XIX International Conference on Electrical Machines - ICEM 2010, Rome

Novel Modular Switched Reluctance Machine

for Safety-Critical Applications
Mircea Ruba, Ioana Benţia, Loránd Szabó

Φ
Abstract -- Electrical machines and drives used in various
safety-critical applications are of special design in order to
achieve the required fault tolerance level. In the paper a novel
modular fault tolerant switched reluctance machine is proposed
and studied. It is proved by means of dynamic simulations that
the proposed machine is able to have continuous operation also
despite of five severe winding fault conditions.
Index Terms -- Fault tolerance, reluctance machines,
reluctance motor drives, machine windings, simulation.
I. INTRODUCTION
Its fault tolerance is studied by means of dynamic
simulations performed by a program set up in the
MATLAB®/Simulink® environment. In the simulation
program the magnetic flux and force computations are
substituted with data taken out from two look-up tables
containing the flux and force characteristics of the machine
obtained via finite elements method (FEM) based numeric
field computations [12].
All the obtained results emphasize the high fault
tolerance of the proposed SRM.

F ault tolerance is the ability of a system to continue

performing its intended function in spite of different
faults, expectedly occurring in any system. As the
II. THE MODULAR FAULT TOLERANT SRM
The proposed modular SRM is given in Fig 1.
Stator Spacer
complexity of a system increases its reliability drastically module
gets worse, unless compensatory measures are taken [1].
An advanced fault tolerant electrical system has to be
capable of detecting its faults and able to adequately
compensate the failures [2]. Fault tolerance is an obligatory
feature in almost all the safety-critical applications, where
loss of life or environmental disasters must be avoided
(aeronautical, aerospace, medical and military applications,
power plants, etc.) [3].
Hence the electrical machines and drives used in such
systems must be of high fault tolerance. Switched reluctance
machines (SRM) seems to be the best solutions for such Rotor
applications [4].
The SRM is inherently more fault tolerant than other Winding
Hole for
electrical machines, because it can continue operating and fixing rod
producing torque in certain limits also with one or more
Fig. 1. The modular SRM in study
faulty phases [5]. This is due in a large part to its
independent concentrated windings. It's brushless and The machine has four phases, each divided into two
permanent magnet free simple construction enables a channels. Each channel is wound on one of the eight
maintenance free utilization also in high temperature, dusty, module's yoke. The modules of a phase are placed
dirty and vibrations exposed harsh environments [6]. diametrically opposed.
Several methods exist for improving the fault tolerance of The detailed construction of the SRM is shown in Fig. 2.
a SRM. As a first step the stator poles and phase numbers Module
can be increased [7], [8], [9]. Another usual solution is the Stator module spacer
division of the phases into individual coils, called channels End
Rotor shield
[10]. This way a fault of a channel will not influence the
operation of the other channels of the same phase or of other
phases. The drawback of this solution is that a more
complex power converter is required, having as many
converter legs as channels [11].
Combining the fault tolerance increasing solutions with
the modular construction concept a novel SRM was
developed, which is high reliable and quickly repairable.

Mircea Ruba, Ioana Benţia and Loránd Szabó are with the Department
of Electrical Machines, Technical University of Cluj, Cluj, Romania
(e-mails: Mircea.Ruba@mae.utcluj.ro, ioana.bentia@yahoo.com, and
Lorand.Szabo@mae.utcluj.ro). Frontal
spacer
Work partially supported from the Romanian PNCDI 2 Partnership Shaft Hole for
Research Grant "Fault-Tolerant Equipment Controlled By Bio-Inspired fixing rod
Electronic Architectures (ElBioArch)", no. 12-121 / 01.10.2008
(http://elbioarch.utcluj.ro). Fig. 2. The construction of the SRM

978-1-4244-4175-4/10/$25.00 ©2010 IEEE

 The distance between two neighbored modules is set by
nonmagnetic spacers. One module without its winding and a
spacer are given in Fig. 3.
Fig. 3. The iron core of the module and a spacer
The entire modular construction is tightened by totally 16
rods, 2 through each module. The modular stator
construction is placed between two end shields.
Nonmagnetic spacers keep the stator in the middle of the
motor. The rotor has a usual construction built of
laminations.
The flux lines in the motor for unaligned and aligned
positions obtained via field computations are shown in
Fig. 4.
a) unaligned poles
b) aligned poles
Fig. 4. The flux lines in the SRM in study obtained by
means of numeric field computations
As it can be seen the magnetic flux is closed between the
two poles of a single module, hence there are not passing
through the central part of the rotor. Therefore due to the
shorter flux paths the losses in the machine are less than in a
classical 4-phase SRM. Also due to this design the forces are
better balanced in the machine.
The modular construction allows both easy
manufacturing and fast replacement of the damaged modules
in case of a winding failure. Only a single end shield and the
two fixing rods of the faulted module have to be detached
and the module can be easily pulled out and replaced. This
way there is no need of decoupling the machine from its
load, a major advantage in industrial environment [13].
The machine's power converter given in Fig. 5 has a
separate half H-bridge for every channel for independent
control [14]. During the conducting period only one switch
of an inverter branch is commanded via a hysteresis current
controller. The other one is held open for the entire period.
+
1
1'
2 2'
3 3'
4 4'
-
Fig. 5. The power converter
The control system of the machine must have the
intelligence to detect the fault, to isolate and remedy it, all to
ensure that the machine's behavior is influenced as less as
possible by the faults [13], [15]. A first answer of the control
system to an open channel is the increase of the currents in
the healthy remained coils up to a predefined value, which
was taken into account when the windings were designed.
The four phase sample machine to be simulated has
350 W. Its rated voltage and current are 300 V and 6 A. It is
capable to develop a rated torque of 5 N·m.
The main data of the sample machine in study are given
in Table I.
TABLE I
THE MAIN DATA OF THE MACHINE
Module height 35 mm
Rotor pole height 26 mm
Air-gap 0.5 mm
Stator and rotor yoke height 11 mm
Rotor and stator pole width 13 mm
Winding height 19 mm
Outer diameter 210 mm
Number of turns of a channel 220
 III. THE SIMULATION PROGRAM In the modularly built up program the main units of the
To be able to study the fault tolerance of the proposed speed control system (the speed controller, the power
machine dynamic simulations in different conditions should converter and the modular SRM) can be easily
be performed [16]. distinguished.
The simulations of the speed control system with the fault The speed controlled is of PI type. The machine's model
tolerant SRM in study were carried out by a program set up with the two 2-D Look-up Table-type blocks integrating the
in the MATLAB®/Simulink® environment. two characteristics mentioned above is given in Fig. 8 [18].
Preliminarily two main characteristics of the machine Mechanic
System
TL
were set up based on the results obtained by means of field v
K Ts
2 TL w
w (rad/s)
1 I (A)

computations performed by the Flux 2D program [17]. z-1

Flux
Flux
Te Teta
teta (rad)

These are the torque of the machine and the magnetic flux
Sum of Scope4
Torque
Elements
Rs

thru the energized coil versus the rotor position and current. Rs
Angle Pos_sensor
These two characteristics are given in Fig. 6. angle w

Flux (V*s)

6
1
m1
w (rad/s)
4 CurrentA.mat

To File

2
Torque [N ⋅ m]

CurrentB.mat

0 To File1

-2 Fig. 8. The Simulink® model of the SRM

-4
The model of the power converter is built up of
SimPowerSystems blocks.
-6
8
The open circuit faults of the windings were simulated by
7
6
5 90
imposing OFF state for both switches of the corresponding
4 80
3
2
1 20 30 40 50 60 70
converter leg.
Current [A] 0 0 10 Angular displacement [degrees]

a) the developed torque IV. THE RESULTS OF SIMULATIONS

In order to emphasize the machine's behavior both in
0.25
normal and faulty operation mode several simulations were
performed for the following conditions [19]:
0.2
a) healthy condition;
b) one channel open;
Magnetic flux [Wb]

0.15
c) two open channels;
0.1
d) three open channels;
e) four open channels;
0.05
f) one completely faulty (open) phase.
All the simulations were performed in identical
0 conditions. The simulation time was 0.5 s. The trapezoidal
8
7
6
5
profiles of the imposed speed and of the resistant torque are
90
4
3
2 40 50 60 70 80
shown in Fig. 9.
1 20 30
Current [A] 0 0 10 Angular displacement [degrees]
6
b) the magnetic flux thru the energized coil 600

Fig. 6. The main characteristics of the SRM computed via numeric field
analysis for different rotor positions and currents
4
The main window of the simulation program is given in 400
n* [r/min]

Fig. 7.
T R [N ⋅ m]

SPEED
CONTROLER CONVERTER
v1 200 2
v I* G v2 To File1
M ODULAR
v3 SRM TORQUE.MAT
v4
V+ v
v11 <I (A)>
m1
300 V v21 TL <Te (N*m)>
V- v31 <w (rad/s)>
v41 0 0
<teta (rad)>
0 0.1 0.2 0.3 0.4 0.5
R_TORQUE.MAT t [s]
RESISTAT
TORQUE
To File3 -K-
Scope1 Fig. 9. The imposed speed and the resistant torque vs. time

sig
w
alfa 4 To File2 The obtained results are given in Fig. 10. In all the six
beta 36
SPEED.MAT
cases in study two sets of currents (those in the first,
POSITION
SENSOR
respectively second channels of all the phases), the speed
and the developed torque were plotted versus time.
Fig. 7. The main window of the simulation program
 8 8

6 6

4
I [A]

I [A]
2 2

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

8 8

6 6

4
I [A]

I [A]
2 2

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

600 600
n [r/min]

n [r/min]
400 400

200 200

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]
15 15

10 10
T [N⋅ m]

T [N⋅ m]
5 5

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

a) healthy condition d) three open channels

8 8

6 6

4 4
I [A]

I [A]
2 2

0 0

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

8 8

6 6

4 4
I [A]

I [A]

2 2

0 0

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

600 600
n [r/min]

n [r/min]

400 400

200 200

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

15 15

10 10
T [N⋅ m]

T [N⋅ m]

5 5

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

b) one open channel e) four open channels

8 8

6 6

4 4
I [A]

I [A]

2 2

0 0

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

8 8

6 6

4 4
I [A]

I [A]

2 2

0 0

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

600 600
n [r/min]

n [r/min]

400 400

200 200

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

15 15

10 10
T [N⋅ m]

T [N⋅ m]

5 5

0 0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
t [s] t [s]

c) two open channels f) one open phase

Fig. 10. Results of simulation. The currents, speed and torque vs. time in different motor conditions

In Fig. 10a the results for the healthy condition of the
machine are presented. For achieving the imposed speed the
rotor has to be accelerated by a torque greater than its rated
value. During the constant speed operation of the machine
also the developed torque is almost constant, with low
ripples. The maximum value of the current pulses are around
5 A, the rated current of the machine.
When a single channel is opened (see Fig. 10b) the
imposed speed profile is still closely fulfilled. To overcome
the missing channels contribution to the torque generation
the currents in the healthy channels were raised by the
control system. Due to higher currents also the torque ripples
become greater.
The SRM was designed (also from the thermal point of
view) to work in continuous regime at a maximum 8 A
phase current.
In the case of two open channels from two different
phases (Fig. 10c) the imposed speed profile is also nearly
fulfilled. The currents in the healthy channels of the faulted
phases are increased to the maximum value of 8 A in order
to compensate the winding faults. In this case the torque
ripples are less than in the previous case, as it can be seen in
Table II. The reason is that two adjacent channels are
opened in this case. Hence the machine has two consecutive
phases fed at the rated current and two at higher current.
When the rotor is aligned with a pole having its winding fed
with different current than that from the previous pole higher
torque ripples occur. The mean developed torque in this
condition is around 5 N·m, the rated torque of the machine
(see Table II).
When three channels from different phases are opened
(Fig. 10d) the machine still can run at the imposed constant
speed. The developed torque ripples are greater in
comparison with the previous case because the opened
channels are not consecutives and the command current's
maximum value is varying from the rated to the maximum
value. As it can be seen in Table II also in this case the
machine is able to develop the rated torque despite of three
winding faults.
If four channels are faulted (Fig. 10e) the machine will
practically operate with only half of its structure. The
machine cannot accelerate to its constant speed as rapidly as
it is imposed, but after about 0.15 s the imposed speed is
reached and the machine is able to maintain this speed at the
imposed load.
As the four channels are from different phases in all the
TABLE II
THE MINIMUM, MAXIMUM AND MEAN TORQUE, RESPECTIVELY THE TORQUE RIPPLE FOR ALL THE CONDITIONS IN STUDY
Condition
Minimum
Healthy 4.2467
One open channel -0.5021
Two open channels 0.1870
Three open channels -0.1212
Four open channels 1.2386
One open phase -2.0694
V. CONCLUSIONS
The novel fault tolerant modular SRM topology completes
the few structures cited in literature and can be interesting
both for researchers working in the field of SRMs and in
fault tolerant systems.
The design of the proposed structure was performed
accurately and taking into account all electromagnetic
phenomena of such a complex structure [20]. The number of
poles was increased and the phase windings were split into
two separately fed channels. As it was proved in a previous
paper, the FEM based numeric computations were in
accordance with the analytical ones, which proved the
correctness of the design [13].
The MATLAB®/Simulink® model of the machine in study
was demonstrated to be a useful tool in dynamic simulations
of diverse conditions of the machine. The integration in the
Simulink® model of the two tables computed via FEM based
numeric field analysis much increased the precision of the
simulations. Hence in short time numerous simulations
healthy remained coils the currents will be maintained at
their maximum value (8 A). It is interesting that in this case,
when the SRM have four open channels, the torque ripples
are the lowest in comparison with other faulty conditions.
The reason is, as it was already pointed out, that in all the
healthy remained channels the currents are of the same
magnitude.
The last condition in study is the most severe one, when
an entire phase is opened (see Fig. 10d). The starting of the
motor is quite heavy. This can be also impossible if the rotor
is in an initial position where the first phase to feed is
exactly the faulted one. If the motor starts, or if the fault
occurs during its movement the inertia of the motor and load
can move further the rotor from a position where torque is
not developed due to the missing phase.
In this case the currents in the rest of the phases are
increased, especially in the adjacent phases to the faulted
one. This way the rotor will develop more torque to overrun
the pole with the faulted phase. Unfortunately in this case
the torque ripples are the greatest ones from all the
conditions in study.
It is important to mention that in all the conditions taken
into study the mean torque developed by the machine is near
the rated one, which means that even in the case of several
winding faults the machine is able to continue its movement
at the imposed speed and torque, the main task in case of a
safety-critical application.
Torque [N·m]
Maximum Mean Ripple
6.0396 5.0814 1.7929
13.6080 5.0937 14.1102
11.3618 5.0661 11.1748
12.9501 5.0952 13.0714
8.1011 5.0936 6.8624
14.8225 5.1058 16.8919
could be performed for various machine and load conditions
[21].
All the obtained results proved the fault tolerant capability
of the proposed modular SRM.
Also in very severe conditions (with up to the half of the
SRM's coils opened) the main task of a fault tolerant
machine was fulfilled: to continue its movement at the given
load. Of course in such conditions the torque ripples are
higher and the speed can be reduced.
Beside its fault tolerance another advantage of the
machine is its simplicity. The modules can be manufactured
separately and the stator can be easily assembled. The
passive rotor is very simple. The proposed SRM can be
quickly repaired if winding faults occur without removing
the machine from the load.
The main drawback of the proposed SRM is the
complexity of its power converter [22]. By splitting into two
channels each phase the number of the power converters
branches were also doubled.
The machine can be used in safety-critical applications
where the reliability is a key issue: advanced factory
automation systems, automotive and aerospace applications,
military, energy and medical equipment, etc.
In the future more faulty conditions should be studied
(short circuits, power converter faults, etc.).
Special attention has to be given to the torque ripple
minimization. This can be improved by increasing the
number of poles (and inherently the number of converter
legs) or by applying more advanced control techniques [23].
The laboratory model of the proposed SRM is in
construction. The measurements to be performed hopefully
will confirm the correctness of the simulated results.
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VII. BIOGRAPHIES
Mircea Ruba received the B.Sc. and M.S. degree from Technical
University of Cluj (Romania) in electrical engineering in 2007, respectively
in 2008. He is a full time Ph.D. student working in the field of fault tolerant
switched reluctance machines.
Ioana Benţia received the B.Sc. degree from Technical University of Cluj
(Romania) in electrical engineering in 2009. She is a full time Ph.D. student
working in the field of modular variable reluctance machines.
Loránd Szabó (M '04) received the B.Sc. and Ph.D. degree from Technical
University of Cluj (Romania) in electrical engineering in 1985, respectively
in 1995. Currently, he is a Professor in the Department of Electrical
Machines of the same university. His research interests are in the areas of
variable reluctance machines, fault detection, etc. He published over 170
scientific papers and books in these fields.