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. 2025 Dec 17;25(24):7655.
doi: 10.3390/s25247655.

Real-Time Zero-Sequence-Voltage Estimation and Fault-Tolerant Control for an Open-Winding Five-Phase Fault-Tolerant Fractional-Slot Concentrated-Winding IPM Motor Under Inter-Turn Short-Circuit Fault

Ronghua Cui  1 , Qingpeng Ji  1 , Shitao Zhang  1 , Huaxin Li  1
Affiliations

Real-Time Zero-Sequence-Voltage Estimation and Fault-Tolerant Control for an Open-Winding Five-Phase Fault-Tolerant Fractional-Slot Concentrated-Winding IPM Motor Under Inter-Turn Short-Circuit Fault

Ronghua Cui et al. Sensors (Basel). .

Abstract

Inter-turn short-circuit (ITSC) faults in motor drives can induce substantial circulating currents and localized thermal stress, ultimately degrading winding insulation and compromising torque stability. To enhance the operational reliability of open-winding (OW) five-phase fault-tolerant fractional-slot concentrated-winding interior permanent-magnet (FTFSCW-IPM) motor drive systems, this paper proposes a real-time fault-tolerant control strategy that provides current suppression and torque stabilization under ITSC conditions. Upon fault detection, the affected phase is actively isolated and connected to an external dissipative resistor, thereby limiting the fault-phase current and inhibiting further propagation of insulation damage. This reconfiguration allows the drive system to uniformly accommodate both open-circuit (OC) and ITSC scenarios without modification of the underlying control architecture. For OC operation, an equal-amplitude modulation scheme based on carrier-based pulse-width modulation (CPWM) is formulated to preserve the required magnetomotive-force distribution. Under ITSC conditions, a feedforward compensation mechanism is introduced to counteract the disturbance generated by the short-circuit loop. A principal contribution of this work is the derivation of a compensation term that can be estimated online using zero-sequence voltage (ZSV) together with measured phase currents, enabling accurate adaptation across varying ITSC severities. Simulation and experimental results demonstrate that the proposed method effectively suppresses fault-phase current, maintains near-sinusoidal current waveforms in the remaining healthy phases, and stabilizes torque production over a wide range of fault and load conditions.

Keywords: feedforward compensation; inter-turn short-circuit; zero-sequence voltage.

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Conflict of interest statement

The authors declare no conflicts of interest.

Figures

Figure 1
Figure 1
3D view of the five-phase FTFSCW-IPM motor.
Figure 2
Figure 2
Prototype of the five-phase FTFSCW-IPM motor.
Figure 3
Figure 3
Comparison of self-inductance and mutual inductance of phase A winding.
Figure 4
Figure 4
Electrical topology of the OW five-phase FTFSCW-IPM motor.
Figure 5
Figure 5
Control architecture of the proposed OW drive system under healthy operation.
Figure 6
Figure 6
Vector diagram of phase currents under (a) normal operation and (b) an open-phase condition.
Figure 7
Figure 7
Equivalent circuit representation of the OW FTFSCW-IPM motor under an ITSC fault.
Figure 8
Figure 8
Current components in the stationary and synchronous reference frames. (a) OC-fault case. (b) ITSC-affected phase connected to the dissipative branch.
Figure 9
Figure 9
Fault-tolerant control structure incorporating ZSV-based compensation for ITSC operation.
Figure 10
Figure 10
Five-phase current waveforms during the transition to fault-tolerant operation.
Figure 11
Figure 11
Torque response during the transition to fault-tolerant operation.
Figure 12
Figure 12
Phase-current waveforms under varying load conditions.
Figure 13
Figure 13
Torque response under varying load conditions.
Figure 14
Figure 14
Short-circuit current waveforms under varying short-circuit turn ratios.
Figure 15
Figure 15
Torque response under varying short-circuit turn ratios.
Figure 16
Figure 16
Estimated feedforward compensation under varying short-circuit turn ratios.
Figure 17
Figure 17
ZSV under different Rs.
Figure 18
Figure 18
ΔZSV with respect to the nominal Rs under stator resistance variations.
Figure 19
Figure 19
ZSV under different Ls.
Figure 20
Figure 20
ΔZSV with respect to the nominal Ls under stator inductance variations.
Figure 21
Figure 21
ZSV under different Rf.
Figure 22
Figure 22
ΔZSV with respect to the Rf under short-circuit resistance variations.
Figure 23
Figure 23
ZSV under ideal inverter operation and non-ideal inverter operation with a dead-time of 4 μs.
Figure 24
Figure 24
ΔZSV with respect to the ideal inverter under dead-time nonlinearity.
Figure 25
Figure 25
Torque responses under ideal inverter operation and non-ideal inverter operation with a dead-time of 4 μs.
Figure 26
Figure 26
ZSV under measurement noise with an SNR of 30 dB.
Figure 27
Figure 27
Torque responses under measurement noise with an SNR of 30 dB.
Figure 28
Figure 28
Experimental setup for the OW five-phase FTFSCW-IPM motor drive system.
Figure 29
Figure 29
Measured phase currents and torque under the ITSC fault condition.
Figure 30
Figure 30
Dynamic phase currents and torque under OC fault.
Figure 31
Figure 31
Dynamic phase currents and torque adopt OC FTC method.
Figure 32
Figure 32
Dynamic currents and torque under ITSC fault.
Figure 33
Figure 33
Dynamic currents and torque during compensated FTC operation with real-time estimation incorporated.
Figure 34
Figure 34
Torque and current response during activation of the ITSC fault-tolerant control.
Figure 35
Figure 35
Current and torque response during the transition from healthy operation to OC injection and ITSC fault-tolerant control.
Figure 36
Figure 36
Tracking performance of the feedforward compensation term under varying short-circuit turn ratios.
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