2026· IEEE Open Journal of Industry Applications· Vol 7, pp. 825-847· 0 citations· 76 references
Abstract
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.
Motor drive systems operating in embedded environments are frequently affected by noise, dynamic loading conditions, and electromagnetic interference, making timely fault diagnosis difficult. To improve diagnostic accuracy and real-time performance, this study proposes an intelligent fault diagnosis framework based on embedded multi-source data acquisition and feature fusion. High-precision sensors are employed to synchronously collect vibration and current signals, while improved wavelet packet decomposition and principal component analysis are combined to extract discriminative multi-dimensional fault features and eliminate redundant information. A lightweight convolutional neural network optimized for embedded deployment is then developed to perform low-latency fault classification and edge inference. Experimental results show that the proposed method achieves an average F1-score exceeding 97% under complex mixed-fault conditions, while maintaining an average detection latency of approximately 45 ms. The proposed framework demonstrates strong robustness and computational efficiency, providing practical support for intelligent industrial maintenance and offering reference solutions for embedded sensing, signal processing, and electromagnetic compatibility environments.
Inter-turn short-circuit faults are a common failure mode in permanent magnet synchronous motors, and their early diagnosis is essential for ensuring safe and reliable operation. In practical applications, however, training data are often contaminated with noisy labels, while incipient fault features are weak and exhibit limited inter-class separability, which further aggravates label misassignment and mixing. To enhance data usability and label reliability, this paper proposes a diagnostic framework integrating high-frequency signal injection with unsupervised learning. High-frequency signal injection is used to strengthen fault-related current features, followed by autoencoder-based feature extraction, UMAP dimensionality reduction, and HDBSCAN clustering to group samples, after which a majority voting strategy is applied for sample relabeling. Experimental results demonstrate that the proposed method can effectively improve noisy-label correction performance even under high noise ratios and low fault severity, thereby providing reliable data for subsequent fault diagnosis.
Haoguang Wang, Baoye Song, Wei Xin et al.· International Conference on...· 0 citations
A novel perspective on noninvasive diagnostics by integrating advanced signal processing with deep learning classifiers is offered, indicating that appropriate signal preprocessing enhances feature representation quality, indicating that the choice of transform method directly impacts diagnostic accuracy.
Konrad Górny, Wojciech Pietrowski· Compel· 0 citations
Accurate fault detection in induction motors (IMs) under varying load conditions remains a critical challenge in industrial condition monitoring (CM). Inspired by the foundational work, which highlighted the impact of mechanical load on fault signature detectability. This study proposes a multi-modal signal analysis approach to bearing fault diagnosis using stator current, rotor speed, and flux-induced voltage signals. A custom fifteen-class dataset was collected, comprising healthy and faulty motor states at 0%, 50%, and 100% load levels. Unlike conventional approaches that rely on extensive preprocessing and handcrafted feature extraction, the proposed framework operates directly on raw signals, enabling a lightweight, computationally efficient, and easily deployable solution. This design significantly reduces implementation complexity while maintaining high diagnostic performance, making it suitable for real-time and industrial applications. Two types of models were evaluated in this study: traditional machine learning models and deep learning models. Experimental results demonstrate significant performance gains compared to single-sensor models, highlighting the benefits of cross-domain signal fusion. Models specifically designed to process time-series data, such as the Temporal Convolutional Network (TCN) and particularly the Long Short-Term Memory (LSTM), exhibit outstanding performance. During the training and validation phases, the LSTM model achieved perfect classification accuracy (100%), outperforming all other evaluated models. However, during the deployment-oriented evaluation on unseen test data, the SVM and TCN models demonstrated the most consistent generalization performance, achieving perfect prediction results across all tested samples. Recent architectures, such as the Transformer, also demonstrate strong potential; with careful hyperparameter tuning, their performance especially in terms of generalization can be further enhanced.
Kamal Hamani, M. Kuchař, Martin Sobek et al.· Scientific Reports· 0 citations
Motor Current Signature Analysis (MCSA) is a non-invasive technique that enables the detection of bearing faults in rotating electrical machines without the need for additional sensors. In this study, the Paderborn University bearing dataset was utilized to perform a two-stage analysis. In the first stage, motor current data were processed directly using 1-Dimensional Convolutional Neural Networks (1D-CNN). In the second stage, scalogram images obtained via Continuous Wavelet Transform (CWT) were used to train five different deep learning models, with the ResNet18-based 2D-CNN model providing the best performance. To prevent data leakage, the training and testing sets were partitioned based on individual bearings to ensure complete isolation. The experimental results demonstrated that both 1D-CNN and ResNet18-based 2D-CNN methods achieved 100% accuracy in detecting outer race faults. However, it was observed that the impact of inner race faults on the stator current remains weak due to the complex physical transmission path of the fault signal, resulting in significantly lower detection rates.
Y. Çekiç, Aydin Akan· Signal Processing and Commun...· 0 citations
This paper investigates the diagnosis of Inter-Turn Short-Circuit (ITSC) faults in Permanent Magnet Synchronous Machines (PMSM) under controlled experimental conditions. The study is based on stator current signals acquired for different speeds, load levels, and fault severities. Since time-domain waveforms under variable speed drive do not clearly reveal the fault, Shannon entropy is used to capture variations in signal complexity and extract a discriminative feature. This feature is then used as input to a Multi-Layer Perceptron (MLP) classifier. The experimental results show that the proposed approach can effectively distinguish healthy and faulty conditions, achieving mean values of 92.8% accuracy, 94% precision, 96.6% recall, and 95.2% F1-score. These results demonstrate the potential of Shannon entropy combined with MLP for reliable ITSC fault diagnosis in PMSMs.
Y. Azzoug, M. Boukhnifer, R. Pusca· International Conference on...· 0 citations