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Published in IET Power Electronics
Received on 17th January 2011
Revised on 20th February 2012
doi: 10.1049/iet-pel.2011.0018

ISSN 1755-4535

Model-based methodology using modified sneak


circuit analysis for power electronic converter
fault diagnosis
R.R. Soman1 E.M. Davidson1 S.D.J. McArthur1 J.E. Fletcher2 T. Ericsen2,3
1
Advanced Electrical Systems Group, Institute for Energy and Environment, Department of Electronic and Electrical
Engineering, University of Strathclyde, Glasgow, UK
2
School of Electrical Engineering and Telecommunications, University of New South Wales, NSW, Australia
3
US Office of Naval Research, Arlington, Virginia, USA
E-mail: raj.soman@eee.strath.ac.uk

Abstract: This study presents a novel research methodology and approach for diagnosing pertinent failures for power electronic
converters. The concept of the generalised connection matrix for a sneak circuit analysis is used in this research. A novel
modification to this process shown in this study produces a usable feature that provides unique signatures under fault
scenarios and could be used to diagnose faults. The novelty lies in using component currents to form the generalised
connection matrix. This study presents the results obtained using data collected from fault scenarios on a hardware set-up for
the dc – dc buck converter.

Nomenclature system (DCZEDS) following the integrated fight through


power (IFTP) approach [2] that is envisioned for US Navy
C1 Input-side filter capacitor warships. The primary objective of the FACS is to take
C2 Output-side filter capacitor necessary action to prevent the system from becoming
unstable and to maintain successful mission control after
L1 Inductor
the action of detecting and isolating faults. Owing to a lack
S1 Semiconductor switch of benchmark systems, the need to understand failures
S2 Freewheeling diode and their effects is vital for efficient fault identification,
V1 Input voltage location and accommodation. Furthermore, the fundamental
differences between shipboard power systems (SPSs) and
V2 Output voltage
land-based systems [3] impose analytical challenges relating
IIN Input current to system behaviour under various operating conditions.
IOUT Output current A preliminary failure mode and effects analysis (FMEA)
IC1 Current through capacitor C1 is proposed as the first step towards achieving the overall
FACS for the medium-voltage DC (MVDC) SPS [4] as a
IC2 Current through capacitor C2 detailed FMEA is the logical starting point to understand
IS1 Current through switch S1 faults and failures in a system or component [5]. This paper
IS2 Current through diode S2 reports focused research stemming from the application of
IL1 Current through inductor L1 relatively new and unproven power electronic equipment
within the envisioned DCZEDS. The new power electronics
|S1on| Final determinant equation for switch S1’s on technology will make possible the plug-and-play operations
state concept of power electronic building block (PEBB)-based
|S1off| Final determinant equation for switch S1’s off devices [6] and rapid power changes (both in quantity and
state direction), thereby facilitating a distributed power and
energy management approach. The automated operation
of such a distributed approach will also introduce risks in
1 Introduction handling of power swings, stability and degradation of
physical parts of power system components. Therefore the
The overall aim of the research reported in this paper is the move towards zonal distribution architecture requires
development of a fault-accommodating control system research into de-risking the system from the effects of faults
(FACS) [1] for the notional DC zonal electrical distribution at all levels, that is component, device, sub-system (zone)

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doi: 10.1049/iet-pel.2011.0018 & The Institution of Engineering and Technology 2012
www.ietdl.org
and system level. Another aspect of the future warship is a
70% (or greater) decrease in the number of crew [7] and the
subsequent increase in automation. Automated diagnostics
may have a number of benefits, the major ones are
enhanced decision support for the on-board crew and
system protection and control.
Fig. 1 shows the zonal MVDC system modelled on a
real-time digital simulator (RTDS) [8, 9] at the Centre for
Advanced Power Systems (CAPS) at Florida State
University (FSU). The architecture follows a multi-zonal,
IFTP approach in order to maximise the operational
capability of the SPS even when the ship is experiencing
adverse conditions, for example, unexpected damage. Ship
service loads are distributed in load centres in four zones,
from bow to stern along the ship, and are fed MVDC
power from both port and starboard DC buses which run
longitudinally along the ship. The zonal load centre
topology is illustrated in Fig. 2 showing the use of various
converter types for the dc – dc and dc – ac power conversions. Fig. 2 Zonal load centre topology
Power electronic conversion forms an integral part of Image courtesy CAPS-FSU
these topologies [1 – 4]. Power electronic converters provide
increased controllability and flexibility in power systems
and find increasing application at various power levels.
Among converter topologies, multi-level and cascaded for fault identification. For the purpose of demonstrating
types have emerged as an important technology in high- such a methodology, the dc – dc buck converter was chosen
power applications [10 – 14]. The evolution of existing by the authors for analysis into fault diagnosis at the device
power semiconductor switches Gate turn-off thyristor and component level. This paper presents a novel approach
(GTO), insulated gate bipolar transistor (IGBT) and the combining FMEA to focus fault diagnosis research with
development of new devices (e.g. integrated gate- sneak circuit analysis (SCA) and heuristics. A heuristics-
commutated thyristor (IGCT), injection enhanced gate based fault diagnosis method using a novel modification to
transistor (IEGT) have allowed the increase of power and conventional SCA is presented. A hardware set-up was used
voltage ratings of electronic converters [15]. to generate data for the fault cases studied. The modified
The research-reported details a methodology aimed at SCA-based diagnostic feature was applied to discriminate
providing high-level diagnostics for crew decision support between the different faults and the normal circuit state.
at system and sub-system levels and focuses on component The results are presented in the form of graphs and
level and incipient failures to provide a general framework confusion matrices.

Fig. 1 Medium-voltage dc shipboard architecture modelled at CAPS-FSU on the RTDS


Image courtesy CAPS-FSU

814 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
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2 Related research Filter capacitors have been the focus of component-level
fault diagnosis apart from previously mentioned literature
2.1 System-level diagnostics, reconfiguration and for semiconductor switch open- and short-circuit faults.
supporting research Capacitor failures and their diagnosis are addressed in
[39 – 41]. A strategy is explained in [42] to find the
The move towards a dc distribution system places emphasis condition of an aluminium electrolytic capacitor based on
on a greater use of power electronics equipment as factors such as equivalent series resistance, capacitance and
described in Section 1. Advances in power electronics make dissipation factor values, which change with temperature,
it feasible and possible to deploy the envisioned power frequency, current ripple as well as ageing. A review of
distribution architecture. The challenges of adopting a dc intelligent techniques applied for fault diagnosis in power
power distribution system for ships are highlighted by electronics is presented in [43]. A model-based diagnostic
Baran and Mahajan [16]. Stability issues relating to the system trained with the machine learning technology for
proposed dc architecture were discussed in [17] and a inverters feeding electric drives is presented in [44].
security assessment is reported by Momoh et al. [18].
Momoh and Ishola-Salawu [19] discuss a neural network
2.3 Concept of fault accommodation
application for arcing fault detection. Butler-Purry [20],
Butler-Purry and Srivastava [21] and Butler-Purry and Fault accommodation is a related area of research which takes
Sarma [22] report the use of multi-agent systems, expert the role of automated fault diagnosis a step further [45, 46]. It
systems and self-healing aspects for the SPS. Agent-based could be viewed as a type of fault tolerance wherein the
reconfiguration is also reported by Baran and Mahajan [23]. system is reconfigured to operate at the best possible
efficiency even with the presence of one or more faults.
2.2 Power electronics development and device/ Although fault tolerance could be achieved in its simplest
component level diagnostic research form using redundancy, fault accommodation in theory is
expected to adapt controller parameters or reconfiguration
The field of high-power drives has been an active research and of the system to avoid and/or minimise the consequences of
development area of power electronic application in the last a fault where performance may degrade. A simple well-
decade. Many industrial processes have increased power- established way of fault accommodation is based on pre-
level needs, giving rise to the development of new power designed controllers, which are trained offline in known and
semiconductors, converter topologies and control methods. expected failure modes. Thereafter, appropriate online
A survey of the most important converter topologies with failure accommodation techniques are suggested by a fault
related control schemes has been presented in [24]. diagnosis system which analyses fault patterns online.
Research has also focused on associated fault diagnosis for Further related work on this methodology can be found in
power electronic equipment. A variety of techniques have [47 – 50]. Similar to fault diagnosis research activities, most
been proposed and employed for diagnosing faults in the of the fault accommodation schemes are primarily
different types of power converters and their components. developed based on the powerful and well-understood
The techniques range from comparing measured values of linear control methodology. Fig. 3 shows the various fault
input and output quantities to detect discrepancies; Artificial accommodation techniques.
Intelligence (AI)-based techniques like neural networks,
fuzzy systems; statistical techniques like Fourier transforms 2.4 Reliability analyses
and wavelets and model-based methods. Furthermore, the
diagnostics proposed include higher level device diagnosis As mentioned earlier, a lack of benchmark systems makes it
as well at the internal component level. vital to understand various pertinent faults and their
Literature exists for voltage–source inverter fault diagnostics associated risks. Following this process, research diagnosing
using normalised dc components [25], open circuit fault these faults can be undertaken. Owing to this pressing need
detection by pole-voltage measurement [26] and also using of understanding system failure at all levels, attention was
output voltage frequency analysis [27]. Dc link current shapes turned to reliability analysis techniques.
were utilised to diagnose faults in zero-voltage switching Reliability analysis techniques such as FMEA can be used
converters [28]. For multi-level inverter a fuzzy-based to support reliability, maintainability, testability, safety and
diagnosis approach is presented in [29], whereas an AI-based logistics analyses. When performed in an accurate and
diagnosis and reconfiguration technique is reported in timely fashion, FMEA information can be used to aid the
[30]. Application of wavelets to detect faults in power systems design of test systems, the development of trouble-shooting
and conversion modules has been demonstrated in [31, 32]. procedures, the planning of scheduled maintenance and
An approach using rotor current space vector angle patterns to the development of integrated diagnostic capabilities. In
detect short and open circuit faults for rectifiers in a sub- addition, an effective FMEA presents an examination of a
synchronous cascade drive is detailed in [33]. Design of system’s strengths and weaknesses [51 – 54]. The two
ground fault detection and overvoltage limiting for three- approaches to FMEA, functional FMEA and hardware
level pulse width modulation (PWM) inverter is covered in FMEA [5], were used in this research and their application
[34–36]. Further, Rothenhagen and Fuchs [37] evaluate is reported in [1].
different fault diagnosis strategies for a voltage–source Another reliability analysis method called SCA was studied
inverter-fed variable speed drive comparing MATLAB- to be utilised in this research. SCA is conventionally used
SIMULINK results with an experimental setup. Here, a during design phases of electronic circuits to help detect
comparison is made among fault-detection techniques such as unwanted current paths so that the circuit could be
Park’s vector approach, slope method and variations of using redesigned if necessary. Although designing a new
direct current methods. A comprehensive comparison and electrical circuit is not a part of this research, conventional
evaluation of over a total of 30 diagnostic methods mainly for SCA was modified to produce diagnostic features able to
IGBT open-circuit and short-circuit faults are provided in [38]. differentiate between different fault states for the dc – dc

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doi: 10.1049/iet-pel.2011.0018 & The Institution of Engineering and Technology 2012
www.ietdl.org

Fig. 3 Known fault accommodation techniques [45]

buck converter. This approach forms the novelty of this


research as explained in later sections.

2.5 Motivation for research reported in this paper


The research work across the various categories described
encompasses studies directly related to the SPS fault issues Fig. 4 Research approach beginning with FMEA leading to
as well as indirectly related but relevant fields such as focusing diagnostic research for identified pertinent failures
general applicable power electronic diagnostics. The
research mainly focuses on system-level issues such as
system reconfiguration to accommodate faults. Power [55] by using local measurements (input/output currents and
electronics research focuses on component failures wherein voltages) and values of component parameters. The
the devices are utilised on terrestrial systems and grids. The advantage lies in the fact that additional sensors are not
gap in research for the particular case presented in this needed to obtain measurements of quantities required.
paper exists for high-level diagnostics that aids in decision Fig. 4 explains the proposed approach to identify pertinent
support for the shipboard crew, capable of indicating failures in a buck converter circuit to inform and direct
failures and faults both at the component level as well as at further research.
subsequently higher levels. The methodology and approach
reported highlights the application of the research novelty
for component level faults in the dc –dc power converter. 3.2 Modification of SCA technique to produce
The potential of the proposed method to upgrade to zonal usable features for diagnosis of faults
and system level fault diagnosis is a matter of further study
that could be either conducted on a real-time digital The other aspect of the novelty lies in the modification of
simulation system or on a scaled-down hardware test-bed SCA to output usable features that were effectively
developed to mimic the proposed warship architecture. employed to differentiate between fault scenarios. The
modification differs from the convention of using
3 Research novelty component symbols to form the generalised connection
matrix as actual current and voltage values are used to form
3.1 Approach using FMEA to focus research for the generalised connection matrix. The determinant of the
the novel shipboard architecture generalised connection matrix outputs numeric values that
are shown to differentiate between various operating
This research follows a methodology informed through a scenarios of the buck converter circuit.
detailed FMEA for the novel SPS architecture. FMEA was Data for various fault cases were generated using a buck
conducted beginning at the device level gradually moving converter hardware circuit. The proposed novel approach
to sub-system (zone) and system levels [1]. FMEA done on was then used to compute features using this simulation
the buck converter was used to increase understanding data. Employing the projective adaptive resonance theory
about its component-level faults and their effects. This (PART) algorithm [56], heuristics were generated utilising
information is then used for simulating fault scenarios to the software tool Weka [57]. Thereafter, these rules were
generate data used for further research and analysis into encoded using conditional statements (IF – ELSE) and tested
diagnostics. The data are used to calculate circuit currents on the data offline to check the diagnostic efficiency. The
and voltages applying circuit laws and component models results showed promising classification rates which have

816 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
www.ietdl.org
the design phase of a device in order to modify a design
if a sneak path is identified. This feature is not utilised in
this research. Instead, the novel modification applied
yields numeric values or signatures from the determinant
of the generalised connection matrix that are shown to
be useful for differentiating between various operating
scenarios.

Fig. 5 Methodology to diagnose pertinent failures in a buck


5 Application of methodology to buck
converter using proposed modified SCA technique and heuristic
classification
converter circuit
5.1 Device – buck converter circuit

been elaborated in later sections. This approach is shown in Fig. 6 shows the dc – dc buck converter circuit used for the
Fig. 5. analysis.
The PART algorithm is based on the assumption that the
model equations of PART (a large-scale singularly 5.2 Fault cases studied
perturbed system of differential equations having a reset
mechanism) have regular computational performance. The The common failure modes for components like
PART neural network developed by Cao and, rule-based semiconductor switches and diodes are typically open and
system developed by Wu have been shown to be effective short circuits. Similar failure modes exist for capacitors and
in clustering data sets in high-dimensional spaces. The inductors. Electrolytic capacitors display electrolyte leakage
proofs and simulation results are available for further and dielectric breakdown, whereas inductors may suffer
reading in [56]. The PART functionality in Weka was inter-turn winding faults. Table 1 shows fault scenarios
chosen as it produces IF – ELSE rules that can be easily conducted for the buck converter considering single and
read and interpreted as opposed to other formats such as multiple fault cases. The notion of incipient capacitor or
decision trees produced by a similar classification algorithm inductor failure was simulated on hardware by manually
called J48 (which is an extension of C4.5). reducing the net capacitance and inductance, respectively.

4 Sneak circuit analysis 5.3 Different states of the circuit

4.1 SCA definition The buck converter circuit has two distinct states when the
switch S1 is ON and when it is OFF. The equivalent
SCA [58 – 61] is a functional reliability analysis technique circuits during these two states are shown in Figs. 7a and
with the potential of detecting unintended and thereby 8a. The modified directed graphs are constructed for the
undesirable system operation. A sneak circuit is a latent two states separately which are shown in Figs. 7b and 8b.
path or condition that inhibits the desired function or
causes undesired operation to occur. In contrast to failure
effects, a sneak circuit does not require a component
failure to occur. SCA is a unique method of evaluating the
electrical circuit topology to detect specific patterns which
are characteristic of sneak paths. A sneak condition or path
is present in a circuit, as designed, but may not always be
active.

4.1.1 Obtaining sneak paths for an electrical circuit


by constructing its directed graph: The sneak paths
or sneak circuits are established through the determinant
of the generalised connection matrix [57, 58] which in
turn is formulated by constructing the directed graph of
the circuit analysed. In general, a directed graph of a Fig. 6 Buck converter circuit
circuit depicts component connections with directions of
associated currents and voltages. From this, an N × N
(where N ¼ no. of nodes) matrix can be constructed using Table 1 Fault cases conducted for buck converter
component symbols. This matrix is known as the
generalised connection matrix and the determinant of this Component Failure induced
matrix provides sneak paths represented in terms of capacitor (C2) (single fault) degrading – net filter capacitance
component symbols. The determinant could output was reduced to half the original
numbers as well as terms with squared or higher order value at start
component symbols. These are ignored as they do not semiconductor Switch (S1) 1. short circuit
provide information regarding a logical path, for example, (single fault) 2. open circuit
a number is not a circuit path and a squared component inductor (L1) (single fault) net inductance was reduced to half
symbol does not indicate its own connection with other the original value at start
components in the circuit. Thus, what remains are capacitor (C2) and inductor values of both C2 and L1 reduced to
possible and legitimate current paths within the given (L1) (multiple fault) half their original amounts
circuit. This information about sneak paths is useful in

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doi: 10.1049/iet-pel.2011.0018 & The Institution of Engineering and Technology 2012
www.ietdl.org
two states are

|S1on | = IC1 × IIN × V1 + V2 × IOUT × IC2 (3)


|S1off | = V2 × IOUT × IC2 (4)

|S1on| and |S1off| differentiate between various operating


scenarios. The quantities V1, V2, IIN and IOUT are directly
measured by voltage and current measurement devices,
respectively. The currents IC1 and IC2 are computed using
IC1 ¼ C1 × d(V1)/dt and IC2 ¼ C2 × d(V2)/dt.

6 Results
6.1 SIMULINK circuit

The buck converter circuit was set up in SIMULINK (Fig. 9)


to generate data for the fault cases in Table 1 and the no-fault
case. The circuit parameters are; V1 ¼ 15 V, V2 ¼ 7.5 V,
IIN ¼ 0.625 A, IOUT ¼ 1.25 A, duty cycle ¼ 0.5, switching
frequency ¼ 10 kHz, C1 ¼ 100 mF, C2 ¼ 13.6 mF made up
of two parallel connected capacitors (6.8 mF), L1 ¼ 1.2 mH
(two 0.6-mH inductors). Disconnecting one of the C2
Fig. 7 Buck converter circuit when the switch S1 is ON capacitors halves the net capacitance of the parallel
a Equivalent circuit in which case IS1 ¼ IL1 connection. This is used to simulate a degrading filter
b Modified directed graph
c Modified connection matrix
capacitor. On a similar basis, one of the series inductors can
be bypassed thereby halving the net inductance to simulate
an inductor failure.
The modified generalised connection matrices are shown in
Figs. 7c and 8c. The determinants of the matrices are 6.2 Hardware set-up
shown below
The buck converter hardware circuit shown in Fig. 10 was set
up to generate experimental data for the fault scenarios in
ON-state = 1 − V12 − IC1
2
+ IC1 × IIN × V1 − IC2
2
+ IC2 Table 1 as well as the no-fault case. The circuit parameters
and strategies to introduce faults were identical to the
× IS1
2
× IC1 + IC2 × IS1
2
× IIN × V1 − V22 SIMULINK model.
It is important to verify the circuit model with the hardware
+ V2 × IOUT × IC2 + V2 × IOUT × IS1
2
set-up to check for the model’s accuracy and reliability. The
× IC1 − V2 × IOUT × IS1
2
× IIN × V1 (1) comparison is shown (first two rows of Table 2) between
the input current and output voltage waveforms obtained
from the two circuits for the two switch failure modes,
inductor and capacitor failures.
OFF-state = 1 − V22 + V2 × IOUT × IC2 − IC2
2 The switch-fault is introduced after approximately three
switching cycles. The waveform at the bottom of the plot is
+ IOUT × IS2
2
× V2 + IS2
2
× IC2 (2) the input current, whereas the one nearer the top is the output
voltage. The horizontal axis in each plot of Table 2 represents
time, whereas the vertical axis represents the quantity
Following SCA convention of ignoring numbers and terms measured (either current or voltage). The measured signal is
with higher order parts, the final usable equations for the marked with an arrow and text indicating the particular quantity.

Fig. 8 Buck converter circuit when the switch S1 is OFF


a Equivalent circuit, where IS2 ¼ IL1
b Modified directed graph
c Modified generalised connection matrix

818 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
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Fig. 9 Buck converter SIMULINK circuit

6.3 Data preparation

For both circuits, the data for fault and no-fault cases were
collected at 10 ns sampling rate over a 1-ms time period
(thus 100 000 samples). Using (3) and (4), the features
|S1off| and |S1on| are computed for the respective cases.
There are then 12 data sets, six for |S1off| (five fault
cases + no fault case) and six for |S1on|. Each set is
separately processed by the classification algorithm to yield
two results.
These data used in the classifier are first divided into ranges
and windows. The range variable reflects the total number of
Fig. 10 Hardware test set-up for buck converter circuit samples considered by the classifier at one time and is set

Table 2 Comparison of waveforms generated by the model and hardware circuit with fault detection results on hardware data

Semiconductor switch (S1) open Semiconductor switch (S1) Inductor fault case: input current Capacitor fault case: input current
circuit case: input current and short circuit case: input current and output voltage and output voltage
output voltage and output voltage

SIMULINK circuit SIMULINK circuit SIMULINK circuit SIMULINK circuit

hardware circuit hardware circuit hardware circuit hardware circuit

semiconductor switch (S1) open semiconductor switch (S1) short inductor fault case: output capacitor fault case: output voltage
circuit case: output voltage with circuit case: output voltage with voltage with fault indication with fault indication
fault indication fault indication
continuous fault indication fault indication approximately fault indication approximately fault indication approximately
approximately 0.3 ms after fault 0.4 ms after fault introduction 0.2 ms after fault introduction 0.17 ms after fault introduction
introduction

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doi: 10.1049/iet-pel.2011.0018 & The Institution of Engineering and Technology 2012
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ideally in integral multiples of one switching cycle (i.e. 6.5 Interpretation of results
10 000 samples).
These ranges are separated and labelled as per the data The rules produced by the PART algorithm can be understood
type. The window is the number of data points considered using conditional execution statements as shown in Tables 3
within each range. The idea is to use a small window size and 4. The algorithm uses the absolute values of the data fed
which then reflects the amount of samples needed per cycle to it (in this case the six data sets) to produce thresholds. The
to classify the data. Thus, a small window size produces a heuristics are derived for these absolute values. The data
faster result. Further, the data are sorted in ascending order stream is input in windows of the specified length. The
within each window. The final data set for the six cases rules are output with reference to the position of every
consists of a number of rows (6 × range) and number of value within the window. Knowing that the data used were
columns (6 × window). An extra column is added at the divided into a window size of 10, then the terms ‘Value1’
end of each row to assign its label. This file is saved in an or ‘Value9’ refer to the first and ninth elements,
attribute relation file format (.arff) to be used in the Weka respectively, in a given window.
classification software [62]. The data sets used in this case were from a SIMULINK
model (Fig. 9) and a corresponding hardware circuit
(Fig. 10). The classifier was trained on these different sets
6.4 Heuristic classification results of data separately and then tested on the same respective
types. This demonstrated the relative lack of confusion and
The data produced were used with the classifier employing
the ability of the feature to discriminate between different
the PART algorithm in the software package Weka. The
faults for the particular type of data presented. The
data were re-sampled at 100 ns, thus reducing the total
classification rates in Figs. 10 and 11 signify the percentage
captured data samples by a factor of 10. Re-sampling eases
of data samples correctly distinguished as being of a certain
the computational effort and memory requirements of the
type. Thus out of 12 000, the number of correctly classified
classifier. The algorithm uses a 10-fold cross validation
samples (as being of a certain type) is 11 997 and there are
testing scheme to calculate error rates. The output is a set of
only three samples which have led to ‘confusion’
rules and a confusion matrix that shows the number of
(Fig. 11a). The high classification rate is a promising result
correctly and incorrectly classified instances.
in this research and indicates the ability to discriminate
between the particular types of faults studied.
6.4.1 Results for the |S1off | equation: The processed
data had the following attributes after re-sampling:
6.6 Application of results
Total samples = 10 000; range = 2000; window = 10 The rules listed in Table 4 (|S1on| equation) were coded in
MATLAB to test the ability to detect the fault types. This
Total number of data sets fault detection was done offline. However, investigation is
= 6 (1 no fault case + 5 fault cases) ongoing to use a similar approach for a real-time online
application. The results of the offline application are plotted
on the same graph as the output voltage waveforms (third
With six data set used, the total range becomes row of Table 2). This shows when the fault was introduced
6 × 2000 ¼ 12 000. The confusion matrix with the rule set and gives an idea of the time taken by the proposed method
is shown in Fig. 11. The 23 classification rules for the to detect it. The plots show that the encoded heuristics are
hardware data are shown in Table 3. able to indicate the presence of a fault for each case. The
data were collected for a total of 2 ms at a 10-ns sampling
6.4.2 Results for the |S1on | equation: The data rate (total 200 000 samples). As before, this is re-sampled at
attributes are identical to the |S1off| case used previously. 100 ns (total 20 000 samples). The fault is introduced at
The data are re-sampled in Weka in a similar manner. The 1 ms for each case.
confusion matrix with the rule set is shown in Fig. 12. The To avoid false alarms, the frequency of the fault indications
13 classification rules for the hardware data are shown in was included over batches of data samples. This was
Table 4. It is important to note that the SIMULINK circuit performed using additional code which counts the number
consists of an ideal voltage source which exhibits zero of fault indications every 5000 samples of the 100-ns
source impedance. This is unlike the case in the real re-sampled data, that is, every 0.5 ms, and indicates a fault
hardware circuit. The implication is that in the simulation, only if more than ten events are counted. A slight
dV1/dt ¼ 0 which means the input capacitor current IC1 ≃ 0. modification to this fault indicator counting scheme had to

Fig. 11 Confusion matrix using |S1off| equation for


a Hardware data
b SIMULINK data

820 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
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Table 3 Rules derived using S1-off equation for classification of hardware data

Rules 1–5 Rules 6 –10 Rules 11– 15 Rules 16– 20 Rules 21 –23

IF Value 8 . 2500.26 AND IF Value 2 . 2349.08 AND IF Value 2 . 2341.57 IF Value 1 . 2349.08 ANDIF Value 8 ≤ 2 500.26 AND
Value 5 ≤ 2 350.48 AND Value 1 . 2341.57 AND THEN data is of type ‘d’ Value 8 ≤ 0 AND Value 4 . 2683.15 AND
Value 1 . 2698.16 AND Value 1 ≤ 2 224.59 Value 7 . 2334.53 AND Value 2 ≤ 2 806.82
Value 9 . 2358.19 AND THEN data is of type ‘c’ Value 1 ≤ 2224.59 AND THEN data is of type ‘f’
Value 8 ≤ 2 212.37 AND Value 3 ≤ 2341.57 AND
Value 4 . 2500.26 Value 4 ≤ 2218.48 AND
THEN data is of type ‘a’ Value 6 ≤ 2334.53
THEN data is of type ‘e’
IF Value 2 ≤ 2665.33 AND IF Value 3 . 2332.666 ANDIF Value 8 ≤ 2 212.37 AND IF Value 1 . 2349.08 ANDIF Value 5 ≤ 2 500.26 AND
Value 2 . 2727.5238 Value 3 ≤ 2218.4866 Value 2 ≤ 2 500.2624 Value 8 ≤ 0 AND Value 2 . 2619.93
THEN data is of type ‘a’ THEN data is of type ‘c’ THEN data is of type ‘e’ Value 7 . 2218.48 AND THEN data is of type ‘f’
Value 6 . 2218.48 AND
Value 1 ≤ 2224.59 AND
Value 3 ≤ 2341.57
THEN data is of type ‘e’
IF Value 1 ≤ 2 349.08 ANDIF Value 2 ≤ 2 698.16 AND IF Value 2 2 . 2349.08 ANDIF Value 8 ≤ 365.89 AND IF Value 1 ≤ 2 500.26
Value 1 . 2500.26 Value 9 ≤ 2212.37 Value 2 ≤ 2341.57 AND Value 4 ≤ 569.77 THEN data is of type ‘f’
THEN data is of type ‘a’ THEN data is of type ‘d’ Value 10 . 2341.57 AND THEN data is of type ‘e’
Value 1 . 2349.08 AND
Value 8 ≤ 2 334.53
THEN data is of type ‘e’
IF Value 8 ≤ 2500.26 AND IF Value 8 ≤ 2212.37 IF Value 1 . 2727.52 AND IF Value 7 ≤ 2 218.48 –
Value 6 ≤ 2 727.5238 THEN data is of type ‘d’ Value 2 . 2349.08 AND THEN data is of type ‘e’
THEN data is of type ‘b’ Value 2 ≤ 2218.48 AND
Value 1 ≤ 2500.26
THEN data is of type ‘e’
IF Value 2 ≤ 2500.26 AND IF Value 3 ≤ 2218.48 IF Value 1 . 2349.08 AND IF Value 8 ≤ 0 AND –
Value 1 ≤ 2619.93 THEN data is of type ‘d’ Value 8 ≤ 20 AND Value 7 . 2218.48 AND
THEN data is of type ‘b’ Value 3 ≤ 2341.57 AND Value 3 . 2218.48 AND
Value 10 . 2174.59 Value 2 . 2218.48
THEN data is of type ‘e’ THEN data is of type ‘e’

Fig. 12 Confusion matrix using |S1on| equation for


a Hardware data
b SIMULINK data

be used for the switch open circuit fault case. As the switch larger or smaller batch size of data samples. Too large a
being ‘open’ is a legitimate state of the circuit, the output batch (over 8000) might not reduce false alarms
would show a fault indicator continuously. significantly, whereas too small a batch (below 4000) may
Hence, to detect the introduction of this type of fault, impose additional computational burden. The authors
consecutive fault indications were counted per 0.5 ms worth preferred to use a batch size of 5000 samples as it
of data as opposed to the total number for other fault types conveniently divides the pre-fault and post-fault parts of the
mentioned. This was done based on the notion that since data into two sub-parts each.
the switch open circuit would occur every cycle, only a
large enough consecutive count will suggest a permanent 7 Discussion
switch open circuit failure. Therefore the added code was
modified to count 200 consecutive fault indications per This research stems from the application of power electronic
5000 data samples (i.e. worth 0.5 ms). converters within the zonal shipboard power distribution
This frequency check was found to reduce the number of architecture for US Navy warships and other tightly
false alarms while preserving the speed and reliability of coupled finite inertia systems. As mentioned before, the
fault detection. A similar procedure could be used over a power converter forms an integral part of these topologies

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Table 4 Rules derived using S1on equation for classification of hardware data

Rules 1–3 Rules 4 –6 Rules 7– 9 Rule 10 –12 Rule 13

IF Value 3 ≤ 2 3473 AND IF Value 1 . 2942.24 IF Value 1 . 22605.36 IF Value 6 . 23563.6 IF Value 5 . 23630 AND
Value 9 ≤ 22001.3696 THEN data is of type ‘c’ AND AND Value 2 ≤ 2350.48
AND Value 7 ≤ 2 491.18 Value 2 . 21800 AND THEN data is of type ‘a’
Value 1 ≤ 24130.2624 THEN data is of type ‘e’ Value 2 ≤ 2499.73
THEN data is of type ‘a’ THEN data is of type ‘f’
IF Value 1 . 23580.4848 IF Value 1 ≤ 21766.7 AND IF Value 1 . 21766.7 IF Value 1 . 24223.15 –
AND Value 2 ≤ 2 1848.24 AND THEN data is of type ‘e’ AND
Value 2 ≤ 23050.2 Value 9 . 23473 Value 1 ≤ 23654.2 AND
THEN data is of type ‘a’ THEN data is of type ‘d’ Value 2 ≤ 23654.2 AND
Value 3 ≤ 23805.2
THEN data is of type ‘f’
IF Value 2 ≤ 2 4983 IF Value 3 ≤ 23998.16 IF Value 1 ≤ 2 4677.37 IF Value 2 ≤ 21536 AND –
THEN data is of type ‘b’ AND THEN data is of type ‘e’ Value 1 . 23998.16 AND
Value 9 . 23890.93 Value 8 . 23360 AND
THEN data is of type ‘d’ Value 1 ≤ 23654.2
THEN data is of type ‘f’

and the buck converter section was chosen by the authors for 7.2 Rationale for using SCA
analysis into automated fault diagnosis. The research is aimed
at providing high-level diagnostics to aid in decision support The need to understand pertinent failures in a novel system
at system and sub-system levels and focuses on component without any prior benchmarking lead this research into
level and incipient failures to provide a general framework reliability analysis, in turn identifying FMEA as a valid
for fault identification. FMEA enables understanding of starting point. Further, SCA being a known reliability
pertinent component-level failures for the devices which in analysis technique to diagnose design stage circuit faults
turn informs the simulation studies to generate fault data. was studied to check its applicability for the novel
Along with a detailed FMEA, modification of an SCA shipboard distribution architecture.
method for electrical circuits is used to produce usable Thereafter, novel modification of conventional SCA
features that are believed to aid in differentiating operating provided a means to conduct component-level fault
scenarios. signature analysis using a high-level approach with basic
measurements such as input and output currents and
7.1 Proposed diagnostic method compared to voltages. This novel methodology thus gives an analysis
existing research technique stemming from well-known design-stage
reliability analysis which is in turn able to provide
In Section 2, a comprehensive literature review highlights diagnostic indicators. Further, as the explained SCA
research in diagnostics for the related areas of this particular methodology can be derived for other converter circuits, its
research arena. As highlighted in the references, a major application to other types of power electronic converters is
research thread is system reconfiguration, restoration and potentially extendable.
automatic mitigation of faults at the system level. Such
faults are typically ground faults or faults at the main 7.3 Relevance and benefits of proposed approach
motor/generator/prime mover side. Research into the need
for autonomous high-level diagnostics providing decision This research is directed at proposed naval shipboard power
support assistance to the reduced numbers of on-board systems which are envisioned to integrate the plug and play
crew, giving fault information and their risk mitigation for PEBB devices, automated diagnostics and reconfiguration
component-level faults has been ignored. This gap in systems among others. One method is that this integration
research led the authors to conduct studies into component could be facilitated by multi-agent systems [63] that aim to
level diagnostics for the dc – dc power electronic converter provide robustness and extensibility. As mentioned earlier,
since the proposed architectures are envisioned to include the reduction in the numbers of onboard crew with increase
a large number of power electronic sub-systems which as of in automation put added importance on enhanced
now is a relatively new and unproven technology for communication systems with decision support besides the
warships. obvious criticality of accurate fault diagnosis and
The proposed approach beginning at FMEA, feeds monitoring. The nature of such envisioned SPS architecture
further research by providing information about pertinent puts emphasis on condition monitoring and diagnostics at
failures at all levels (FMEA can be conducted at system, various system levels.
sub-system and device/component level), whereas the The diagnostic indicators explained in this paper arise from
modified SCA methodology provides diagnosable features the changes in voltage and current during the various
for faults for the shown converter type. Done together as operating conditions (fault and no-fault). These measured
part of a systematic methodology as proposed, the FMEA quantities change during various operating scenarios to
and modified-SCA approach can be extended to other provide signatures that could be used as diagnostic
power electronic systems to provide high-end diagnosable indicators for those respective cases using a similar rule-
features. It could also potentially provide diagnosable based approach. SCA provides the means of understanding
features for zone- and system-level faults, which forms part circuit connectivity at a device/component level and also on
of future research. a sub-system/zonal level. The novelty proposed here by

822 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
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modifying conventional SCA provides the potential for recorded (in microseconds) and computing the time needed
single-signal diagnostics for individual inter-connected to diagnose the data (,0.5 ms as shown in Table 2), the
devices. Further, the key to the technique lies in its counting schemed does not have any major detrimental
potential extendibility to more complex systems (a zone in impact on the speed of diagnosis.
the case of notional shipboard systems followed by
interconnected zones), where the circuit connectivity 7.5 Observability condition and effective series
information coupled with a fault diagnostic indicator could resistance
provide valuable additions for a crew’s decision support
which is an important application considering the heavy The experiments reported include four measurement signals,
reduction in crew numbers on future ships. Also, a positive namely the input current, input voltage and output current
is that owing to the approach using one signal for and output voltage. All other internal currents and voltages
diagnostics per device (or per zone), the potential for are computed using well-known circuit laws as explained
adding to the burden of the notional warship’s in Section 5. However, if quantities internal to a circuit
communication network is minimal. are not measurable satisfactorily by indirect methods, then
Ongoing research aims to investigate the novel modified additional sensors may be needed to obtain these
SCA methodology reported in this paper to generate single- measurements.
signal fault diagnostic indicators at various levels of the For low-voltage supplies, capacitor ESR can be the greatest
system’s power distribution architecture. This paper reports contributor to voltage ripple in comparison with the voltage
an application of the methodology at one such level, that is, ripple across the capacitive element of the capacitor. In the
the device level (buck converter). Further research is case studied in this paper, the voltage supply is high and
actively aimed at extending this methodology to higher the relative contribution to voltage ripple from ESR is
levels of the network wherein not only device-level small. In general, the technique is capable of including ESR
diagnostics is available but ideally ship-wide diagnostics in the algorithm and derivation process. The main change is
with resourceful decision support can be provided. in the modified-SCA that is performed, wherein ESR could
be considered as a resistor in series with the capacitor. This
7.4 Fault introduction procedure in hardware added ‘component’ changes the determinant obtained from
circuit and avoiding false alarms the modified SCA method, although the analysis and
derivation technique to obtain the diagnostic feature is
A hardware setup was used to simulate specific faults and fundamentally same as proposed.
failures that are known to occur in the semiconductor
devices (typically open-circuit failures which usually have a 7.6 Scalability issue of proposed method
pre-cursor of a rapid short-circuit time prior to bond wires
arcing in plastic packages). In the passive components the The advantage of utilising data from local measurements such
authors simulated the effects of electrolyte leakage in as input/output measured currents and voltages as well as
capacitors (an incipient fault) or rapid turn – turn failures in known circuit parameters avoids the use of additional
inductor windings. These tests are realistic in terms of the sensors. Furthermore, the novel diagnosis method presented
overall impact on the performance of the converter circuit. makes use of this local data for each converter to produce
The halving of net capacitance by parallel connected usable features from the determinant of the modified
capacitors (and halving of net inductance by series generalised connection matrix for the respective device.
connected inductors) is used to simulate respective fault This is irrespective of the number of interconnected devices
cases. Although the step changes are not representative of as each converter will have its own matrix. Thus, for a
practical failure modes, it provides an accelerated test scaled up complex system with many power electronic
method in order to assess the suitability of the proposed converters, the modified matrix would be constructed
technique to detect and diagnose such faults. However, it is separately for each device to provide localised diagnosis at
acknowledged that the actual failure because of such the component level for each converter. This concept
incipient faults is a slower process potentially occurring prevents the modified generalised connection matrix from
over several hundred hours of operation. An alternative becoming too large to pose any issues relating to
method for simulation of a capacitor fault of this type could computational burden.
be to employ differently aged capacitors in parallel, such
that the progressive blocking of individual capacitors at 7.7 Future research plans
designated instants in time would switch to the more ‘aged’
or worn-out capacitor with prior-estimated (or known) In order to form a topology-independent approach, the
changes in related parameters [64]. This method potentially proposed methodology is to be applied to dc – dc converter
may provide more accurate capacitor fault data and is circuits such as the boost and buck – boost converters. The
anticipated to be applied in future research plans. verification could be similarly carried out using hardware
For the switch open and short circuit faults, the faults setups. The next step is to implement the methodology on a
are introduced when the switch is open and closed, real-time basis, for example, using field programmable gate
respectively. However, in a real system it is difficult to arrays [65]. Fig. 13 shows the basic setup to investigate
predict the switch’s state when the passive component fails real-time diagnostics.
because of electrolyte leakage or inductor windings fault. This research was conducted on a single isolated
In this case, however, as fault introduction is manual, it is buck converter circuit with fixed parameters. Applying
known that the faults for both the capacitor and inductor the proposed diagnosis technique in a grid-connected
have been introduced when the switch S1 is open (off state). environment is a matter of further investigation. This could
The counting scheme explained in Section 6.6 checks for ideally be done by using the converter with loads (such as
consistency in the data stream thus reducing the possibility motors) the parameters of which can be changed when
of a false diagnosis. Owing to the time scales of the data faults are introduced in the converter circuit. The feasibility

IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813–826 823


doi: 10.1049/iet-pel.2011.0018 & The Institution of Engineering and Technology 2012
www.ietdl.org
PART algorithm in Weka show that the |S1on| and |S1off|
equations could be utilised to discriminate between
identified pertinent failures. The threshold values to perform
the diagnosis (in Tables 3 and 4) are computed by the
PART algorithm for the particular operating parameters of
the buck converter circuit used. The authors believe the
marginal improvement in accuracy using the |S1on| equation
is due to the fact that it contains two terms as opposed
to the single term in the |S1off| equation. This extra
information provided to the classifier via the |S1on| equation
is believed to increase the rate of discrimination. However,
considering computational time and power needed for both
computations, the |S1off| equation needs half the efforts
Fig. 13 Real-time diagnostic setup following proposed modified compared to the |S1on| equation while providing a
SCA-based heuristics technique negligibly lower classification rate.
Furthermore, there are fundamental differences between
the SIMULINK model and hardware circuit owing to the
lack of real-world parameters like line inductance, parasitic
capacitance and imperfect square wave pulse. But the
SIMULINK model used is within acceptable limits to
generate additional fault data for cases which would be
relatively unsafe to conduct on the hardware circuit, for
example, freewheeling diode and capacitor short-circuit
faults.
The proposed technique provides a potential for a fast-
acting fault diagnostic system. In order to avoid false
alarms, an additional piece of code employing a fault
indication frequency counter was utilised. In the presented
case, this code checked batches of the data every 0.5 ms
and indicated a fault only if more than 10 events occurred
Fig. 14 System with loads to test feasibility of proposed dc –dc every 0.5 ms. The off-line application of the heuristics, for
converter diagnosis technique in a more complex set-up the switch failures produces permanent fault indications
approximately within 4500 samples after the fault is
of the presented technique will then be tested against issues introduced. With a 100-ns sampling rate that means the
relating to more complex networks as shown in the line fault is detected within 0.45 ms of its introduction. For
diagram of Fig. 14. inductor and capacitor faults, the indication in both cases
An important part of further research plans is simulation of occurs well before 2200 samples after the fault inception,
fault scenarios using an interconnected system to mimic that is, within 0.22 ms of its introduction.
the power-dense finite inertia shipboard architecture. As The proposed approach to generate heuristics for identified
mentioned, the research reported in this paper is from pertinent failures could be evaluated with data from
experiments conducted on an isolated buck converter sophisticated high-fidelity software models. One possible
circuit, whereas the real system would have interconnected method would be to employ converter models run on an
devices, loads as well as multiple power conversions. A RTDS. Advanced models on the RTDS could better
count-based scheme was proposed to prevent false alarms simulate circuit behaviour in the presence of faults which
(Section 6.6). This method obviously will need to be tested are relatively unsafe to conduct on hardware circuitry. The
along with the proposed diagnostic approach on a power- data from such RTDS tests could be processed in the
dense system. manner presented in this paper to generate heuristics to
diagnose pertinent component level faults. This could also
positively aid the research into component-level diagnostics
8 Conclusions for power electronic converters in more complex networks
and on a real-time basis.
The method presented makes use of a model-based approach, The work reported in this paper used the classifier to train
utilising local measurements without the need for extra and test the same type of data separately, that is, either from
sensors to compute a signature. These quantities are used to the model or the hardware circuit. The next step is planned
produce the usable feature derived from the determinant of to be the evaluation of the classifier by training it on
the generalised connection matrix from the directed graph simulation data from a model and then testing it on data
of the electrical circuit. The modification of using currents from a hardware set-up. This evaluation will test the
and voltages for constructing the directed graph helps to classifier’s ability to generalise and form heuristics that
provide quantifiable numbers that aid in diagnosing various could be encoded for diagnosis purposes as explained
component-level faults for the two types of converter previously.
circuits examined. The proposed method tested on a The extension of this research is aimed at conducting a
SIMULINK model was verified using hardware data which similar approach for the other types of dc – dc converters
showed that the signature distinguishes various single-fault namely the boost and buck – boost. This is with the view
cases as well as a multiple fault case. of developing a topology-independent approach to detect
For SIMULINK model and hardware data, the results of and diagnose pertinent component-level faults. Also,
classification using a rule-based technique employing the investigation is ongoing for application of the proposed

824 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018
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826 IET Power Electron., 2012, Vol. 5, Iss. 6, pp. 813 –826
& The Institution of Engineering and Technology 2012 doi: 10.1049/iet-pel.2011.0018

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