Robust Open-Circuit Fault Diagnosis of PMSMs Using Feature Fusion of Current Signatures With Deep Neural Networks
Permanent magnet synchronous motors (PMSMs) are broadly used in diverse applications due to their inherent advantages. Open-circuit faults (OCFs) are among the major fault classifications in PMSMs, posing significant concerns due to their contribution to torque ripples, vibrations, and efficiency degradation. Therefore, accurate and real-time OCF diagnosis is essential for reliable operation and predictive maintenance practices. This underscores the importance of a robust diagnostic framework that enables early fault detection and localization, supports embedded integration, and requires no additional dedicated sensors. However, existing studies rarely address these requirements together. To overcome these limitations, this article proposes a novel OCF diagnostic framework that fuses features derived from multiple strategies, including wavelet energy-based features, frequency-domain features extracted from current waveforms, and speed measurement data. The extracted feature vector is used as input to a lightweight deep neural network. The proposed approach enhances interpretability and enables seamless embedded integration compared to conventional raw-data-driven machine learning models. In addition, an extended refinement layer is incorporated to enable integrated fault detection and classification for OCF while enhancing diagnostic transparency. The effectiveness of the proposed method is demonstrated through MATLAB/Simulink simulations using the PLECS Blockset and further validated in real-time with an RTBox-based hardware-in-the-loop setup using a C2000 launchpad. Furthermore, experimental validation is conducted using a domain-adaptation strategy based on transfer learning. Performance evaluation confirms diagnostic accuracy exceeding 99% across varying operating conditions. The validation process achieves fault detection within 22% of a fundamental electrical cycle, with fault localization occurring within 40% of an average, demonstrating the robustness and adaptability of the proposed method. A sensitivity analysis of the proposed algorithm’s feature vector validates the effectiveness of high-frequency features. Furthermore, the risk distribution matrix provides insights supporting informed maintenance decisions.