In this paper, binary Hall-effect sensor faults are investigated in rectangular-current-fed brushless dc (BLDC) drives and a very effective methodology for their detection, identification, and compensation is explored. It is shown that these faults cause erroneous commutation, generally leading to unstable operation. Using a fault detection and identification technique proposed by the authors in a recent paper on low-cost field-oriented drives, it is possible to pinpoint the faulty sensors. In this paper, it is demonstrated that the destabilizing effect of these faults on motion-state estimation can be compensated for in any position and speed estimation algorithm, as long as it is properly readapted. To this end, it is shown how to incorporate such fault-compensation in three state-of-the-art estimation algorithms: (1) the zeroth-order algorithm (ZOA); (2) the hybrid observer (HO); and (3) the vector-tracking observer (VTO). Comparative experimental tests are performed and it is verified that stable operation is achieved with three, two, or only a single Hall-effect sensor functioning correctly. These results show that the classical BLDC drive with three Hall-effect sensors has an inherent double redundancy to position-sensor faults. With the proposed method, this property can be exploited in systems that require very high reliability, such as in aerospace and automotive applications. Redundancy can be increased, using more than three Hall-effect sensors; reduced using two sensors; or eliminated using a single sensor, in ultra low-cost applications where redundancy is not a requirement.

In this paper it is shown how to obtain a low-cost, high-resolution and fault-robust position sensing system for permanent magnet synchronous motor drives operating in safety-critical systems, by combining high-frequency signal injection with binary Hall-effect sensors. It is shown that the position error signal obtained via high-frequency signal injection can be merged easily into the quantization-harmonic-decoupling vector tracking observer used to process the Hall-effect sensor signals. The resulting algorithm provides accurate, high-resolution estimates of speed and position throughout the entire speed range; compared to state-of-the-art drives using Hall-effect sensors alone, the low speed performance is greatly improved in healthy conditions and also following position sensor faults. It is envisaged that such a sensing system can be successfully used in applications requiring IEC 61508 SIL 3 or ISO 26262 ASIL D compliance, due to its extremely high mean time to failure and to the very fast recovery of the drive following Hall-effect sensor faults at low speeds. Extensive simulation and experimental results are provided on a 3.7 kW permanent magnet drive.

This paper deals with an original control strategy for AC multidrive systems able to mitigate the effects of failures occurring on one or more drives. A key feature of the proposed technique is that fault tolerance capability is achieved by a suitable reconfiguration of the system in order to allow the healthy drives to provide additional paths for the currents of the faulty drives. Moreover, a modified control algorithm able to enforce the vector control in damaged drives has been implemented, by cooperatively managing some or all the drives of the system. Therefore, differently from previous techniques, the fault tolerance capability is achieved by exploiting the healthy drives, rather than activating back-up inverter legs. As a result, no additional high-frequency switching power devices and related drives circuitries are needed. In the following, two different scenarios will be analyzed, highlighting pros and cons of the proposed approach through simulations and experimental results.

This paper investigates the performance of a three-phase permanent magnet synchronous motor (PMSM) drive operating under a single fault, adopting a low cost and fault-tolerant control based on deadbeat-direct torque and flux control (DB-DTFC). Under faulty operation, this fault-tolerant DB-DTFC offers an independent regulation of the electromagnetic torque and the stator flux linkage by using the same torque line equation, stator flux linkage, and current observers adopted during healthy conditions, requiring very limited hardware reconfigurations. In particular, it has been demonstrated that in a fault situation, the same drive model equations adopted for the healthy electric drive can be exploited with very limited detrimental effects on the drive performance simply by applying a suitable reference frame transformation set in the torque and flux control structure. The proposed fault-tolerant DB-DTFC has been validated by experimental tests, confirming that the proposed fault-tolerant DB-DTFC ensures satisfactory faulty operations and drive stability, without significant degradation of parameter sensitivity, keeping limited the increment of computational efforts.

This paper deals with the development and implementation of an on-line technique for the identification of the stator resistance and permanent magnet flux linkage on three-phase, open-end winding, permanent magnet synchronous motor drives. The stator resistance and permanent magnet flux linkage are independently determined by exploiting a special current vector control strategy, which holds at zero one of the phase currents, while suitably modifying the other two in order to make unchanged the magnetomotive force. As will be demonstrated, no additional sensors, neither special tests are required by the proposed technique, moreover, motor electrical parameters can be on-line estimated in a wide operating range, avoiding any detrimental impact on the torque capability of the PMSM drive. Finally, the electrical machine thermal status can be also estimated from obtained values of the stator resistance and permanent magnet flux linkage.