Single and Multiple Open-Switch Fault Diagnosis in Electric Drives via Zero-Current Interval Analysis
Keywords:
Detection and isolation, Electric Drives, Fault Diagnosis, Inverter, Open-Switch FaultsAbstract
In this work, a new and simple method for open-switch fault diagnosis in electric drives based on zero-current detection is proposed. The approach requires only two phase current sensors, with the measured currents being normalized and separated into positive and negative half-cycles. A variable-sample-time moving average is introduced for post-processing the signals. Zero-current interval detection is employed to diagnose both single and multiple open-switch faults. The proposed method was experimentally validated under various fault conditions, including single-switch, crossed-switch, full-leg, and two upper- or lower-switch open-circuit faults. Experimental results demonstrate that, despite its simplicity and ease of implementation, the method reliably detects all single and double open-switch fault scenarios in less than one electrical cycle, across different motor operating conditions.
Downloads
References
S. Yang, A. Bryant, P. Mawby, D. Xiang, L. Ran, and P. Tavner, “An industry-based survey of reliability in power electronic converters,” IEEE Transactions on Industry Applications, vol. 47, no. 3, pp. 1441–1451, 2011. doi: 10.1109/TIA.2011.2124436.
Y. Wu, G. F. Olson, C. Henriksson, and L. Peretti, “Open fault detection in variable phase-pole machines based on harmonic plane decomposition,” IEEE Transactions on Power Electronics, vol. 39, no. 4, pp. 4557–4566, 2024. doi: 10.1109/TPEL.2023.3348973.
K. Hu, Z. Liu, Y. Yang, F. Iannuzzo, and F. Blaabjerg, “Ensuring a reliable operation of two-level IGBT-based power converters: A review of monitoring and fault tolerant approaches,” IEEE Access, vol. 8, pp. 89 988–90 022, 2020. doi: 10.1109/ACCESS.2020.2994368.
M. Alavi, D. Wang, and M. Luo, “Short-Circuit Fault Diagnosis for Three-Phase Inverters Based on Voltage-Space Patterns,” IEEE Transactions on Industrial Electronics, vol. 61, no. 10, pp. 5558–5569, 2014. doi: 10.1109/TIE.2013.2297298.
U.-M. Choi, F. Blaabjerg, and K.-B. Lee, “Study and handling methods of power IGBT module failures in power electronic converter systems,” IEEE Transactions on Power Electronics, vol. 30, no. 5, pp. 2517–2533, 2015. doi: 10.1109/TPEL.2014.2373390.
Z. Gao, S. X. Ding, and C. Cecati, “Real-time fault diagnosis and fault-tolerant control,” IEEE Transactions on industrial Electronics, vol. 62, no. 6, pp. 3752–3756, 2015. doi: 10.1109/TIE.2015.2417511.
C. Yong, J.-j. Zhang, and Z.-y. Chen, “Current observer based online open-switch fault diagnosis for voltage source inverter,” ISA transactions, vol. 99, pp. 445–453, 2020. doi: 10.1016/j.isatra.2019.09.019.
S. Xu, X. Chen, F. Liu, H. Wang, Y. Chai, W. X. Zheng, and H. Chen, “A Novel Adaptive SMO-Based Simultaneous Diagnosis Method for IGBT Open-Circuit Faults and Current Sensor Incipient Faults of Inverters in PMSM Drives for Electric Vehicles,” IEEE Transactions on Instrumentation and Measurement, vol. 72, pp. 1–15, 2023. doi: 10.1109/TIM.2023.3305653.
F. Naseri, E. Schaltz, K. Lu, and E. Farjah, “Realtime open-switch fault diagnosis in automotive permanent magnet synchronous motor drives based on kalman filter,” IET Power Electronics, vol. 13, no. 12, pp. 2450–2460, 2020. doi: 10.1049/iet-pel.2019.1498.
H. Yan, Y. Xu, F. Cai, H. Zhang, W. Zhao, and C. Gerada, “PWM-VSI fault diagnosis for a PMSM drive based on the fuzzy logic approach,” IEEE Transactions on Power Electronics, vol. 34, no. 1, pp. 759–768, 2019. doi: 10.1109/TPEL.2018.2814615.
C. N. Ibem, M. E. Farrag, A. A. Aboushady, and S. M. Dabour, “Multiple open switch fault diagnosis of three phase voltage source inverter using ensemble bagged tree machine learning technique,” IEEE Access, 2023. doi: 10.1109/ACCESS.2023.3304238.
I. Bandyopadhyay, P. Purkait, and C. Koley, “Performance of a classifier based on time-domain features for incipient fault detection in inverter drives,” IEEE Transactions on Industrial Informatics, vol. 15, no. 1, pp. 3–14, 2019. doi: 10.1109/TII.2018.2854885.
H. Yan, Y. Peng, W. Shang, and D. Kong, “Open-circuit fault diagnosis in voltage source inverter for motor drive by using deep neural network,” Engineering Applications of Artificial Intelligence, vol. 120, p. 105866, 2023. doi: 10.1016/j.engappai.2023.105866.
C. Choi and W. Lee, “Design and evaluation of voltage measurement-based sectoral diagnosis method for inverter open switch faults of permanent magnet synchronous motor drives,” IET Electric Power Applications, vol. 6, no. 8, pp. 526–532, 2012. doi: 10.1049/ietepa.2011.0315.
Z. Li, H. Ma, Z. Bai, Y. Wang, and B. Wang, “Fast transistor open-circuit faults diagnosis in grid-tied three phase VSIs based on average bridge arm pole-to-pole voltages and error-adaptive thresholds,” IEEE Transactions on Power Electronics, vol. 33, no. 9, pp. 8040–8051, 2017. doi: 10.1109/TPEL.2017.2773130.
M. A. Rodr´ıguez-Blanco, A. Vazquez-Perez, L. Hernandez-Gonzalez, V. Golikov, J. Aguayo-Alquicira, and M. May-Alarcon, “Fault detection for IGBT using adaptive thresholds during the turn-on transient,” IEEE Transactions on Industrial Electronics, vol. 62, no. 3, pp. 1975–1983, 2014. doi: 10.1109/TIE.2014.2364154.
C.-J. Bae, D.-C. Lee, and T. H. Nguyen, “Detection and identification of multiple IGBT open-circuit faults in PWM inverters for AC machine drives,” IET Power Electronics, vol. 12, no. 4, pp. 923–931, 2019. doi: 10.1049/iet-pel.2018.5188.
M. Trabelsi, M. Boussak, and M. Benbouzid, “Multiple criteria for high performance real-time diagnostic of single and multiple open-switch faults in ac-motor drives: Application to IGBT-based voltage source inverter,” Electric Power Systems Research, vol. 144, pp.136–149, 2017. doi: 10.1016/j.epsr.2016.11.021.
D. U. Campos-Delgado, J. A. Pecina-S´anchez, D. R. Espinoza-Trejo, and E. R. Arce-Santana, “Diagnosis of open-switch faults in variable speed drives by stator current analysis and pattern recognition,” IET Electric Power Applicat., vol. 7, no. 6, pp. 509–522, 2013. doi: 10.1049/iet-epa.2013.0015.
X. Sun, N. Diao, C. Song, Y. Qiu, and X. Zhao, “An Open-Circuit Fault Diagnosis Method Based on Adjacent Trend Line Relationship of Current Vector Trajectory for Motor Drive Inverter,” Machines, vol. 11, no. 10, p. 928, 2023. doi: 10.3390/machines11100928.
I. Jlassi and A. J. M. Cardoso, “A Single Method for Multiple IGBTs, Current-and Speed-Sensor Faults Diagnosis in Regenerative PMSM Drives,” IEEE
Trans. Emerg. Sel. Topics Power Electron., 2020. doi: 10.1109/JESTPE.2019.2918062.
M. Salman, J. Riccio, S. K. El Khil, P. Zanchetta, and C. Boccaletti, “Unified diagnosis and localization method of open switch faults in voltage source
inverters-fed synchronous reluctance motors,” IEEE Transactions on Industry Applications, 2025. doi: 10.1109/TIA.2025.3577113.
Z. Jian-Jian, C. Yong, C. Zhang-Yong, and Z. Anjian, “Open-Switch Fault Diagnosis Method in Voltage-Source Inverters Based on Phase Currents,” IEEE Access, vol. 7, pp. 63 619–63 625, 2019. doi: 10.1109/ACCESS.2019.2913164.
A. M. S. Mendes, M. B. Abadi, and S. M. A. Cruz, “Fault diagnostic algorithm for three-level neutral point clamped ac motor drives, based on the average current park’s vector,” IET Power Electronics, vol. 7, no. 5, pp. 1127–1137, 2014.
H. Yang, Y. Zhou, and J. Zhao, “Current covariance analysis-based open-circuit fault diagnosis for voltage source-inverter-fed vector-controlled induction motor drives,” Journal of Power Electronics, vol. 20, pp. 492–500, 2020. doi: 10.1007/s43236-020-00043-5.
X. Sun, C. Song, Y. Zhang, X. Sha, and N. Diao, “An Open-Circuit Fault Diagnosis Algorithm Based on Signal Normalization Preprocessing for Motor
Drive Inverter,” IEEE Transactions on Instrumentation and Measurement, vol. 72, pp. 1–12, 2023. doi: 10.1109/TIM.2023.3268461.
C. Song, X. Zhao, X. Sun, N. Diao, and J. Zhao, “Fast in-loop single-tube open-circuit fault diagnosis for voltage source inverter based on duality of current time pairs,” IEEE Transactions on Industrial Electronics, vol. 70, no. 9, pp. 9572–9581, 2023. doi: 10.1109/TIE.2022.3212398.
H. Yan, Y. Xu, J. Zou, Y. Fang, and F. Cai, “A novel open-circuit fault diagnosis method for voltage source inverters with a single current sensor,” IEEE Transactions on Power Electronics, vol. 33, no. 10, pp. 8775–8786, 2018. doi: 10.1109/TPEL.2017.2776939.
Z. Chen, D. Liang, S. Jia, S. Yang, and L. Yang, “A simple open-switch fault detection and diagnosis method for permanent magnet synchronous machines drive system based on DC-link current,” IET Power Electronics, vol. 16, no. 4, pp. 584–595, 2022. doi: 10.1049/pel2.12410.