Modelling, Diagnosis, and Fault-Tolerant Control of Open-Circuit Faults in Three-Phase Two-Level PMSM Drives

Attributing to the high efficiency, compact structure, and rapid dynamics, powertrains utilizing Permanent Magnet Synchronous Motors (PMSM) have emerged as a promising alternative and have seen extensive deployment in various industrial and transportation sectors, including electric vehicles (EVs), more-electric aircraft, and robotics. Despite ongoing interest in advanced redundant topologies for PMSM drives from both academia and industry, the three-phase two-level (3P2L) PMSM drive continues to dominate the majority of the electric drive market. However, when compared to its multi-phase counterparts, the most-commonly used 3P2L PMSM drive exhibits limited reliability and fault tolerance capabilities, particularly in safety-critical or cost-sensitive scenarios. Therefore, the development of embedded reliability-enhancing techniques holds great significance in enhancing the safety and maintenance of on-site powertrains based on the 3P2L PMSM drive. The purposes of this study are to investigate post-fault system models and develop hardwarefree fault diagnostic and fault-tolerant methods that can be conveniently integrated into existing 3P2L PMSM drives. Special attention is dedicated to the open-circuit fault, as it represents one of the ultimate consequences of fault propagation in PMSM drives. In the first place, the fault propagation from component failures to open-circuit faults is analyzed, and the existing literature on the modelling, diagnosis, and fault-tolerant control of PMSM drives is comprehensively reviewed. Subsequently, the study delves into the postfault system model under the open-phase (OP) fault, which includes the examination of postfault phase voltages and current prediction. Based on the phase voltages observed under the OP fault, a phenomenon of particular interest is modelled: the remaining current that flows through the free-wheeling diodes of the faulty phase under the open-switch (OS) fault. The conduction mechanism is elucidated, and a real-time estimation model is established. Furthermore, a sampling method is designed to enable the motor drive to detect the remaining current in the OS phase, along with a set of diagnostic rules to distinguish between OS and OP faults. Finally, an embedded fault-tolerant control method is introduced to enhance the post-fault speed and torque outputs of 3P2L PMSM drives.