6th IFAC Symposium on Mechatronic Systems

The International Federation of Automatic Control

April 10-12, 2013. Hangzhou, China

Remedial Operations of Permanent Magnet Fault Tolerant Motor

for Short-Circuit Fault
Si Binqiang* Zhu Jihong* Ji Jinghua**

*Department of Computer Science & Technology, Tsinghua University, Beijing, China

(e-mail: sibq09@mails.tsinghua.edu.cn, jhzhu@tsinghua.edu.cn)
**School of Electrical and Information Engineering, Jiangsu University, Zhenjiang, China
(e-mail: jjh@ujs.edu.cn)

Abstract: Due to their concentrated windings and modular topology, permanent-magnet fault-tolerant
(PMFT) motors inherently offer decoupling phases and fault-tolerant capability. Two fault-tolerant drive
topologies for these motors, namely H-bridge and star-connection, are presented and compared for short-
circuit fault. In order to keep torque performance invariant during the faulty operation, the current
amplitude of healthy phases should be increased, and only the phase angle of the adjacent phases should
be changed in the H-bridge mode, while both the current amplitude and the phase angle of healthy phases
should be changed in the star-connection mode. Both strategies are derived, compared and analyzed.
Finally, the simulated results are given, verifying the effectiveness of theoretical analysis.
Keywords: Fault tolerance, short-circuit fault, permanent-magnet motor, drive topology.

In [Ji Jinghua et al. (2010)], its fault-tolerant characteristic

1. INTRODUCTION
As an important part of the more- [J.A.Weimer (2003);
B.Mecrow et al. (2011); R.Bojoi et al. (2012)] and all-
[D.P.Rubertus et al. (1984); G.Atkinson et al. (2010)] electric
aircraft, electric actuation system relates to the safety and
performance of the entire flight system. In order to increase
the safety and reliability of the electric actuation system,
multi redundancy technique [Jiang Dong et al.
(2008);H.Jaison et al. (2011)] was employed for uprating the
safety factor. However, it not only increases the weight and
the volume, but also raises the probability of failure of the
whole system with the increase in the number of redundancy.
In order to overcome these drawbacks, it is an alternate way
to improve reliability and fault tolerant capability of the
motor. A motor with high reliability and fault tolerant
capability is one of the key parts of electric actuation system,
which have been current hot spot and future trends.
Permanent-magnet fault-tolerant motor (PMFTM)
incorporates the merits of high efficiency, high power density
of ordinary PMBLM and high fault-tolerant capability, due to
its electrical, magnetic, thermal, physical isolation
[B.Mecrow et al. (1996); K.Atallah et al. (2000); J.D.Ede et
al. (2002); Ji Jinghua et al. (2010);Si Binqiang et al. (2013)].
When one or some phases are with fault, it has a capability to
ensure remaining windings continuous operation. Therefore,
this PMFTM is very suitable for high reliability applications
such as aerospace [J.Bennett et al. (2012)], nuclear power
stations, electric vehicles [Zhao Wenxiang et al. (2012a)] and
ships [M.Radaelli et al. (1997)].
Recently, 5-phase [C.Bianchini et al. (2008)], 6-phase
[K.Atallah et al. (2003)], 7-phase [F.Locment et al. (2008)]
PMFT motors have been hotspots, while 4-phase [B.Mecrow
et al. (2004)] one is relatively treated less as research object.
was analysed, and the optimal design of machine dimensions
and parameters for maximum torque per volume are also
discussed. In [Ren Yuan et al. (2009)], SVPWM control was
presented, but it has not fault-tolerant strategies under fault
conditions. In [Si Binqiang et al. (2013)], two strategies were
presented for open-circuit fault. Under the premise of
meeting requirements of the high power density and fault
tolerance, and considering the volume and power, the current
authors have designed a four-phase PMFTM for
electromechanical actuators.
In drive systems, as far as motor body is concerned, there are
mainly open- and short-circuit faults. In contrary to an open-
circuit fault, a short-circuit fault of windings is more severe
and hazardous. For an open-circuit fault, it produces
pulsating torque. However, a short-circuit fault not only
produces more pulsating torque, but also may destroy the
faulty winding, if magnetic circuit is not designed in
particular, as the short-circuit current is in direct proportion
to the turn number of a winding. In order to remedy the short-
circuit hazard, the increasing air-gap reactive resistor should
be taken into account, hence limiting the short-circuit current.
Therefore, both the design method and the control strategy
are essential for a PMFTM, which can meet the torque
requirements.
The structure of a four-phase PMFTM is shown in Fig. 1(a).
Fault-tolerant tooth (without windings) separates
magnetically and physically adjacent phases. Then, each
phase can be seen as a modular part, making the motor still
produce torque as normal in a phase or several phases failure.
Each phase of four-phase PMFTM can be driven not only by
independent H-bridge [Zhao Wenxiang et al. (2008, 2011,
2012b)] (Fig. 2(a)), but also by star-connection [Yang

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Zhengzhuan et al. (2009); Zhao Wenxiang et al. (2009)] (Fig.
2(b)) drive topology. The former is more flexible to control
separately, yet it needs more power devices and volume,
hence producing more dissipation heat. Meanwhile, the latter
obeys the Kirchhoff’s Current Law that the sum of each
current is zero, so the control algorithm is more complex. In
recent years, research of multiphase PMFTMs is mainly
based on H-bridge or star-connection drive topology.
However, their impacts on the fault tolerance and system
performance are ignored. The purpose of this paper is to
investigate different remedial strategies for improve torque
performance of a four-phase PMFTM with short-circuit fault.
(a) Structure
1000
800
600 L(A,A) [uH]
L(A,B) [uH]
L/uH
The structure of the paper is as follows. Section 2 sets up the
mathematical model of the four-phase PMFTM. Section 3,
according to H-bridge and star-connection drive topology,
presents individually fault-tolerant strategy for a short-circuit
fault. Section 4 analyses the effect of both control strategies.
Some conclusions are drawn in Section 5.
2. MATHEMATICAL MODEL
As is shown in Fig. 1(a), differing from distributed winding,
the four-phase PMFTM adopts concentrated winding around
a stator tooth, in which fault-tolerant teeth interleave with
armature teeth. Since windings completely isolated in electric,
magnetic, thermal, and physical circuits, a phase fault will
not impact on, neither pass to other phases. Thereby, when
there is a fault in one of the phase windings, the remaining
healthy phase windings can continually operate with
reasonable performance.
Comparatively, in [B.Mecrow et al. (2011)], the ratio of the
mutual inductance to self-inductance of 6-phase PMFTM is
just 3.5%, but in this work, that is only 3.2%. Therefore, as
shown in Fig. 1(b), windings of a multiphase PMFTM can be
treated as multiple decoupled independent circuits. Then k-
phase PMFTM can be described as follow.
The stator voltage equations are given by
dψ k
uk = Rik + ek = Rik + (1)
dt

400 L(A,C) [uH]

L(A,D) [uH] The air-gap flux linkages are presented by
200
ψ k = Lk ik +ψ rp (2)
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 where Lk is the self-inductance of Phase k, and ψ rp is the PM
Time/ms
flux linkage of the rotor.
(b) Self and mutual inductances
Fig. 1 Structure and inductances of four-phase PMFTM The electromotive force (EMF) equations are described by

dψ k dik dLk dψ rp
ek = = Lk + ik +
dt dt dt dt
dik dLk dψ rp
= Lk + ik ωr + ωr   (3)
dt dθ dθ
dik
= Lk + eω + erp
dt r

where Lk dik dt is the transformer EMF,

(a) H-bridge
eωr = ik ωr dLk dθ is the rotary EMF, erp = ωr dψ rp dθ is
the PM EMF, ωr is the rotor angular velocity, θ is the rotor
position angle. By ignoring the copper loss and the core iron
loss, by (1) and (3):
Pk = uk ik ≈ ek ik
d 1 1 dL dψ rp
= ( Lk ik2 ) + ( ik2 k + ik )ωr (4)
dt 2 2 dθ dθ
(b) Star-connection dWsf
= + Tek ωr
Fig. 2 Two drive topologies dt
where dWsf dt = 0.5ik2 dLk dθ is the PM energy.

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Due to its surface-mounted magnet topology, the PMFTM
has a nearly constant value of phase inductance. Hence, its
reluctance torque generated by the variation of inductance is
zero. Electromagnetic torque produced by k-phase winding is
expressed asÖ
1 2 dLk dψ rp
Tek = ik + ik = f rpk (θ )ik (5)
2 dθ dθ
where f rpk (θ ) = dψ rp dθ is the PM torque coefficient
caused by the variation of PM flux in different rotor positions.
Therefore, the total output torque of the multiphase PMFTM
under normal condition can be written asÖ
Te = ∑ Tek = ∑ f rpk (θ )ik (6)
Due to the decoupled phases, unfaulty phases are immune to
the influence of the kth-phase, and the total torque is:
 0 open-circuit 
Te _ fault = ∑ f rp j (θ )i j +  (7)
j ≠k  f rpk (θ )ik short-circuit
3. FAULT DIAGNOSIS
Fault diagnosis and fault tolerance are two important aspects
of motor systems. Many professors presented different fault
diagnosis methods [O. A. Mohammed et al. (2007); Byoung-
Gun Park et al. (2011); Du Bochao et al. (2012)] for motor
systems. In this paper, a simple diagnosis method is proposed,
so it is able to do on-line fault diagnosis and fault tolerance.
In order to monitor its working states, it is essential to detect
on-line main voltage, main current, phase currents, velocity,
torque, and so on. Based on above information, fault type
(open- or short-circuit fault) and faulty position can be
determined.
This fault diagnosis method is described as follow.
Torque of the four-phase PMFTM can be written asÖ
P U main I main
Te = = (8)
ω ω
Torque ripple can be calculated after a period of torque
computation by (8). According to torque ripple, fault type can
be determined. As is listed in Table 1, when torque ripple is
about 7 times the normal operation, and one phase current is
zero, then this phase is in open-circuit fault. When torque
ripple is about 11 times the normal operation, and amplitude
of one phase current is 1.2283 times others, then this phase is
in short-circuit fault. According to the result of fault
diagnosis, control law will be switched from normal mode to
the corresponding (open- or short-circuit) fault tolerance
mode. Two fault-tolerant strategies were presented for open-
circuit fault in [Si Binqiang et al. (2013)]. It is assumed that
there is a short-circuit fault detected in the Phase B, based on
the above fault diagnosis method. This paper mainly
investigates different remedial strategies for improve torque
performance of a four-phase PMFTM with short-circuit fault.
645
4. FAULT-TOLERANT CONTROL
4.1 Analysis of Short-circuit Fault
Fig. 3 compares torque performances of PMFTM under
various conditions, showing that the average torque of
normal PMFTM drive is 10.62Nm and torque ripple is 4.67%.
These results are also listed in Table 1. For the open-circuit
[Si Binqiang et al. (2013)] fault, the average torque is
7.95N.m, while the torque ripple is 35.95%. For the short-
circuit fault, the average torque is 7.624N.m while the torque
ripple is 55.18%. Therefore, in contrast to an open-circuit
fault, a short-circuit fault has not only a more severe decline
in the average torque, but also a larger torque pulsation,
which is nearly 12 times the normal operation. Consequently,
it is more harmful to followings: devices with louder noise,
more wear-and-tear gears and less stable rudder. Thus, the
stability and the safety of the aircraft will be endangered.
Corresponding fault-tolerant control should be active in time,
for smooth and steady torque after a short-circuit fault is
detected.
In order to remedy a short-circuit fault, the performance
should be analysed in fault term. As well known, the motor
torque is in proportion to phase currents. It is an instinct to
analyse phase currents in short-circuit fault. Fig. 5(a) shows
the phase currents under normal condition, and Fig. 5(b)
shows the phase currents in short-circuit fault. From the
comparison between Fig. 5(a) and Fig. 5(b), in short-circuit
fault, the current of Phase B leads 90º, coinciding with the
Phase A in phase, and enlarges 1.2283 times of the rated
value in amplitude. As far as the current amplitude is
concerned, the four-phase PMFTM has the capability of
inhibiting the short-circuit current around the rated current,
namely, it meets the requirements of the fault-tolerant motor.
With the four-phase PMFTM as a research object, and
supposing the Phase B is in short-circuit fault, and according
to different drive topologies, we present two fault-tolerant
strategies for single-phase winding in a short-circuit fault.
Table 1. Performance comparison under three conditions
State Avg Torque/N.m Ripple/%
Normal 10.62 4.64
Open-circuit 7.95 35.95
Short-circuit 7.624 55.18
13
12
11
10
Torque/N.m
9
8
7
6
5
4
3 Normal
2 Open-circuit
1 Short-circuit
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Time/ms
Fig. 3 Torque in normal, open-circuit and short-circuit
conditions
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April 10-12, 2013. Hangzhou, China

6 Phase A
times of the rated value in amplitude, resulting in pulsating
Phase B torque. A direct method is to minimize torque ripple by
5
Phase C compensating torque, namely, the current of Phase A lags 90º
Torque/N.m
4 Phase D
in phase, and equates the current of Phase B in amplitude.
3 Similarly, the current of Phase C leads 90º in phase, and
2 equates the current of Phase B in amplitude, so the torque
ripple produced by Phase B is counteracted. Meanwhile, in
1
order to produce the torque as normal, other phases double in
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 amplitude with invariability in phase. Thus, the currents of
Time/ms unfaulty phases are obtained as follow.

(a) Four single-phase working
 I ′ = 1.2283 I
a b

11 Phase A&B 
10 Phase A&C I ′ = 2I
c c
(11)
9  ′
8
I = 2I
Torque/N.m

d d
7
6
5 or
4
3
2 I ′ = 2I
a a
1 
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0  I ′ = −1.2283 I
c b
(12)
Time/ms  ′
I = 2I

(b) The adjacent and opposite two-phase working d d

Fig. 4 Single- and two-phase working torque

4.2 H-bridge Fault-tolerant Strategy

In brief, suppose each winding is driven by H-bridge drive
topology, and the Phase B is in short-circuit fault. To
When H-bridge drive topology is adopted, each winding is maintain the same torque capability as the normal operation,
independent physically and electrically, without mutual the current of Phase A or Phase C lags or leads 90º in phase,
constraint. Thus, it is flexible in control algorithm. and equates the current of Phase B in amplitude. Also, the
According to the electromagnetic characteristics of the four- other phases double in amplitude with invariability in phase.
phase PMFTM, there are 90º (electrical degree) between the Other a short-circuit fault of single phase is treated as such.
two adjacent-phase magnetic flux. For the oppositing phases,
Phase A and C (or Phase B and D), they produce torque in 4.3 Star-connection Fault-tolerant Strategy
same-phase, as is shown in Fig. 4(a). In other words, if Phase
A and C (or Phase B and D) work individually, their torque When star-connection drive topology is adopted, each
totally coincide by each other. However, for the adjacent two winding is joint, dependent electrically, and constrained
phases, if Phase A and B (or Phase C and D, or Phase A and mutually. Thus, it is less flexible in control algorithm.
D, or Phase B and C) work individually, their torque
completely inverse (180º) in phase. Therefore, when the In normal operation, the phase currents are expressed by:
adjacent two phases work simultaneously, the torque is
smooth. However, as is shown in Fig. 4(b), when the I a
= I cos( pω m t + φ )
oppositing two phases work simultaneously, the torque is I
 = I cos( pωm t + φ − π / 2)

b
pulsating. (13)
I c
= I cos( pωm t + φ − π )
During the Phase B is in short-circuit fault, the torque can be
 I = I cos( pω m t + φ + π / 2)
expressed by: d

The resultant rotating magnetic force can be described by:

Te _ fault = ∑ f rp (θ )i j + f rp (θ )i2
j 2
(9)
j ≠2
MMF = MMFa + MMFb + MMFc + MMFd
To maintain the same torque capability as the normal 2 3

operation, a remedial operation under short-circuit fault = NI a + α NI b + α NI c + α NI d (14)

condition can be obtained by setting (9) equal to (6), leading jθ
= 2 NIe = 2 NI (cos θ + j sin θ )
to the following relation:
where N is number of turns per phase, α = 1∠90o ,
∑ f rp (θ )i j + frp (θ )i2 = ∑ frp (θ )ik
j 2 k
(10)
θ = pωm t + φ  p is number of pole-pairs, ωm is mechanical
j≠2

angular velocity, and φ is initial phase angle.

In the short-circuit fault, the current of Phase B leads 90º in
phase, then coincides with the Phase A, and enlarges 1.2283

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In short-circuit fault, the current of Phase B leads 90º in volume and dissipation heat, while the latter is less than half
phase, coinciding with the Phase A, and enlarges 1.2283 of power devices, so it is suitable for the occasion that space
times of the rated value in amplitude. It is described as follow. is limited. In flexibility of control, each phase of the former
can be controlled separately for adjusting the amplitude and
I b ′ = 1.2283 I cos( pω m t + φ ) = 1.2283 I cos θ (15) phase of each current, so it is flexible and fit to do fault-
tolerant control for multiphase PMFTM. But the latter obeys
and the EMF is:
the Kirchhoff’s Current Law that the sum of each current is
2 3
MMF ′ = NI a ′ + α NI b ′ + α NI c′ + α NI d ′ zero, so the control algorithm is more complex. On the failure
(16) rate, the former is very flexible to control, but it also make
= N [ I a ′ − I c ′ + j ( I b ′ − I d ′ )] some phases overloaded (saturate), then reduces the working
life and increases the failure rate. While due to cooperation,
To maintain the same torque capability as the normal
the power of each unfaulty phase is approximately even, so
operation, a remedial operation under short-circuit fault
the latter has longer (lower) working life (failure rate). In
condition can be obtained by setting (16) equal to (14),
copper loss, the former is 2.75 times, and the latter is 3.5
leading to the following relation:
times of the loss as normal. In control effect, compared with
the latter, the former has a more decline in the averaged
 I ′ − I ′ = 2 I cos θ
a c
torque, while a less increase in torque ripple, close to the

 I ′ − I ′ = 2 I sin θ torque ripple as normal. These results are also listed in Table

b d
(17) 2. The two remedial strategies have their advantages and
 I ′ = 1.2283I cos θ
b
disadvantages, so the drive topology and corresponding
 ′ ′ ′ ′ remedial strategy should be chosen, according to situations,
I + I + I + I = 0
a b c d control-orientation and so on.
Thus, the currents of unfaulty phases are obtained as follow. 50 Input IA
40 Input IB
Input IC
 I ′ = I − 0.2283I
a b a
30
20 Input ID

Current/A

10
 I ′ = 1.2283I 0

b a
(18) -10
 I ′ = I + 2.2283I
c b c
-20
 ′ -30
 I = 1.2283I + 2 I
d a d
-40
-50
0.0 0.5 1.0 1.5 2.0 2.5 3.0
In short, suppose each winding is driven by star-connection Time/ms
drive topology, and the Phase B is in short-circuit fault. To
maintain the same torque capability as the normal operation, (a) Normal
in contrast to H-bridge fault-tolerant strategy, it is more 60 Short IB
complex, not only with modification in amplitude of the 50
40 Input IA
residual unfaulty phases, but also with shift in phase. Other a 30 Input IC
short-circuit fault of single phase is treated as such. 20 Input ID
Current/A

10
0
Table 2 Performance comparison under various -10
-20
conditions -30
-40
-50
Avg Torque -60
State Ripple/% Copper loss/W 0.0 0.5 1.0 1.5 2.0 2.5 3.0
/N.m Time/ms
Normal 10.62 4.67 4I2R 
(b) Short-circuit of the Phase B
Short- 80 Short IB
7.624 55.18 4.5I2R Input IA
circuit 60
Input IC
40
Input ID
11I2R
Current/A

H-bridge 9.17 6.65 20

0
Star-
9.56 21.44 14I2R -20
connection -40
-60
4.4 Comparative Analysis -80
0.0 0.5 1.0 1.5 2.0 2.5 3.0

Each phase of multiphase PMFTM can be driven not only by Time/ms

independent H-bridge drive, but also by star-connection drive.

(c) H-bridge fault-tolerant strategy
In structure of drive, the former has more power devices,

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and phase of the unfaulty residual windings agree with the

100 Short IB theoretical analysis in Section 4.3. Also, as is shown in Table
Input IA
80
Input IC
2 and Fig. 6, the averaged torque is 9.56N.m, lower than that
60
40 Input ID of the normal by 9.98%, but torque ripple is 21.44%, more
Current/A

20 than that of the normal by 459.1%. Differing from the H-

0 bridge fault-tolerant strategy, the star-connection one has a
-20
-40
less decline in the averaged torque, but a more increase in
-60 torque ripple. So, it also meets the torque requirements.
-80
-100
0.0 0.5 1.0 1.5 2.0 2.5 3.0
6. CONCLUSIONS
Time/ms
(d) Star-connection fault-tolerant strategy On the premise of meeting demand of the output torque after
Fig. 5 Current waveforms under different conditions remedial control, and according to the H-bridge and star-
connection drive topologies, we present different fault-
tolerant strategies for single-phase winding short-circuit fault.
5. SIMULATIONS The effectiveness of the proposed two fault-tolerant strategies
is verified by derivation and simulation. Besides, from drive
Simulations have been performed to verify the proposed two structure, flexibility, failure rate, copper loss and fault-
fault-tolerant strategies. The data of comparison are also tolerant effect, the two fault-tolerant strategies are analysed
listed in Table 2. Simulated currents and torques of the four- comparatively.
phase PMFTM in four situations are shown in Fig. 5 and Fig.
6, respectively. The four-phase PMFTM can employ not only the H-bridge,
but also the star-connection fault-tolerant strategy, if there is
a short-circuit fault taken place in one winding. The two
12 fault-tolerant strategies have their advantages and
disadvantages, and in contrast with the latter, the former has a
10
more decline in the averaged torque, but a less increase in the
Torque/N.m

8 torque ripple and copper loss. Therefore, the fault-tolerant

6 strategy should be chosen, according to the control-
Short-circuit
4
Normal
2 H-bridge
Star-connection
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Time/ms
Fig. 6 Torque waveforms under different conditions of the
four-phase PMFTM
Fig. 5 shows phase currents of the four-phase PMFTM under
different situations. Four normal phase currents are shown in
Fig. 5(a), amplitude of which is 41.7A, and phase difference
of which is 90º. In a short-circuit fault, the current of Phase B
leads 90º in phase, coinciding with the Phase A, and enlarges
1.2283 times of the rated value in amplitude, and others are
as normal and shown in Fig. 5(b). After the H-bridge fault-
tolerant strategy is active, the remedial currents are shown in
Fig. 5(c), and amplitude of the Phase A and D are 83.4A, 2
times as normal, and unchanged in phase, for producing the
normal torque. Meanwhile, the current of the Phase C leads
90º in phase angle, and equates the current of Phase B in
amplitude. This result show that the torque ripple caused by
the short-circuit current of the Phase B is compensated,
which agree with the theoretical analysis in Sections 4.2.
Simultaneously, as is shown in Table 2 and Fig. 6, the
averaged torque is 9.17N.m, lower than that of the normal by
13.65%. However, its torque ripple is 6.65%, more than that
of the normal by 142.4%. It is able to meet the normal
demand, verifying the correctness of H-bridge fault-tolerant
strategy. After employing the star-connection fault-tolerant
strategy, the currents are shown in Fig. 5(d), and amplitude
orientation. The comparative analysis of the two fault-
tolerant strategies makes their respective advantages and
disadvantages more distinct, and provides a certain extent of
theoretical foundations for drive design and a fault-tolerant
strategy of multiphase PMFTMs.
ACKNOWLEDGEMENTS
The authors would like to thank the National Natural Science
Foundation of China (No.51007031, No.60974142,
No.61104082) for supporting the research work.
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