Real-Time Fault Diagnosis and Fault-Tolerant Control Strategy for Hall Sensors in Permanent Magnet Brushless DC Motor Drives

The Hall sensor is the most commonly used position sensor of the permanent magnet brushless direct current (PMBLDC) motor. Its failure may lead to a decrease in system reliability. Hence, this article proposes a novel methodology for the Hall sensors fault diagnosis and fault-tolerant control in PMBLDC motor drives. Initially, the Hall sensor faults are analyzed and classified into three fault types. Taking the Hall signal as the system state and the conducted MOSFETs as the system event, the extended finite state machine (EFSM) of the motor in operation is established. Meanwhile, a motor speed observer based on the super twisting algorithm (STA) is designed to obtain the speed signal of the proposed strategy. On this basis, a real-time Hall sensor fault diagnosis strategy is established by combining the EFSM and the STA speed observer. Moreover, this article proposes a Hall signal reconstruction strategy, which can generate compensated Hall signal to realize fault-tolerant control under single or double Hall sensor faults. Finally, theoretical analysis and experimental results validate the superior effectiveness of the proposed real-time fault diagnosis and fault-tolerant control strategy.

[1]  Juri Jatskevich,et al.  Fault Diagnosis and Signal Reconstruction of Hall Sensors in Brushless Permanent Magnet Motor Drives , 2016, IEEE Transactions on Energy Conversion.

[2]  Ronghai Qu,et al.  Post-fault model predictive control of asymmetrical six-phase permanent magnet machine with improved mathematical model , 2017, 2017 IEEE International Electric Machines and Drives Conference (IEMDC).

[3]  Ilhem Slama-Belkhodja,et al.  Easy and Fast Sensor Fault Detection and Isolation Algorithm for Electrical Drives , 2012, IEEE Transactions on Power Electronics.

[4]  Derrick Holliday,et al.  The effect of magnetic saturation on sensorless control of a brushless permanent magnet motor under AC and DC excitation , 2011, 2011 IEEE Energy Conversion Congress and Exposition.

[5]  Qian Zhang,et al.  Fast Fault Diagnosis Method for Hall Sensors in Brushless DC Motor Drives , 2019, IEEE Transactions on Power Electronics.

[6]  Ignacio Garcia-Vargas,et al.  Finite State Machines With Input Multiplexing: A Performance Study , 2015, IEEE Transactions on Computer-Aided Design of Integrated Circuits and Systems.

[7]  R. Grepl,et al.  Fault tolerant BLDC motor control for hall sensors failure , 2015, 2015 21st International Conference on Automation and Computing (ICAC).

[8]  K. Jezernik,et al.  Finite-State Machine Motion Controller: Servo Drives , 2012, IEEE Industrial Electronics Magazine.

[9]  Jianglin Lan,et al.  A new strategy for integration of fault estimation within fault-tolerant control , 2016, Autom..

[10]  Nesimi Ertugrul,et al.  Wide Speed Range Sensorless Operation of Brushless Permanent-Magnet Motor Using Flux Linkage Increment , 2016, IEEE Transactions on Industrial Electronics.

[11]  Xing Ling,et al.  Position Sensorless Control Based on Coordinate Transformation for Brushless DC Motor Drives , 2010, IEEE Transactions on Power Electronics.

[12]  Ahmed Masmoudi,et al.  An approach to diagnose and remediate failures of Hall Effect sensors in BLDC motors , 2015, 2015 International Conference on Sustainable Mobility Applications, Renewables and Technology (SMART).

[13]  Bin Liu,et al.  Real-time embedded software testing method based on extended finite state machine , 2012 .

[14]  Lianqing Zhu,et al.  Adaptive Commutation Error Compensation Strategy Based on a Flux Linkage Function for Sensorless Brushless DC Motor Drives in a Wide Speed Range , 2018, IEEE Transactions on Power Electronics.

[15]  Araz Darba,et al.  A Back-EMF Threshold Self-Sensing Method to Detect the Commutation Instants in BLDC Drives , 2015, IEEE Transactions on Industrial Electronics.

[16]  Z.Q. Zhu,et al.  Practical Issues in Sensorless Control of PM Brushless Machines Using Third-Harmonic Back-EMF , 2006, 2006 CES/IEEE 5th International Power Electronics and Motion Control Conference.

[17]  Jaime A. Moreno,et al.  Strict Lyapunov Functions for the Super-Twisting Algorithm , 2012, IEEE Transactions on Automatic Control.

[18]  Haitao Li,et al.  Fault-Tolerant Inverter for High-Speed Low-Inductance BLDC Drives in Aerospace Applications , 2017, IEEE Transactions on Power Electronics.

[19]  Jiancheng Fang,et al.  Online Inverter Fault Diagnosis of Buck-Converter BLDC Motor Combinations , 2015, IEEE Transactions on Power Electronics.

[20]  Bingqiang Li,et al.  Sliding-Mode Clamping Force Control of Electromechanical Brake System Based on Enhanced Reaching Law , 2021, IEEE Access.

[21]  Robert M. Hierons Controllable Testing from Nondeterministic Finite State Machines with Multiple Ports , 2011, IEEE Transactions on Computers.

[22]  Wenxin Huang,et al.  Fault diagnosis of low-cost hall-effect sensors used in controlling permanent magnet synchronous motor , 2016, 2016 19th International Conference on Electrical Machines and Systems (ICEMS).

[23]  Tao Wang,et al.  Sensor-Less Control for Brushless DC Motors Based on Hybrid Sliding Mode Observer , 2014, 2014 7th International Conference on Intelligent Computation Technology and Automation.

[24]  Michael Defoort,et al.  Decoupled current control and sensor fault detection with second-order sliding mode for induction motor , 2015 .

[25]  D. Mahinda Vilathgamuwa,et al.  A Sensor Fault Detection and Isolation Method in Interior Permanent-Magnet Synchronous Motor Drives Based on an Extended Kalman Filter , 2013, IEEE Transactions on Industrial Electronics.

[26]  Xiaojiao Chen,et al.  Design of Real-Time Control in Poloidal Field Power Supply Based on Finite-State Machine , 2019, IEEE Transactions on Plasma Science.

[27]  M. Pulvirenti,et al.  Hall-Effect Sensor Fault Detection, Identification, and Compensation in Brushless DC Drives , 2016 .

[28]  O. Honorati,et al.  AC brushless drive with low-resolution Hall-effect sensors for surface-mounted PM Machines , 2006, IEEE Transactions on Industry Applications.

[29]  M. Abdullah Eissa,et al.  Improved fuzzy Luenberger observer-based fault detection for BLDC motor , 2015, 2015 Tenth International Conference on Computer Engineering & Systems (ICCES).

[30]  Jin Hur,et al.  Detection Technique for Stator Inter-Turn Faults in BLDC Motors Based on Third-Harmonic Components of Line Currents , 2017 .

[31]  Haitao Li,et al.  Self-Correction of Commutation Point for High-Speed Sensorless BLDC Motor With Low Inductance and Nonideal Back EMF , 2017, IEEE Transactions on Power Electronics.

[32]  Changhee Cho,et al.  On-line detection of rotor eccentricity for PMSMs based on hall-effect field sensor measurements , 2017, 2017 IEEE Energy Conversion Congress and Exposition (ECCE).

[33]  Mickaël Hilairet,et al.  Design of a Fault-Tolerant Controller Based on Observers for a PMSM Drive , 2011, IEEE Transactions on Industrial Electronics.

[34]  Kalyana Chakravarthy Veluvolu,et al.  Sliding-Mode-Based Observer–Controller Structure for Fault-Resilient Control in DC Servomotors , 2018, IEEE Transactions on Industrial Electronics.

[35]  Aiman H. El-Maleh Finite state machine-based fault tolerance technique with enhanced area and power of synthesised sequential circuits , 2017, IET Comput. Digit. Tech..

[36]  Wootaik Lee,et al.  Observer-Based Phase-Shift Fault Detection Using Adaptive Threshold for Rotor Position Sensor of Permanent-Magnet Synchronous Machine Drives in Electromechanical Brake , 2015, IEEE Transactions on Industrial Electronics.

[37]  A. Tashakori,et al.  A simple fault tolerant control system for Hall Effect sensors failure of BLDC motor , 2013, 2013 IEEE 8th Conference on Industrial Electronics and Applications (ICIEA).

[38]  Jianqiu Li,et al.  Rule-based fault diagnosis of hall sensors and fault-tolerant control of PMSM , 2013 .

[39]  Fabio Giulii Capponi,et al.  Fault-tolerant rotor position and velocity estimation using binary hall-effect sensors for low-cost vector control drives , 2014 .

[40]  Kirti Rathod,et al.  Hall sensor fault detection and fault tolerant control of PMSM drive system , 2015, 2015 International Conference on Industrial Instrumentation and Control (ICIC).

[41]  Juri Jatskevich,et al.  Improved Fault-Tolerant Control for Brushless Permanent Magnet Motor Drives With Defective Hall Sensors , 2016, IEEE Transactions on Energy Conversion.