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Fault Diagnosis and Fault Tolerant Control of a Three-Phase VSI Supplying


Sensorless Speed Controlled Induction Motor Drive

Article  in  Electric Power Components and Systems · December 2018


DOI: 10.1080/15325008.2018.1534899

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Electric Power Components and Systems

ISSN: 1532-5008 (Print) 1532-5016 (Online) Journal homepage: http://www.tandfonline.com/loi/uemp20

Fault Diagnosis and Fault Tolerant Control of


a Three-Phase VSI Supplying Sensorless Speed
Controlled Induction Motor Drive

Rebah Maamouri, Mohamed Trabelsi, Mohamed Boussak & Faouzi M'Sahli

To cite this article: Rebah Maamouri, Mohamed Trabelsi, Mohamed Boussak & Faouzi M'Sahli
(2018): Fault Diagnosis and Fault Tolerant Control of a Three-Phase VSI Supplying Sensorless
Speed Controlled Induction Motor Drive, Electric Power Components and Systems

To link to this article: https://doi.org/10.1080/15325008.2018.1534899

Published online: 24 Dec 2018.

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http://www.tandfonline.com/action/journalInformation?journalCode=uemp20
Electric Power Components and Systems, 0(0):1–15, 2018
Copyright # Taylor & Francis Group, LLC
ISSN: 1532-5008 print / 1532-5016 online
DOI: 10.1080/15325008.2018.1534899

Fault Diagnosis and Fault Tolerant Control of a


Three-Phase VSI Supplying Sensorless Speed
Controlled Induction Motor Drive
Rebah Maamouri1,2,3 , Mohamed Trabelsi1, Mohamed Boussak2, and
Faouzi M'Sahli3
1
Laboratoire d'Informatique et Systemes (LIS), Ecole Centrale Marseille, France
2
National Engineering School of Sousse, University of Sousse, Tunisia
3
Research unit of Study of Industrial Systems & Renewable Energy, University of Monastir, National Engineering School
of Monastir, Tunisia

CONTENTS
Abstract—Fault diagnosis in variable speed drives under inverter
1. Introduction faults has been widely addressed in the literature. However,
research activities in this field have been always focused only on
2. SMO Model
sensored motor drives. This paper deals with a mixed model-based
3. Inverter IGBT Open-Switch Fault Diagnosis and signal-based approach for both insulated-gate bipolar transistor
4. Fault Compensation Strategy (IGBT) open-circuit fault diagnosis and fault tolerant control in
5. Experimental Results sensorless speed-controlled induction motor (IM) drive. Sliding
mode observer (SMO) is used for speed and stator currents
6. Conclusions estimation and simultaneously open-switch fault diagnosis. Unlike
References the classical sensored drive systems, this structure presents
particular dynamics under faulty operation-mode which can be
taken into account for fault detection and identification (FDI)
process designing. The proposed diagnostic algorithm is based on
similarity test between measured and estimated currents to define
the FDI index in the inverter. The proposed method allows
detection and localization of single and multiple IGBT open-
switch faults. To improve the reliability of the motor drive, the
ability of the SMO to reconstitute the motor state estimation after
the disturbance stage of the FTC application is verified. The
proposed FDI and FTC schemes are implemented on a dSPACE
DS1104 controller board for a 3-kW IM drive system. Several
experiments are displayed to show the effectiveness and feasibility
of the proposed method.

1. INTRODUCTION
Associated with increasing demands for systems with higher
Keywords: induction motor, sliding mode observer (SMO), sensorless performance on one side and more cost efficiency on another
control, voltage source inverter (VSI), IGBTs open-circuit faults, fault
diagnosis (FD), fault tolerant control (FTC), fault tolerant analysis, side, the degree of automation and the complexity of indus-
reliability trial processes are continually increasing. This development
Received 16 December 2017; accepted 9 September 2018
requires more reliability and safety. For such systems, low
Address correspondence to Rebah Maamouri, Laboratoire d'Informatique
et Systemes (LIS), UMR 7020 – Ecole Centrale Marseille (ECM) – cost, safety and dependability issues are of significant import-
38 rue Frederic Joliot Curie 13451 Marseille, France. E-mail: ance for the design of modern industrial processes. Thus, to
maamouri.ribeh@yahoo.com
Color versions of one or more of the figures in the article can be found
satisfy these issues, sensorless control, faults diagnosis (FD),
online at www.tandfonline.com/uemp. and fault tolerant control (FTC) have attracted significant

1
2 Electric Power Components and Systems, Vol. 0 (2018), No. 0

attention in research and industrial domains and all are analyzing of the error between measured and estimated pole
assembled to form the goal of this paper. voltages of the inverter. In [12], an approach based on the
Due to their reliability, high performance, and low cost, line-to-line voltages and pulse width modulator/modulation
induction motors are widely used in various industrial (PWM) switching signals was proposed and a fast fault
applications. In order to further reducing the cost of IM detection is accomplished. The major disadvantage of these
control and improving its reliability, the use of state approaches is that they require additional equipment or volt-
observers or the so-called software sensors in the control age sensors which introduce a significant cost and decrease
of electrical machines presents a trend that attracts the reliability in industrial applications. In [14], the FDI is
interest of industrialists and keeps growing since its first accomplished using Park’s vector approach by calculation of
applications in the late 1980s [1, 2]. the position of the current trajectory’s midpoint. This
Furthermore, it is important to note that in the industrial approach is also associated to pattern recognition approach
environment, sensorless IM drives are subjected to several for single and multiple open-switch fault detection in [15].
faults because of mechanical, electrical, and thermal In [16], a classification of the open-switch faults into differ-
stresses. According to previous statistic studies, the per- ent groups is used for the detection and identification of
centage of faults for variable speed drives was evaluated to faulty switches. The localization of the damaged switch
63% of the user-experienced drives faults in the first year takes about one fundamental current period.
of operation. A percentage of 70% of these faults is related The FDI method based on residual value was proposed
to power devices [3, 4]. Fault types that may be generated in [17]. This method is limited to systems based on closed-
in the power switch device are generally classified into two loop control structure. In [18], a signal-based approach has
categories, short-circuit fault and open-circuit fault [5, 6]. been proposed. It consists of analyzing and the combin-
Similar to sensored speed systems, the open-circuit ation of the information provided by line currents shapes in
faults in inverter-fed sensorless-controlled IM drive gener- (a-b) reference frame and their corresponding normalized
ates a current distortion effects which can lead to system average values. This method allows the detection of the
shutdown or secondary faults in other drive components simple and multiple IGBTs open-switch faults.
through induced vibrations, high stator currents, and sig- Regarding the model-based approaches, the diagnostic
nificant ripple rates of the estimated speed. Therefore, to of faults is based on the system model. Several
improve the safety and the reliability of the drive system, model–based approaches were developed in [19–23]. In [19],
reconfiguration techniques must be added to guarantee sys- a sliding mode observer (SMO) has been proposed for FDI.
tem protection and continuity of operation. These reconfig- The fault detection index is based on comparing the similar-
uration techniques consist of three essential tasks [6, 7]: (a) ity between measured and estimated currents using a cross
fault detection, it is achieved by deciding whether the sys- correlation factor. In [23], a bank of observers was proposed
tem operates under faulty or healthy conditions; (b) fault to detect simple and simultaneous open-switch faults.
identification, this task is performed to identify the faulty It is important to underline here that the majority of the
devices; (c) fault isolation, it is performed after the fault aforementioned diagnosis methods concern only the classical
identification, it consists of removing the faulty device and sensored electrical drive systems where the mechanical
reconfiguring the system. In these fault-tolerant strategies, speed is always available by speed sensor. However, in the
fault diagnostic constitutes the first step. In this paper, case of sensorless control and in post-fault operation mode,
insulated-gate bipolar transistor (IGBT) open-circuit fault most of the proposed sensorless algorithms make use of the
diagnosis in voltage source inverter (VSI)-fed sensorless- same signal measurements for the reconstruction of the rotor
controlled IM drive will be considered. speed, thereby suffering from the inverter faults. This dis-
The classification and evaluation of fault diagnosis turbance affects much of the estimation of speed or position
approaches addressed in the literature have been presented in several sensorless estimation algorithms [24, 25] and can
in [8]. Generally, these methods can be broadly classified lead under such functioning conditions to a total shutdown
as model-based or signal-based approaches [9, 10]. of the drive. Regarding faults diagnosis, diagnostic algo-
Regarding signal-based method, it needs the measurement rithms which depend on measured speed may lose their
of the stator currents or the output inverter voltages. Voltage effectiveness and robustness in the case of sensorless con-
signal-methods are addressed in [11–13]. In [11], an field- trolled motor drives because of the affected estimated cur-
programmable gate array (FPGA)-based FDI approach was rents and speed errors. When the affected estimated speed is
developed, the detection of faults is achieved by the considered as input to the diagnosis algorithms and noting
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 3

especially those based on open-loop observers [22], it can is the rotor flux vector, Rr and Rs are the rotor and stator
affect the fault indices used for FDI. Consequently, the diag- resistances. Lr and Ls are the rotor and stator inductances.
nosis algorithm will be affected and cannot be effective for M is the mutual inductance, J is the moment of inertia. r
a robust faults detection. is the dispersion coefficient, np is the pole-pairs number,
The main objective of this paper is to propose an effect- xr is the rotor speed and Tl is the load torque.
ive FDI process for a robust IGBT open-switch faults diag-
nosis in sensorless speed-controlled induction motor drive.
2.2. SMO design
A closed-loop observer is used for both speed estimation
and faults diagnosis. The estimated speed and stator cur- The observation model is expressed in the stationary refer-
rents are used as inputs for the FDI scheme. Thus, the ence frame ða; bÞ with the rotor velocity and the rotor flux
are the quantities to be observed, the stator voltages are sup-
affected signals in post-fault operation mode are taken into
plied by the applied control and the stator currents are meas-
consideration for the design of the FDI algorithm.
ured by two current sensors. The SMO model is given by:
Finally, in order to improve the system’s reliability and
study the behavior of the sensorless controlled IM based x^_ðtÞ ¼ f ð^x Þ þ gðxÞu þ K : signðsÞ (4)
on SMO during the transient time between the diagnosis
where, ½x ¼ ½x1 x2 x3 x4 T ¼ ½ias ibs /ar /br T and K is
and the compensation of inverter fault (pre-fault operation
the matrix of observation gains.
mode), the FDI method is included in a fault-tolerant strat- 2 3
egy and a reconfiguration process is achieved by using an K^ ^
6 ki as þ / þ ^
x K / br 7
sr ar
r
extra redundant inverter-leg. The ability of the used SMO 6 7
6 K 7
to reconstitute the motor state estimation after this dis- h i 6 ki þ ^
/  ^
x K ^
/ 7
6 bs br r ar 7
^i_ ^_i bs /^_ar /^_br ¼ 6 sr 7
turbed stage is experimentally verified. as 6 M 1^ 7
6 ^
^ r / br 7
6 sr ias  sr / ar x 7
6 7
4 M 1^ ^ 5
2. SMO MODEL ibs  / br þ x ^ r / ar
sr sr
2.1. Induction motor model 2 3
The behavior of the IM can be expressed by its model in 1 2 3
6 rL 0 7 K11 K12  
the stationary reference frame ða; bÞ in terms of rotor flux 6 s 7 
6 1 7 6 K22 7
þ6 7 as þ 6 K21
v 7 Is1 (5)
and stator current as follows: 6 0 rLs 7 4 K31 K32 5 Is2
2 3 6 7 vbs
K 4 0 0 5 K41 K42
ki þ / þ x 2 3
3 6 br 7
as K/
2 sr ar 0 0
r 1
6 7
i_ as 6 K 7 6 rL 0 7
6 i_ 7 6 6 kibs þ /br xr K/ar 7 7
6 s
6 1 7
7 
ð^_i as ; ^i_ bs Þ are the estimation of stator currents compo-
6 bs 7 6 sr 7þ6 0 7 vas
6 _ 7¼6 M ^ ^
4 / ar 5 6 1 7 6
7 6 rL 7 vbs
7 nents, ð/_ ar ; /_ br Þ are the estimation of rotor flux compo-
6 sr ias  sr /ar xr /br 7 4 0
s
_/ 0 5 nents, and x ^ r is the estimated rotor speed. Is is the
br 6 7
4 M 1 5 0 0
ibs  /br þ xr /ar switching vector and “sign” is the sign function.
sr sr    
I signðs1 Þ
(1) Is ¼ s1 ¼ (6)
Is2 signðs2 Þ
2
r ¼ 1ðLMr Ls Þ; sr ¼ RLrr ; k ¼ r1 ðs1s þ 1r
sr Þ, K ¼ 1r
rM ,
n2p M
The sliding surface is written as a function of the stator
m ¼ JLr current errors and it is chosen as in [26]
The electromechanical equation is given by    
s1 1 eas
dxr S¼ ¼C (7)
s2 ebs
Te ¼ J þ f xr þ Tl (2)
dt 0 1 1
Where the electromagnetic torque is expressed as xr
B C
With, C ¼ @ sr 1 A
M 
xr
Te ¼ np ibs /ar ias /br (3) sr
Lr
iabs ¼ ½ias ; ibs T is the stator current vector, vabs ¼ eas ¼ i_ as ^_i as and ebs ¼ i_ bs ^i_ bs are the estimation errors of
½vas ; vbs T is the stator voltage vector, /abr ¼ ½/ar ; /br T the stator currents.
4 Electric Power Components and Systems, Vol. 0 (2018), No. 0

K represents the currents and flux matrix gain observer, The time derivative of Eq. (11) can be derived as
it is expressed as: Dxr d
  V_ ¼ e_ / ðe/ Þt þ Dxr <0 (12)
Ki q3 dt
K¼ (8)
K/ Calculating e/ and e_ / from (10) and substituting them
   
K11 K12 K31 K32 in (12) and then verifying the Lyapunov stability condition
Where, Ki ¼ and K/ ¼
K21 K22 K41 K42 (V_ <0), the adaptive mechanism of the rotor speed is writ-
ten as follows:
More details about the calculation of observer gains are
^r
dx h iT
given in [26]. T ^ ^
¼ q3 ðKi Is Þ / rb / ra (13)
dt

2.3. Rotor speed estimation The block diagram of the sensorless control of the vec-
tor-controlled induction motor drive is given in Figure 1.
For the sensorless speed control IM drive, the estimation
of the rotor speed is achieved by using the Lyapunov
approach. Using the IM and SMO models, the estimator 3. INVERTER IGBT OPEN-SWITCH
error dynamics is given by: FAULT DIAGNOSIS
8  
>
> 1 3.1. Sensorless IM drive behavior under
>
> _
e ¼ k e þ ^
x e þ kDxr ^x 4 K11 Is1 K12 Is2 ðaÞ
>
>
x1
sr 3
x r x4
fault conditions
>
>  
>
> 1
>
< e_ x2 ¼ k ^ r ex3 kDxr^x 3 K21 Is1 K22 Is2
ex4 þ x ðbÞ Figure 2 illustrates the three-phase VSI topology. We con-
s
r  sidered an IGBT switch open-circuit fault in the VSI. Each
>
> 1
>
> e_ x3 ¼  s ex3 þ x ^ r ex4 Dxr^x 4 K31 Is1 K32 Is2 ðcÞ leg is composed of two transistors (TK and TKþ1 , K ¼ 1, 3,
>
>
>
>  r  5) with antiparallel freewheeling diodes (DK and DKþ1 )
>
> 1
>
: e_ x4 ¼  ex x^ r ex3 þ Dxr^x 3 K41 Is1 K42 Is2 ð dÞ
sr 4 used to provide a negative current path through
(9) the switches.
    This paper is an extended and modified version of [21],
e e
where, ei ¼ x1 , e/ ¼ x3 are the currents and it aims essentially to highlight the potentialities and the
ex2 ex4
fluxes errors. features of sensorless-controlled induction motor under
Dxr ¼ xr x ^ r is the speed error. inverter faults for diagnosis and FTC purposes. A compara-
Considering that the currents trajectory reaches the slid- tive analysis regarding the classical sensored electric drive
ing surface ðs  0 : ei ¼ 0; e_ i ¼ 0Þ, one has the following is firstly illustrated. Experimental results described in
results: Figure 3 present the time-domain waveforms of the refer-
8  
> ence, measured and estimated rotor speed of the IM under
>
> 1
ex3 þ x^ r ex4 þ kDxr^x 4 K11 Is1 K12 Is2 ¼ 0
<k an IGBT open-circuit fault.
e_ i ¼ sr  In pre-fault operation mode, the measured and estimated
>
> 1
>
: k s ex4  x ^ r ex3 kDxr^x 3 K21 Is1 K22 Is2 ¼ 0 rotor speed follow the reference. On the contrary, in post-
r
fault operation mode, the measured rotor speed undergoes
8
>
> 1 a small oscillation in comparison to the high-level oscilla-
< e_ x3 ¼  ex3 xr ex4 Dxr^x 4 K31 Is1 K32 Is2
e_ U ¼ s r tion of the estimated one. From the diagnosis point of
>
> e_ x4 ¼  1 ex4 þ xr ex3 þ Dxr ^x 3 K41 Is1 K42 Is2 view, the measured rotor speed is usually used as an input
:
sr of the real-time FDI process [10, 17, 18]. However, in case
(10) of a sensorless control, this measure is not available and is
By choosing now a positive definite Lyapunov candidate only provided by an estimator or observer. Therefore, it
function V such that its derivative must be negative. This can lead to false alarms when it will be used in the FDI
function is selected as process. In order to improve the performance of the diag-
nostic algorithm proposed in this work, the average value
1 11
V ¼ ðe/ ÞT e/ þ ðDxr Þ2 (11) of the estimated rotor speed is used instead of the meas-
2 2 q3
ured one. Regarding the safety and the continuity of
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 5

FIGURE 3. Experimental results IM drive behavior under


VSI open-switch fault.

When an open-switch fault occurs in the VSI, consider-


ing the closed-loop sensorless vector control of the IM,
speed and current controllers cannot be able to achieve
zero errors under a fault condition. In addition, the SMO,
derived from an idealized machine model obtained for a
FIGURE 1. Block diagram of the proposed sensorless con- healthy operation mode, is no longer valid. As a conse-
trol based on SMO speed observer. quence, faulty phase currents (measured and estimated)
will be limited to flow only in the negative or positive dir-
ection according to the affected power switch, and conse-
quently, alternative waveforms cannot be shaped (Figure
4). Here, it should be noted that the evolution of the meas-
ured phase current, in post-fault operation mode, is differ-
ent from the evolution of the estimated current.

3.2. Fault diagnostic method in sensorless IM drive


The block diagram of the FDI processing algorithm is
shown in Figure 5. First, three-phase currents ia, ib, and ic
are measured. These signals together with the estimated
FIGURE 2. Inverter topology.
currents and speed derived from the SMO are used for
accurate fault indices extraction in natural frame abc. The
fault diagnostic variables are defined from the measured
operation, the high-level oscillation of the estimated speed currents combined with the estimated ones. These variables
generated by the damaged power components in the together with additional variables derived from the esti-
inverter causes vibration, which is harmful to the IM and mated currents are used for open-switch faults
leads to significant decreases in the reliability of the sys- identification.
tem. When it happens, it is essential to react quickly to The detection of the damaged inverter leg is performed
compensate the fault by the application of a FTC. If this is by direct evaluation of the ratio between moving average
not the case, long-term or immediate damage can be value of the measured and observed currents of each phase.
expected and may result in security issues or Then, fault diagnostic variables are given by rn :
motor shutdown. !
hjin jiðtÞ
Experimental results depicted in Figure 4 illustrate the rn ¼   (14)
hj^i n jiðtÞ 1
experimental time-domain waveforms of the measured and t t þ T s ðt Þ
estimated phase currents under a healthy condition and 2
when an open-switch fault occurs in the both cases of an where, the subscript n represents the motor phase symbol
upper and a lower transistors TK and TKþ1. and n ¼ a; b; c.
6 Electric Power Components and Systems, Vol. 0 (2018), No. 0

FIGURE 4. Time-domain waveforms of the measured and


estimated phase currents according to the fault location
(Tk, Tkþ1).

The real and the observed current average value are cal-
culated depending on the estimated rotor speed given by FIGURE 5. Block diagram of the proposed FDI algorithm.
SMO. The current average value is computed over a mov-
ing window of a half fundamental current-period and it is thus the residual quantities ~e in are around zero ð~e in ¼ 0Þ.
calculated as follows: Consequently, the diagnostic variables rn corresponding to
tþ12Ts ðtÞ
ð each phase will be around 1.
1
hjin jiðtÞ ¼ jin jdt (15) In contrary, under fault operating mode, the damaged
Ts ðtÞ phase current suddenly drops to zero during a half current
t
period. Considering the effect of the control method and
and
T^ s ðtÞ
tþ12ð simplifications in the observer model, the observer cannot
1 estimate accurately the motor states. This is due to the con-
hj^i n jiðtÞ ¼ j^i n jdt (16)
^
T s ðt Þ siderable error between the measured and estimated cur-
t
rents of the affected phase, thus, its corresponding residual
where, T^ s ðtÞ ¼ jx^2p
s ðtÞj
is the estimated stator current period, quantity increase will be important. Then the corresponding
^ s ðtÞ ¼ xslip þ np X
x ^ r ðtÞ diagnostic variable value during conduction period of the
^ r ðtÞ is the estimated rotor speed derived from the damaged transistor will be nearly zero:
where, X
SMO, xslip is the slip speed, and np is the pole- 0
rn ¼ (19)
pairs number. hj0 þ ein jiðtÞ
The estimated current ^i n can be expressed as a sum Then, the fault detection flag is given by:
between the measured current in and a quantity of error ~e in 
1 if rn  K d ; fault
known as residual or observer estimation error, then: Rn ¼ (20)
0 else; normal
^i n ¼ in þ ~e in (17)
where, Kd is a selected threshold for fault detection.
The diagnostic variables will be written as: After the detection of the damaged leg, it is necessary
! to identify the faulty switch. Then, the identification of
hjin jiðtÞ
rn ¼   (18) faulty IGBTs can be achieved by determining the sign of
hjin þ ~e in jiðtÞ 1
ð
t t þ Ts t Þ the estimated current in the faulty leg(s). In pre-fault oper-
2
ation mode, the motor is fed by a healthy VSI generating a
Under normal operating conditions of sensorless-con- balanced three-phase sinusoidal currents. In these condi-
trolled IM, the estimated current tracks its measured signal, tions, the estimated currents follow the measured ones. On
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 7

of operation but it does not preserve the previous process


functionality. A careful assessment of the required post-
fault capacity is essential to define which topology that
best suits each application.
Whatever the configuration strategy chosen, three essen-
tial steps must be followed from fault diagnosis to fault
compensation as shown in Figure 6. The transition between
the isolation phase and the reconfiguration phase is usually
accompanied by system disturbances. Therefore, the pur-
FIGURE 6. Sequences of a system reconfiguration strategy
pose of this section is to study the behavior of the sensor-
after the occurrence of fault.
less-controlled system and the ability of the observer to
resist against the transient phase induced by reconfiguration
the contrary, under an open-switch of an IGBT in the VSI, step and to reconstitute the motor state after the perturb-
the fault occurrence limits the estimated currents to flow ation stage.
only in the positive or negative direction over a fundamen- A high-performance FD method should be included in a
tal current period, as addressed in Figure 4. As a result, the fault compensation strategy. The block diagram of the
diagnostic variables sn become equal to 61 according to mixed model-based and signal-based approach for sensor-
the location of the fault. Then, the identification variables less and FTC of the system based on IM drive is presented
are given as follows: in Figure 7, it consists of the vector control, the SMO for
   1 high switch is damaged sensorless control, the FDI approach based on measured
sn ¼ sign ^i n ¼ (21)
1 low switch is damaged and estimated signals for IGBTs faults diagnosis and the
reconfiguration block for fault isolation and redundancy
Finally, by combining the identification variables sn and
compensation strategy.
the detection flags Rn , the fault identification flags are for-
The FTC PWM-VSI is presented in Figure 8. It has
mulated as follows:
8 been described in [10] and it is realized by using an extra
< 1 H redundant leg in the voltage source inverter. Once the fault
Sn ¼ sn : Rn ¼ 1 L (22) is detected and localized, the inverter topology is modified
:
0 else by connecting the faulty motor phase (a, b or c) to the
H: Open switch fault in the upper IGBT TK; L: Open fourth leg. The isolation process is performed by removing
switch fault in the upper IGBT TKþ1. the IGBT switching signals of the damaged leg. The fault-
The diagnostic algorithm is designed over a half current reconfiguration is achieved by means of the bidirectional
period, then, each IGBT is diagnosed separately during the devices that are obtained by the use of back-to-back SCRs.
half period corresponding to its conduction state. Under
open-phase fault and because the upper and lower switch 5. EXPERIMENTAL RESULTS
do not conduct together, this approach is still available but
each IGBT is located during its conduction period. 5.1. FDI and FTC implementation and
thresholds selection
Three main goals have to be completed in this subsection.
4. FAULT COMPENSATION STRATEGY
The first one is to show the effectiveness of the proposed
In the case of electrical system monitoring, the fast detec- three-phase VSI FDI approach based on SMO under nor-
tion and isolation of faults are very important as IGBTs mal and faulty operation mode. The second one is to study
inverter failures usually cause high electromagnetic torque and verify the capacity of the SMO to reconstruct the esti-
oscillations. Therefore, not only diagnosis but also compen- mated IM states after the application of the FTC. The third
sation of fault should be achieved immediately. For safety- goal is to verify the FDI robustness and immunity under
related processes, FTC system with redundancy is required different functioning conditions such as speed variation and
to reach a comprehensive system integrity. However, con- load torque change.
sidering its high manufacturing cost, this solution is often To accomplish the first goal, an experimental evaluation
recommended in the case of safety-critical drive applica- has been realized using a 3-kW IM coupled to a magnetic-
tions. Using software redundancy guarantees the continuity powder brake. The experimental test bench is presented in
8 Electric Power Components and Systems, Vol. 0 (2018), No. 0

FIGURE 7. Mixed model-based and signal-based approach for sensorless and fault-tolerant control of system based on induction
motor drive.

Figure 9. The proposed diagnosis and fault-tolerant strat- electric drive system, the estimated and measured currents
egies are tested in closed-loop function of sensorless rotor are equal resulting in non-zero value of diagnostic varia-
field-oriented control. A SMO is used for motor speed esti- bles rn which are usually equal to þ1. On contrary, if a
mation. The control, speed observation, and diagnosis algo- switch fails, the corresponding phase current suddenly
rithms are implemented through a DS1104 real time drops to zero, resulting in a near zero value of variable rn
controller board with a switching frequency of 5 kHz. The associated to the faulty leg. Taking this into account and
three-phase VSI is manufactured with SEMIKRON IGBTs assuring a safety margin, threshold Kd can assume a value
components. The IGBTs switching signals are generated between 0.1 and 0.25. The selected interval is also verified
from DS1104 board by an adaptation stage using the by various experimental tests in the laboratory under sev-
IR2130 three-phase bridge driver. Magnetic relays are used eral operating conditions.
for creating IGBTs open-switch fault condition by remov-
ing the gate-signals of the corresponding transistors.
An important step in the FDI designing is its tuning 5.2. Sensorless control under healthy conditions
effort. A robust scheme should work with as little tuning Before testing the SMO for VSI IGBTs faults diagnosis, an
as possible. The proposed FDI algorithm needs only one experimental test has been carried out under normal oper-
threshold value Kd : Similar to the majority of the existing ation mode (without IGBTs faults) in order to evaluate the
fault diagnosis approaches, the selection of this threshold robustness of the system with respect to motor state esti-
value is accomplished by analyzing the diagnostic variables mation and load torque variation. Initially, the experiment
in pre-fault and post-fault operation mode. The threshold is carried out for a no load starting of the IM and then a
Kd is used to detect whether the ratio between average load torque of 8 Nm is applied at t ¼ 6 s. The behavior of
absolute values of measured and estimated currents the system is illustrated in Figure 10, it presents the actual,
(rn variable) are close to zero or not. Under a healthy estimated, and reference speed, the real and estimated
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 9

FIGURE 9. Overview of the experimental setup.


FIGURE 8. The fault-tolerant PWM-VSI configuration.

in a zero value of the fault detection and fault identification


stator currents and the estimated rotor flux in the synchron-
flags Rn and Sn for a healthy state of the SVI.
ous ðd; qÞ reference frame.
After creating an open-circuit fault into the lower tran-
This test describes the good performances of the sen-
sistor T4 at t ¼ 4.96 s by removing its gate-signal for a
sorless-controlled system associated with a SMO in
short delay of 0.12 s, the phase current ib suddenly drops to
terms of trajectory tracking and disturbance rejection
zero and the estimated state ^i b no longer follows the meas-
where the estimated speed is close to the measured one
ured one, resulting in a high estimation error. Thus, phase
and the both converge perfectly to the reference speed.
current ib is flowing only in positive direction and its cor-
Subplots 2 and 3 show a better performance of the SMO
responding mean absolute value during negative alternation
for stator currents estimation and subsequently for rotor
is zero. Indeed, diagnostic variable rb immediately
flux estimation.
decreases to reach the threshold Kd and converge to a close
zero value. Therefore, a fast detection of fault is accom-
5.3. FDI effectiveness and performances evaluation plished at t ¼ 4.966 s, since it takes only 5.9 ms (with a
In order to verify the feasibility of the diagnosis approach time delay of 21% of fundamental current-period). The
based on SMO under fault conditions, an experimental test high level of fault flag Rb (Rb ¼ þ1) indicates successfully
under normal operation mode with a reference speed of the occurrence of the fault in the second inverter leg (leg
1,000 rpm has been performed. An open-circuit fault of b). The localization of the damaged switch is accomplished
transistor T4 is introduced for a short-time of 0.12 s. Figure based on the state of the identification variables together
11 presents from top to bottom, the actual and estimated with the detection flags Rn . Therefore, the identification
rotor speed, the stator currents, the diagnostic variables rn , flag Sb changes from zero to –1 during the occurrence of
the fault detection flags Rn, and the fault identification fault, thus, indicating the occurrence of fault in the lower
flags Sn. switch T4 .
Experimental results show the good performances of the The capability of the FDI approach to detect multiple
sensorless control system based on SMO in terms of motor IGBTs open-switch faults is addressed in Figure 12. The
state estimation and trajectory tracking. Under normal oper- open-circuit faults are introduced simultaneously in transis-
ating condition, the estimated currents are close to their tors T3 and T6 at t ¼ 12.82 s with a functioning condition
corresponding real signals. Therefore, the diagnostic varia- of –1,000 rpm and 50% of load torque. Regarding detection
bles ra ; rb; ; and rc are always close to þ1 which results faults, after the occurrence of faults the detection variables
10 Electric Power Components and Systems, Vol. 0 (2018), No. 0

FIGURE 10. Experimental result of sensorless-controlled


IM under healthy operation mode (1,000 rpm, 8 Nm).

rb and rc converge immediately to a near zero value and


across the defined threshold Kd . Consequently, the detec-
tion flags Rb and Rc become equal to þ1 at t ¼ 12.826 and
t ¼ 12.828 s, respectively, indicating the occurrence of fault
in the second and third inverter legs (leg b and leg c). The
localization of the damaged IGBT is achieved based on the
identification flags Sb and Sc which become equal to þ1
and -1, respectively, indicating the occurrence of fault in FIGURE 11. Experimental results under open circuit fault
the upper IGBT T3 and the lower IGBT T6 . of T4 with no load and 1,000 rpm.

attention will be addressed to the motor performances ana-


5.4. Experimental implementation of FTC for lysis when applying the reconfiguration strategy to a sen-
sensorless IM drive and performances analysis sorless-controlled induction motor drive.
The behavior of a sensored-controlled motor drive during The proposed FDI method is included in the fault-toler-
the diagnosis of open-switch faults or the application of the ant control and a reconfiguration process is achieved by
fault tolerant control (FTC) is extensively studied in the lit- using an extra redundant leg in the VSI. Figure 13 presents
erature [10]. Therefore, in this section, a particular the experimental waveform of the FTC sensorless control
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 11

its corresponding gate signals and the extra-leg in the VSI


is switched on. The fault detection and isolation are
quickly accomplished since they take only about fourth of
the fundamental current period.
As shown in Figure 13, after the fault compensation, the
SMO is still affected by the transient changes of the motor
unbalanced condition and the reconfiguration system for a
short delay of about two current periods. This perturbation
is related to the error between the measured and the esti-
mated currents and speeds. This error is due to the fact
that the observer used for sensorless control is derived
from a simplified IM model obtained for a healthy oper-
ation mode and is no longer valid in the case of faulty
operation conditions.
After this disturbance stage, the observer has success-
fully reestablished its correct operation to accurately recon-
stitute the motor state estimation (stator currents and rotor
speed) and consequently guarantee the continuity of system
drive operation in safety conditions.

5.5. FDI immunity to false alarms


The robustness of the proposed FDI approach is verified
under speed and load torque variations. Figure 14(a) shows
the experimental results of estimated and real speeds, stator
currents and diagnosis variables rn for a variation of speed
from 1,000 r/min to 400 r/min. Figure 14(b) shows the
experimental results regarding load torque change from
rated load torque to no-load under healthy conditions.
Here, it is observed that for both transient changes of load
torque and motor speed, the diagnostic signals rn corre-
sponding to the detection of faults remains always
unchanged, resulting thus in no false alarms in the FDI
process. In conclusion, these experiments prove that the
proposed FDI process is robust against the transient states
induced by the motor operating conditions.
Since the FD methods are based on SMO, it is import-
ant to check its immunity against motor parameters varia-
tions. Simulations tests have been carried out under healthy
FIGURE 12. Experimental results under open circuit fault
of T3 and T6 with 50% of load torque and a reverse speed operating mode for stator and rotor resistances changes.
of -1000rpm. Figure 15(a) shows the impact of 170% of stator resistance
variation on the diagnostic process, the motor runs at
based on SMO in case of open-switch fault of IGBT T3 . 1,000 rpm with a load torque change from 30% to 80% of
The first subplot shows the experimental IM phase c meas- rated torque at t ¼ 1 s. The resistance variation is intro-
ured and estimated currents. The second subplot presents duced at t ¼ 0.8 s and removed at t ¼ 1.4 s. Diagnostic vari-
the real and estimated IM speeds. The fault condition is ables rn used for fault detection are exposed to a small
introduced in the upper switch of the third leg (leg c) at variation but remain usually around 1. Diagnostic fault
t ¼ 2.8 s. After the detection and the identification of the flags remain zero and no false alarms are issued by this
damaged transistor, the faulty leg is isolated by removing disturbance.
12 Electric Power Components and Systems, Vol. 0 (2018), No. 0

FIGURE 13. Experimental waveforms of the fault-tolerant sensorless control in case of open-switch fault of T3 : Real and
observed speed, measured and estimated currents (ic (black), icest (red)).

FIGURE 14. Experimental robustness check of the proposed FDI approach: (a) under transient load change, (b) under
speed change.

Figure 15(b) shows the impact of the variation of rotor These results illustrate the immunity of the proposed
resistance Rr on the diagnostic process, a variation of FDI approach based on SMO to false alarms that may be
þ70% of nominal resistance value is introduced at caused by parameters variation and motor function-
t ¼ 0.85 s, then, a speed deceleration from 1,250 rpm to ing conditions.
150 rpm is also applied. The motor operates with 50% of
load torque. Regarding diagnosis process, diagnostic varia-
6. CONCLUSIONS
bles rn are slightly affected by this variation but remain
usually around 1. Then, diagnostic fault flags remain zero In this paper, a remedial strategy against open-switch fault
and no false alarms are issued by this disturbance. occurring in the three-phase VSI semiconductor power
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 13

FIGURE 15. Robustness check of the proposed approach: (a) under stator resistance variation, (b) under rotor resist-
ance variation.

devices of a sensorless speed-controlled IM drive has been ORCID


described: regarding diagnosis approach, a simple, low cost
Rebah Maamouri http://orcid.org/0000-0002-6502-1174
and robust FDI strategy based on SMO has been proposed
for single and simultaneous IGBTs open-switch faults diag-
nosis. In this work, the use of SMO for both sensorless
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[16] S. Jae-Hwan, and K. Kyeong-Hwa, ‘‘Reliable Open-switch Rebah Maamouri received the Engineering and M.S.
Fault Localization Scheme in Multiple Switches for degrees in electrical engineering from Ecole Nationale
Inverter-fed Permanent Magnet Synchronous Machine d’Ingenieurs de Monastir (ENIM), Tunisia, in 2012 and
Drives,’’ Electr. Power Components Syst., vol. 45, pp. 2013, respectively, and the Ph.D. degree in electrical
1973–1984, 2018. DOI: 10.1080/15325008.2017.1401685. engineering jointly from Ecole Centrale Marseille (ECM),
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France, and Ecole Nationale d’Ingenieurs de Sousse
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PWM motor drives by the reference current errors,” IEEE (ENISo), Tunisia, University of Sousse, in 2017. She is
Trans. Ind. Electron., vol. 60, no. 8, pp. 3496–3505, Aug currently a research teacher with Lorraine University and
2013. DOI: 10.1109/TIE.2012.2188877. GREEN (Groupe de Recherche en Energie Electrique de
Maamouri et al.: FD and FTC of a 3-Phase VSI Supplying Sensorless Speed Controlled Induction Motor Drive 15

Nancy) Laboratory, France. Her research areas include September 1986, he received a French cooperation award
modeling and sensorless control of induction motor, fault to prepare his Ph.D. degree in Electrical Engineering at the
diagnosis, and fault tolerant control of AC motor drives University Pierre et Marie Curie (Paris 6), obtained in June
and power converters. 1989. In March 2004, he received his Habilitation to
Supervise Research (HDR) in Electrical Engineering from
Mohamed Trabelsi received the B.S. and M.S. degrees in the Aix-Marseille University (AMU), France. He is cur-
electrical engineering from the Ecole Superieure des rently Full Professor at Ecole Centrale Marseille (ECM)
Sciences et Techniques, University of Tunis, Tunis, and he conducts research in the Laboratory of Information
Tunisia and the Ph.D. degree in electrical engineering and Systems (LIS UMR 7020), Marseille, France. His
jointly from the Aix-Marseille University, Marseille, research areas are modeling and parameter observation of
France, and the Ecole Superieure des Sciences et AC electrical machines, power conversion systems, sensor-
Techniques, University of Tunis, in 2012. He is currently a less vector control, advanced digital motion control, diag-
researcher with French Naval Academy (Institut de nosis faults, and fault tolerant control of AC motor drives.
Recherche de l’Ecole Navale) in Brest, France. He is also
an Associate Professor of electrical engineering with the
Ecole Nationale d’Ingenieurs de Sousse, ENISO, Sousse, Faouzi M'Sahli received his Master of Science and DEA
Tunisia. His research interests include marine renewable from ENSET, Tunis, Tunisia in 1987 and 1989, respect-
energy, modeling, control, and diagnostics of conventional ively. In 1995, he obtained his Doctorate Degree in
three-phase AC motor drives, power converters, and multi- Electrical Engineering from ENIT, Tunisia. He is currently
phase drives. Professor of Electrical Engineering at National School of
Engineers, Monastir, Tunisia. His research interests include
Mohamed Boussak received the B.Sc. and the M.Sc. Modeling, Identification, Predictive and Adaptive Control
degrees from the Ecole Normale Superieure de Systems. He has published over 80 technical papers and
l'Enseignement Technique de Tunis (ENSET, become coauthor of a book "Identification et commande numerique
ENSIT), Tunisia, in 1983 and 1985, respectively. In des procedes industriels" Technip editions, Paris, France.

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