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Abstract—High-resistance connections in electric drives can corrosion or contamination. The increase in the resistance due
cause localized overheating and motor supply voltage unbalance, to poor contacts can cause overheating to reach an unacceptable
which degrade the performance, efficiency, and reliability of the level, which can eventually cause open-circuit failures due to
system. An enhanced field-oriented control scheme for induction
machines that is capable of detecting resistive unbalance due to the melting of copper conductors, as shown in Fig. 1. Excessive
high-resistance connections, and regulating the negative-sequence overheating in the contact points can also deteriorate insulation
current is proposed as the main contribution of this paper. Re- and expose the copper conductor to serious damages such as
sistive unbalance is detected and located while maintaining the short-circuit failures between conductors or to the ground. Lo-
symmetric drive behavior both under transient and steady-state calized temperature rise or arching due to poor or loose contacts
operating conditions. The negative-sequence regulator adopted
in addition to the traditional current regulator for rotor field- can also initiate fire. In addition, the asymmetries of the stator
oriented control is used to compensate for the voltage unbalance voltage induced by poor contacts may cause negative-sequence
caused by the inherent asymmetries in the cable and stator wind- currents to circulate in the motor windings, thus reducing the
ing and by the poor contacts. A model that shows the relationship motor output power, efficiency, and reliability [1]–[3]. If the
between the resistive unbalance and negative-sequence current evolution of this type of electrical fault is not detected at an
components is derived from the analysis of the proposed scheme.
The theoretical analysis and the validity of the detection technique early stage, its propagation can lead to more serious unexpected
are confirmed with an experimental study on a 4-kW induction forced outages.
motor drive. The traditional approach for the detection of high-resistance
Index Terms—Fault detection, fault-tolerant drive, high- connections includes methods such as the offline resistive un-
resistance connections, induction motor drive. balance test, visual inspection, the voltage drop survey, and
IR thermography. To avoid specialized equipments, recently,
I. I NTRODUCTION sensorless online techniques based on the negative-sequence
current and zero-sequence voltage have been proposed for
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1580 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 2, MARCH/APRIL 2015
Fig. 1. Pictures of a laboratory prototype of an induction motor drive for experimental tests on high-resistance connections. (a) and (b) Induction motor and the
detail of its terminal box. (c) and (d) Corresponding infrared (IR) thermal images that reveal the presence of a hot spot artificially created. While the temperature
of the motor case reaches 60 ◦ C at most, the temperature of the hot spot is much higher.
and identify the faulty phase(s), while keeping the drive op- As a consequence of (2), it is worth noting that the sum of
eration unchanged. The key idea of this control scheme is to the resistance deviations ΔRk (k = 1, 2, 3) must be zero
adopt multireference frame controllers to cancel the negative-
sequence components of the stator currents. At the same time,
3
ΔRk = 0, k = 1, 2, 3. (3)
the information generated by these regulators is used to detect
k=1
the unbalance condition and identify the affected phase.
The use of resonant controllers to cancel the negative- Equation (1), combined with (2), can be rewritten in the
sequence current or the use of controller implemented in stator reference frame in terms of space vectors, which are very
counter-rotating reference frames is well known for applica- useful for the field-oriented control of electric drives. It can be
tions with regard to the control of grid-connected converters and shown that the final result can be derived as
active filters [14]–[16]. However, this methodology is adopted 3
here to tackle a totally different problem, i.e., the online fault dϕ̄S 1
diagnosis of induction machines. v̄S = RS īS + + ΔRk ᾱk ī∗S
∗
(4)
dt 3
k=1
The validity of the theoretical analysis and the feasibility of
the control scheme are confirmed by experimental tests. where
2π
ᾱk = ej 3 (k−1) , k = 1, 2, 3 (5)
II. M OTOR DYNAMIC M ODEL W ITH A SYMMETRIC
S TATOR R ESISTANCES and the symbol “∗” denotes the complex conjugate operator.
Equation (4) is very similar to that of a balanced induction
Let us consider a three-phase induction machine, where
machine, except for the additional terms that are propor-
the resistances of the stator phases are not assumed equal to
tional to the resistance deviations ΔRk (k = 1, 2, 3) and to the
each other. The voltage equation of the kth phase can be ex-
current ī∗S .
pressed as
To analyze (4) further, it is necessary to consider the behavior
dϕSk of the rotor currents. The stator flux vector in (4) can be
vSk = RSk iSk + , k = 1, 2, 3 (1) expressed as a function of the stator current and rotor flux
dt
vectors as
where vSk is the voltage applied to the kth stator phase, RSk is
M
its resistance, and ϕSk is the stator flux linkage. The resistances ϕ̄S = σLS īS + ϕ̄R (6)
LR
can be expressed as the sum of two terms, i.e., the mean value
RS and the deviation ΔRk from the mean value RS where σLS , M , and LR are the total leakage inductance, the
mutual inductance, and the rotor self-inductance, respectively.
RSk = RS + ΔRk , k = 1, 2, 3. (2) Finally, ϕ̄R is the space vector of the rotor flux. It is well known
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MENGONI et al.: DETECTION OF HIGH-RESISTANCE CONNECTIONS WITH REGULATORS IN MOTOR DRIVES 1581
Fig. 3. Block diagram of the proposed control scheme, with the capability to detect and compensate for the phase unbalance.
regulators implemented in the synchronous reference frame B. Unbalance Detection and Localization
with the rotor flux.
As long as the regulators perform correctly, i.e., the negative
The solution adopted to control these current components
sequence of the current is cancelled, the output signals of
in the scheme of Fig. 3 is to implement another pair of PI
the negative-sequence PI regulators can be used to detect the
regulators (d) in a reference frame rotating in the opposite
resistance unbalance and identify the faulty phases.
direction of the field-oriented reference frame. This reference
The voltage in the negative-sequence reference frame
frame is synchronous with the negative components of the
3
stator currents at steady state and is identified by the superscript 1
∗
(n),neg ∗
“neg.” The current error, which is expressed in the reference v̄S,ref = ΔRk ᾱk īsync
S,ref (17)
3
frame that is synchronous to the rotor flux vector, has the k=1
following expression:
can be found by multiplying both sides of (13) by ejθ . Voltage
(i),neg
v̄S,ref contains information with regard to the unbalance of the
= īS,ref − īS e−jθ .
(p)
Δīsync
S (14) three phases. It is possible to calculate the resistance deviations
ΔRk by solving (3) and (17), which form a set of three linear
Similarly, the expression of the current error in the negative- and independent equations
sequence reference frame is as follows: (n),neg
v̄S,ref
ΔRk = 2
∗ · ᾱk∗ , k = 1, 2, 3. (18)
(p) sync
Δīneg
S = īS,ref − īS e .
jθ
(15) īS,ref
Fig. 4. Behavior of the electric drive when the resistance of phase 1 is Fig. 6. Behavior of the electric drive when the resistance of phase 1 is
(n),neg increased by 0.1 Ω, and then the resistance of phase 2 is increased by 0.18 Ω.
increased by 0.1 Ω. From top to bottom: waveforms of the voltage vd
(n),neg From top to bottom: waveforms of the resistance deviations ΔRk (0.1 Ω/div)
(40 mV/div), waveform of the voltage vq (40 mV/div), resistance devia- and phase current (10 A/div).
tion ΔR1 (40 mΩ/div), and phase current (10 A/div).
Fig. 7. Behavior of the electric drive during a speed transient from 40% to
Fig. 5. Behavior of the electric drive when the resistance of phase 1 is 90% of the base speed, when the resistance of phase 1 is increased by 0.1 Ω.
increased by 0.1 Ω. From top to bottom: waveforms of the resistance deviations From top to bottom: waveforms of the rotor speed (500 r/min/div), motor torque
ΔRk (40 mΩ/div), phase current (10 A/div). (10 N · m/div), resistance deviation ΔR1 (40 mΩ/div), and phase current
(10 A/div).
A. Steady-State and Transient Operation The behavior of all the resistance deviations is shown in
detail in Fig. 5. As can be noted, ΔR1 , ΔR2 , and ΔR3 become
Fig. 4 shows the behavior of the control system when the equal to the expected values and their sum is always zero.
additional resistor of the first phase is increased from zero to Fig. 6 shows the behavior of the machine when two phases
0.1 Ω. Initially, the resistance deviation ΔR1 and the voltages are unbalanced. Initially, the resistance of phase 1 is increased
generated by the negative-sequence regulator are zero. As soon by 0.1 Ω. Then, the resistance of phase 2 is increased by 0.18 Ω.
(n),neg (n),neg
as the unbalance takes place, vd and vq change At the end of the test, the mean value of the phase resistances is
to avoid that the stator is affected by the phase asymmetry. (0.55 + 0.63 + 0.45)/3 ∼ = 0.543 Ω; and the expected values of
As can be seen, the waveform of the stator current does not ΔR1 , ΔR2 , and ΔR3 are nearly 0.007, 0.087, and −0.093 Ω,
show any particular variation. At the same time, the estima- respectively, which are in good agreement with the experimen-
tion of the resistance deviation ΔR1 change from 0 to about tal results.
0.08 Ω. This result is in good agreement with the theoretical Finally, Fig. 7 shows the behavior of the electric drive during
analysis. In fact, the mean value of the phase resistances be- a speed transient from 40% to 90% of the base speed after the
comes (0.55 + 0.45 + 045)/3 ∼ = 0.48 Ω. The theoretical value resistance of the first phase has been increased by 0.1 Ω. The
of ΔR1 is 0.55 − 0.48 ∼ = 0.07 Ω, whereas ΔR2 and ΔR3 are aim of the test is to verify the robustness of the estimation
0.45 − 0.48 = −0.03 Ω, respectively. technique in case of transient operating conditions. As can
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MENGONI et al.: DETECTION OF HIGH-RESISTANCE CONNECTIONS WITH REGULATORS IN MOTOR DRIVES 1585
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1586 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 2, MARCH/APRIL 2015
Michele Mengoni (M’13) was born in Forlì, Italy, Fiorenzo Filippetti (M’00) was born in Fano, Italy,
in 1981. He received the M.S. and Ph.D. degrees in in 1945. He received the M.S. degree in electrical en-
electrical engineering (with honors) from the Univer- gineering from the University of Bologna, Bologna,
sity of Bologna, Bologna, Italy, in 2006 and 2010, Italy, in 1970.
respectively. In 1976, he became an Assistant Professor with
He is currently an Assistant Professor with the the Department of Electrical Engineering, University
Department of Electric, Electronic and Information of Bologna, where he is currently a Full Professor
Engineering “G. Marconi,” University of Bologna. of electrical drives. In 1998, he held a position with
His research interests include design, analysis, and the University Claude Bernard, Lyon, France as a
control of three-phase electric machines, multiphase member of the Scientific Council of the Centre de
drives, and ac/ac matrix converters. Génie Electrique de Lyon (CEGELY). From 1993 to
2002, he was an Adjunct Professor of electrotechnics and electrical drives with
the University of Parma, Parma, Italy. He was a Visiting Professor with the
Luca Zarri (M’05–SM’12) was born in Bologna, University Claude Bernard, CEGELY, University Claude Bernard, Lyon, and
Italy, in 1972. He received the M.S. degree in electri- the University of Picardie Jules Verne, Amiens, France. He is a Lecturer for
cal engineering (with honors) and the Ph.D. degree the European Master in Advanced Power Electrical Engineering program rec-
from the University of Bologna, Bologna, Italy, in ognized by the European Commission in 2004. He has authored or coauthored
1998 and 2007, respectively. more than 200 scientific papers published in scientific journals and conference
From 1989 to 1992, he worked as a freelance Soft- proceedings, and one textbook. He is the holder of one industrial patent. His
ware Programmer and from 1998 to 2002, as a Plant main research interests include the simulation and modeling of electric circuits
Designer with an engineering company. In 2003, he and systems, and the study and application of condition-monitoring and fault-
became a Laboratory Engineer with the Department detection techniques for ac electrical machines.
of Electrical Engineering, University of Bologna. He was the recipient of the Best Paper Award at the conferences IEEE IAS
Since 2005, he has been an Assistant Professor with 2000, IEEE SDEMPED 2011 and 2013, and the recipient of the IEEE PELS
the same department. He is the author or coauthor of more than 100 scientific Diagnostic Achievement Award 2013.
papers. His research activity concerns the modulation strategies of innovative
converters and the robust control of electric drives.
Dr. Zarri is a member of the IEEE Industry Applications, IEEE Power
Electronics, and IEEE Industrial Electronics Societies.
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