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

Xi Zhang,Hassan Elahi,Saleem Riaz,Hui Lin,Yiyun Zhao

doi:10.3390/electronics10111268

Xi Zhang, Hassan Elahi + Show 3 more

Open Access

https://doi.org/10.3390/electronics10111268

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Abstract

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.

Highlights

Permanent magnet brushless direct current (PMBLDC) motors have been widely used in various industrial and commercial fields, benefit from the characteristics of high power density, simple structure, and low cost [1,2,3]
The Hall sensors have advantages of simplicity and inexpensive, which make them well suited for the position sensors of the permanent magnet brushless direct current (PMBLDC) motor drives
Once there is a fault in the Hall sensors, the dynamic performance of the motor drives will be significantly reduced or even overcurrent, which can lead to extensive damage to the whole system [17,18,19]

Summary

Introduction

Permanent magnet brushless direct current (PMBLDC) motors have been widely used in various industrial and commercial fields, benefit from the characteristics of high power density, simple structure, and low cost [1,2,3]. Several FTC methods of the Hall sensors faults in PMBLDC motor drives have been proposed in different researches, such as in [27], G. In [30], an improved fault-tolerant control strategy based on the vectortracking observer was proposed based on [29], which reduced the transient current and speed dip of the motor during the Hall sensor fault diagnostic process. We extend the research of Dong et al [29,30] and Zhang et al [31] by proposing a real-time fault diagnosis (RFD) method using an extended finite state machine (EFSM) and super twisting algorithm (STA) based motor speed observer. Considering the above analysis, this article proposed a real-time fault diagnosis and fault-tolerant control strategy for Hall sensors in PMBLDC motor drives.

C2 C3 C4 C5 C6

Signal Reconstruction and Fault-Tolerant Control

Experimental Verification

Ha and Hb Fault Point

Findings

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