Development of an online condition monitoring based system for the partial demagnetization fault diagnosis of SPM‐type BLDC motor

Abstract

Abstract This study investigates partial demagnetization faults arising from stator interturn faults in a surface‐mounted permanent‐magnet‐type brushless direct current motor. Because of rotor demagnetization, the fault severity increases significantly owing to an increase in the stator phase current and temperature. The effect of such a fault is reflected in machine parameters such as the motor back‐EMF and radial magnetic flux, which are used to analyse the characteristics of faults. A mathematical model of a machine under possible fault conditions is developed using the finite element method and advanced hybrid model approaches. Experimental investigations are conducted to validate the proposed methodology. Subsequently, the machine parameters used for fault diagnosis are employed to develop an online expert‐based system that can detect, classify and estimate the percent increase in the values of the parameters to determine the fault severity of the machine under fault conditions. It is discovered that the proposed approach is suitable for industrial and commercial applications in electric vehicles, where the machine's state‐of‐health estimation is crucial for avoiding major faults that may result in its failure.