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Early Detection Technique For Stator Winding Inter-Turn Fault in BLDC Motor Using Input Impedance
Early Detection Technique For Stator Winding Inter-Turn Fault in BLDC Motor Using Input Impedance
Early Detection Technique For Stator Winding Inter-Turn Fault in BLDC Motor Using Input Impedance
1, JANUARY/FEBRUARY 2015
Index Terms—Brushless dc (BLDC) motors, detection algo- breakdown in the adjacent coil. Moreover, the propagation of
rithm, early detection, input impedance, inter-turn fault. the faults in a single phase could quickly lead to complete
failure or shutdown of the motor. However, the ITF and com-
I. I NTRODUCTION plete failure of the motor do not occur at the same time. Thus,
fast detection of the ITF during motor operation can eliminate
Fig. 4. Speed change according to ITF. (a) Four-turn fault (Fr = 4.16%).
Fig. 3. Comparison of back electromotive force and input current. (a) Steady (b) Twelve-turn fault (Fr = 16.67%).
state (Fr = 0%). (b) Fault state (Fr = 4.16%).
A. Database Algorithm
The input impedance, which consists of the resistance and
In this paper, we propose an early detection technique using the reactance, can be easily obtained in real time using only the
the input impedance. The winding function theory (WFT) is input current and voltage. In addition, the reactance consists of
applied to calculate the impedance. This impedance is utilized the angular velocity and the inductance, as shown in (1)–(6).
in a database. In addition, this technique does not require the Thus, we select the input impedance as a detection parameter
calculation of the negative-sequence impedance and the appli-
cation of the FFT to the input voltage or current. Therefore, ITF Va
Za = (1)
detection using this approach has received a wide response and Ia
is easier than the previous method. where Va and Ia are true-RMS values of the phase voltage and
current in phase-A.
Under a healthy state,
II. D ETECTION T ECHNIQUE U SING AN A LGORITHM
Za1 = Ra +jXa = Ra2 +(ωa La )2 (2)
In this paper, we propose the impedance algorithm, as shown La = Lself +Lmutual = Laa +Lab , ωa = 2πfsteady state (3)
in Fig. 2. An ITF causes a change in the input current, input
voltage, rotating speed, coil resistance, and stator inductance where Za1 , Ra , Xa , ωa , and La are the input impedance,
[13], [14]. Thus, these factors should be considered to ac- resistance, reactance, angular velocity, and inductance of phase,
curately detect the ITF. In particular, the phase of the input respectively.
current lags because of the decrease in the inductance under Under a faulty state,
an ITF condition, as shown in Fig. 3. As a result, it leads to an
Za2 = Ras + jXas = Ras 2 + (ω L )2 (4)
as as
increase in the rotating speed, as shown in Fig. 4. Therefore, the Ras = (1 − Ff )Ra (5)
input impedance is selected as a detection parameter because it Las = Lself + Lmutual = Laa + Lab + Laf ,
includes all these factors. ωas = 2πffault state (6)
The impedance algorithm consists of three types, namely,
the database, fault diagnosis (in real time), and comparison where Za2 , Ras , Xas , ωas , and Las are the input impedance,
algorithms. The impedance algorithm can monitor the input resistance, reactance, angular velocity, and inductance of phase,
impedance in real time and compare it with the database. respectively.
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242 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015
TABLE II
C OMPARISON OF AVERAGE VALUES OF I NDUCTANCE
Fig. 6. Inductance values obtained by the WFT and FEA. (a) WFT results.
(b) FEA results.
and (10). The other functions caused by the ITF are listed in
Table I. Thus,
Fig. 5. Turn function ni and winding function Nj . (a) Healthy state. Total number of turns N
(b) Faulty state. t_h = = (9)
Number of slots per phase 3
t_h N
TABLE I T _h = = . (10)
FACTORS OF T URN AND W INDING F UNCTIONS 2 6
The self-inductance and mutual-inductance can be calculated
using these functions. In particular, the air-gap length of an in-
terior permanent magnet (IPM)-type BLDC motor depends on
the inverse air-gap function because the air gap varies along the
d−q axis [16]. Thus, the stator inductance can be calculated as
⎡ 2π ⎤
Lij = μ0 · r · lst · ⎣ g −1 (θ)ni (θ)Nj (θ)dθ⎦ (11)
0
where ni (θ) and Nj (θ) are the turn and the winding functions,
The fault fraction ratio is respectively; i, j, r, and lst are the phase of the turn func-
tion, phase of the winding function, rotor radius, and stack
Number of shorted winding length, respectively; and g −1 (θ) is the inverse air-gap function.
Ff = (7)
Number of total winding Fig. 6 shows the inductance results according to Fr using
Fr = Ff × 100. (8) the WFT and FE analysis (FEA). Table II lists the comparison
of the average inductance values obtained from the WFT and
FEA. These inductance values can be utilized to calculate the
The databases of phase-B and phase-C can also be calculated
impedance, which will become the database of the healthy
in the same manner. In this paper, we applied the WFT, which
and fault states. We prefer the WFT because it is relatively
uses a numerical function to the basic geometry and the winding
faster than the FEA. Moreover, the WFT offers considerable
layout of the machine, to calculate the accurate database values.
simplicity and lower computational cost [13], [15].
WFT is not used to calculate in real time but is only used to
However, the WFT cannot realize the magnetic saturation
calculate the inductance of the machine [13], [15].
characteristics because it does not consider the material char-
Fig. 5(a) shows the healthy state of the turn and winding
acteristics. Thus, the ITF is applied in the range where no
functions. Fig. 5(b) shows the change in the turn and the
magnetic saturation occurs. In Fig. 7, we show the variation in
winding functions according to the ITF. The turn function,
the magnetic flux of the stator teeth obtained by the WFT and
which is a distributed function of the turn number at the stator,
FEA simulation to confirm the magnetic characteristics. Here,
is reduced as the turn numbers at the faulted slot decrease. The
the magnetic flux density of the stator teeth can be calculated
winding function, which is a distributed function of the current
using the air-gap flux density
density in the conductor, is reduced at the faulted slot and is
increased at the healthy slot. Bair-gap = g −1 (θm )Nj (θm )iA (12)
The turn and the winding functions of the healthy state are ϕteeth = Bair-gap Aair-gap (13)
calculated by the number of poles per phase and the number of ϕteeth
Bteeth = (14)
turns per phase. These function values can be obtained by (9) Ateeth
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PARK et al.: TECHNIQUE FOR STATOR WINDING ITF IN BLDC MOTOR USING INPUT IMPEDANCE 243
Fig. 10. Real-time and true-RMS values of input voltage at 600 r/min.
Fig. 8. Real-time and true-RMS values of input voltage at 3500 r/min. (a) Real-time value of input voltage (Fr = 4.16%); (b) True-RMS value of
(a) Real-time value of input voltage (Fr = 4.16%). (b) True-RMS value of input voltage (Fr = 4.16%).
input voltage (Fr = 4.16%).
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244 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015
C. Comparison Algorithm
The comparison algorithm shows how to compare the real- Fig. 13. Experimental setup.
time calculation of the input impedance with that of the
database. This algorithm continuously receives feedback.
In this paper, 4.16% (three-turn fault) was selected as the
database for the fault state. When Fr is larger than 0% and
less than 4.16%, a weak alarm level is designated. When
Fr is greater than 4.16%, a strong alarm level is designated.
Because the input voltage and input current can change under a
variety of situations, Fr can change even under the steady state;
thus, we chose 4.16%. In the same manner, we performed a
comparison under a low-speed (600 r/min) condition to validate
the accuracy of the comparison algorithm.
The fault diagnosis circuit was developed using the proposed IV. R ESULTS AND D ISCUSSION
impedance algorithm. Then, we verified by the simulation and A. Experimental Setup
experiment whether the diagnosis circuit is fast and accurate.
Fig. 13 shows the experimental setup. Fig. 14 shows the block
Two types of diagnosis circuits that use the proposed algo-
diagram of the experimental setup for detailed explanation. In
rithm are shown in Fig. 12. Fig. 12(a) shows the configuration
this experiment, the inverter used is a current-controlled voltage
of the diagnosis circuit for the simulation. Here, the simulation
source inverter, which considers the speed control. The load part
used Proteus 7.6 developed at Labcenter Electronics. Moreover,
consists of the dynamo set for experiment with a 0.5 N · m load.
the low-priced ATmega128, which is coded as the proposed
algorithm, was utilized instead of the expensive digital signal
processor. In addition, a light-emitting diode is used for the B. Simulation and Experimental Models
fault alarm, and a liquid crystal display shows the motor state Fig. 15 shows the experimental and simulation models. In
(e.g., how many turn faults are generated) in real time. The fault this paper, a six-pole and nine-slot IPM-type BLDC motor is
diagnosis circuit for the experiment was developed on the basis used for the simulation and experiment of the ITF characteris-
of the simulation circuit, as shown in Fig. 12(b). tics. Table III lists the motor specifications.
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PARK et al.: TECHNIQUE FOR STATOR WINDING ITF IN BLDC MOTOR USING INPUT IMPEDANCE 245
Fig. 15. IPM-type BLDC motor for test and simulation. (a) Test motor.
(b) Simulation motor. Fig. 17. Simulation circuit for the dynamic fault.
TABLE III
S PECIFICATIONS OF THE IPM-T YPE BLDC M OTOR
Fig. 16. Construction of the contactor for the dynamic fault experiment.
(a) Actual structure. (b) Block diagram.
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246 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 51, NO. 1, JANUARY/FEBRUARY 2015
V. C ONCLUSION
In this paper, we have proposed an early fault diagnosis
technique for an accurate and rapid detection of the ITF us-
ing the input impedance. In addition, we have simulated and
experimented detection characteristics at 3500 and 600 r/min
to validate the accuracy of the proposed detection algorithm
under various rotating-speed conditions. The proposed fault-
detection technique calculates the input impedance using the
input voltage and input current and compares it with the value
in the database. This technique provides faster and simpler
diagnosis than the previous methods because it does not require
the FFT or complicated formula. The proposed algorithm had
been verified to be suitable for early fault detection using
the fault diagnosis circuit. Therefore, the proposed diagnosis
technique can be advantageously used to reduce the loss of lives
and property damages and to protect the system.
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[16] K. T. Kim, J. Hur, and B. W. Kim, “Calculation of distributed magnetic Seung-Tae Lee was born in Busan, Korea, in 1988.
flux density under the stator-turn fault condition,” J. Power Electron., He received the B.S. degree in electrical engineering
vol. 13, no. 4, pp. 552–557, Jul. 2013. in 2012 from the University of Ulsan, Ulsan, Korea,
[17] P. Neti and S. Nandi, “An improved strategy to detect stator inter-turn where he is currently working toward the M.S. de-
faults in reluctance synchronous machines using both negative sequence gree in electrical engineering.
quantities and stored magnetic energy after supply disconnection,” in His current research interests include motor de-
Conf. Rec. IEEE IAS Annu. Meeting, Sep. 2007, pp. 2234–2241. sign, motor drives, and fault diagnosis of the motor.
[18] Y. G. Park, D. S. Han, Y. S. Suh, and W. Y. Choi, “Minimization of active
power and torque ripple for a doubly fed induction generator in medium
voltage wind power systems under unbalanced grid conditions,” J. Power
Electron., vol. 13, no. 6, pp. 1032–1041, Nov. 2013.
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