Uncontrolled generation (UCG) is a phenomenon that occurs in electric drives when operating in a field‑weakening and a gate signal is suddenly removed from switches. When the induced voltage is higher than the DC link voltage, a path is created for current to flow from the machine through the freewheeling diodes of the converter back into the DC link. While UCG is commonly associated with three-phase drives, the topology of some multiphase machine drives—comprising separate three-phase winding sets—enables the manifestation of UCG in only one winding set. This arrangement allows the remaining two winding sets to facilitate post-fault operation.

Multiple three-phase machine drives are inherently fault-tolerant due to their multiphase structure; however, they remain susceptible to inverter-related faults. A common fault is the loss of gate signals in one inverter leg, resulting in an open-phase condition. Under such conditions, a reverse conduction path is established through the freewheeling diodes of the faulted leg, leading to uncontrolled freewheeling diode current generation. The resulting freewheeling diode current becomes particularly critical in the field-weakening region, when the back-EMF may exceed the DC-link voltage and a large reverse current can occur. This paper derives an analytical expression for real-time prediction of the freewheeling diode current in a triple three-phase surface-mounted permanent magnet synchronous machine drive. The method is applicable in both the constant-torque and field-weakening regions. The analytical prediction is validated through comparison with both experimentally measured and numerically simulated freewheeling diode current waveforms over a wide range of operating points, including no-load and loaded conditions. The results show that the proposed model accurately reproduces the envelope and conduction boundaries, while maintaining good agreement with simulations and measurements. The predicted current can be utilized in post-fault control, fault detection, and sensorless position estimation.