240 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO.

1, JANUARY/FEBRUARY 2015

Early Detection Technique for Stator Winding

Inter-Turn Fault in BLDC Motor
Using Input Impedance
Jun-Kyu Park, Chae-Lim Jeong, Seung-Tae Lee, and Jin Hur, Senior Member, IEEE

Abstract—This paper proposes a diagnosis technique algorithm

for a brushless dc motors under a stator inter-turn fault (ITF) con-
dition using input impedance. The algorithm has early detection
and various speed-range detection advantages. To early and ac-
curately detect the ITF, the rotating speed, input current, voltage,
resistance, and inductance must be analyzed. Therefore, we choose
the input impedance as the detection factor because it includes
all these factors. In this paper, the fault-detection system works
without requiring a fast Fourier transform and the calculation
of the negative-sequence impedance from the comparison of the
measured impedance with the database impedance. The proposed
technique was verified by the simulation and experiment. Fig. 1. ITF occurrence in a single phase.

Index Terms—Brushless dc (BLDC) motors, detection algo-
rithm, early detection, input impedance, inter-turn fault.
I. I NTRODUCTION
breakdown in the adjacent coil. Moreover, the propagation of
the faults in a single phase could quickly lead to complete
failure or shutdown of the motor. However, the ITF and com-
plete failure of the motor do not occur at the same time. Thus,
fast detection of the ITF during motor operation can eliminate

B RUSHLESS DC (BLDC) motors have been widely used

in industrial and electric vehicles owing to their high
torque density and high efficiency. To improve the product
performance and ensure securing competitiveness, the develop-
ment of motors requires much improved stability and reliability.
Thus, effective monitoring and accurate fault diagnosis are very
important [1], [2].
Fault types can be classified according their locations such
as in the stator, rotor, inverter, power circuit, sensor, and other
mechanical devices [3]. Among these types, the stator winding
inter-turn fault (ITF) is one of the most common faults that
occur in BLDC motors [4]. ITF denotes insulation failure
between two coils in the same phase, as shown in Fig. 1. The
heat generated in the short circuit is proportional to the square
of the circulating current if , and therefore, it causes insulation
Manuscript received November 12, 2013; revised February 28, 2014 and
May 22, 2014; accepted May 23, 2014. Date of publication June 10, 2014;
date of current version January 16, 2015. Paper 2013-IDC-896.R2, presented at
the 2013 IEEE Energy Conversion Congress and Exposition, Denver, CO, USA,
September 16–20, and approved for publication in the IEEE T RANSACTIONS
ON I NDUSTRY A PPLICATIONS by the Industrial Drives Committee of the IEEE
Industry Applications Society. This work was supported by the Energy Effi-
ciency and Resources of the Korea Institute of Energy Technology Evaluation
and Planning (KETEP) Grant funded by the Korea government Ministry of
Knowledge Economy under Grant 20122010100130.
The authors are with the Department of Electrical Engineering, University
of Ulsan, Ulsan 680-749, Korea (e-mail: porpoise17@nate.com; love816827@
nate.com; forever_air@nate.com; jinhur@ulsan.ac.kr).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIA.2014.2330067
0093-9994 © 2014 IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission.
See http://www.ieee.org/publications_standards/publications/rights/index.html for more information.
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subsequent damage to the adjacent coils and stator core. An
early detection technique can help minimize loss of assets and
reduce repair costs and downtime of motor [5].
In the past, simple techniques such as overcurrent or over-
voltage detection were applied in machine fault detection. In
addition, it was required to bring the machine offline to clear
the fault after the fault diagnosis. However, in life-critical appli-
cations such as in home and industrial applications, shutdown
of the motor may not be acceptable. For this reason, developing
better fault-detection and remediation strategies is required [6].
Therefore, many studies have been conducted on the diagnosis
of ITF using various methods [7]. Kim [8] used the Fourier
series to monitor the second-order harmonic component of
the q-axis current in a permanent-magnet synchronous motor
(PMSM) under fault. In [9], robust fault detection was achieved
in closed-loop induction motors by monitoring the change in
the value of negative–positive-sequence impedance. To detect
stator faults in a synchronous machine, the rotor field voltage
was analyzed in [10]. To increase the sensitivity of the method,
search coils mounted on the rotor were proposed. Lee and
Habetler [11] discussed the short-circuit fault detection based
on the reference voltages generated by current controllers of
an interior-type PMSM. Mohammed et al. [12] used the finite-
element (FE)-based phase-variable model for fault detection.
Although these fault-detection schemes were simple and easy,
they were inadequate in detecting initial failure because of the
complex calculation required, such as the fast Fourier trans-
form (FFT) or the negative-positive-sequence impedance value.
Therefore, to early diagnose a fault, a simpler diagnosis process
is required.
 PARK et al.: TECHNIQUE FOR STATOR WINDING ITF IN BLDC MOTOR USING INPUT IMPEDANCE 241

Fig. 2. Proposed impedance algorithm.

Fig. 4. Speed change according to ITF. (a) Four-turn fault (Fr = 4.16%).
Fig. 3. Comparison of back electromotive force and input current. (a) Steady (b) Twelve-turn fault (Fr = 16.67%).
state (Fr = 0%). (b) Fault state (Fr = 4.16%).
A. Database Algorithm
The input impedance, which consists of the resistance and
In this paper, we propose an early detection technique using the reactance, can be easily obtained in real time using only the
the input impedance. The winding function theory (WFT) is input current and voltage. In addition, the reactance consists of
applied to calculate the impedance. This impedance is utilized the angular velocity and the inductance, as shown in (1)–(6).
in a database. In addition, this technique does not require the Thus, we select the input impedance as a detection parameter
calculation of the negative-sequence impedance and the appli-
cation of the FFT to the input voltage or current. Therefore, ITF Va
Za = (1)
detection using this approach has received a wide response and Ia
is easier than the previous method. where Va and Ia are true-RMS values of the phase voltage and
current in phase-A.
Under a healthy state,
II. D ETECTION T ECHNIQUE U SING AN A LGORITHM 
Za1 = Ra +jXa = Ra2 +(ωa La )2 (2)
In this paper, we propose the impedance algorithm, as shown La = Lself +Lmutual = Laa +Lab , ωa = 2πfsteady state (3)
in Fig. 2. An ITF causes a change in the input current, input
voltage, rotating speed, coil resistance, and stator inductance where Za1 , Ra , Xa , ωa , and La are the input impedance,
[13], [14]. Thus, these factors should be considered to ac- resistance, reactance, angular velocity, and inductance of phase,
curately detect the ITF. In particular, the phase of the input respectively.
current lags because of the decrease in the inductance under Under a faulty state,
an ITF condition, as shown in Fig. 3. As a result, it leads to an 
Za2 = Ras + jXas = Ras 2 + (ω L )2 (4)
as as
increase in the rotating speed, as shown in Fig. 4. Therefore, the Ras = (1 − Ff )Ra (5)
input impedance is selected as a detection parameter because it Las = Lself + Lmutual = Laa + Lab + Laf ,
includes all these factors. ωas = 2πffault state (6)
The impedance algorithm consists of three types, namely,
the database, fault diagnosis (in real time), and comparison where Za2 , Ras , Xas , ωas , and Las are the input impedance,
algorithms. The impedance algorithm can monitor the input resistance, reactance, angular velocity, and inductance of phase,
impedance in real time and compare it with the database. respectively.

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 242 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015

TABLE II
C OMPARISON OF AVERAGE VALUES OF I NDUCTANCE

Fig. 6. Inductance values obtained by the WFT and FEA. (a) WFT results.
(b) FEA results.

and (10). The other functions caused by the ITF are listed in
Table I. Thus,
Fig. 5. Turn function ni and winding function Nj . (a) Healthy state. Total number of turns N
(b) Faulty state. t_h = = (9)
Number of slots per phase 3
t_h N
TABLE I T _h = = . (10)
FACTORS OF T URN AND W INDING F UNCTIONS 2 6
The self-inductance and mutual-inductance can be calculated
using these functions. In particular, the air-gap length of an in-
terior permanent magnet (IPM)-type BLDC motor depends on
the inverse air-gap function because the air gap varies along the
d−q axis [16]. Thus, the stator inductance can be calculated as
⎡ 2π ⎤

Lij = μ0 · r · lst · ⎣ g −1 (θ)ni (θ)Nj (θ)dθ⎦ (11)
0

The fault fraction ratio is
Number of shorted winding
Ff =
Number of total winding
Fr = Ff × 100.
The databases of phase-B and phase-C can also be calculated
in the same manner. In this paper, we applied the WFT, which
uses a numerical function to the basic geometry and the winding
layout of the machine, to calculate the accurate database values.
WFT is not used to calculate in real time but is only used to
calculate the inductance of the machine [13], [15].
Fig. 5(a) shows the healthy state of the turn and winding
functions. Fig. 5(b) shows the change in the turn and the
winding functions according to the ITF. The turn function,
which is a distributed function of the turn number at the stator,
is reduced as the turn numbers at the faulted slot decrease. The
winding function, which is a distributed function of the current
density in the conductor, is reduced at the faulted slot and is
increased at the healthy slot.
The turn and the winding functions of the healthy state are
calculated by the number of poles per phase and the number of
turns per phase. These function values can be obtained by (9)
where ni (θ) and Nj (θ) are the turn and the winding functions,
respectively; i, j, r, and lst are the phase of the turn func-
tion, phase of the winding function, rotor radius, and stack
length, respectively; and g −1 (θ) is the inverse air-gap function.
(7)
Fig. 6 shows the inductance results according to Fr using
(8) the WFT and FE analysis (FEA). Table II lists the comparison
of the average inductance values obtained from the WFT and
FEA. These inductance values can be utilized to calculate the
impedance, which will become the database of the healthy
and fault states. We prefer the WFT because it is relatively
faster than the FEA. Moreover, the WFT offers considerable
simplicity and lower computational cost [13], [15].
However, the WFT cannot realize the magnetic saturation
characteristics because it does not consider the material char-
acteristics. Thus, the ITF is applied in the range where no
magnetic saturation occurs. In Fig. 7, we show the variation in
the magnetic flux of the stator teeth obtained by the WFT and
FEA simulation to confirm the magnetic characteristics. Here,
the magnetic flux density of the stator teeth can be calculated
using the air-gap flux density
Bair-gap = g −1 (θm )Nj (θm )iA (12)
ϕteeth = Bair-gap Aair-gap (13)
ϕteeth
Bteeth = (14)
Ateeth

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 PARK et al.: TECHNIQUE FOR STATOR WINDING ITF IN BLDC MOTOR USING INPUT IMPEDANCE 243

Fig. 9. Real-time and true-RMS values of input current at 3500 r/min.

Fig. 7. Variation in magnetic flux density at the stator. (a) WFT result. (a) Real-time value of input current (Fr = 4.16%). (b) True-RMS value of
(b) Simulation result. input current (Fr = 4.16%).

Fig. 10. Real-time and true-RMS values of input voltage at 600 r/min.
Fig. 8. Real-time and true-RMS values of input voltage at 3500 r/min. (a) Real-time value of input voltage (Fr = 4.16%); (b) True-RMS value of
(a) Real-time value of input voltage (Fr = 4.16%). (b) True-RMS value of input voltage (Fr = 4.16%).
input voltage (Fr = 4.16%).

where Bair-gap is the air-gap flux density, iA is the input current,

ϕteeth is the magnetic flux of the teeth, Aair-gap is the cross-
sectional area of the air gap, Bteeth is the magnetic flux density
of the teeth, and Ateeth is the cross-sectional area of the teeth.
Consequently, the magnetic flux density of the stator teeth at
the faulty phase decreases because the occurrence of ITF results
in reduced inductance, as shown in Fig. 7.

B. Fault Diagnosis Algorithm

Monitoring the real-time input current and voltage is very
important to accurately detect a faulty condition. To compare
the database and real-time impedance values, we measured the
true-RMS values of the real-time input current and voltage.
Then, we obtained the real-time impedance calculated by an
automatic voltage regulator.
Fig. 11. Real-time and true-RMS values of input current at 600 r/min.
Figs. 8–11 show the real-time and true-RMS values of the (a) Real-time value of input current (Fr = 4.16%). (b) True-RMS value of
input voltage and current under a three-turn fault condition and input current (Fr = 4.16%).

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 244 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015

Fig. 12. Fault diagnosis circuit using the proposed algorithm.

two rotating-speed types. The real-time input impedance is not

only calculated using these true-RMS values but also compared
with that of the database. At 3500 r/min, the input voltage and
current values noticeably change. Thus, ITF detection is easy
because the input impedance can be calculated easily. On the
other hand, fault detection is difficult at the 600 r/min condition
compared with the 3500 r/min condition because the variation
in the input voltage and current is very small.
Thus, this fault diagnosis algorithm can detect early the
presence of an ITF under various speed-range conditions.

C. Comparison Algorithm
The comparison algorithm shows how to compare the real- Fig. 13. Experimental setup.
time calculation of the input impedance with that of the
database. This algorithm continuously receives feedback.
In this paper, 4.16% (three-turn fault) was selected as the
database for the fault state. When Fr is larger than 0% and
less than 4.16%, a weak alarm level is designated. When
Fr is greater than 4.16%, a strong alarm level is designated.
Because the input voltage and input current can change under a
variety of situations, Fr can change even under the steady state;
thus, we chose 4.16%. In the same manner, we performed a
comparison under a low-speed (600 r/min) condition to validate
the accuracy of the comparison algorithm.

III. D IAGNOSIS C IRCUIT U SING

THE P ROPOSED A LGORITHM Fig. 14. Block diagram of the experimental setup.

The fault diagnosis circuit was developed using the proposed
impedance algorithm. Then, we verified by the simulation and
experiment whether the diagnosis circuit is fast and accurate.
Two types of diagnosis circuits that use the proposed algo-
rithm are shown in Fig. 12. Fig. 12(a) shows the configuration
of the diagnosis circuit for the simulation. Here, the simulation
used Proteus 7.6 developed at Labcenter Electronics. Moreover,
the low-priced ATmega128, which is coded as the proposed
algorithm, was utilized instead of the expensive digital signal
processor. In addition, a light-emitting diode is used for the
fault alarm, and a liquid crystal display shows the motor state
(e.g., how many turn faults are generated) in real time. The fault
diagnosis circuit for the experiment was developed on the basis
of the simulation circuit, as shown in Fig. 12(b).
IV. R ESULTS AND D ISCUSSION
A. Experimental Setup
Fig. 13 shows the experimental setup. Fig. 14 shows the block
diagram of the experimental setup for detailed explanation. In
this experiment, the inverter used is a current-controlled voltage
source inverter, which considers the speed control. The load part
consists of the dynamo set for experiment with a 0.5 N · m load.
B. Simulation and Experimental Models
Fig. 15 shows the experimental and simulation models. In
this paper, a six-pole and nine-slot IPM-type BLDC motor is
used for the simulation and experiment of the ITF characteris-
tics. Table III lists the motor specifications.

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 PARK et al.: TECHNIQUE FOR STATOR WINDING ITF IN BLDC MOTOR USING INPUT IMPEDANCE 245

Fig. 15. IPM-type BLDC motor for test and simulation. (a) Test motor.
(b) Simulation motor. Fig. 17. Simulation circuit for the dynamic fault.

TABLE III
S PECIFICATIONS OF THE IPM-T YPE BLDC M OTOR

Fig. 16. Construction of the contactor for the dynamic fault experiment.
(a) Actual structure. (b) Block diagram.

C. Real-Time ITF Generating System

For the dynamic fault experiment, we installed the real-time
ITF generating system using the winding tap, contactor, and
switch, as shown in Fig. 16(a). Here, the cable length of the
faulty teeth should be increased to connect the contactor. Thus,
it could affect the supply balance [17], [18]. However, the
resistance of the contactor is very low (0.006 Ω) to generate
the unbalanced supply condition in the experiment. By using
this system, we can generate an ITF in real time. The winding
tap, which can generate 1-, 3-, 5-, 7-, 9-, and 12-turn faults,
was installed in front of the motor for the ITF characteristics
experiment. Fig. 16(b) shows the block diagram of this system
for detailed explanation.
By using this method, we performed experiments on the
dynamic failure under a four-turn fault. In addition, we imple-
mented the dynamic fault simulation using switches, as shown
in Fig. 17. When the S_H switch functioned, the simulation
circuit is operated in the steady state. When the S_F switch
functioned, the simulation circuit operated in the faulty state.
Here, the S_H and S_F switches were turned off and on at the
same time for the dynamic fault.
D. Simulation and Experimental Results of the
Proposed Algorithm
Fig. 18 shows the simulation and experimental results for the
fault detection at 3500 r/min. In the simulation, the fault was
Fig. 18. Simulation and experimental results of fault detection at 3500 r/min.
(a) Simulation verification of fault detection (3500 r/min). (b) Experimental
verification of fault detection (3500 r/min).
detected in only 7 ms after the occurrence of the ITF, as shown
in Fig. 18(a). In the experiment, the fault was detected in 18 ms
after the ITF occurrence, as shown in Fig. 18(b).
In addition, Fig. 19 shows the results for the fault detection
at 600 r/min. Although the input voltage and current changed
only slightly, the fault was detected by the simulation (30 ms)
and experiment (36 ms).
The period of the input voltage and current waveforms was
reduced per unit time under the low-speed condition. Thus, the
fault-detection time at low speed (600 r/min) is longer than that
at the rated speed (3500 r/min).
The time to detect the faults in the experimental result was
longer than that of the simulation result. Because ideal switches
were used in the simulation, the waveform continuously flowed.

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 246 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015
Fig. 19. Simulation and experimental results of fault detection at 600 r/min.
(a) Simulation verification of fault detection (600 r/min). (b) Experimental
verification of fault detection (600 r/min).
A magnetic contactor, however, was used in the experiment.
Thus, when the magnetic contactor changed from normally
open to normally close, the value of the input current became
zero because the circuit was opened for approximately 6 ms
(at 3500 r/min) and 10 ms (at 600 r/min). Therefore, the fault-
detection times in the experiment were 12 ms (at 3500 r/min)
and 26 ms (at 600 r/min) when the open circuit parts are
excluded.
Although the diagnosis times between the simulation and
experiment did not match perfectly, the results were almost
the same because 7 ms versus 12 ms and 30 ms versus 36 ms
are very short times. In addition, the proposed fault-detection
algorithm has some deficiencies. For example, it is difficult to
detect fault condition under single turn fault and very low speed
(lower than 600 r/min) conditions because the variation of input
voltage and current are little changed. However, in the real
application of industrial field, it is important to detect the fault
condition when the motor is driven with rated operation because
the motor is driven in a range of ±40% of rated operation. Us-
ing the proposed detection algorithm, fault detection is possible
within a range of ±40% of rated operation. In particular, fault
detection is also possible at a low speed of 600 r/min (about
17% of the rated speed).
Therefore, by using this fault diagnosis technique, fast and
accurate detection of the ITF is possible under various rotating-
speed range conditions.
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V. C ONCLUSION
In this paper, we have proposed an early fault diagnosis
technique for an accurate and rapid detection of the ITF us-
ing the input impedance. In addition, we have simulated and
experimented detection characteristics at 3500 and 600 r/min
to validate the accuracy of the proposed detection algorithm
under various rotating-speed conditions. The proposed fault-
detection technique calculates the input impedance using the
input voltage and input current and compares it with the value
in the database. This technique provides faster and simpler
diagnosis than the previous methods because it does not require
the FFT or complicated formula. The proposed algorithm had
been verified to be suitable for early fault detection using
the fault diagnosis circuit. Therefore, the proposed diagnosis
technique can be advantageously used to reduce the loss of lives
and property damages and to protect the system.
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Jun-Kyu Park was born in Busan, Korea, in 1986.
He received the B.S. and M.S. degrees in electrical
engineering in 2011 and 2013, respectively, from the
University of Ulsan, Ulsan, Korea, where he is cur-
rently working toward the Ph.D. degree in electrical
engineering.
His current research interests include motor de-
sign, motor vibration analysis, and fault diagnosis of
the motor.
Chae-Lim Jeong was born in Ulsan, Korea, in 1989.
She received the B.S. and M.S. degrees in electrical
engineering in 2012 and 2014, respectively, from
the University of Ulsan, Ulsan, where she is cur-
rently working toward the Ph.D. degree in electrical
engineering.
Her current research interests include motor de-
sign, motor vibration analysis, and fault diagnosis of
the motor.
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247
Seung-Tae Lee was born in Busan, Korea, in 1988.
He received the B.S. degree in electrical engineering
in 2012 from the University of Ulsan, Ulsan, Korea,
where he is currently working toward the M.S. de-
gree in electrical engineering.
His current research interests include motor de-
sign, motor drives, and fault diagnosis of the motor.
Jin Hur (S’93–M’98–SM’03) received the Ph.D.
degree in electrical engineering from Hanyang Uni-
versity, Seoul, Korea, in 1999.
From 1999 to 2000, he was with the Department
of Electric Engineering, Texas A&M University,
College Station, TX, USA, as a Postdoctoral Re-
search Associate. From 2000 to 2001, he was a Re-
search Professor of electrical engineering for BK21
projects at Hanyang University. From 2002 to 2007,
he was Director of the Intelligent Mechatronics Re-
search Center, Korea Electronics Technology Insti-
tute (KETI), Puchon, Korea, where he worked on the development of special
electric machines and systems. Since 2008, he has been an Associate Professor
with the School of Electric Engineering, University of Ulsan, Ulsan, Korea. He
is the author of over 140 publications on electric machine design, analysis and
control, and power electronics. He has one granted pending U.S. patent and
20 granted pending Korean patents. His current research interests include high-
performance electrical machines, modeling, drives, new concept actuators for
special purposes, and numerical analysis of electromagnetic fields.
Dr. Hur was a Technical Program Chair for the 2012 IEEE Vehicle Power
and Propulsion Conference. He is currently an Associate Editor of the IEEE
T RANSACTIONS ON P OWER E LECTRONICS.