NPC Type Inverter Open Circuit Fault Diagnosis Method Based on Residual Performance Evaluation
Chen Chaobo1, Dai Jiawei2, Sun Tianyu1, Zhang Binbin1, Gao Song1
1. School of Electronic Information Engineering Xi'an Technological University Xi'an 710021 China; 2. School of Mechatronic Engineering Xi'an Technological University Xi'an 710021 China
Abstract：During the contemporary scenario of "Industry 4.0 era", motors and theirs drive systems are widely used in metallurgy, petrochemical, chemical and other industrial fields. They are the largest power consumption machinery. Therefore, to guarantee the safety and stability of motors and theirs drive systems and improve the performance of them, it has become a research hotspot in the present industry and academia. However, the power switching devices in the motor drive system, such as the insulated gate bipolar transistor, work continuously at high switching frequency. They have to withstand the electrical and thermal overstress. It is prone to open circuit failure. It causes the output waveform harmonics increase, the motor torque ripple increase and brings bad effects on the system. Hence, it is urgent to solve the problem of open circuit fault of inverter power switching devices. In the fault diagnosis system based on analytical model, the system is composed of residual generator, residual evaluation with threshold and fault decision part. In this process, the difference information obtained by comparing the actual variable with the reconstructed variable is called the residual. Residual signals can reveal fault information and reflect fault signals. However, the technique of filtering and extracting effective fault information from residual signals has been regarded as a challenge. Furthermore, there are few research results on residual evaluation and threshold calculation. In order to manifest the ability of fault information contained in residual signals, a fast open circuit fault diagnosis method for NPC three-level three-phase inverter is proposed via residual performance evaluation. Firstly, aiming at the hybrid characteristics of the inverter, the health state mathematical model of the inverter based on hybrid logic dynamic method was established. Meanwhile, the diagnostic observer was constructed to obtain the three-phase current observations and calculate current residuals. Three phase current residuals were calculated by observation matrixes. Next, by introducing the standard evaluation function based on norm, the residual performance indicators and threshold were calculated. Current residuals were converted into usable characteristic signals and compared with the threshold to achieve efficient and accurate fault detection. At the same time, by means of analyzing the residual current numerical characteristics of different power switching devices under the open fault condition, the fault isolation table of the NPC inverter was derived. The accurate fault isolation is achieved according to the fault isolation table. Ultimately, the proposed algorithm was verified on the simulation and semi-physical experiment platform. The simulation and semi-experimental platform results show that compared with the traditional signal and knowledge-based diagnosis method, the introduction of residual performance evaluation can improve the diagnosis speed by more than 80%. In the fault isolation simulation, three phase residual signals are generated for four different open circuit fault types of the inverter power switching device. The numerical characteristics are consistent with the fault isolation conditions derived in Tab.1~Tab.3. It verifies the effectiveness and accuracy of fault isolation. Furthermore, the fault diagnosis scheme proposed in this paper is simulated and discussed under the complex working condition, that is, under the condition of process disturbance and random noise. The simulation results indicate that the residual performance evaluation has good robustness under noise and disturbance. In summary, in this paper, the fast and accurate fault detection and isolation can be realized for the four common open circuit fault conditions of NPC three-level three-phase inverters.
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