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This article has been accepted for publication in a future issue of this journal, but has not been

fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIA.2020.3019779, IEEE
Transactions on Industry Applications
IEEE TRANSACTION ON INDUSTRY APPLICATIONS, VOL. XX, NO. X, XXX/XXX 2020 1

Differential Mathematical Morphological Based On-


line Diagnosis of Stator Inter-Turn Failures in Direct
Torque Control Drive Systems
Hassan H. Eldeeb, Grad. Student Member, IEEE, Alberto Berzoy, Member, IEEE Ahmed A. Saad, Grad.
Student Member, IEEE Haisen Zhao, Senior Member, IEEE, and Osama A. Mohammed, Fellow, IEEE

Abstract— This study presents an in-service non-invasive fault faster than the FOC. Moreover, unlike the FOC, the torque and
diagnosis (FD) routine to detect incipient stator's inter-turn failure flux estimation in the DTC is less dependent on IM's inductance
(ITF) in direct torque control (DTC) driven induction motors parameters [9]-[10]. The IM's inductances are highly sensitive
(IM). The developed FD routine is based on the application of the
to the motor's temperature. Being less dependent on them (if
mathematical morphological gradient (MMG) technique on the
stator currents. Being a time-domain technique, it is less compared to FOC), makes the DTC a robust and fast vector
computational burdensome than the frequency-domain based FD. control drive technique [10]. Consequently, DTC became the
To detect the faulty phase, we introduced and implemented the most employed vector control drive technique industrially [10].
differential MMG (ΔMMG) algorithm concept. A comprehensive However, its robustness and redemptive nature hide the fault
electromagnetic investigation of harmonics and inter-harmonics signatures present in grid-connected (GC) IMs or IMs fed by
contents due to the ITF, the DTC controller's reaction, the
open-loop controlled voltage source inverters (VSIs) (e.g.,
inverter's switching activity is presented. A design guideline of
selecting the structuring element (SE) length for in the FD routine 𝑉/𝑓). Thus, it obstructs the fault diagnosis (FD) process.
was introduced. A physics-based co-simulation platform was built Stator's inter-turn faults (ITF) is the second prevalent fault
to investigate the feasibility of the proposed FD algorithm. within the IM drive system (about 36% of the IM's failures
Simulation reinforced by experimental results depicted the [12]); still, it is the most grueling one to be recognized [13].
robustness of the FD method. The comparative analysis is Stator's ITF causes: 1) Local thermal stress over the windings
presented between the developed ΔMMG and the conventional
adjacent to the defected turns. Previous studies reported one
motor current signature analysis (MCSA). The experimental
results proved that developed FD is faster, and more robust than turn ITF for 6s. elevated the temperature of the turns from 60
the MCSA in detecting the ITFs at their embryonic stages. to 120 °C [14], and 2) Rise in the voltage per turn value of the
faulty phase. Those two results in addition to the high switching
Index Terms—Current analysis, DTC, Fault detection,
Induction motor, Mathematical Morphology, Stator winding fault. frequency (𝑓𝑠 ) of the VSI accelerates the propagation of the ITF
within the phase winding. Despite its seriousness, FD of ITF in
I. INTRODUCTION DTC drives is inadequately investigated in literature if
compared to GC fed IMs, open-loop controlled IMs, or the
I NDUCTION motors (IMs) are the backbone of numerous
industries, including transportation electrification [1]. Their
design, control, and condition monitoring have been a topic of
field-oriented controlled IMs [15]-[22].
FD of ITF in DTC controlled IM via motor current signature
significant interest industrially for decades [2]-[7]. In high- analysis (MSCA) in the frequency domain (F-domain) and
performance industries, induction motors are typically vector positive sequence component (SC) of motor's current (𝑖𝑠 ) were
controlled due to its high performance and precise control presented in [23]. Whereas in [24], ITF was detected by
nature [8]-[9]. The two most famous and classical families of monitoring the harmonic spectrum of the developed power. The
motor vector controls are: 1) the field-oriented control (FOC), experimental results in both studies revealed the imprecision of
and 2) the direct torque control (DTC). The Classical DTC has those techniques for low-power rated DTC driven IMs. In [2],
several merits over the FOC [10]-[11], among which the the harmonic spectrum of the stray flux was utilized to detect
absence of: the ITFs by monitoring higher-order harmonics. Unfortunately,
1) Current and proportional-integral regulators; the F-domain based FDs face several challenges in practice, as
2) 𝑑 − 𝑞 (Synchronous rotating frame) transformation; and they require long sampling time, and they are accurate only in
3) PWM signal generators (thus, no timers are utilized). steady-state conditions [14].
Those advantages made the DTC algorithm to be simpler and In [25], the off-diagonal components of the impedance’s
sequence components (SC) matrix was utilized to detect ITFs
Manuscript received Feb. 29, 2020, revised in June 9, 2020, August 1, 2020,
and accepted in August 14, 2020. Corresponding author: Prof. O. Mohammed
in direct torque controlled motors. The technique was faster
(email: mohammed@fiu.edu). than the MCSA based FD. However, it has two burdens:
Part of the paper 2020-PSPC-0107.R2 was presented at the 2019 IEEE 1) The impedance SC matrix of the direct torque controlled
Applied Power Electronics Conference and Expo. (APEC), Anaheim, CA, in IM under healthy conditions under various speed, and loading
March, 2019 (DOI: 10.1109/APEC.2019.8721967.), and approved for
publication in the IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS factors should be known in advance.
by the Power Systems Protection Committee of the IEEE Industry Applications 2) Any anomaly in the motor (i.e., eccentricity, broken end-
Society. This work was partially supported by grants from the Office of Naval ring, broken bar …etc.) will vary the SC impedance; thus, the
Research (ONR) and the US Department of Energy (DOE).
The authors are with the Department of Electrical and Computer technique in [25] was incapable of distinguishing the ITF.
Engineering, Florida International University (FIU), Miami, FL 33174, USA. Furthermore, none of the aforementioned studies,[1] and

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This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIA.2020.3019779, IEEE
Transactions on Industry Applications
IEEE TRANSACTION ON INDUSTRY APPLICATIONS, VOL. XX, NO. X, XXX/XXX 2020 2

[23]-[25], was able to determine the faulty phase. From the Actual Flux and
(a) λsβ (b) Center of VSI Plane
presented review, it evident that the ITF diagnosis in the DTC Stator Flux DTC Estimated
drive system is not adequately addressed. λsβ Plane and R 2 Flux and Center of
Trajectory of the VSI Plane
The mathematical morphological gradient (MMG) is a time- 2 3 Regions Constant |λs|
ϕ Trajectory of
domain (T-domain) signal processing technique [26]-[27], that S3 (Actual)
Constant |λs| (DTC)
λs VSI CV
6 1
2
showed promising results in detecting broken bar faults [28],
λ^s S
Plane
λs6 ωr
and ITFs [29] for grid-connected IMs, as well as transformer S4 4 5
1
1 λsα ^
λs
protection [30]. Consequently, it is selected as a building block 5
Trajectory of

of the proposed FD technique [31].


S5 S6 Trajectory of
Constant Te (Actual)

Constant Te (DTC) R1 λsα


The contributions of this study to the ITF diagnosis state-of-
the-art are:
HBλ
2
λref
1) A thoughtful mathematical analysis of the electromagnetic Fig. 2. (a) Estimated and actual 𝝀𝒔 (𝑡𝑘 ), (b) Explanatory view of DTC action
behavior of DTC driven IMs with ITFs is presented TABLE I. DTC SWITCHING LOOK-UP TABLE
2) A real-time non-intrusive current based MMG routine is
presented to detect incipient ITFs in DTC driven IMs. 𝜏, 𝜓 ↓↓ ↑↓ ↓↑ ↑↑ 0
3) The faulty phase is determined by the aid of the introduced 𝑆1 𝑣𝑠4 𝑣𝑠2 𝑣𝑠5 𝑣𝑠3 0
𝑆2 𝑣𝑠5 𝑣𝑠6 𝑣𝑠1 𝑣𝑠2 0
differential MMG (ΔMMG) approach.
𝑆3 𝑣𝑠1 𝑣𝑠4 𝑣𝑠3 𝑣𝑠6 0
4) Performance indices and guidelines for designing the 𝑆4 𝑣𝑠3 𝑣𝑠5 𝑣𝑠2 𝑣𝑠4 0
structuring element (SE) of the FD algorithm are presented. 𝑆5 𝑣𝑠2 𝑣𝑠1 𝑣𝑠6 𝑣𝑠5 0
The FE co-simulation and the experimental results show the 𝑆6 𝑣𝑠6 𝑣𝑠3 𝑣𝑠4 𝑣𝑠1 0
ability of the developed FD to detect and allocate the ITF at According to the controllers' outputs (𝜓, 𝜏) and the space
various loading conditions and for different fault severity vector (SV) sector (𝑆𝑥 = {1: 6} ) of the previous switching
factors. A comparison is given between the proposed MMG-FD cycle (𝑡𝑘−1), the SV sector of the new cycle (𝑡𝑘 ) is determined,
and the conventional MCSA based FD experimentally. as in Fig.2., using the switching look-up table, as in Table I.
II. OVERVIEW OF THE DTC DRIVE SYSTEM III. THEORETICAL ANALYSIS OF HARMONIC COMPONENTS IN
This section reviews the basic theory of the conventional THE STATOR'S CURRENT DUE TO ITF- DTC INTER-ACTION
DTC algorithm. The DTC's aims to control the developed This section analyzes the anticipated harmonics in the IM's
torque (𝑇𝑒 ) and the magnitude of the flux-linkage (|𝜆𝑠 |), via a current theoretically in a DTC drive system with ITF.
2-level and a 3-level hysteresis controller, respectively [9]-[11],
A. ITF Reflection on the Estimated Torque and Flux
as in Fig. 1. The dc-link's voltage (VDC ), and two of the motor’s
currents (𝑖𝑠𝑏 and𝑖𝑠𝑐 ) are measured, while the third one (𝑖𝑠𝑎 ) is As the ITF occurs, the IM transfers into an unbalanced
calculated via (1). The VSI’s output voltage ([𝑣̂𝑠 ]) is found by system. Thus, the ITF will boost the positive SC, and insert a
the switching status ([𝑑𝑖𝑎 𝑑𝑖𝑏 𝑑𝑖𝑐 ]𝑡 ) as in (2). Based on 𝛼𝛽 negative SC in 𝑖𝑠 as in (5) [31]-[32]:
of [𝑣̂𝑠 ] and([𝑖𝑠 ] = [𝑖𝑠𝑎 𝑖𝑠𝑏 𝑖𝑠𝑐 ]𝑡 ), 𝜆̂𝑠 and 𝑇𝑒 are estimated by ̅ |𝑒 𝑗(𝜔𝑡+𝜙𝑖𝑠𝑃 ) + |𝐼𝑠𝑁
𝑖𝑠 = |𝐼𝑠𝑃 ̅ |𝑒 −𝑗(𝜔𝑡+𝜙𝑖𝑠𝑁 ) (5)
(3) and (4), respectively, where 𝑅𝑠 is the stator’s resistance. ̅ | and |𝐼𝑠𝑁
where |𝐼𝑠𝑃 ̅ | are the magnitudes of the positive and
𝑖𝑠𝑎 = −(𝑖𝑠𝑏 + 𝑖𝑠𝑐 ) (1) negative SC of 𝑖𝑠 , respectively, 𝜔 = 2𝜋𝑓. Based on (3), 𝜆̂𝑠
𝑣̂𝑠𝑎 2 −1 −1 𝑑𝑖𝑎 will inherit a negative SC, and will suffer from suppression in
𝑉 0; off
[𝑣̂𝑠 ] = [𝑣̂𝑠𝑏 ] = 𝐷𝐶 [−1 2 −1] [𝑑𝑖𝑏 ] ; 𝑑𝑖 = { (2) positive SC, as in (6):
3 1; on
𝑣̂𝑠𝑐 −1 −1 2 𝑑𝑖𝑐
𝜆̂𝑠 = |𝜆̅𝑠𝑃 |𝑒 𝑗(𝜔𝑡+𝜙𝜆𝑠𝑃 ) + |𝜆̅𝑠𝑁 |𝑒 −𝑗(𝜔𝑡+𝜙𝜆𝑠𝑁 ) (6)
𝜆̂𝑠 = ∫(𝑣̂𝑠 − 𝑅𝑠 𝑖̂𝑠 )𝑑𝑡 (3)
3𝑃 3𝑃
where |𝜆̅𝑠𝑃 | and |𝜆̅𝑠𝑁 | are the magnitudes of the positive and
𝑇̂𝑒 = |𝜆̂𝑠𝛼𝛽 × 𝑖 ∗ 𝑠𝛼𝛽 | = (𝑖𝑠𝛽 𝜆̂𝑠𝛼 − 𝑖𝑠𝛼 𝜆̂𝑠𝛽 ) (4) negative SC of 𝜆̂𝑠, respectively. According to (4), the estimated
22 22
3𝑝 ∗
Power IM FE model 𝑇̂𝑒 by the DTC controller will be as in (7) 𝑇̂𝑒 = Im{𝝀̂𝒔 𝒊𝒔 }.
2 Level-VSI Position of 22
VDC vCircuit
sa isa TTF From (7) it is evident that the estimated torque has three
vsb isb components: 1) 𝑇ℎ𝑒𝑎𝑙𝑡ℎ𝑦 which is the useful developed torque
vsc isc
due to the positive SC of flux and current, 2) 𝑇𝐼𝑇𝐹𝐷𝐶 that is the
ADC isa Short Time Buffer
constant error due to the interaction between the negative SC of
MMG for phase (b)
MMG for phase (a)
MMG for phase (c)

Absolute
ADC dai dbi dci
[is] Hysteresis
Te isb flux and current rotating at the same speed, and 3) the double
Controls Dilation Erosion
VDC τ -HBT δT Tref frequency error component due to the ITF (𝑇𝐼𝑇𝐹𝐷𝐹 ) resulting
3
DTC LUT
ψ
HBT
δλ isc + _
0 HBλ
λref
MAF from the interaction between the negative SC of the current with
[dai dbi dci] Sx
λs δc δ b δa the positive SC of the flux, and vice-versa. The DTC controllers
z-1 REGION DETECTOR
|λs| Differential MMG Reset
λs AND Te ESTIMATOR
|.|
DTC computaion stage Buffer observe those errors in the estimated flux and estimated torque.
δca δbc δab
if Healthy

[is] Te
ITF Alarm

Routine
Differential MMG
YES 3 If-Else
Statements to detect B. DTC Reaction to the Estimated Torque Error Due to ITF
ITF
FD Routine To compensate for the errors in the estimated 𝑇̂𝑒 , the
Fig. 1. FE platform of the DTC drive system and the MMG FD routine. controller has one of two compensatory options:

0093-9994 (c) 2020 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.
Authorized licensed use limited to: Cornell University Library. Downloaded on September 04,2020 at 17:01:42 UTC from IEEE Xplore. Restrictions apply.
This article has been accepted for publication in a future issue of this journal, but has not been fully edited. Content may change prior to final publication. Citation information: DOI 10.1109/TIA.2020.3019779, IEEE
Transactions on Industry Applications
IEEE TRANSACTION ON INDUSTRY APPLICATIONS, VOL. XX, NO. X, XXX/XXX 2020 3

3𝑝 |𝜆̅𝑠𝑃 ||𝐼𝑠𝑁 ̅ | sin (2𝜔𝑡 + (𝜙𝜆 − 𝜙𝑖 ))


𝑇̂𝑒 = |𝜆
⏟ ̅ 𝑠𝑃 ||𝐼 ̅
𝑠𝑃 | sin(𝜙 𝑖 − 𝜙 𝜆 ) − |𝜆
⏟ ̅ 𝑠𝑁 ||𝐼 ̅
𝑠𝑁 | sin(𝜙 𝜆 − 𝜙 𝑖 ) + [ 𝑠𝑃 𝑠𝑁
] (7)
𝑠𝑃 𝑠𝑃 𝑠𝑁 𝑠𝑁
22 −|𝜆 ̅ ||𝐼 ̅ | sin(2𝜔𝑡 + (𝜙 − 𝜙
𝑇ℎ𝑒𝑎𝑙𝑡ℎ𝑦 𝑇𝐼𝑇𝐹𝐷𝐶 ⏟ 𝑠𝑁 𝑠𝑃 𝑖𝑠𝑃 𝜆𝑠𝑁 ))
{ 𝑇𝐼𝑇𝐹𝐷𝐹 }
Option 1: to inject a negative SC in the stator's flux as a |𝐸 ⃑⃑⃑⃑⃑⃑
𝑎ℎ | = 4.44(ℎ𝑓)𝑁 𝑘
𝑠 𝑤ℎ 𝑔ℎ𝜙 (11)
reaction from the DTC controller. However, as shown in Fig. µ𝐷𝑙 (𝑊𝑎 𝑘𝑤ℎ ) 2
2 (b), due to the DTC hysteresis controller nature, the 𝑋𝑠ℎ = 6(ℎ𝑓) (12)
𝑔𝑘𝑔 𝑝2
maximum allowed negative SC flux component that can be
where 𝑁𝑠 is the number of turns per stator coil, 𝑘𝑤ℎ is the
injected by the DTC controller in this option
winding factor coefficient corresponding to the order ℎ, 𝜙𝑔ℎ the
(|𝜆̅𝑠𝑁 |𝐷𝑇𝐶−𝑟𝑒𝑎𝑐𝑡_𝑂𝑝𝑡1 ) is limited by the hysteresis bandwidth
ℎth harmonic air-gap flux, 𝜇 is the permeability, 𝑔 is the air gap's
(𝐻𝐵𝜆s ), as shown in (8). The narrow 𝐻𝐵𝜆s makes this option average length, 𝐷 is the stator's inner diameter, 𝑙 is the stator's
infeasible practically. effective length, 𝑘𝑔 is the air-gap harmonic coefficient, 𝑊𝑎 is
1 𝐻𝐵𝜆s × |𝜆̅𝑠𝑃 |
|𝜆̅𝑠𝑁 |𝐷𝑇𝐶−𝑟𝑒𝑎𝑐𝑡_𝑂𝑝𝑡1 ≤ (8) the winding coefficient, and 𝑝 is the number of pole pairs. 𝜙𝑔ℎ
2 𝜆ref is in (13), where 𝜏𝑝 is the pole's pitch. From (10)-(13), ⃑⃑⃑⃑⃑⃑⃑ 𝑖𝑠𝑎ℎ can
 Option 2: The DTC controller can change the angle between be expressed as in (14):
the stator's and rotor's flux vectors by injecting a positive 2𝜏
𝜙𝑔ℎ = 𝑝 𝑙𝐵𝑔ℎ (13)
sequence flux with frequency double the fundamental 𝜋ℎ
⃑⃑⃑⃑⃑⃑⃑⃑
𝜋𝑉𝑎ℎ −8.88𝑓𝑁𝑠 𝑘𝑤ℎ 𝜏𝑝 𝑙𝐵𝑔ℎ
frequency (2𝑓)[32]. To do so, the injected flux by the DTC to 𝑖𝑠𝑎ℎ =
⃑⃑⃑⃑⃑⃑⃑ µ𝐷𝑙 𝑊𝑎 𝑘𝑤ℎ
2 (14)
̂
react to the error in this option (𝜆𝑠 𝐷𝑇𝐶−𝑟𝑒𝑎𝑐𝑡 ) as in (9): 𝑗6(ℎ𝑓)
𝑔𝑘𝑔
(
𝑝
) +𝑅𝑠

𝑗(𝜔𝑡+𝜙𝜆𝑠𝑃 +𝑐(2𝜔𝑡+(𝜙𝜆𝑠𝑃 −𝜙𝑖𝑠𝑁 )))


For higher orders of ℎ in IM, 𝑅 𝑠 can be neglected (i.e. 𝑅𝑠 ≪
𝜆̂𝑠 𝐷𝑇𝐶−𝑟𝑒𝑎𝑐𝑡 = 𝜆ref 𝑒 (9) 𝑋𝑠ℎ ). Thus, (14) can re-written as in (15):
𝜋𝑉𝑎ℎ −8.88𝑓𝑁𝑠 𝑘𝑤ℎ 𝜏𝑝 𝑙𝐵 ⃑⃑⃑⃑⃑⃑⃑⃑
where 𝑐 is an arbitrary constant determined by the DTC 𝑖𝑠𝑎ℎ = 𝑝2 𝑔𝑘𝑔 {
⃑⃑⃑⃑⃑⃑⃑
𝑔ℎ
} (15)
𝑗6(ℎ𝑓)µ𝐷(𝑊 𝑘 ) 2
controller to compensate for the torque error, this option is more 𝑎 𝑤ℎ

practical than the former one, as there is no limit on the value From (14) it is evident that ⃑⃑⃑⃑⃑⃑⃑ 𝑖𝑠𝑎ℎ will carry the same harmonic
of 𝑐 by the controller. The harmonics resulted from (9) are the orders as in 𝐵𝑔ℎ , and the magnitude of ⃑⃑⃑⃑⃑⃑⃑ 𝑖𝑠𝑎ℎ is inversely
tripplen-order harmonics. The most dominant one is the 3rd proportional to the harmonic order ℎ. Consequently, it is vital
order harmonic component (3𝑓). to investigate the distinguishing harmonic components in 𝐵𝑔
due to the ITF fault combined with the DTC controlled VSI.
C. Air Gap's Flux Density Reflection on Stator's Current
Harmonics D. Time-Space Harmonics in Air-Gap's Magnetic Flux
In this sub-section the inter-relation between the harmonic Density for a Healthy IM
contents in the air-gap's flux density (𝐵𝑔 ) and 𝑖𝑠 are studied. The developed air gap's flux is basically the summation of
A the induced stator's flux density (𝐵𝑠 ) and the rotor's flux density
2 Level VSI
(𝐵 𝑟 ). For a healthy three-phase IM connected to a balanced
A Eah sinusoidal supply (i.e., GC), the stator's time-space magneto-
VDC ias Vah motive force (𝐹𝑠 (𝑡, 𝑥)) can be expressed as in (16). Whereas,
ibs ics Rs the air gap's permanence (Ʌ) can be expressed as in (17) [14].
N ∞
B Xsh 𝐶𝑝ℎ ℎ 𝑠 𝜋𝜏𝑖 ℎ 𝑠 𝜋𝑥
C isak [∑𝑖=1 sin ( )] sin (𝜔𝑡 − )1
2𝜏𝑝 𝜏𝑝
[dix] Three phase IM Stator 𝐹𝑠 (𝑡, 𝑥) = ∑ 𝑠 (16)
6
(a) (b) 𝜋ℎ
DTC Algorithm N { 3√2𝑁𝑠 𝐼𝑠 }
ℎ𝑠 =6𝑘±1
∞ ∞
Fig. 3. (a) Simplified block diagram of DTC drive system, (b) Phase "a"
equivalent circuit of healthy Induction motor. Ʌ = ∑ ∑ Γ𝑚,Ɣ cos[(Ɣ𝑍2 ± 𝑚𝑍1 )𝛼 𝑠 − Ɣ𝑍2 𝜔𝑟 𝑡] (17)
𝑚=0 Ɣ=0
The importance of this section comes from the fact that 𝐵𝑔
carries information about stator's and rotor's magnetic flux Where, 𝐼𝑠 is the RMS value of ⃑⃑𝑖𝑠 , ℎ 𝑠 is the harmonic rank of 𝐹𝑠 ,
densities. As depicted in Fig. 3, the ℎth order harmonic (ℎ 𝑠 = 6𝑘 ± 1; 𝑘 = 0,1,2, . . ), 𝐶𝑝ℎ is the number of coils per
component of the phase "a" stator's current (𝑖𝑠𝑎ℎ ) is dependent stator's phase, 𝜏𝑖 is the 𝑖 th coil pitch. Whereas, 𝑚 and Ɣ are non-
on the ℎth order harmonic component of the VSI's output phase null integers representing the orders of stator's and rotor's slot
voltage (𝑉𝑎ℎ ), the induced ℎth order back 𝑒𝑚𝑓 (𝐸𝑎ℎ ), the stator's harmonics, respectively; Γ𝑚,𝑛 is the peak permeance for a given
ℎth harmonic reactance (𝑋𝑠ℎ ), and 𝑅𝑠 as expressed in (10). The 𝑚 and Ɣ; 𝑍1 and 𝑍2 are the number of stator's and rotor's slots,
mathematical expressions of 𝐸𝑎ℎ and 𝑋𝑠ℎ are displayed in (11) respectively. 𝐵𝑠 is the product of 𝐹𝑠 and Ʌ, as presented in (18)
and (12), respectively. 𝑅𝑠 is assumed to be independent of ℎ, ℎ 𝑠 𝛼 𝑍1 𝜋ℎ 𝑠
∞ sin ( ) sin ( ) sin(𝜔𝑡 − 𝑝ℎ 𝑠 𝛼 𝑠 )
𝑠 2 6𝑝
⃑⃑⃑⃑⃑⃑
𝑉𝑎ℎ − ⃑⃑⃑⃑⃑⃑
𝐸𝑎ℎ 𝐵𝑠 (𝛼 ) = ∑ (18)
𝑖𝑠𝑎ℎ =
⃑⃑⃑⃑⃑⃑⃑ (10) 𝜋ℎ 𝑠 𝑔𝜋ℎ 𝑠
𝑗𝑋𝑠ℎ +𝑅𝑠 ℎ𝑠 𝑍1 sin ( )
{ 𝑍1 18√2 µ𝐼𝑠 }

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where, 𝛼 𝑍1 is the angle between two sides of the stator's turns. 𝐵𝑔 (𝑡, 𝛼 𝑠 ) for a given ℎ𝐵 and 𝑁𝑝 , respectively. Where ℎ𝐵 and 𝑁𝑝
It is clear from (18) that the 𝐵𝑠 will include harmonics of the are the time-harmonic orders in 𝐵𝑔 , and the pole pair number of
order 𝑝ℎ 𝑠 . 𝐵𝑠 can be referred to the rotor's side using the relation a flux density component, respectively, as in (25).
between the rotor's referred angle (𝛼 𝑟 ) with respect to the 𝑍2
stator's referred angle (𝛼 𝑠 ), as in (19). The stator's flux density ℎ𝐵 = Ɣ (1 − s) ± 1; 𝑁𝑝 = 𝑝(ℎ 𝑠 + 𝑚𝑍1 ∓ Ɣ𝑍2 ) (25)
𝑝
at the rotor's side (𝐵𝑠 (𝛼 𝑟 )) is as in (20) and (21), where 𝑠 is the
slip ratio. Relation (21) is the simplification of (20) [33]. E. ITF Effect on Air Gap Magnetic Flux Density
(1−𝑠) 𝑁𝐼𝑇𝐹
𝛼𝑟 = 𝛼 𝑠 + 𝜔𝑡 (19) 𝑝
In the ITF on-set, additional flux density (𝐵ℎ𝐼𝑇𝐹 ) appears in
𝑝
ℎ𝑠 𝛼𝑍1 𝜋ℎ𝑠 the air gap due to short-circuit. One major difference between
sin( 2
) sin( 6𝑝 ) sin((1±ℎ𝑠 (1−𝑠))𝜔𝑡−𝑝ℎ𝑠 𝛼 𝑟)
𝐵𝑠 (𝛼 𝑠 ) = ∑∞
ℎ𝑠 { 𝜋ℎ𝑠 𝑔𝜋ℎ𝑠 } (20) the additional magnetic flux density due to the ITF and 𝐵𝑔 , is
𝑍1 sin( )
𝑍1 18√2 µ𝐼𝑠 the fact that the ITF is localized in one spot. Consequently,

𝑁𝐼𝑇𝐹
𝑝
(𝛼 𝑟 ) = ∑ 𝐵̂ 𝑠 𝑠 𝑟 𝐵ℎ𝐼𝑇𝐹 as in (26) will have its peak value near the ITF location
𝐵𝑠 𝑠 𝑟 sin([1 ± ℎ (1 − 𝑠)]𝜔𝑡 − 𝑝ℎ 𝛼 ) (21)
ℎ𝑠 and decreases as the mechanical angle between the ITF location
The stator's flux cut the rotors bars to induce a voltage. and any random point on the stator's body (𝛼 𝐼𝑇𝐹 ) increases.
Consider a healthy rotor (with no broken bars); it can be divided 𝑁𝐼𝑇𝐹
𝑝
2𝜋
𝐵ℎ𝐼𝑇𝐹 , shown in (26), is similar to (25), with replacing ℎ𝐵 and
into 𝑍2 loop, each loop's pitch is . Assuming that each rotor's 𝑁𝑝 by ℎ𝐼𝑇𝐹 and 𝑁𝑝𝐼𝑇𝐹 , respectively, as in (27). Moreover, Where
𝑍2
bar has a resistance 𝑅2 , the current of the 𝑗th loop due to the ℎ 𝑠 th ̂ 𝐼𝑇𝐹
𝑁𝑝 𝐼𝑇𝐹
𝑁𝑝
stator's flux can be calculated according to Faraday's law as in 𝑚̀ and Ɣ̀ are analogous to 𝑚 and Ɣ; 𝐵ℎ𝐼𝑇𝐹 and ∅ℎ𝐼𝑇𝐹 are similar
(22). The conceptual diagram of the IM's rotor's current loop ̂𝑁 𝑁 ̂ 𝐼𝑇𝐹
𝑁𝑝
to 𝐵ℎ𝐵𝑝 and ∅ℎ𝐵𝑝 , respectively, in the case of ITF. 𝐵ℎ𝐼𝑇𝐹 is
and its equivalent windings are displayed in Fig. 4.
𝜋 2𝜋
directly proportional to the fault severity factor (𝜇𝑓 ). 𝜇𝑓 is the
𝑙𝜔(1±ℎ𝑠 (1−𝑠))𝐵̂
𝑠𝑟 sin(ℎ
𝑠 ) cos((1±ℎ𝑠 (1−𝑠))𝜔𝑡±ℎ𝑠 (𝑗−1) )
𝑗
𝑖ℎ𝑠 =
𝑍2 𝑍2
(22) ratio between the number of faulty turns (𝑁𝐼𝑇𝐹 ) to 𝑁𝑠
𝑅2 ℎ𝑠 𝑍2
Rotor s equivalent current s loop ℎ𝐼𝑇𝐹 = Ɣ̀ (1 − s) ± 1; 𝑁𝑝𝐼𝑇𝐹 = 𝑣 + 𝑝(𝑚̀ 𝑍1 + Ɣ̀𝑍2 ) (27)
𝑝
for squirrel cage rotor
Z 2-1 Z 2 1 2 3 j 𝑣 is a non-zero integer (i.e., 𝑣 = ±1, ±2, ±3, …) related to the
MMF due to the ITF. Therefore, 𝑣 contain all the values of ℎ 𝑠 .
From (25) and (27) it can be concluded that the ITF does not
Rotor tooth
Rotor Slot add new harmonic orders to the air-gap flux density, as ℎ𝐵 and
(a) (b) ℎ𝐼𝑇𝐹 carries the same values. Thus, the ITF changes only in the
magnitude of the ℎ𝐵 components.
Fig. 4. (a) Rotor's current loop. (b) Fictitious equivalent winding of IM's rotor That finding is a significant demerit in the MCSA based
The induced rotor's current per each stator's harmonic order diagnosis of ITFs. As under different loading conditions, and
develops the rotor's magnetic flux density (𝐵𝑟 (𝛼 𝑟 )), which can with the switching activity of the VSI, it is impractical to detect
the fault by monitoring specific harmonic orders.
be referred to the stator's reference angle (𝐵𝑟 (𝛼 𝑠 )) as in (23):
The presented analysis is valid for various speed and loading
From (23) it is evident that 𝐵𝑟 (𝛼 𝑠 ) is divided into two terms:
conditions, as the slip factor (s) is considered in (18)-(27).
1) The first is the armature reaction, which has the same
harmonic orders as those in 𝐵𝑠 (𝛼 𝑠 ) (i.e. 𝑝ℎ 𝑠 as in (18)).
2) Whereas the second term introduces new time-harmonic F. Side-Band Harmonics due to the DTC Controlled VSI
𝑍 Switching Activity and Its Effect on MCSA Based Diagnosis
components of the orders (i.e. Ɣ 2 (1 − 𝑠) ± 1), and space
𝑝
An additional burden with the MCSA based diagnosis
harmonics of the order (i.e., Ɣ𝑍2 ∓ 𝑝ℎ 𝑠 ). Those harmonics are procedure appears from the switching activity of the DTC
introduced due to the discrete nature of the rotor's design (slot's controlled VSI. As explained in section II, the DTC controllers
harmonics). act to make the flux linkage constant. Consequently, the
𝐵𝑔 is basically the summation of (17) and (22), as shown in (24). fundamental frequency (𝑓) of the IM will vary with the loading
∞ ∞
̂
𝑁 𝑁 condition and reference torque. That is a burden in the MCSA
𝐵𝑔 (𝑡, 𝛼 𝑠)
= ∑ ∑ 𝐵ℎ𝐵𝑝 × cos (ℎ𝐵 𝜔𝑡 − 𝑁𝑝 𝛼 𝑠 − ∅ℎ𝐵𝑝 ) (24)
based diagnosis, as harmonic order to be monitored as
ℎ𝐵 𝑁𝑝
indicators to the ITF will vary with the operational condition.
̂
𝑁 𝑁
where 𝐵ℎ𝐵𝑝 and ∅ℎ𝐵𝑝 are the peak value and phase angle of In this study, the inverter's 𝑓𝑠 is kept constant (𝑓𝑠 = 10kHz).
𝜋ℎ𝑠 𝜋(Ɣ𝑍2 ∓𝑝ℎ𝑠 ) Ɣ𝑍 (1−𝑠)±𝑝
𝑍2 µ𝑙𝜔(1±ℎ𝑠 (1−𝑠))𝐵̂ sin( 𝑍 ) cos(𝜔𝑡±𝑝ℎ𝑠 𝛼 𝑠 ) sin cos[𝜔𝑡 2 𝑝 ∓(Ɣ𝑍2 ∓𝑝ℎ𝑠 )𝛼 𝑠 ]
𝑠𝑟 𝑍2
𝐵𝑟 (𝛼 𝑠 ) = ∑∞
ℎ𝑠 { ⏟ 2
+ ∑∞ } (23)
ℎ𝑠 𝑔𝜋𝑅 2 ℎ𝑠 ⏟Ɣ=1 Ɣ𝑍2 ∓𝑝ℎ𝑠
𝑟𝑜𝑡𝑜𝑟 ′𝑠 𝑎𝑟𝑚𝑎𝑡𝑢𝑟𝑒 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑡𝑖𝑚𝑒−𝑠𝑝𝑎𝑐𝑒 ℎ𝑎𝑟𝑚𝑜𝑛𝑖𝑐𝑠 𝐷𝑢𝑒 𝑡𝑜 𝑅𝑜𝑡𝑜𝑟 ′𝑠 𝐶𝑜𝑛𝑠𝑡𝑟𝑢𝑐𝑡𝑖𝑜𝑛

∞ ∞ ̂
𝑁𝑝𝐼𝑇𝐹 𝐼𝑇𝐹
𝑁𝑝
𝐵𝑔𝐼𝑇𝐹 (𝑡, 𝛼 𝑠 ) = {∑ ∑ 𝐵ℎ𝐼𝑇𝐹 × 𝑐𝑜𝑠 ((ℎ𝐼𝑇𝐹 )𝜔𝑡 − (𝑁𝑝𝐼𝑇𝐹 )𝛼 𝑠 − ∅ℎ𝐼𝑇𝐹 )} × cos(𝑝𝛼 𝐼𝑇𝐹 ) (26)
ℎ𝐼𝑇𝐹 𝐼𝑇𝐹
𝑁𝑝

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The switching activity of the VSI will create what so-called 1) Dilation Operator (⨁)
"side-band" harmonics. The side-band harmonics effect is For a planar signal (i.e., 1-D signal), the dilation operator
simply that around each integral multiple of 𝑓𝑠 , the power aims to create a new signal of the same length of the main signal
harmonics multiples will appear. In other words, the switching that carries information about the peak values of the main
effect will replace the harmonic order term (ℎ) by (28). signal. Let the main signal to be (𝜌(𝑥)), and the SE to be (𝑟(𝑠)),
𝑓𝑠 where the length of 𝑟 is significantly shorter than 𝜌 (i.e., 𝑠 ⊂
𝑎 ± ℎ; 𝑎 = 0,1,2,3 … (28) 𝑥), then the dilated signal (𝜎) is defined as in (29):
𝑓
𝜎 = 𝜌 ⨁𝑟
For example, for a given operational condition, the IM's 𝑓 (29)
𝜎 = 𝑚𝑎𝑥{𝜌(𝑥 + 𝑠) + 𝑟(𝑠)} ∀ (𝑥 + 𝑠) ∈ 𝐷𝜌 , , 𝑆 ∈ 𝐷𝑟
was 60Hz, and the 3rd order harmonic (the one at 180 Hz) has
where 𝐷𝜌 , 𝐷𝑟 are the domains of 𝜌 and 𝑟, respectively.
a significant value. The harmonics at 𝑎 ×10,000±180 (i.e.,
9820 Hz, 10180 Hz, 19820 Hz, 20180 Hz…) will have 2) Erosion Operator (⊝)
significant values as well. For open-loop drive systems, as the Erosion can be described as a shrinking of the shapes
contained in the input signal by the SE [26]. Erosion is
value of 𝑎 increases, the amplitude of the harmonic contents
described as the minimum interaction between the signal and
decreases. However, for a vector control drive system (e.g.,
the SE. It is similar to the dilation but instead of supreme will
DTC), the compensatory nature of the DTC controllers within
be replaced by minutest as in (30), where 𝜀 is the eroded signal of
the low-frequency orders makes the inverse relationship
of 𝜌 with 𝑟
between 𝑎 and the amplitude of harmonics no longer valid [21].
𝜀 =𝜌⊝𝑟
(30)
IV. THE PROPOSED DIAGNOSIS TECHNIQUE (DIFFERENTIAL 𝜀 = 𝑚𝑖𝑛{𝜌(𝑥 + 𝑠) + 𝑟(𝑠)} ∀ (𝑥 + 𝑠) ∈ 𝐷𝜌 , 𝑆 ∈ 𝐷𝑟
MATHEMATICAL MORPHOLOGICAL GRADIENT) 3) Mathematical Morphological gradient (𝑀𝑀𝐺(𝛿))
In this section, the presented diagnosis technique is The mathematical morphological gradient (MMG) is
illustrated and discussed. Due to the numerous burdens in the defined to be the arithmetic difference between the dilation and
erosion of a signal by the SE.
MCSA based diagnosis explained in section III, the proposed
The MMG (𝛿) describes the envelope of the main signal
diagnosis algorithm is based on the real-time time-domain
after removing the steady-state low-frequency components. The
based technique: the mathematical morphology (MM). In this
MMG is represented as in (31).
section, the basics of the MM technique and its adaptation to
𝑀𝑀𝐺 = 𝜎 − 𝜀 (31)
the DTC drive system for ITF diagnosis will be highlighted. The MMG reflects the change between maximum and
A. The Philosophy of Mathematical Morphology minimum obtained within the sampling length of the SE.
To smoothen the output of the MMG, a finite impulse
Mathematical morphology is a descendant of the spatial
response (FIR) moving average filter (MAF) is implemented on
structures' analyzing techniques. It was introduced to the image
the calculated MMG, as in (32) [34]. The output of the MAF is
processing field by Matheron and Serra at the École des Mines
denoted as 𝛿. Despite its simplicity, the MAF is optimal for
de Paris, France[26]. It is based on set theory, integral reducing the random noise. This makes it the premier filter for
geometry, and lattice algebra[27]. It is conceptually different time-domain encoded signals.
from the integral transformations approaches (i.e., FFT and ∑𝐴−1
𝑠=0 𝑀𝑀𝐺[𝑥 + 𝑠]
Wavelet Transform (WT)) with respect to basic principles, 𝛿= (32)
𝐴
algorithmic operations, and approach. In contrast to FFT/WT, Where 𝐴 is the ratio between the length of the SE and the
MM is a non-linear signal processing technique [28]. sampling time (𝑇𝑠𝑎𝑚𝑝𝑙 ). The sampling time is the inverse of the
Furthermore, it depends on the time domain pattern of the signal 1
sampling frequency (𝑓𝑠𝑎𝑚𝑝𝑙 ); 𝑇𝑠𝑎𝑚𝑝𝑙 = .
rather than the frequency spectrum. Consequently, the 𝑓𝑠𝑎𝑚𝑝𝑙
estimation and/or tracking of the signal's frequency is not
C. Adaptation of MMG to the DTC Drive System for
required in the MM technique.
Realtime Fault Diagnosis (Differential MMG)
The morphological operators aim to extract quantitative
features from a non-linear signal in the time domain. A typical The objective of the diagnosis technique is to detect the ITF
at its incipient stage and to allocate the faulty phase (to
feature commonly extracted by the MM is edge detection. The
determine in which phase the ITF occurred). That is a major
structure of sets could be a 1-D (i.e., electrical signal) or 2-D
contribution if compared to the existing state of the art in
signal (i.e., digital image). The extraction is performed by the
literature. The previous studies in the ITF diagnosis [23]-[25],
interaction between the main (mother) signal and the [31] were unable to determine the faulty phase. To overcome
Structuring Element (SE). The latter is another signal set that is this critical disadvantage in the former studies, in this study the
simpler and significantly shorter than the main signal under "Differential MMG (ΔMMG)" concept is introduced to
study. The SE selection is discussed in section IV-D. determine the faulty phase.
B. Mathematical Morphological Gradient Algebra In the case of the DTC drive system, the real-time values of
the IM's stator's currents (𝑖𝑠𝑎 , 𝑖𝑠𝑏 , and 𝑖𝑠𝑐 ) are available
The MM operation is based on two basic morphological
operators: dilation (⨁) and erosion (⊝), which form a pair of continuously. The MM technique will be applied to [𝑖𝑠 ]. In
dual transforms. other words, there will be three MM subroutines programmed
in the drive system's controller, running in parallel. The MM
routine of each phase begins with a short buffering stage,

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IEEE TRANSACTION ON INDUSTRY APPLICATIONS, VOL. XX, NO. X, XXX/XXX 2020 6

followed by getting the absolute value of the current signal (i.e., One distinguishing feature of the stator's ITF fault, which was
𝜌 = |𝑖𝑠𝑦 |; 𝑦 = {𝑎, 𝑏, 𝑐}). The length of the buffered signal highlighted in detail through section III.E, is the fact that
equals to the length of the SE. Afterward, the dilation and induced flux density due to the ITF is heterogeneous in space,
erosion operations are performed via the SE, followed by as in (26). Consequently, the ITF will have an uneven effect on
calculating the MMG of each phase's current according to (29), the IM's phase currents. It will have a higher effect on the faulty
phase than the other two healthy phases.
(30), and (31), respectively. Then the computed MMG of each
Due to that finding, monitoring the MMG value of each
phase is passed through a MAF to get 𝛿, as in (32). The
phase might be deceptive in detecting the fault. However,
computed MMG of the buffered current of each phase (𝛿𝑦 ; 𝑦 = monitoring the difference between the MMG (ΔMMG) of each
{𝑎, 𝑏, 𝑐}) is now available. phase will be more reliable. Thus, the three ΔMMG values will
continuously be computed: δ𝑎𝑏 , δ𝑏𝑐 , and δ𝑐𝑎 , as in (33).
Direct Torque Controlled IM

VSI
Power & Control
VDC vsa Circuit δ𝑎𝑏 = 𝛿𝑎 − 𝛿𝑏
vsb isa
isb
δ𝑏𝑐 = 𝛿𝑏 − 𝛿𝑐 (33)
vsc
System

isc δ𝑐𝑎 = 𝛿𝑐 − 𝛿𝑎
ADC

ADC
[dxi] 6
[is] By monitoring (ΔMMG), not only the ITF could be
CONTROL ROUTINE
diagnosed, but it will also be allocated (the faulty phase can be
[is] IM FE model
determined). For instance, if the ITF occurred at phase (𝑎), then
isa isb isc 𝛿𝑎 will witness a significant rise than 𝛿𝑏 and 𝛿𝑐 . Moreover, as
SE length Buffer SE length Buffer
SE length Buffer
the ITF did not occur in phase (𝑏) nor (𝑐), the change in 𝛿𝑏 and
MMG Routine stage
(3 parallel MMGs)

MMG phase a MMG phase b MMG phase c


Absolute ( ρ=|isa|) Absolute ( ρ=|isb|) Absolute ( ρ=|isc|) 𝛿𝑐 will not be profoundly affected by the fault. Consequently,
Dilation Erosion Dilation Erosion Dilation Erosion δ𝑎𝑏 will increase as a positive value, δ𝑐𝑎 will increase as a
Eq. (29) Eq. (30) Eq. (29) Eq. (30)
σa + _ εa σb + _ εb σc
Eq. (29)
+ _
Eq. (30)
εc negative value, whereas δ𝑏𝑐 will witness almost no change (i.e.
MMGa MMGb MMGc δ𝑏𝑐 ≈ 0).
MAF Eq. (32) MAF Eq. (32) MAF Eq. (32)

δa δb δc
An additional advantage of the proposed differential
_ _
ITF Diagnosis Algorithm

Δ MMG

+ + approach is that it immunizes the diagnosis algorithm from the


Reset Buffers
Stage

Eq. (33) Differential MMG _ + inherited errors in current sensors, as ITF diagnosis is based on
δab δbc δca the subtraction of two quantities originated from the current
Detection and Allocation of Faulty Phase Logic

sensors. The details of the proposed FD routine and its


If: δab> 0 Alarm:
And δbc~ 0
YES
ITF in flowchart are displayed in Fig. 5.
And δca< 0 Phase (a) The advantages and abilities of the proposed MM-based FD
NO technique to diagnose ITFs in DTC drive systems over the
already existing approaches in the literature for the same
Else-If: δbc> 0 Alarm:
Stage

And δca~ 0
YES purpose is summarized in the following Table II, the acronym
ITF in
And δab < 0 Phase (b) DFP in the table stands for “detection of faulty phase.” All the
NO
FD techniques enlisted in the table utilized the current signal
either directly or indirectly (in developed power or impedance
Else-If: δca> 0 Alarm:
YES
ITF in
calculation) to detect the ITF. However, unlike the presented
And δab~ 0
And δbc < 0 Phase (c) FD routine in the article, none of them was able to determine
NO the faulty phase. Furthermore, the developed technique reveals
its supremity by not requiring neither the prior knowledge of
Fig. 5. A detailed flowchart of the proposed Differential MMG FD Algorithm the motor’s model in healthy mode nor frequency tracking.
TABLE II. MERITS OF THE PROPOSED MM-BASED FD TECHNIQUE OVER THE CURRENT ITF DIAGNOSIS IN DTC DRIVES STATE-OF-THE-ART

Ref Variable Domain Frequency IM Model Immunity to IM Studied in FE Training data Computational burden Diagnostic DFP
Used Analysis tracking Requirement asymmetries domain required capability (𝝁𝒇 )
[23] Current Frequency Required Not required Unimmune No No Highest (frequancy 8.16%
tracking + FFT)
[23] Current Time Not Required Unimmune No Yes High (𝑑𝑞 transformation 2.04%
to
Unable

required + model required)


[24] Developed Frequency Required Not required Unimmune No No Highest (frequancy 2.04%
power tracking + FFT)
[25] SC Time Required Required Immune No Yes Moderate (frequency 1.08%
Impedance tracking)
[2] Stray Flux Frequency Required Not Required Unimmune Yes No Highest (frequancy 2%
tracking + FFT)+ Loop
Antenna adjustiment
burdens
This current Time Not Not required Immune Yes No Low (No frequency 1.08% Able
study Required tracking, No
transformation, No model
required)

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Besides, none of the aforementioned studies ([23]-[25]) It is noteworthy to mention that no equation in the literature
investigated the FD technique performance in FE domain. describes how the optimal SE length could be determined.
Consequently, they are vulnerable to IM’s construction
asymmetries. The technique in [25] is immune to the sensor’s V. FE COUPLED SIMULATION RESULTS
errors, as it is based on differential impedance. This section presents the FE platform and the results of the
Moreover, the time-based methods in [23] and [25] required developed diagnosis routine. Firstly, the details of the FE co-
the prior knowledge of the IM’s model, training data and simulation environment are explained. Then, the breakdown of
continuous tuning. the MMG process is shown for a healthy case and two faulty
The frequency domain-based diagnosis techniques in [23]- cases. Afterward, The effect of the SE length of the FD index
[24] require the highest computational efforts as they demand performance is discussed. Finally, the performance of the
frequency tracking and FFT. Thereby, their response is the diagnosis routine was investigated for 45 operational cases for
slowest. On the other hand, the time domain-based algorithms healthy and faulty motor conditions under various loading
in [23] and [25] are faster as they do not require frequency torques.
transformation. Still, they require either frequency tracking or
𝑑 − 𝑞 conversion, which delay their responce. Main File (in MATLAB) IM FE Model
Furthermore, the diagnostic capability (lowest severity factor  Initializations and definitions (VSI Model & DTC Programming)
[vsk]
 For Loop setup
(𝜇𝑓 ) detected) of all the previous studies, [23] -[25], was either For Loop
DTC controllers send switching pattern [dxk] of instant (tk) toVSI
greater than or equal to the diagnosis capability of the The VSI sent the output voltage [vsk] to the IM FE model
The FE of the IM is solved, and [isk] and speed are obtained
developed ∆ 𝑀𝑀𝐺 based FD presented in this study, as shown DTC controllers estimate Tek and λsk [isk]
DTC update its operation for the new cycle Interrupt
in Table II. Thus the proposed routine is less computational
Interrupt routine: FD algorithm Routine
burdensome, more sensitive to ITFs, and more reliable than the Update the new cycle: k=k+1
FD Algorithm:
If k< kmax: Return to the beginning
techniques that exist in the literature. Moreover, unlike all the ΔMMG (Fig. 5)
previous studies, it is capable of determining the faulty phase
Fig. 6. FE Co-simulation and FD routine platform Programming concept
D. Proper Selection of Structure element (SE) Healthy Coil Faulty Coil 80
4.45
In this section a basic guideline for selecting the length of the 30
60
SE for diagnosis application is highlighted. It is evident from 16.5
3.285
39
13.215
(28)-(32) that SE plays a fundamental role in the MM 22 160 40

operations, and hence on the FD performance. Thus, it should 4.48


13 2.5 20
be adequately selected.
3.5 60
The structuring element (SE) could be of linear (flat) or a (a) 13.5 (b)
0 20 40 60
(c)
80
two-dimensional shape (i.e., circular, triangular,
Fig. 7. (a) IM geometry. (b) Finite elements (FE) model of IM in mm. (c) IM
elliptical…etc.) or a three-dimensional form (i.e., spherical, meshing in FE domain
cylindrical…etc.). For one-dimensional signals (i.e., current TABLE III. NAMEPLATE RATINGS OF THE IM UNDER STUDY.
signals), the linear SEs are the most commonly used in the
Param. Value Param. Value Rating Value Rating Value
mathematical morphological process [35]. 𝐿𝑙𝑠 ( 𝑚𝐻) 32.1 𝑅𝑠 (Ω) 9.292 𝑃𝑟 (ℎ𝑝) 1 𝑃𝐹 0.8
For linear SEs, the selection of an appropriate SE length is 𝐿𝑙𝑟 (𝑚𝐻) 37.0 𝑅𝑟 (Ω) 7.231 𝑉𝑟 (V) 460 p 2
constrained by 1) the frequency and type of disturbance 𝐿𝑚 (𝐻) 0.895 𝐽𝑚 (𝐾𝑔𝑚2 ) 0.053 𝐼𝑟 (𝐴) 1.47 𝑛𝑟 (𝑟𝑝𝑚) 1730
phenomenon that is required to be detected; 2) 𝑇𝑠𝑎𝑚𝑝𝑙 . There is TABLE IV. ITF CASES STUDIED
no defining rule for selecting the length of SE other than the 𝝁𝒇 (%) 𝝁𝒇 (%)
NITF Case NITF Case
fact that it should be significantly shorter than the length of the 6 1.08 𝐶1 28 5.55 𝐶5
main signal [35]. The length of SE is an integral multiple of 14 2.68 𝐶2 42 8.25 𝐶6
𝑇𝑠𝑎𝑚𝑝𝑙 , as in (34), the integral multiple (𝐴) was selected to 20 3.98 𝐶3 47 9.31 𝐶7
follow the power-of-two binary rule [36]. The power-of-two 24 4.70 𝐶4 61 12.01 𝐶8
rule is not obligatory in the case of single-stage MMG, [37]. A. FE Co-Simulation Platform Details
However, it makes the MMG stage modular [36], if a multi-
resolution MMG was required in either the control or the To examine the proposed FD routine, an active finite element
diagnosis logic. (FE) coupled simultions (co-simulation) platform of the DTC
drive system was established. The FE co-simulation platform
𝑙𝑒𝑛𝑔𝑡ℎ (𝑆𝐸) = 𝐴 × 𝑇𝑠𝑎𝑚𝑝𝑙 ; 𝐴 = 2𝑎 ; 𝑎 ∈ {1,2,3 … } (34)
was realized via the interactive coupling of the DTC-VSI
The length of the SE defines the window size of all the MM’s
simulation models with the physics-based model of the IM. The
transformations, and hence the delay in the output.
VSI model, DTC algorithm, and the FD routine were
For SE of length 𝐴 × 𝑇𝑠𝑎𝑚𝑝𝑙 , then the delay in the fault programmed in the Simulink/MATLAB environment while the
diagnosis (FD) routine output will be as in (35) [35]. IM model was built in the FE domain. The IM's FE model is a
𝑑𝑒𝑙𝑎𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑜𝑢𝑡𝑝𝑢𝑡 = (𝐴 − 1) × 𝑇𝑠𝑎𝑚𝑝𝑙 (35) physics-based model. It was established by mapping all the
According to (35), as the length of SE increases (i.e., 𝐴 materials' characteristics and dimensional details of the IM. The
increases), the following consequences occur: FE Co-simulation programming concept is displayed in Fig.6
1) The performance of the FD technique will be slower The advantages of the FE Co-simulation platform:
2) The feature extraction will be more reliable

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 Not only the IM circuit under healthy and faulty conditions To determine the proper length of SE, two selections
is considered, but also the effect of the motor's materials on parameters were defined: 1) Settling time of the FD response
its performance is considered in the physics-based model. (𝑇𝑠𝑒𝑡 ), a shorter 𝑇𝑠𝑒𝑡 indicates a faster response of the diagnosis
 The IM harmonic contents including stator slots, rotor routine; 2) Fault sensitivity index (FSI).
slots, saturation, switching activity, and fault are simulated
The FSI is defined to be the degree of deviation between the
 Dangerous experimentations of a faulty IM can be
avoided. Therefore, we can safely study all the fault diagnosis index (𝛿) of the healthy phases and the faulty
characteristics of a faulty IM in the possible accurate one at the lowest possible 𝜇𝑓 (i.e., 𝐶1 (𝜇𝑓 =1%)).
approach. (|δ𝑎𝑏 − δ𝑏𝑐 | + |δ𝑏𝑐 − δ𝑐𝑎 |)𝐚𝐭 𝝁𝒇=𝟏%
The 1 hp IM studied has 𝑍1 = 36 and 𝑍2 = 44. The rotor has 𝐹𝑆𝐼 = (36)
2
aluminum bars of 3.8× 107 Ʊ/m, while the stator windings are The FD routine was examined under six different lengths
copper. The dimensions of the IM (in mm) are shown in Fig. of SE (i.e., 𝐴 = {2,4,8,16,32,64}) under three different
7(a) and (b). The IM ratings and parameters are in Table III. operational conditions (i.e., 𝐶1 , 𝐶4 , and, 𝐶7 ) against the healthy
The number of turns per phase (𝑁𝑠 ) is 510. Nine cases (1 condition. All of those cases were investigated under 2Nm
healthy and 8 faulty) were examined experimentally and in FE loading conditions. The results are shown in Fig. 9 (a), (b), and
platform. The 8 ITF cases (C1 -C8 ) are listed in Table IV. (c), respectively.
The IM model in the FE environment had 10164 nodes and
20245 elements. The meshing grid is shown in Fig. 7(c). The
DTC driven IM was operated in the FE domain using a 32 GB
RAM, AMD Ryzen 7 processor 64 − bit computer under
healthy and faulty cases with different loading conditions.

Fig. 8. FEA Co-Simulation results for healthy, 𝐶1 and 𝐶3 cases (a): 𝑖𝑠𝑎 , (b):
Zoom-in of 𝑖𝑠𝑎 , (c): 𝜎, (d): 𝜀, (e): 𝑀𝑀𝐺𝑎 , (f): 𝛿𝑎 .

B. MMG Stages Illustration for Healthy and Faulty IM Cases


In this subsection, the waveforms of the MMG routine stages Fig. 9. 𝛿𝑎𝑏 response at A=2,4,8,16,32, and 64 for (a) healthy vs 𝐶1 , (b):
are shown to illustrate the SE action in the MMG technique. healthy vs 𝐶4 , (c): healthy vs 𝐶7 , (d): Settling time vs FSI .
Consequently, only 𝑖𝑠𝑎 obtained from FE analysis (FEA) co- As the figure shows, for different 𝜇𝑓 , as the length of SE
simulation environment for three cases (healthy 𝐶1 and 𝐶3
increases (i.e., 𝐴 increases) two concurrent consequences
faulty cased) are displayed for clarification purposes, as in Fig.
occurs, 1) the difference between δ𝑎𝑏 between the healthy and
8(a). Their zoomed-in view is displayed in Fig. 8(b). The
faulty cases for any given fault severity factor increases, that is
dilation (𝜎) and erosion (𝜀) of the obtained signals are displayed
a merit. 2) 𝑇𝑠𝑒𝑡 also increases (i.e., the response of the FD
in Fig. 8(c) and Fig. 8(d), respectively.
technique becomes slower). That trend was consistent for
As Fig. 8(c) shows, the maximums of the absolute current of
different fault severity factors.
the 𝐶3 case is higher than that of 𝐶1 which is higher than that of
The 𝑇𝑠𝑒𝑡 was recorded, and FSI was computed at 𝜇𝑓 = 1%,
the healthy case. Whereas in Fig. 8(d), the 𝜀 signal the
as in (36), and the result is displayed in Fig. 9 (d). As the figure
difference between the three cases is small. Thus, 𝑀𝑀𝐺𝑎 , has
shows, at 𝐴 = 16 the FSI is high enough to discriminate the
the highest value in 𝐶3 , and the lowest in the healthy case, as in
fault at its embryonic stages and is sufficiently fast (11 ms). At
Fig. 8(e). The output of the MAF (𝛿𝑎 ) is shown in Fig. 8(f). 𝛿𝑎
higher values of 𝐴, FSI enhances at the cost of 𝑇𝑠𝑒𝑡 . Where, at
is the input to the differential stage in the FD routine, as
lower values of A, the opposite happens. Consequently, the
explained in section IV-C. As the results illustrate, the FD
technique did not require the knowledge of the IM's frequency, selected SE length was 16𝑇𝑠𝑎𝑚𝑝𝑙 (i.e., 𝐴 = 16)
and it depends on simple arithmetic computation. D. Verification of the Developed Differential MMG FD
C. Investigating the effect of SE’s length on the Diagnosis The DTC driven IM was operated under 5 different loading
Technique’s performance conditions (𝑇𝑟𝑒𝑓 = {0.6 Nm, 1 Nm, 1.4 Nm, 1.6Nm, 2 Nm})
The fast and reliable response of the FD routine are major for the 9 cases (i.e., the healthy case as well as the 8 faulty cases
factors to consider, to avoid false alarms. (𝐶1 − 𝐶8 ) enlisted in Table IV). Consequently, 45 test cases

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(9 × 5) were examined in the FE co-simulation domain. In each differential MMGs (𝛿𝑎𝑏 , 𝛿𝑏𝑐 , and 𝛿𝑐𝑎 ) tends to be almost equal
case study, [𝑖𝑠 ] was obtained, the MM operations (i.e., relations zero (as shown in the first row), regardless of the loading
(29) to (32)) were performed on-line on each line current (i.e., condition. On the other hand, when an ITF occurs in phase "𝑎,"
𝑖𝑠𝑎 , 𝑖𝑠𝑏 , and 𝑖𝑠𝑐 ), and 𝛿𝑎 , 𝛿𝑏 , and 𝛿𝑐 were obtained, as enlisted 𝛿𝑎𝑏 increases as a positive value, and simultaneously 𝛿𝑐𝑎
in Table V. Afterward, by (33), 𝛿𝑎𝑏 , 𝛿𝑏𝑐 and 𝛿𝑐𝑎 were computed increases as a negative value (i.e., become more negative),
on-line, and the results are presented in Table VI. And in Fig. whereas 𝛿𝑏𝑐 is kept around the zero value. Another interesting
10. Those values are the fault detection indices, by which the observation is that 𝛿𝑎𝑏 and 𝛿𝑐𝑎 are proportional to 𝜇𝑓 . Thus,
ITF is detected (if existing), and the faulty phase is determined. as the severity of the ITF increases, the deviation of 𝛿𝑎𝑏 and
It is noteworthy to mention that the 45 case studies include 𝛿𝑐𝑎 from the zero value increases.
embryonic stages of the fault (𝜇𝑓 = 1%), as well as relatively Moreover, as the defined SE length is kept constant (A =
high fault severity factors (𝜇𝑓 = 9.3% and 12%). Moreover, 16), as explained in section V. C, then the response of the
the proposed diagnosis routine was examined, as shown in proposed MM-based FD technique did not depend on the
Tables VI and VII, when the DTC system was operated under variation of the fundamental frequency with the variation of the
low reference torque (0.6 Nm), and high reference torque (2 Tref , as explained in section II. The authors believe that it is an
Nm) and intermediate ones. Those case studies were established advantage in the proposed technique that the FD routine does
to investigate the performance of the MM-based FD routine not require to change the SE length with the loading condition.
under various operational conditions. Furthermore, the proposed FD was able to detect incipient
From Table VI and Fig. 10, the accuracy and efficiency of faults (𝜇𝑓 = 1%) under various loading conditions without the
the proposed FD technique are verified. As the results in the need of any modification in any of the FD parameters.
table show, when the DTC driven IM is healthy, all the

TABLE V. MATHEMATICAL MORPHOLOGICAL GRADIENT OF EACH PHASE CURRENT FOR THE 45 FE CO-SIMULATION CASE STUDIES
𝑇𝑟𝑒𝑓 0.6 Nm 1 Nm 1.4 Nm 1.6 Nm 2 Nm
Case 𝛿𝑎 𝛿𝑏 𝛿𝑐 𝛿𝑎 𝛿𝑏 𝛿𝑐 𝛿𝑎 𝛿𝑏 𝛿𝑐 𝛿𝑎 𝛿𝑏 𝛿𝑐 𝛿𝑎 𝛿𝑏 𝛿𝑐
Healthy 0.416 0.407 0.400 0.426 0.430 0.438 0.527 0.535 0.527 0.511 0.514 0.514 0.516 0.513 0.511
𝐶1 0.430 0.399 0.406 0.468 0.436 0.442 0.551 0.515 0.508 0.534 0.503 0.497 0.538 0.503 0.499
𝐶2 0.426 0.373 0.368 0.466 0.419 0.425 0.549 0.491 0.485 0.532 0.476 0.481 0.536 0.483 0.474
𝐶3 0.457 0.369 0.351 0.504 0.418 0.419 0.594 0.515 0.507 0.576 0.493 0.48 0.583 0.498 0.498
𝐶4 0.468 0.342 0.316 0.523 0.404 0.401 0.616 0.492 0.476 0.596 0.478 0.459 0.606 0.478 0.48
𝐶5 0.476 0.299 0.279 0.539 0.37 0.353 0.638 0.468 0.441 0.614 0.439 0.428 0.62 0.450 0.451
𝐶6 0.508 0.295 0.285 0.594 0.408 0.398 0.661 0.456 0.44 0.632 0.439 0.406 0.677 0.470 0.474
𝐶7 0.517 0.268 0.258 0.61 0.376 0.363 0.72 0.478 0.467 0.685 0.435 0.415 0.696 0.443 0.451
𝐶8 0.542 0.245 0.252 0.655 0.351 0.344 0.775 0.489 0.497 0.732 0.440 0.451 0.723 0.415 0.410

TABLE VI. DIFFERENTIAL MMG (ΔMMG) OF THE 45 FE CO-SIMULATION CASE STUDIES FOR ITF DIAGNOSIS.
𝑇𝑟𝑒𝑓 0.6 Nm 1 Nm 1.4 Nm 1.6 Nm 2 Nm
Case 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎
Healthy 0.009 0.007 -0.008 -0.004 -0.008 0.009 -0.008 0.008 0 -0.003 0 0.003 0.003 0.002 -0.005
𝐶1 0.032 -0.007 -0.032 0.032 -0.006 -0.031 0.035 0.007 -0.034 0.031 0.006 -0.031 0.035 0.004 -0.035
𝐶2 0.053 0.005 -0.052 0.047 -0.006 -0.047 0.058 0.005 -0.056 0.056 -0.005 -0.05 0.054 0.009 -0.053
𝐶3 0.088 0.018 -0.083 0.086 -0.002 -0.076 0.078 0.008 -0.081 0.083 0.013 -0.072 0.085 0.000 -0.084
𝐶4 0.126 0.026 -0.112 0.119 0.003 -0.114 0.124 0.016 -0.107 0.119 0.018 -0.117 0.128 -0.002 -0.104
𝐶5 0.177 0.02 -0.142 0.168 0.017 -0.144 0.17 0.027 -0.144 0.175 0.011 -0.138 0.170 -0.001 -0.143
𝐶6 0.213 0.011 -0.179 0.186 0.01 -0.201 0.204 0.017 -0.186 0.193 0.033 -0.192 0.207 -0.004 -0.183
𝐶7 0.249 0.01 -0.206 0.234 0.013 -0.247 0.243 0.011 -0.216 0.25 0.02 -0.196 0.253 -0.007 -0.195
𝐶8 0.298 -0.007 -0.281 0.305 0.007 -0.286 0.286 -0.008 -0.273 0.292 -0.011 -0.278 0.308 0.005 -0.310

Fig. 10. ΔMMG (𝛿𝑎𝑏 , 𝛿𝑏𝑐 , and 𝛿𝑐𝑎 ) Trends of the 45 FE Co-Simulation Case Studies

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VI. EXPERIMENTAL RESULTS TABLE VII. EXPERIMENTAL RESULTS: MM OF EACH PHASE CURRENT
(𝛿𝑎 , 𝛿𝑏 , AND 𝛿𝑐 ) FOR 18 CASES
In this section, the experimental setup of the motor drive 𝑇𝑟𝑒𝑓 1.5 Nm. 2Nm.
system is explained. Then the performance of the diagnosis Case 𝛿𝑎 𝛿𝑏 𝛿𝑐 𝛿𝑎 𝛿𝑏 𝛿𝑐
method is discussed experimentally. The experimental studies healthy 0.4644 0.4694 0.4683 0.5392 0.5302 0.5216
were divided into two parts: the first is to validate the proposed 𝐶1 0.4833 0.4443 0.4438 0.5499 0.5031 0.5023
FD routine experimentally on-line under 18 experimental case 𝐶2 0.4824 0.4324 0.4329 0.5788 0.5248 0.5122
studies, whereas the second is to compare the proposed method 𝐶3 0.5238 0.3848 0.3918 0.6345 0.4833 0.4833
to the conventional MCSA based diagnosis. 𝐶4 0.5454 0.3754 0.3789 0.6484 0.4594 0.4612
The experimental test-bench of the DTC-IM drive system is 𝐶5 0.558 0.3530 0.3605 0.6756 0.4452 0.4560
𝐶6 0.6093 0.3293 0.3388 0.7611 0.4381 0.45116
displayed in Fig. 11. The IM is mechanically coupled into a 250 𝐶7 0.6264 0.2834 0.2949 0.7756 0.4138 0.42648
W, 42 V DC PM Generator to act as a variable mechanical load. 𝐶8 0.6462 0.2196 0.2239 0.7944 0.3444 0.35070
The DTC algorithm and FD routine were programmed to the TABLE VIII. EXPERIMENTAL RESULTS: ΔMMG OF EACH PHASE
CURRENT (𝛿𝑎𝑏 , 𝛿𝑏𝑐 , AND 𝛿𝑐𝑎 ) FOR 18 CASES
DSP dSPACE 1104 board. Experimentally, the IM motor was
dismantled, and the insulation coating between some turns were 𝑇𝑟𝑒𝑓 1.5 Nm. 2Nm.
removed via sandpaper to create the 8 faulty cases enlisted in Case 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎 𝛿𝑎𝑏 𝛿𝑏𝑐 𝛿𝑐𝑎
Table IV. To avoid the bold short circuit’s hazard while doing healthy -0.005 0.0072 0.010 0.009 0.0072 -0.0162
the experiments, a fault resistance (𝑅𝑓 = 1 Ω) was used. 𝐶1 0.039 0.005 -0.035 0.0468 0.0072 -0.0412
𝐶2 0.050 -0.001 -0.050 0.054 0.0162 -0.063
PC 𝐶3 0.139 0.005 -0.120 0.1512 0 -0.1512
𝐶4 0.17 0.001 -0.1620 0.189 -0.0018 -0.1872
Oscilloscope 𝐶5 0.205 -0.005 -0.195 0.2304 -0.0108 -0.2196
DC PM Gen. 𝐶6 0.280 0.001 -0.260 0.323 -0.018 -0.315
dSPACE 1104 𝐶7 0.343 -0.005 -0.325 0.3618 -0.0126 -0.3492
𝐶8 0.4266 0.008 -0.410 0.450 0.0054 -0.432
DC supply
IM
Sensors

AVO meter ITF taps I and V Probes

Fig. 11. DTC drive system experimental test-bench.

A. Experimental Verification of the Developed FD technique


To verify the proposed technique experimentally, the DTC
drive system was operated at two different loading conditions
(𝑇𝑟𝑒𝑓 = 1.5 Nm, and 2Nm). For each loading condition, the IM Fig. 12. Experimental Results ΔMMG (𝛿𝑎𝑏 , 𝛿𝑏𝑐 , and 𝛿𝑐𝑎 ) for 18 cases
operatedThe IM motor was operated under 9 cases (1 healthy
and 8 faulty (C1-C8)). That results in 18 experimental case
study. The on-line FD technique was embedded in the system's
controller, and it was performed in real-time on [𝑖𝑠 ]. The DSP
controller's sampling frequency is 20 kHz. The FD results are
enlisted in Tables VII and VIII, and displayed in Fig. 12.
As the results reveal, the developed MM-based FD technique
to detect ITF faults for practical DTC driven IMs even for a 1%
fault severity factor. Furthermore, the results prove the
feasibility of the co-simulation platform, as the FD in both of
them showed the same variation trend. Moreover, the
experimental results showed that the technique was not only Fig. 13. Experimental Result: Stator currents for the DTC system under the
conditions: (a) healthy, (b) 𝐶1 , (c) 𝐶3 , (d) 𝐶5 , (e) 𝐶6 , and (f) 𝐶8
able to diagnose the ITF fault at its embryonic stages but also
was able to distinguish the faulty phase (phase "a") via B. Comparing the developed FD routine to the MCSA
monitoring the differential MMG value (𝛿𝑎𝑏 , 𝛿𝑏𝑐 , and 𝛿𝑐𝑎 ). To investigate the effectiveness of the proposed diagnosis
It is noteworthy to mention that there were a few minor technique, a comparative analysis was done in the experimental
mismatches between the experimental and FE simulation platform between the presented ΔMMG based diagnosis and the
results, for the following reasons: the ITFs were implemented conventional MCSA based diagnosis. The setup was run
experimentally outside the IM , whereas in the FE domain, they experimentally at 2Nm loading condition, under six conditions
were applied inside the motor. Thereby, some differences in the (healthy, and 𝐶1 , 𝐶3 , 𝐶5 , 𝐶6 , 𝑎𝑛𝑑 𝐶8 ), and the three-phase
flux densities exist. Moreover, the aging and the inherited currents, and the harmonic spectrum of the faulty phase (i.e.,
design asymmetries were not mapped into the FE platform. MCSA of 𝑖𝑠𝑎 ) are presented in Fig. 13 and Fig. 14, respectively.
Nevertheless, those effects were minimal, and the experimental It is evident from Fig. 13, that for low severity factors (i.e., 𝐶1
results reinforced the FE co-simulation ones. and 𝐶3 ), the mismatch between the three-phase currents in

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miniature, as shown in Fig. 13 (a) to (c), and can not be detected analysis, the mathematical morphological gradient (MMG)
by the conventional unbalance protection system. Thus, the routine was designed and applied to the three-phase line
undetected ITF will propagate. The unbalance between the currents of the DTC controlled VSI. The differential MMG
phase’s current become more evident at high fault severity (ΔMMG) concept and implemented was introduced to
factors (i.e., 𝐶5 , 𝐶6 , and 𝐶8 ), as displayed in Fig. 13 (d) to (f). At distinguish the faulty phase. The principles of designing the
such high ITF severity factors, the temperature of the motor and structure element (SE) in the developed FD technique were
the VSI will be increasing rapidly, and the IM’s insulation will proposed and investigated. The merits of the developed FD
be burning out. technique was highlighted and compared to the analogous FD
From the MCSA of 𝑖𝑠𝑎 in Fig. 14 it is evident that none of methods in the literature.
The established FD routine was examined in a physics-based
the harmonic orders classically used for ITF diagnosis
FE co-simulation platform and experimentally. The merits of
(fundamental, 2nd, 3rd, 5th, 6th, and 7th orders) is trustworthy in
the FE co-simulation platform are: 1) All the reasons for
the DTC drives case. For example, in the fundamental and 2nd harmonics in the drive system are mapped; 2) It provides an
order harmonics, the healthy IM has a higher value than insightful view of the electromagnetic parameters that can be
𝐶1 , 𝐶3 , 𝐶6 , and 𝐶8 but it has a lower value than 𝐶5 . Similarly, for measured neither on the actual motor nor in the conventional
the 5th and 6th ordered harmonics, the healthy case had a lower mathematical based models.
value than all the faulty cases except 𝐶3 . Whereas at the 6th The developed FD routine was validated by 45 simulations
ordered harmonic, the healthy case had a higher value than the and 18 experimental case studies, including different loading
𝐶3 and 𝐶8 , but it had a lower value than the remaining faulty conditions and various fault severity factors. The results
cases. Thereby, none of those, as mentioned earlier, showed that the developed differential MMG based FD was
components were able to diagnose the fault. capable of detecting ITFs with 1% fault severity factors, and
On the other hand, the 3rd order harmonic is the only one that determining the faulty phase. Finally, an experimental
all the faulty cases had a higher value than the healthy one. comparison between the developed ΔMMG and the
However, two crucial observations exist, 1) The difference conventional MCSA was investigated. Experimental results
between the faulty cases and the healthy case is not large showed the capability of the developed FD technique to detect
enough, especially for incipient faults, 2) The components are the ITFs more accurately than MCSA.
not following the fault severity factor (e.g., 𝐶5 has a higher Among the advantages of the proposed technique is:
value than 𝐶9 ). 1) The routine does not require frequency tracking
2) The developed FD technology does not require any prior
Moreover, all the MCSA analysis and investigation started
knowledge of IM parameters in healthy conditions.
from the fact that the faulty phase is already known (the FFT
3) The ΔMMG routine is based on buffering, addition, and
analysis was performed on 𝑖𝑠𝑎 ), which is never the case subtraction, which expedites its digitalization.
practically. The ITF by nature starts between two turns in any
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0093-9994 (c) 2020 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.
Authorized licensed use limited to: Cornell University Library. Downloaded on September 04,2020 at 17:01:42 UTC from IEEE Xplore. Restrictions apply.
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Transactions on Industry Applications
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1545-1554, May 2011. Hassan H. Eldeeb (S’15) received the B.Sc. (with 1st
[16] M. Z. Ali, M. N. S. K. Shabbir, S. M. K. Zaman and X. Liang, "Single- class Hons.) and M.Sc. degrees in Electrical Power
and Multi-Fault Diagnosis Using Machine Learning for Variable and Machine Engineering from Ain Shams
Frequency Drive-Fed Induction Motors," in IEEE Transactions on University, Cairo, Egypt, in 2011 and 2016,
Industry Applications, vol. 56, no. 3, pp. 2324-2337, May-June 2020 respectively. He also received M.Sc. degree in
[17] Igor Tsyokhla, Antonio Griffo, Jiabin Wang, "Online Condition Electrical Engineering from Florida International
Monitoring for Diagnosis and Prognosis of Insulation Degradation of University (FIU), Miami, FL, USA, in 2019. Since
Inverter-Fed Machines", IEEE Transactions on Industrial Electronics, 2016, he started working towards a Ph.D. degree in
vol. 66, no. 10, pp. 8126-8135, 2019. electrical engineering at FIU, and he has been
[18] Riccardo Leuzzi, Vito Giuseppe Monopoli, Luca Rovere, Francesco Graduate Research Assistant at the Energy Systems Research Laboratory.
Cupertino, Pericle Zanchetta, "Analysis and Detection of Electrical Aging His research interests include real-time diagnosis, control, and design of
Effects on High-Speed Motor Insulation", IEEE Transactions on Industry electric motors and drive systems. He is the author/ co-author of 9 articles in IEEE
Applications, vol. 55, no. 6, pp. 6018-6025, 2019 Journals and 25 papers at major international conferences, and he holds 1 US
[19] Hamid A. Toliyat, Subhasis Nandi, Seungdeog Choi, and Homayoun patent awarded in the area of electric drives diagnosis.
Meshgin-Kelk, “Electric Machines: Modeling, Condition Monitoring, Mr. Eldeeb is the recipient of the Outstanding Presentation Award at the IEEE
and Fault Diagnosis”, Boca Raton, FL, USA: CRC Press, March 2017. Applied Power Electronics Conf (APEC) 2019, Anaheim, CA, USA, in March
[20] D. Zheng and P. Zhang, "An Improved Broadband Common-Mode 2019, and the Best Student Poster Award at the 53rd IEEE IAS Annual Meeting
Electrical Machine Model for Online Condition Monitoring of Stator CMD Poster Contest, Portland, OR, USA, in Sept. 2018. He has been the
Insulation Degradation," 2019 IEEE Energy Conversion Congress and Secretary of the IEEE Miami Section since Jan. 2019, and he is an active reviewer
Exposition (ECCE), Baltimore, MD, USA, 2019, pp. 7012-7018 in several IEEE journals, including the Transaction on Industry Applications.
[21] Dybkowski, M.; Bednarz, S.A. Modified Rotor Flux Estimators for
Stator-Fault-Tolerant Vector Controlled Induction Motor Alberto Berzoy (S’13-M’19) received the B.Sc. and
Drives. Energies 2019, 12, 3232. M.Sc. degrees in Electronics Engineering from the
[22] Tarchała, G.; Wolkiewicz, M. Performance of the Stator Winding Fault Universidad Simon Bolivar, Caracas, Venezuela, in
Diagnosis in Sensorless Induction Motor Drive. Energies 2019, 12, 1507 2003 and 2008, respectively. He received PhD degree
[23] S. M. A. Cruz and A. J. M. Cardoso, "Diagnosis of stator inter-turn short from Florida International University (FIU), Miami,
circuits in DTC induction motor drives," IEEE Trans. Ind. Appl., vol. 40, USA in 2018. He is currently working as a Power
no. 5, pp. 1349–1360, Sep. 2004. Electronics and Control Engineer at the R&D
[24] M. Drif and A. J. M. Cardoso, "Stator Fault Diagnostics in Squirrel Cage department of sonnen inc where he is working on the
Three-Phase Induction Motor Drives Using the Instantaneous Active and development of last generation of inverters for Energy
Reactive Power Signature Analyses," in IEEE Trans. on Ind. Info, vol. 10, Storage Systems in residential applications. His
no. 2, pp. 1348-1360, May 2014. seventeen years of research and ten teaching experience
[25] A. Berzoy, et al., "On-Line Detection of Stator Faults in DTC-Driven IM include power electronics converter design and control,
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systems. Among the research interest areas, Dr. Berzoy is captivated by electric
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vehicles and renewable energy applications. He has served or currently serves as
Application to Signal Processing", Int' l. Workshop on Mathematical
reviewer of several IEEE Transactions including the IEEE Transactions on
Morphology and its Applications to Signal Processing (ISMM), 1993.
Energy Conversion, the IEEE Transactions on Power Electronics, IEEE
[27] A. Baug, et al., "Identification of single and multiple partial discharge
Transactions on Industry Applications and IEEE Transactions on Magnetics.
sources by optical method using mathematical morphology aided sparse
representation classifier," in IEEE Transactions on Dielectrics and Ahmed Saad (S’18) received the B.Sc. and M.Sc.
Electrical Insulation, vol. 24, no. 6, pp. 3703-3712, Dec. 2017. degrees in electrical engineering from Helwan
[28] J. de Jesus Rangel-Magdaleno, et al., "FPGA-Based Broken Bars University, Cairo, Egypt, in 2007 and 2012,
Detection on Induction Motors Under Different Load Using Motor respectively. He is currently working toward the Ph.D.
Current Signature Analysis and Mathematical Morphology," in IEEE degree in electrical engineering at Florida International
Transactions on Instrumentation and Measurement, vol. 63, no. 5, pp. University (FIU), Miami,FL, USA since 2019, where
1032-1040, May 2014 he is a Graduate Research Assistant at the Energy
[29] Y. Zhang, et al., "Application of morphological max-lifting scheme for Systems Research Laboratory. He was a Teacher and
identification of induction motor stator inter-turn short circuit," in CSEE Research Assistant with the Department of Electrical
Journal of Power and Energy Systems, vol. 1, no. 4, pp. 92-100, Dec. 2015 Power and Machines Engineering, Helwan University.
[30] Y. Zhao and P. Crossley, "Countermeasure to Prevent the Incorrect His research interests include integration of renewable energy in smart grids,
Blocking of Differential Protection Applied to Converter Transformers," optimal distributed control and optimization, cyber-physical security, machine
in IEEE Trans. on Power Delivery, vol. 35, no. 1, pp. 95-105, Feb. 2020 learning, internet of things and digital twin. He is the author/co-author of multiple
[31] H. H. Eldeeb, et al., "On-line Monitoring of Stator Inter-Turn Failures in peer-reviewed articles at IEEE journals and international conferences in the areas
DTC driven Asynchronous Motors using Mathematical Morphological of microgrids and smart grid operations. Mr. Saad holds two US patents awarded.
Gradient," 2019 IEEE APEC, Anaheim, CA, USA, 2019, pp. 1018-1023.
[32] H. H. Eldeeb, A. Berzoy and O. Mohammed, "Comprehensive
Investigation of Harmonic Signatures Resulting from Inter- Tum Short-

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Transactions on Industry Applications
IEEE TRANSACTION ON INDUSTRY APPLICATIONS, VOL. XX, NO. X, XXX/XXX 2020 13

Haisen Zhao (M’10-SM’18) was born in Hebei,


China, in 1982. He received B.E. in agricultural
electrification and automation from the Agriculture
University of Hebei, Baoding, China, in 2004. He
received his M.E. and Ph.D. in electric machines and
apparatus from North China Electric Power
University (NCEPU), Beijing, China, in 2007, and in
2011, respectively.
He is currently an associate professor with the
School of Electrical and Electronic Engineering and
Yangzhong Intelligent Electrical Institute, North
China Electric Power University. Moreover, he was a visiting scholar in the
Energy Systems Research Laboratory, Department of Electrical and Computer
Engineering at Florida International University (FIU), Miami, FL, USA, from
Dec 2018 to Dec. 2019.
Dr. Zhao is the author and co-author of more than 100 articles in peer-
reviewed journals and major international conferences. Furthermore, he has 15
patents awarded in the area of electric machine design, control, and energy-
saving technologies. His research interests include electrical motors design,
diagnosis, energy-saving technologies of electric machines and drive systems,
and wireless power transfer.

Osama A. Mohammed (S’79-M’83-SM’84-F’94)


received the master’s and doctoral degrees in
electrical engineering from Virginia Tech,
Blacksburg, VA, USA, in 1981 and 1983,
respectively. He is currently a Distinguished
Professor of and Associate Dean of Research at the
College of Engineering, Florida International
University (FIU), Miami, FL, USA. He is also the
Director of the Energy Systems Research
Laboratory, FIU and a Professor of electrical and
computer engineering.
Dr. Mohammed is a world-renowned expert on various topics in power and
energy systems, including design optimization and physics-based modeling in
electric machines and drives, energy storage systems, and power electronics.
He currently has active research projects for several federal agencies in these
areas. Additionally, he has research interests in smart-grid distributed control,
interoperability, and energy cyber-physical systems. His presentations are
frequently invited at academic and industrial organizations and conferences
worldwide. He has authored/co-authored more than 800 articles in refereed
journals and international conferences and holds 15 patents awarded and several
others filed. He has also authored a book and several book chapters.
Dr. Mohammed is also an elected Fellow of the Applied Computational
Electromagnetic Society ACES. He is a recipient of the prestigious IEEE Power
and Energy Society Cyril Veinott Electromechanical Energy Conversion
Award and the 2012 Outstanding Research Award from FIU, the 2017
Outstanding Doctoral Mentor, and the Distinguished Professor designation in
2018.

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