Improving fault tolerant drives for aerospace applications

D EngThe aerospace industry is moving towards the more electric aeroplane where traditional hydraulic systems are being replaced with electrical systems. Electrical technology offers some strong advantages compared to hydraulic technology including; cost, efficiency, power on demand and relative ease of maintenance. As with most new technologies, a major disadvantage is its limited reliability history. A lot of research in the aerospace field therefore focuses on improving fault tolerant electrical systems. Work done in this thesis builds on an existing fault tolerant drive, developed by Newcastle University and Goodrich Actuation Systems as part of the ELGEAR (Electrical Landing Gear) project. The purpose of this work is to continue improving the drive’s fault tolerant features; especially in areas where the drive is most vulnerable. The first part of this thesis focuses on improving the overall system reliability by monitoring the health of the dc-link capacitors in the fault tolerant drive. The implemented estimation technique makes use of voltage and current sensors which are already in place for protection and control purposes. The novel aspect of the proposed technique relates to monitoring capacitors in real time whilst the motor is operational. No external interferences, such as injected signals or special operation of the drive, are required. The condition monitoring system is independent of torque and speed, and hence independent of a variation in load. The work was validated using analytical methods, simulation, low voltage experimentation and high voltage implementation on the ELGEAR drive. The second part of this thesis focuses on single shorted turn faults, in fault tolerant permanent magnet (PM) motors. Despite the motor being able to withstand a wide range of faults, the single shorted turn fault remains a difficult fault to detect and handle. The problem arises from the magnets on the spinning rotor that cannot be ‘turned off’ at will. This thesis investigates the severity of the faulted current in a shorted turn and how it varies depending on the turn’s location in the stator slot. The severity of the fault is studied using 2D finite element analysis and practical implementation on the ELGEAR rig. Finally, recommendations are proposed for improving the ELGEAR motor for future fault tolerant designs.EPRSC and Goodrich Aerospace (now United Technologies

A 3D Reduced Common Mode Voltage PWM Algorithm for a Five-Phase Six-Leg Inverter

Neutral point voltage control converters (NPVCC) are being considered for AC drive applications, where their additional degree of freedom can be used for different purposes, such as fault tolerance or common mode voltage (CMV) reduction. For every PWM-driven converter, the CMV is an issue that must be considered since it can lead to shaft voltages between rotor and stator windings, generating bearing currents that accelerate bearing degradation, and can also produce a high level of electromagnetic interference (EMI). In light of these considerations, in this paper a three-dimensional reduced common mode voltage PWM (3D RCMV-PWM) technique is proposed which effectively reduces CMV in five-phase six-leg NPVCCs. The mathematical description of both the converter and the modulation technique, in space-vector and carrier-based approaches, is included. Furthermore, the simulation and experimental analysis validate the CMV reduction capability in addition to the good behaviour in terms of the efficiency and harmonic distortion of the proposed RCMV-PWM algorithm.This work has been supported in part by the Government of Basque Country within the fund for research groups of the Basque University system IT1440-22 and MCIN/AEI/10.13039/ 501100011033 within the project PID2020-115126RB-I00

The Age of Multilevel Converters Arrives

This work is devoted to review and analyze the most relevant characteristics of multilevel converters, to motivate possible solutions, and to show that we are in a decisive instant in which energy companies have to bet on these converters as a good solution compared with classic two-level converters. This article presents a brief overview of the actual applications of multilevel converters and provides an introduction of the modeling techniques and the most common modulation strategies. It also addresses the operational and technological issues

An intelligent electronic fuse for selective isolation of faulty switching cells in power electronic converter legs to guarantee continuous operation

© 2022 IEEE. Personal use of this material is permitted. Permission from IEEE must be obtained for all other uses, in any current or future media, including reprinting /republishing this material for advertising or promotional purposes, creating new collective works, for resale or redistribution to servers or lists, or reuse of any copyrighted component of this work in other worksThis article proposes a novel device designated as an intelligent electronic fuse (iFuse) intended to be connected in series with any current-bidirectional voltage-unidirectional active switch present in a power converter. The iFuse duty is to selectively isolate its series-associated switch from the rest of the converter circuit immediately after detecting that this switch has failed in short circuit. Nonetheless, it maintains the reverse (free-wheeling) current path originally offered by the failed switch. The failure detection is typically performed when the failed switch causes a shoot-through event. Therefore, the iFuse is able to block large currents. The iFuse allows increasing the power-converter fault tolerance and reliability with regard to switch short-circuit failures (SCFs), as in converters featuring switches in parallel, redundant legs, and multilevel neutral-point-clamped topologies. The reliability model analysis of a two-level converter leg with two parallel switches per position reveals that its reliability can be increased up to four times when an iFuse is implemented in series with each switch. The iFuse device feasibility and good performance are verified through experimental tests, proving that it can detect and isolate the associated-switch failure in 6 µs , while stopping short-circuit currents of up to 1 kA without incurring in harmful di / dt values.Peer ReviewedPostprint (author's final draft

Fault tolerant drives for safety critical applications

PhD ThesisThe correct operation of adjustable speed drives, which form part of a larger system, is often essential to the operation of the system as a whole. In certain applications the failure of such a drive could result in a threat to human safety and these applications are termed 'safety critical'. The chance of a component failure resulting in non-operation of the drive can be dramatically reduced by adopting a fault tolerant design. A fault tolerant drive must continue to operate throughout the occurrence of any single point failure without undue disturbance to the power output. Thereafter the drive must be capable of producing rated output indefinitely in the presence of the fault. The work presented in this thesis shows that fault tolerance can be achieved without severe penalties in terms of cost or power to mass ratio. The design of a novel permanent magnet drive is presented and a 'proof of concept' demonstrator has been built, based on a 20 kW, 13000 RPM aircraft fuel pump specffication. A novel current controller with near optimal transient performance is developed to enable precise shaping of the phase currents at high shaft speeds. The best operating regime for the machine is investigated to optimise the power to mass ratio of the drive. A list of the most likely electrical faults is considered. Some faults result in large fault currents and require rapid detection to prevent fault propagation. Several novel fault sensors are discussed. Fault detection and identification schemes are developed, including new schemes for rapid detection of turn to turn faults and power device short circuit faults. Post fault control schemes are described which enable the drive to continue to operate indefinitely in the presence of each fault. Finally, results show the initially healthy drive operating up to, through and beyond the introduction of each of the most serious faults.EPSR

Converter fault diagnosis and post-fault operation of a doubly-fed induction generator for a wind turbine

Wind energy has become one of the most important alternative energy resources because of the global warming crisis. Wind turbines are often erected off-shore because of favourable wind conditions, requiring lower towers than on-shore. The doubly-fed induction generator is one of the most widely used generators with wind turbines. In such a wind turbine the power converters are less robust than the generator and other mechanical parts. If any switch failure occurs in the converters, the wind turbine may be seriously damaged and have to stop. Therefore, converter health monitoring and fault diagnosis are important to improve system reliability. Moreover, to avoid shutting down the wind turbine, converter fault diagnosis may permit a change in control strategy and/or reconfigure the power converters to permit post-fault operation. This research focuses on switch fault diagnosis and post-fault operation for the converters of the doubly-fed induction generator. The effects of an open-switch fault and a short-circuit switch fault are analysed. Several existing open-switch fault diagnosis methods are examined but are found to be unsuitable for the doubly-fed induction generator. The causes of false alarms with these methods are investigated. A proposed diagnosis method, with false alarm suppression, has the fault detection capability equivalent to the best of the existing methods, but improves system reliability. After any open-switch fault is detected, reconfiguration to a four-switch topology is activated to avoid shutting down the system. Short-circuit switch faults are also investigated. Possible methods to deal with this fault are discussed and demonstrated in simulation. Operating the doubly-fed induction generator as a squirrel cage generator with aerodynamic power control of turbine blades is suggested if this fault occurs in the machine-side converter, while constant dc voltage control is suitable for a short-circuit switch fault in the grid-side converter.Wind energy has become one of the most important alternative energy resources because of the global warming crisis. Wind turbines are often erected off-shore because of favourable wind conditions, requiring lower towers than on-shore. The doubly-fed induction generator is one of the most widely used generators with wind turbines. In such a wind turbine the power converters are less robust than the generator and other mechanical parts. If any switch failure occurs in the converters, the wind turbine may be seriously damaged and have to stop. Therefore, converter health monitoring and fault diagnosis are important to improve system reliability. Moreover, to avoid shutting down the wind turbine, converter fault diagnosis may permit a change in control strategy and/or reconfigure the power converters to permit post-fault operation. This research focuses on switch fault diagnosis and post-fault operation for the converters of the doubly-fed induction generator. The effects of an open-switch fault and a short-circuit switch fault are analysed. Several existing open-switch fault diagnosis methods are examined but are found to be unsuitable for the doubly-fed induction generator. The causes of false alarms with these methods are investigated. A proposed diagnosis method, with false alarm suppression, has the fault detection capability equivalent to the best of the existing methods, but improves system reliability. After any open-switch fault is detected, reconfiguration to a four-switch topology is activated to avoid shutting down the system. Short-circuit switch faults are also investigated. Possible methods to deal with this fault are discussed and demonstrated in simulation. Operating the doubly-fed induction generator as a squirrel cage generator with aerodynamic power control of turbine blades is suggested if this fault occurs in the machine-side converter, while constant dc voltage control is suitable for a short-circuit switch fault in the grid-side converter

Integrated on-board battery chargers for EVs based on multiphase machines and power electronics

The concept of integration of an electric vehicle (EV) drivetrain’s components into the charging process is not novel. It has been considered over the years in both industry and academia, which resulted in a number of published papers and patents in this area. Possibilities of charging from single-phase and three-phase mains were both considered. In the former group the charging power rating cannot exceed the limit set by the single-phase mains. Therefore, the topologies are characterised with low charging powers, leading to a long duration of the charging process. Although the topologies supplied form three-phase mains are capable of achieving fast charging, they were considered to a much lesser extent. The main reason is the undesirable torque production in machines integrated into the charging process during the battery charging, which is unavoidable when a three-phase machine of either synchronous or induction type is used. The thesis investigates integrated on-board battery chargers for electric vehicles (EVs) based on multiphase machines and multiphase power electronics. At present, EVs rely on three-phase systems for machine propulsion. However, recent advances in multiphase drive technology have firmly established their potential advantages over their three-phase counterparts for this application. One of the most notable features of multiphase drive systems is their excellent fault tolerance, which is highly desirable in EVs since it enables realisation of the requirement for “limp-home” operation in the propulsion mode, in case of a fault. The thesis demonstrates that multiphase drives have an additional major advantage over three-phase systems in vehicular applications, which is related to the aspect of battery charging. It shows a clear superiority of multiphase over three-phase systems in designing integrated charging topologies for EVs. In order to support the statement, the thesis provides a multitude of novel charging solutions that incorporate multiphase machines and multiphase power electronics into the charging process. The developed solutions could contribute to achieve significantly faster and cost-free (or at a minimum additional cost) on-board chargers in the near future. The thesis demonstrates how additional degrees of freedom that exist in multiphase systems can be conveniently utilised to achieve torque-free charging operation. Therefore, although three-phase currents flow through machines’ stator windings, they are not capable of producing a torque; thus the machines do not have to be mechanically locked. The principal advantage is that either very few or no new elements are required in order to realise the charging process. Thus savings are made with regard to cost and weight, and available spare space in the vehicle is increased. The novel integrated charging solutions, developed in the thesis, are based on primarily five-phase, asymmetrical and symmetrical six-phase, and asymmetrical and symmetrical nine-phase systems. Solutions with other phase numbers are also considered. Thus, in essence, all the possible phase numbers are encompassed by the research and the solutions are valid for both induction and synchronous machines. A common attribute of all discussed topologies is that they do not require a charger as a separate device since the charging function is performed by the drivetrain elements, predominantly a multiphase machine and an inverter. Further, each topology is capable of operating in both charging and vehicle-to-grid (V2G) mode. Three types of voltage sources are considered as a power supply for the charging process, namely single-phase, three-phase, and multiphase. For each supply type, and each phase number, viability of torque-free charging operation is theoretically assessed. Mathematical models of multiphase rectifiers are developed. For each topology equivalent scheme in the charging/V2G mode of operation is constructed. A control scheme, which aims at achieving unity power factor operation and complete suppression of the low order grid current harmonics, is designed for each solution. Finally, the validity of theoretical considerations and control algorithms for the developed solutions is experimentally assessed in charging, V2G, and propulsion mode of operation. Experimental performances of all discussed topologies are compared, and advantages and shortcomings of each solution are identified and discussed

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