Fuzzy Based Health Monitoring of Electric Vehicle

Motor using Time Domain Analysis

Shweta S Hooli Anusha Vadde Krishnan Manickavasagam
Electrical Engineering Department Electrical Engineering Department Electrical Engineering Department
Ramaiah University of Applied Ramaiah University of Applied Ramaiah University of Applied
Sciences Sciences Sciences
Bangalore, India Bangalore, India Bangalore, India
shwetahooli99@gmail.com anushav.ee.et@msruas.ac.in manicavasagam2003@yahoo.com

Govind R Kadambi
Electrical Engineering Department
Ramaiah University of Applied
Sciences
Bangalore, Karnataka, India

Abstract—Detection of low-level electrical winding faults in
Squirrel Cage Induction Motor (SCIM) is prime importance in
Electric Vehicle (EVs). This analysis is carried out to predict
flux distribution inside and outside of SCIM using Finite
Element Analysis (FEA). In FEA, time domain analysis is
performed to determine flux at the instant of fault with respect
to time whereas steady state analysis will not give such a results.
Flux distribution provides significant information about the
behavior of SCIM. For analyzing the leakage flux in the surface
vicinity of SCIM a 15kW machine is chosen. The analysis
indicates magnetic flux distribution and ideal location of flux
sensor. From FEM model, leakage flux on the surface of SCIM
is captured and exported to MATLAB for health monitoring.
Fuzzy rule base is developed for mapping the flux with health
monitoring of SCIM used in Electric Vehicle (EV). Continuous
health monitoring of the machine is captured by fuzzy controller
and displayed in EV or vehicle monitoring centre.
Keywords— Finite Element Analysis (FEA), Squirrel Cage
Induction Motor (SCIM), Leakage Flux, Flux Density
I. INTRODUCTION
Induction motors have spread the wings across various
fields of industries presently on EVs. They are most
commonly used drives because of the robustness, simple
construction, efficiency and reliability. Many studies are being
carried over decades to improvise efficiency and reduce
losses. Condition monitoring of induction motor is a process
that may be used to great advantage of improvising efficiency
and reducing losses in EVs. The study on flux distribution and
its behavior helps in predicting health condition of SCIM for
improvising the performance of motor.
A winding deterioration in induction motors are
investigated in [1]–[5]. Stator fault diagnosis using power
decomposition is discussed in [1]. R. R. Schoen is dealt with
current-based condition monitoring operating under arbitrary
load conditions in induction motor [2]. Insulation failure
detection in the stator winding is done by M. A. Cash in [3]
and [5]. An inter-Turn stator winding fault diagnosis is
explained in [4].
Simple models are required to analyse the effect of an
internal fault on the stray flux [6] for analysis of complicated
magnetic flux distribution of SCIM. An accurate evaluation of
magnetic field distribution and mechanical performance of
SCIM is obtained by field analysis as in [7]. Turn-to-Turn
Fault (TTF) detection and identification of defective region in
inverter-fed SCIM using new air-gap flux-based technique is
proposed in [8]. A 3-D FEM approach for the study of locked
rotor, no-load and rated load conditions is presented in [9-10]
to capture magnetic stray fields outside the machine to reduce
the electromagnetic signature. Broken rotor bar fault detection
techniques, classification based on fault signature, various
monitoring conditions and signal processing techniques a
survey is done in [11]. Both finite element method and the
Fourier approach [12] is applied for field quantities in a
longitudinal plane along the axis of an axial flux machine
(AFM) are calculated. A novel sensor less control of SCIM is
proposed in [13].
The response of air is dominant and electromagnetic
signals in the earth are strongly diffusive at away from the
motor. This leads to direct more appropriate requirement of
measured data, efficient modelling, inversion algorithm and
time domain measurements [14]. Measurement of torque
using leakage flux in SCIM and health monitoring of EVs
using digital twin are given in [15] and [16].
Flux distribution plays a key role in the working of
induction motor and it is mandatory to understand its behavior
in the stator, in rotor and also in surface vicinity of the motor.
The magnetic flux distribution analysis describes the strength
and direction of flux in the motor and also helps in
determining the flux distribution in stator, flux linking the
rotor, stray flux, air gap flux and leakage flux. The flux around
the stator slot and the flux that successfully links with the rotor
contribute for useful flux or flux linkage. Current flowing
varies according to the condition of the motor. Suppose the
SCIM exposed to broken bar, the corresponding variation of
flux distribution can be observed in that region using time
domain analysis.
Time domain analysis is considered in this paper to
capture magnetic flux inside and outside the motors. FEA is
the standard tool for solving the systems of governing
equations over a continuous physical system. Leakage flux
distribution in the surface vicinity of SCIM on outer frame and
away from outer frame are performed using time domain
analysis. The time domain FEA is used to get values of
leakage flux under different conditions which is very much
required to classify health condition of SCIM based on normal
and abnormal leakage flux variations. The main focus and
novelty of the paper is listed as follows:
• To develop model of 15 kW SCIM in time domain
and analyse the leakage flux

978-1-7281-5681-1/21/$31.00 ©2021 IEEE

 • To observe the leakage flux on the surface vicinity of The main flux produced in motor is distributed in stator,
SCIM flux linking the rotor, stray flux, air gap flux and leakage flux
• To develop FLC for health monitoring of SCIM used as mentioned in Fig.3.
in EV
II. BLOCK DIAGRAM
A 15 kW induction motor is modelled to study the flux
behaviour using FEA. The observed value of leakage flux is
export to FLC developed in MATLAB as shown in Fig.1. The
condition of the motor will be displayed in EV or vehicle
monitoring centre.

Fig. 3 Flux distribution in SCIM

III. TIME DOMAIN ANALYSIS

The magnitude of leakage flux during normal and abnormal
conditions are performed. The motor not engaged with EV,
normal operating, fully loaded and maximum loaded are
treated as normal operating condition and open rotor bar is
Fig. 1 Block diagram of health monitoring system treated as internal fault.
The condition of SCIM is predicted based on the leakage A. Time Domain Analysis of normal operating condition of
flux values on the surface. The magnitude of leakage flux SCIM
under different conditions such as motor not engaged with EV, Normally, FEA is performed in steady state analysis on
normal operating, fully loaded, maximum loaded and internal electrical machines. Magnetic flux density norm is analyzed
faults are simulated using Comsol. in steady state FEA with respect to y-coordinate, the obtained
plot is shown in Fig. 4a. Magnetic flux density at any instant
A. Development of SCIM FEA Model
of fault can be captured with respect to time domain FEA as
The procedure involved in execution of FEA is shown in Fig .4.b. In Fig.4.a, the magnetic density norm is
presented in steps as follows: 0.08 at 50 mm y-coordinate is capture at 0.1 to1 sec. In Fig.4.b,
1. Collect the specifications of SCIM the magnetic density norm is captured for 0.1 to1 sec, it is
2. Calculation of number of turns of coil per slot as input to giving information of change in flux with respect to time
the model from given motor specifications for different which will be useful for fault analysis. Hence time domain
loads (different current, frequency) analysis is preferred in this work.
3. 2D modelling and meshing of the motor
4. Create domain, add boundary conditions, assign material
for each 2D meshed component
5. Run the simulation under different loads
6. Analyzing magnetic vector potential and contour plots
7. Acquiring flux density values at various cut points
B. Modelling of SCIM
Modelling of SCIM involves designing of stator slots,
rotor bars, stator, rotor and assembly. The design
specifications of motor, inputs provided are frequency, current
and number of turns for FEA analysis and materials assigned
for different parts of the motor are listed in annexure in Table
IV, V and VI. Fig. 2 depicts the model of stator slot, rotor bar Fig. 4 a. Plot of magnetic flux density using steady state FEA
and motor designed. Closed type rotor bar is considered for
modelling and analysis. The flux distribution is almost same
as that of open type.

Fig. 2 SCIM modelled in FEA tool

Fig .4.b. Plot of magnetic flux density using time domain FEA
 The flux variation in each part of motor is observed on
the developed FEM mesh model. The contour plots of
magnetic vector potential distribution for full load condition
is depicted in Fig.5.

Fig. 7 Magnetic vector potential of SCIM under full load condition

Fig.7 also contains distribution of magnetic vector

potential in rotor to airgap, airgap to stator, inside stator, stator
to casing and 6mm away from casing. Leakage flux is
Fig. 5 Magnetic vector potential distribution in motor for full load condition observed at casing of motor, the vector potential distribution
is more in casing compared to 6mm away from the SCIM.
In Fig.5, the right top corner depicts the vector potential
distribution in the air gap and the right bottom corner depicts
the vector potential distribution of the stator as marked. The
flux is more concentrated near stator slot and rotor bar
compared to other parts. Location of cut points to capture
magnetic flux density in SCIM is represented in Fig.6.

Fig. 8 Cut points on vicinity of SCIM to capture magnetic flux density

Fig.8 represents the cut points where magnetic vector

Fig. 6 Location of cut points in SCIM to capture Magnetic flux density
A.1 Internal Distribution of Flux with Load
The flux distribution inside of SCIM is analysed by
applying torque from no load to full load. This section is
presented to analyse the flux distribution inside the SCIM.
Flux density in stator, air gap and rotor are decreasing when
load increases from no load, half load, 3/4th load and full load.
potential is observed. These cut points are located away from
casing at distances of 6mm, 12 mm, 18mm, 24mm, 50mm and
100 mm. Flux leakage is decreased if move away from casing
of SCIM as shown in Fig.9. Leakage flux reduces to a
negligible value 100mm away from casing. Practically, the
flux sensor is placed near the surface of SCIM to capture the
maximum value and avoid heat due to conduction.

A.2 External Distribution of Flux with Load

The outer environment of motor is considered to capture
the flux leakages happening in the vicinity of motor. A circular
air domain is created at 6mm distance away from motor. The
magnetic vector potential distribution is observation of
magnetic flux along radial or axial direction. In this work,
radial distribution is presented from centre of the rotor to away
from the motor. The values of stator leakage flux is captured
inside and on surface of SCIM is listed in Table I.

Fig. 9 Magnetic Flux Density Away from Motor for Full Load Condition
 TABLE .I LEAKAGE FLUX IN STATOR AND ON SURFACE OF MOTOR B. Time Domain Analysis of abnormal operating condition
UNDER LOAD CONDITIONS
of SCIM
Stator leakage The leakage flux variation in each part of motor is
Stator leakage
Load conditions Flux (inside)
Flux (on surface observed on the developed FEM mesh model.
of motor)
in wb
in wb

No load 0.626347199 0.0003232

Half load 0.628949312 0.0003256

Three fourth load 0.626302543 0.000415
Full load 0.6402759 0.000515

Fig.10 depicts the cut points taken at centre of slot, edge

of slot and middle of two adjacent slot which are equal to
angles 900, 87.50 and 850 to analyse the variation of magnetic
flux leakage inside and outside the frame of motor. The flux
values repeats all over the motor since motor is axial Fig. 12 A 2D view of Open Rotor bar of 15 kW SCIM
symmetric. The points along the 900 travels through the centre
of stator slot and rotor bar. A 87.50 travels through the edge of
the stator slot while the 850 travels in between adjacent two
stator slots as shown in Fig.10.
The leakage flux values are captured outside the motor
from casing at distances of 6mm, 12 mm, 24mm, 50mm and
100 mm with three different position of the slot angles as
shown in Fig.11. Leakage flux density towards the end at 900
angle is less compared to the other two angles while other two
angles the flux density is reducing in almost same rate.

Fig. 13 Distribution of Magnetic Flux in Open Rotor Bar

The contour plots of magnetic vector potential

distribution for full load condition under open rotor bar
under fault condition is depicted in Fig.12. Three rotor bars
are opened and magnetic leakage flux is observed as shown
Fig. 10 Cut Points along Motor at Different Angles in Fig .12. Leakage flux on surface of SCIM is more
compared to normal condition.
C. Design of Fuzzy Controller
In this work, fuzzy controller is developed for mapping flux
related to display the condition of SCIM. Flux observed by
FEM is given as input and different health conditions of
SCIM is considered as output as shown in Fig 14.a and 14.b.
The rule base is created to directly mapping flux to health
conditions as given in Fig 14.c. In general, triangular
membership function is chosen among various membership
function due to zero value of the reconstruction error at 50%
overlap level and yielding the optimal values of the
introduced criteria [15]. In this work, fuzzy is used for
mapping leakage flux magnitude with various fault condition
of the motor which required clear demarcation between
faults. At any instant, there is no chance of occurrence of two
or more event in motor except internal fault. Internal fault can
Fig. 11 Magnetic leakage flux density at cut points of different slot position
happened along with any of the conditions mentioned in
Table II. Hence high values is assigned for internal fault as in
Fig.14.a. So, the triangular membership with different values
are chosen as in Fig .14.b which is satisfying the mapping
criteria.
 In real time, the sensor is placed on the surface of SCIM
and observed flux is transmitted to EV/ Vehicle service center
as shown in Fig.15.
To verify the possibility of the magnetic leakage flux from
surface and away from surface a 3 phase, 3.6 kW SCIM and
a 24V, 300 rpm, 2A BLDC motor is considered for the
experiment in electric machines laboratary. Magnetic
Fig. 14.a. Input membership function
leakage flux is captured while motor is running under no load
at distances of 6mm, 12 mm, 24mm, 50mm and 100 mm
away from casings for 3.6 kW, SCIM as shown in Fig.16.
Same way in a 24V, 300 rpm, 2A, BLDC motor also
measured using Gauss meter as shown in Fig.17 and the
results are given in Table. III, indicates, 3.6kW SCIM, 15 kW
SCIM and BLDC motor are exerting maximum flux near the
casing. Even at a distance of 50mm also the flux is 0.1 µT.

Fig.14.b. Output membership function

Fig. 16 Experimental measurement of magnetic leakage flux at various cut

Fig.1.4.c. Fuzzy Rule points of 3.6kW SCIM using Gauss meter

IV. REAL TIME MEASUREMENT OF FLUX IN SCIM

The value of flux observed under normal and abnormal

conditions are given in Table. II.

TABLE II LEAKAGE FLUX UNDER NORMAL AND ABNORMAL

CONDITIONS

Leakage Flux range

outside the frame of Health Condition of SCIM
motor
[0 0.000162 0.000323] Motor not encaged with vehicle
[0.000323 0.000515] Normal operation
[0.000515 0.000615] Full load condition
[0.000615 0.000715] Maximum load condition Fig. 17 Experimental measurement of magnetic leakage flux at various
[0.000715 < all values] Under fault condition distances of 24V, 300 rpm, 2A, BLDC motor

TABLE .III AVERAGE MAGNETIC LEAKAGE FLUX DENSITY VALUES FROM

THE CASING OF MOTOR

15 kW 3.6 KW
24V, 300 rpm,
Distance Induction induction motor
2A, BLDC
from Casing Motor (Practical
motor run for 3
of motor (Simulatio results) run for 3
minutes
n results) minutes
On surface 0.51 mT 0.6 µT 0.4 µT
12 mm 0.16 mT 0.4 µT 0.3 µT
50 mm 0.14 mT 0.1 µT 0.1 µT
100 mm 0.13 mT 0T 0 µT

V. CONCLUSION
Fig. 15 Real Time implementation of health monitoring of EV Magnetic leakage flux in the vicinity of SCIM is analysed
by simulation and conduction of experiment. A 15 kW SCIM
model is analysed using FEA tool for various load conditions
at various distances from surface of the motor. The simulation
results illustrates that leakage flux is more concentrated near
the casing and moving away from the casing it reduces.
However in magnitude the flux leakage in strongly present in
the vicinity of motor and slowly deteriorates as one moves
away from it. At the end of 100mm away from motor the flux
leakage becomes negligible. The location of flux sensor is
decided based on these results. Any performance variation of
SCIM is reflected in leakage flux and it is given as input to
fuzzy controller. Fuzzy mapping technique is used to predict
the condition of SCIM. From this research, it can be concluded
that the SCIM used in EVs can be monitored continuously for
its normal and abnormal behavior. In future, different fault
conditions can be performed and be added in fuzzy controller
to get whole status of SCIM in EVs.
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ACKNOWLEDGEMENT APPENDIX

The authors gratefully acknowledge the management of TABLE .IV DESIGN SPECIICATIONS OF 15KW SCIM
M. S. Ramaiah University of Applied Sciences for their
encouragement and provided facility to perform this research. Parameters Dimensions (mm)
Stator outer diameter 255.815 mm
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