Condition Monitoring and Fault Tolerant Control Techniques in Electric Vehicle Drives

Authors

Hassan H. EldeebFollow

Document Type

Dissertation

Degree

Doctor of Philosophy (PhD)

Major/Program

Electrical and Computer Engineering

First Advisor's Name

Osama Mohammed

First Advisor's Committee Title

Committee chair

Second Advisor's Name

Ahmed Ibrahim

Second Advisor's Committee Title

Committee member

Third Advisor's Name

Shubhendu Bhardwaj

Third Advisor's Committee Title

Committee member

Fourth Advisor's Name

Mohammed Hadi

Fourth Advisor's Committee Title

Committee member

Keywords

Electric Vehicles (EV), Electric Drives, Condition Monitoring, Fault Diagnosis, Turn-to-turn Faults, Direct Torque Control, hybrid energy storage system, EV parking station, Induction Motors, Power electronic Inverters

Date of Defense

3-16-2021

Abstract

With the growth in the electric vehicles (EV) use, transportation electrification methodologies ensure improved reliability and security of the EVs and its powertrain as significant factors to consider. Any failure in the EV’s motor drive system or any of its components will directly impact the powertrain's reliability and passenger safety. Due to their robustness and mature design, EV powertrains utilize vector-controlled power inverter-fed induction motor (IM) as their drive system. Therefore, fast, reliable, non-destructive, and non-invasive fault diagnosis (FD) and condition monitoring (CM) techniques are required to detect faults in EV drive systems at their development stage.

Two novel real-time current-based FD techniques were developed and implemented in the laboratory on digital signal processing (DSP) to detect stator’s turn-to-turn faults (TTFs). In the first technique, the differential mathematical morphological gradient () concept was developed. The second method utilizes the developed differential discrete wavelet energy () algebra. An Ostu’s-thresholding problem was formulated to determine and enhance the reliability of the FD technique. Both methods were validated, and their effectiveness was verified experimentally to detect TTFs under various loading conditions. This provided more accurate and fast results than the conventional motor current signature analysis (MCSA)-based FD algorithms.

Furthermore, two FD algorithms were introduced to detect TTFs using the IM's magnetic dispersal flux captured via an external magnetic sensor. The side-band harmonics in the radiated flux were analyzed, and a time-frequency domain FD algorithm was developed and implemented experimentally.

An extended Kalman filter (EKF) was developed with the recursive least squares (RLS) to estimate and update the IM’s parameters online experimentally to estimate the drive systems' efficiency.

A multi-objective optimization problem (MOOP) was formulated and solved to optimally size and control a hybrid energy storage system (HESS) in the EV powertrain. The objectives are to minimize the cost, mass, and volume of the HESS while maximizing the battery's lifetime.

To integrate photovoltaic (PV)-based-EV station into the medium voltage grid, an optimal power scheduling is proposed to maximize the station’s revenues and minimize the station-battery’s capacity fading under the power fluctuation restrictions imposed by the grid. Furthermore, a control strategy was developed to coordinate the powers injected by each grid-tied power inverter to support voltage, frequency stability and improve the power factor.

Identifier

FIDC009681

ORCID

https://orcid.org/0000-0002-4981-940X

Previously Published In

Published Journal Articles:

H. H. Eldeeb, H. Zhao and O. A. Mohammed, "Detection of TTF in Induction Motor Vector Drives for EV Applications via Ostu’s- Based DDWE," in IEEE Transactions on Transportation Electrification, vol. 7, no. 1, pp. 114-132, March 2021

H. H. Eldeeb, A. Berzoy, A. A. Saad, H. Zhao, and O. A. Mohammed, "Differential Mathematical Morphological Based On-line Diagnosis of Stator Inter-Turn Failures in Direct Torque Control Drive Systems," in IEEE Trans. on Industry Applications, vol. 56, no. 6, pp. 6272-6285, Nov.-Dec. 2020

H. H. Eldeeb, A. Berzoy and O. Mohammed, "Stator Fault Detection on DTC-Driven IM via Magnetic Signatures Aided by 2-D FEA Co-Simulation," in IEEE Transaction on Magnetics, vol. 55, no. 6, pp. 1-5, June 2019

H. H. Eldeeb, A. T. Elsayed, C. R. Lashway and O. Mohammed, "Hybrid Energy Storage Sizing and Power Splitting Optimization for Plug-In Electric Vehicles," in IEEE Trans. on Industry Applications., vol. 55, no. 3, pp. 2252-2262, May 2019.

H. H. Eldeeb, S. Faddel, O. A. Mohammed, ”Multi-Objective Optimization Technique for the Operation of Grid-tied PV Powered EV Charging Station”, Electric Power Systems Research, Vol.164, 2018, PP. 201-211

H. Zhao, H. H. Eldeeb, J. Kang, Y. Zhan, G. Xu, and O. Mohammed, “Parameter Identification Based On-line Non-invasive Estimation of Rotor Temperature in Induction Motors” IEEE Transaction on Industry Applications, vol. 57, no. 1, pp. 417-426, Jan.-Feb. 2021

H. Zhao, H. H. Eldeeb, Yang Zhan, Z. Ren, G. Xu, and O A. Mohammed, “Robust Electromagnetic Design of Double-Canned IM for Submergible Rim Driven Thrusters to Reduce Losses and Vibration”, in IEEE Transaction on Energy Conversion, vol. 35, no. 4, pp. 2045-2055, Dec. 2020

A. Berzoy, H. H. Eldeeb and O. A. Mohammed, "Online Detection of Stator Faults in DTC-Driven IM Using SC Impedance Matrix Off-Diagonal Term," in IEEE Transactions on Industry Applications, vol. 55, no. 6, pp. 5906-5915, Nov.-Dec. 2019

H. Zhao, C. Chu, H. H. Eldeeb, Y. Zhan, G. Xu, and O. A. Mohammed, "Optimal Design of High-speed Solid Rotor Cage Induction Motors Considering Ferromagnetic Materials Behavior and Manufacturing Process," in IEEE Transactions on Industry Applications, vol. 56, no. 4, pp. 4345-4355, July-Aug. 2020

Y. Wang, H. H. Eldeeb, H. Zhao and O. A. Mohammed, "Sectional Variable Frequency and Voltage Regulation Control Strategy for Energy Saving in Beam Pumping Motor Systems," in IEEE Access, vol. 7, pp. 92456-92464, July 2019

H. Zhao, Y. Wang, H. H. Eldeeb, J. Ge, J. Kang, O. A. Mohammed, “Optimal Coupling Coefficient Range to Suppress Decline in WPTS Efficiency Due to Increased Resistance with Temperature Rise,” IEEE Open Journal of the Industrial Electronics Society, vol. 1, pp. 148-156, 2020

H. H. Eldeeb, H. Zhao, O. Mohammed, “Effect of Stator Insulation Failure on the Motor Drive System Performance” Applied Computational Electromagnetics Society Journal, Vol 35, no. 11, pp. 1370-1371, Nov. 2020

J. Ge, H. H. Eldeeb, K. Liu, J. Kang, H. Zhao, O. Mohammed, “Optimal Range of Coupling Coefficient of Loosely Coupled Transformer Considering System Resistance”, Applied Computational Electromagnetics Society Journal, Vol. 35, no. 11, pp. 1368-1369, Nov. 2020

Conference papers

H. H. Eldeeb, H. Zhao and O. A. Mohammed, "Time-Frequency Domain-Based Diagnostics of Stator Faults in Motors Drives via Dispersal Magnetic Field," 2020 IEEE Energy Conversion Congress and Exposition (ECCE 2020), Detroit, MI, USA, 2020, pp. 4903-4907.

H. H. Eldeeb, H. Zhao and O. A. Mohammed, "Power Losses and Magnetic Flux Analysis of Vector Controlled Induction Motor with Stator Turn-to-Turn Fault," 2020 IEEE Applied Power Electronics Conference and Exposition (APEC 2020), New Orleans, LA, USA, 2020, pp. 724-728

H. H. Eldeeb, H. Zhao and O. Mohammed, "Effect of Stator's Insulation Failure on the Performance of Motor Drive system," 2020 International Applied Computational Electromagnetics Society Symposium (ACES 2020), Monterey, CA, USA, 2020, pp. 1-2

H.H. Eldeeb, H. Zhao, and O. Mohammed, “Investigating the Influences of Stator Winding Faults on the Electromagnetic Behavior of DTC Drive system by FE Analysis”, 19th Biennial Conference on Electromagnetic Field Computation (CEFC 2020), Pisa, Italy, Nov 2020 pp. 1-2

H. H. Eldeeb, A. Berzoy, A. A. Saad and O. A. Mohammed, "On-line Monitoring of Stator Inter-Turn Failures in DTC driven Asynchronous Motors using Mathematical Morphological Gradient," 2019 IEEE Applied Power Electronics Conference and Exposition (APEC 2019), Anaheim, CA, USA, 2019, pp. 1018-1023 [BEST PAPER AWARD]

H. H. Eldeeb, H. Zhao and O. Mohammed, "Wavelet Transformation-Based Diagnosis of Turn-to-Turn Faults in Vector Control Drive system," 2019 IEEE Energy Conversion Congress and Exposition (ECCE 2019), Baltimore, MD, USA, 2019, pp. 339-344. [3^rd PLACE POSTER AWARD at FIU GSAW contest]

H. H. Eldeeb, A. Berzoy and O. Mohammed, "Radiated EM Flux Based Diagnostic Approach for Stator Insulation Failures in Inverter Fed Motors," 2019 International Applied Computational Electromagnetics Society Symposium (ACES 2019), Miami, FL, USA, 2019, pp. 1-2

H. H. Eldeeb, H. Zhao, and O. Mohammed,” Time-Domain Frequency-Domain Based Detection of Stator Incipient Failures in Vector Controlled Machines using Dispersal Magnetic Field”, 22^nd International Conference on the Computation of Electromagnetic Fields (COMPUMAG 2019), Paris, France, July 2019, pp.1-2

H. H. Eldeeb, A. T. Elsayed, C. R. Lashway and O. Mohammed, "Hybrid Energy Storage Sizing and Power Splitting Optimization for Plug-in Electric Vehicles," 2018 IEEE Industry Applications Society Annual Meeting (IAS 2018), Portland, OR, 2018, pp.1-8 [BEST POSTER AWARD]

H. H. Eldeeb, A. Berzoy and O. Mohammed, "Comprehensive Investigation of Harmonic Signatures Resulting from Inter- Tum Short-Circuit Faults in DTC Driven IM Operating in Harsh Environments," 2018 XIII Inter. Conference on Electrical Machines (ICEM 2018), Alexandroupoli, 2018, pp. 2579-2585

H. H. Eldeeb and O. A. Mohammed, "Control and Voltage Stability of A Medium Voltage DC Micro-Grid Involving Pulsed Load," 2018 IEEE International Conference on Environment and Electrical Engineering and 2018 IEEE Industrial and Commercial Power Systems Europe (EEEIC / I&CPS Europe), Palermo, 2018, pp. 1-6

H. H. Eldeeb, A. Berzoy, and O. Mohammed, “Stator Fault Detection on DTC Driven IM via Magnetic Signatures aided by 2DFEA Co-simulation”, 18^th Biennial Conference on Electromagnetic Field Computation (CEFC 2018), Hangzhou, China

H.H. Eldeeb, A.A. Saad, A. Berzoy, and O. Mohammed, “Mathematical Morphology Based Diagnosis of Stator Incipient Faults in Asynchronous Motor Drive System via Electromagnetic Signatures”, 18^th Biennial Conference on Electromagnetic Field Computation (CEFC 2018), Hangzhou, China

H. H. Eldeeb, A. O. Hariri and O. A. Mohammed, "Coordinated control for the integration of a large scale electric vehicle park with PV into the MV grid," 2017 IEEE International Conference on Environment and Electrical Engineering and 2017 IEEE Industrial and Commercial Power Systems Europe (EEEIC / I&CPS Europe 2017), Milan, 2017, pp. 1-6

H. H. Eldeeb, A. O. Hariri, C. R. Lashway and O. A. Mohammed, "Optimal sizing of inverters and energy storage for power oscillation limiting in grid-connected large scale Electric Vehicle park with renewable energy," 2017 IEEE Transportation Electrification Conference and Expo (ITEC), Chicago, IL, 2017, pp. 288-29

H. H. Eldeeb and O. A. Mohammed, "Coordinated Power Management for the Integration of Active Distribution Networks with High PV Penetration into the Medium Voltage Grid," 2017 Ninth Annual IEEE Green Technologies Conference (GreenTech 2017), Denver, CO, 2017, pp. 254-259

H. Zhao, H. H. Eldeeb, Y. Zhang, Y. Zhan, G. Xu and O. A. Mohammed, "An Improved Core Loss Model of Ferromagnetic Materials Considering High-Frequency and Non-Sinusoidal Supply," 2020 IEEE Industry Applications Society (IAS 2020) Annual Meeting, Detroit, MI, USA, 2020, pp. 1-6

J. Ge, H. H. Eldeeb, K. Liu, J. Kang, H. Zhao and O. Mohammed, "Optimal Range of Coupling Coefficient of Loosely Coupled Transformer Considering System Resistance," 2020 International Applied Computational Electromagnetics Society Symposium (ACES 2020), Monterey, CA, USA, 2020, pp. 1-2

H. Zhao, H.H. Eldeeb, and O. Mohammed, “Finite Element Analysis on Vibration and Noise Performance of Cage Induction Motors with Non-Skewed Asymmetrical Rotor Bars”, 19th Biennial Conference on Electromagnetic Field Computation (CEFC 2020), Pisa, Italy, Nov 2020

H. Zhao, H. H. Eldeeb, J. Wang, Y. Zhan, G. Xu and O. A. Mohammed, "Online Estimation of Rotor Temperature in Induction Motors Based on Parameter Identification," 2019 IEEE Energy Conversion Congress and Exposition (ECCE 2019), Baltimore, MD, USA, 2019, pp. 1629-1634

A. Berzoy, H. H. Eldeeb and O. Mohammed, "Online fault detection of stator winding faults in IM driven by DTC using the off-diagonal term of the symmetrical component impedance matrix," 2018 IEEE Applied Power Electronics Conference and Exposition (APEC 2018), San Antonio, TX, 2018, pp. 2482-2487

H. Zhao, X. Guo, H. H. Eldeeb, G. Xu, Y. Zhan, and O. A. Mohammed, "Design and Analysis of Inverter-Fed High-Speed Induction Motors with Closed Rotor Slots Taking Enclosure Effect into Account," 2020 IEEE Applied Power Electronics Conference and Exposition (APEC 2020), New Orleans, LA, USA, 2020, pp. 729-733

H. Zhao, Y. Wang, H. H. Eldeeb, Y. Zhan, G. Xu, and O. A. Mohammed, "Design of Loosely Coupled Transformer of Wireless Power Transfer for Higher Misalignment Tolerance of System Efficiency," 2019 IEEE Energy Conversion Congress and Exposition (ECCE), Baltimore, MD, USA, 2019, pp. 4569-4574

H. Zhao, C. Chu, H. H. Eldeeb, Y. Zhan, G. Xu, and O. A. Mohammed, "Optimal Design of High-speed Solid Rotor Cage Induction Motors Considering Ferromagnetic Materials Behavior and Manufacturing Process," 2019 IEEE Industry Applications Society Annual Meeting (IAS 2019), Baltimore, MD, USA, 2019, pp. 1-8,

H. Zhao, X. Guo, X. Dai, H. H. Eldeeb, Y. Zhan, G. Xu, J. Kang, and O. Mohammed., "Improved Rotor Bar Structure in High-Voltage High-Power Induction Motors to Eliminate Local Thermal Spot and Avoid Broken Bar faults," 2020 IEEE Energy Conversion Congress and Exposition (ECCE 2020), Detroit, MI, USA, 2020, pp. 2046-2051

Issued Patent

H. H. Eldeeb, A. Berzoy, A.A. Saad, and O. Mohammed “Condition monitoring and fault detection in induction motors” U.S 10,686,394 B1, Issued June 16, 2020

Recommended Citation

Eldeeb, Hassan H., "Condition Monitoring and Fault Tolerant Control Techniques in Electric Vehicle Drives" (2021). FIU Electronic Theses and Dissertations. 4650.
https://digitalcommons.fiu.edu/etd/4650