAD R = 100 Ω, AND
L = 20 mH, PD PWM)
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ANAND et al.: GENERALIZED SWITCH FAULT DIAGNOSIS FOR CASCADED H-BRIDGE MLIs USING MEAN VOLTAGE PREDICTION 1571
Fig. 12. Variation of HCMVs with load inductance in a seven-level CHB MLI Fig. 13. HCMVs of a five-level CHB MLI with different LS PWM schemes
under the OSF (MI = 1, fs = 2 kHz, and R load = 200 Ω, PD PWM). from simulation and experimentation under (a) no-fault condition (Mx(ref) ) and
(b) OSF at HB-1 (M I = 1, fs = 2 kHz, load R = 200 Ω, and L = 45 mH).
TABLE VIII
HCMVS OF A NINE-LEVEL CHB MLI WITH DIFFERENT fs (MI = 1,
LOAD R = 100 Ω, AND L = 20 mH, POD PWM)
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1572 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
Fig. 15. Hardware results of OSF detection. (a) SR14 of the nine-level CHB
MLI with PD PWM. (b) SR11 of the seven-level CHB MLI with POD PWM
(MI = 1, fs = 2 kHz, load R = 100 Ω, and L = 20 mH).
Fig. 16. Hardware results of OSF detection for SR24 in a five-level CHB MLI
with PD PWM (a) for light-load condition and (b) for a highly inductive load
(MI = 1, fs = 2 kHz, load R = 100 Ω, and L = 20 mH).
Fig. 17. Hardware results of fault detection in a seven-level CHB MLI under
multiple OSFs at (a)–(c) SR11 and SR31 , (d) SR11 and SR12 , (e) SR11 , SR12 ,
at SR14 for a nine-level CHB MLI and the OSF at SR11 for the and SR23 (MI = 1, fs = 2 kHz, load R = 100 Ω, and L = 40 mH, PD PWM).
seven-level CHB MLI is represented in Fig. 15. The recognition
of a faulty switch is indicated by a positive going edge of the fault
identifier flag (Fi ), as in Figs. 14 and 15. Ti and Td designate the multiple faults at upper switches within a bridge. A multiple fault
instant of occurrence of fault and fault detection, respectively. condition involving OSFs at SR11 , SR12 , and SR23 is considered
The detection time for the algorithm is Ti − Td , and the fault in Fig. 17(e). The faults at SR11 , SR12 , and SR23 are introduced
classier system can determine the fault position within 12 ms at Ti1 , Ti2 , and Ti3 , respectively. Here, fault flag for SR12 is not
in all cases of fault at HB-1. The OSF at SR34 is also analyzed, shown due to the channel limitation of the four-channel digital
since the detection of a fault at this switch position includes storage oscilloscope. Fig. 17 proves that multiple faults within
the maximum number of calculation steps for the system under a bridge and at different bridges can also be identified using
consideration, and the faulty switch was located after 12.5 ms. the proposed diagnostic strategy, and the multiple OSFs are
The effectiveness of the classifier algorithm is studied under identified within one fundamental period of the output voltage.
light-load condition, as well as under low-power-factor loads. The essential features of an eminent fault diagnosis strategy
The hardware results are given in Fig. 16, and under these are economical implementation and operation, reliability, ac-
operating conditions, the fault position is identified within 16 ms. curacy, optimal detection time, adaptability to different operat-
Since the bridge voltages are used for the OSF diagnosis, the ing conditions of the system, lesser computational complexity,
single OSF at multiple bridges can be easily identified using and easier hardware realization. The analysis proves that the
the same proposed algorithm. The hardware results of multiple proposed classifier possess all these characteristics; hence, this
OSFs in a seven-level CHB MLI are given in Fig. 17. For scheme is a superior switch fault-diagnostic strategy for the
a seven-level inverter, as HB-3 is the bridge with maximum CHB MLI than the existing systems. The diagnostic approaches
conduction time, the fault at SR31 or SR34 is identified as a pair presented in literature [5]–[11] need input data processing tools,
SR31 /SR34 . In Fig. 17(a), OSFs at SR11 and SR31 are created like discrete Fourier transform and principal component anal-
at instant Ti , and these multiple faults at different bridges are ysis, and use heuristic methods to locate the fault positions.
identified simultaneously at Td after 14 ms. OSFs are introduced The training of these fault classifiers is time-consuming, and
at SR31 and SR11 at Ti1 and Ti2 , respectively, in Fig. 17(b) and a large amount of training and testing data are required as N
17(c), and these faulty switches are identified at Td1 and Td2 , increases. The detection methods addressed in [4], [6], [9], and
respectively. The fault positions SR31 and SR11 are identified [11] are not capable of locating the individual faulty switch.
with the positive going edge of the fault identifier flags Fi1 and The techniques in [4], [5], [7], [9], and [12] require more than
Fi2 , respectively. In Fig. 17(c), the fault at SR31 is cleared at Ti2 . one cycle to locate the OSF positions, and effectiveness of the
Fig. 17(d) shows the result under multiple OSFs at SR11 and SR12 detection algorithm under various operating conditions has not
of HB-1, and the detection algorithm efficiently classifies the been validated for these methods. In general, for an N -level CHB
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ANAND et al.: GENERALIZED SWITCH FAULT DIAGNOSIS FOR CASCADED H-BRIDGE MLIs USING MEAN VOLTAGE PREDICTION 1573
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Power Energy Eng. Conf., Mar. 2012, pp. 1–4. rently working toward the Ph.D. degree in electrical
[7] X. Hao, Z. Jian, Q. Jie, W. Tianzhen, and H. Jingang, “RPCA-SVM fault engineering with the National Institute of Technology
diagnosis strategy of cascaded H-bridge multilevel inverters,” in Proc. 1st Calicut, Kozhikode, India.
Int. Conf. Green Energy, Mar. 2014, pp. 164–169. She is also an Assistant Professor with the De-
[8] T. Wang, H. Xu, J. Han, E. Elbouchikhi, and M. El Hachemi Benbouzid, partment of Electrical and Electronics Engineering,
“Cascaded H-bridge multilevel inverter system fault diagnosis using a PCA Government College of Engineering Kannur, Kannur, India. Her current research
and multiclass relevance vector machine approach,” IEEE Trans. Power interests include multilevel inverters, condition monitoring, and fault-tolerant
Electron., vol. 30, no. 12, pp. 7006–7018, Dec. 2015. operation of inverter-fed drives.
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1574 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 56, NO. 2, MARCH/APRIL 2020
Akhil Vinayak B (S’17) received the B.Tech. de- Jagadanand G (M’10) received the B.Tech. degree
gree in electrical and electronics engineering from in electrical and electronics engineering from the NSS
College of Engineering Trivandrum, India, in 2010, College of Engineering, Palakkad, India, in 1989,
and the M.Tech. degree in power and energy systems the M.Tech. degree in electrical engineering from
from the National Institute of Technology Karnataka, Regional Engineering College Calicut, Kozhikode,
Surathkal, India, in 2012. He is currently working India, in 1991, and the Ph.D. degree in electrical
toward the Ph.D. degree in electrical engineering engineering from the National Institute of Technology
with the National Institute of Technology Calicut, Calicut, Kozhikode, in 2013.
Kozhikode, India. He is currently an Associate Professor with the
He has two years of experience in the field of Department of Electrical Engineering, National In-
cockpit simulation and virtual reality for airplane pilot stitute of Technology Calicut. His current research
training. His research interests include condition monitoring of inverter-fed interests include power electronic circuits and control, multilevel inverters,
motor drives, fault modeling of electrical machines, and fault diagnosis in switching-mode power supplies, condition monitoring and diagnosis of drives
multilevel inverters. and converters, and induction motor drives.
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