Fault Diagnosis of Cascaded NPC Inverter Based on Single Sensor
Accurate and low-cost fault diagnosis is essential for improving the reliability of cascaded neutral-point-clamped (NPC) inverters. This paper proposes a single-sensor fault diagnosis method for a single-phase three-module cascaded NPC inverter. Only one DC-side current sensor is required for the diagnostic algorithm, while the voltage sensor used in the outer voltage-control loop is not involved in fault-feature extraction. The measured DC-side current is decomposed via Fourier analysis, and a low-dimensional feature vector is constructed using the amplitudes of the zeroth, 2nd, 3rd, and 4th harmonics together with the phases of the 1st and 3rd harmonics. The six Fourier features are normalized using feature-wise Min–max parameters determined exclusively from the training data. A back-propagation (BP) neural network is then adopted to identify and locate 24 single-switch open-circuit faults in the three-module system. The investigated inverter produces 13 output-voltage levels under healthy operation, and the BP network converges after 5835 training iterations to an error threshold of 1 × 10−6. An adaptive confirmation criterion based on consecutive diagnosis-code consistency and inter-window feature convergence is introduced. For the nominal 25-class simulation test set, the accuracy, macro-precision, macro-recall, and macro-F1-score are all 100%. In addition, 134 of the 136 dynamic-condition simulation runs are correctly diagnosed, corresponding to an overall robustness-test accuracy of 98.53%. One confirmed, but incorrect final code occurs under the load disturbance applied at 90° of the output-voltage fundamental, and another occurs at an SNR of 20 dB, while no unconfirmed run is observed. Under the severe RL-load condition with τ/T0 = 1, the mean and maximum diagnostic delays are 41.7 ms and 52 ms, respectively.