IET Electrical Systems in Transportation

Research Article

Artificial neural network-based fault diagnosis

in the ACDC converter of the power supply of
series hybrid electric vehicle

ISSN 2042-9738
Received on 16th August 2014
Revised on 26th June 2015
Accepted on 14th July 2015
doi: 10.1049/iet-est.2014.0055
www.ietdl.org

Seyed Saeid Moosavi 1, 2 , Abdesslem Djerdir 1, Youcef Ait-Amirat 3, Davood Arab Khaburi 4,
Abdoul NDiaye 1
1

Laboratory of IRTES-SET, University of Technology Belfort Montbliard (UTBM), Belfort, France

Engineering Department, Amol University of Special Modern Technology, Amol, Iran
3
Energy Department of the FEMTO-ST Institute UMR CNRS 6174, University of Franche-Comte, France
4
Center of Excellence for Power System Automation and Operation, Electrical Engineering Department of Iran, University of Science &
Technology (IUST), Tehran, Iran
E-mail: anchepoli@gmail.com
2

Abstract: ACDC converter switches of the drive train of series hybrid electric vehicles (SHEVs) are generally exposed to
the possibility of outbreak open-phase faults because of troubles with the switching devices. In this framework, the present
study proposes an artificial neural network (ANN)-based method for fault diagnosis after extraction of a new pattern. The
new pattern under ACDC converter failure in view of SHEV application has been used for train-proposed ANN. To achieve
this goal, four different levels of switches fault are considered on the basis of both simulation and experimental results.
Ensuring the accuracy and generalisation of the introduced pattern, several parameters have been considered, namely:
capacitor size changes, load, and speed variations. The experimental results validate the simulation results thoroughly.

Introduction

Nowadays, because of its advantages, the use of the series hybrid

electric vehicle (SHEV) must be taken into consideration. A
decoupled engine from the drive train leads to better engine
efciency and emission and controls optimisation. This also leads
to a better generator design optimisation, an E-drive capability,
and to the startstop control of the internal combustion engine
(ICE). Note that the lack of a requirement for a special
transmission integrated with electric machines, the better transient
efciency because of a more powerful traction system, and an
optimal combination of speed and torque for ICE are considered
as the main advantages of SHEVs [18].
In general, the most common drive train of the SHEV consists of a
three-phase AC generator coupled with a rectier bridge, an inverter,
and the traction motor. The ICE mechanical power output is rst
converted into the electricpower by the AC generator. Then, the
three-phase rectier converts the AC voltage to the DC one with a
ripple component, which is generally ltered by using a capacitor
to reduce the harmonics of the currents owing in the motor.
Finally, the inverter converts a DC voltage to an AC one with
limited harmonic content due to a suitable choice of the switching
strategy [9, 10].
Faults in each part of an SHEV, such as a generator, ACDC
converter, inverter, and motor, will lead to the disturbance in its
operations and decrease the efciency of the whole system. In
addition, there is a high risk of unforeseen failure because its
relation with the safety of the drivers and the passengers directly
leads to the necessity of reliable operation.
Among the different electric elements of hybrid electric vehicle
(HEV), many papers deal with ACDC converter failure problems.
These studies focus on: nding robust solutions, multi-level
converter designs, and on control of the auxiliary power unit [1114].
In [15], a fault-tolerant power-train topology for SHEVs is
presented. A redundant phase-leg is introduced. It is shared by
three converters in a standard SHEV power train, which allows
maximum improvement in reliability with minimal part-count
increase. In [16], a statistical moment is used to detect and identify
faults in multi-converter SHEVs with the help of current and

96

voltage sensors. In [17], an open winding fault in a power

conversion system with two conventional six-switch voltage
source converters is studied. Advantages and disadvantages of the
proposed solution are discussed. In [14], the estimation of an
equivalent series resistance of the DC-link electrolytic capacitor in
three-phase ACDC pulse-width modulation (PWM) converters is
proposed to ensure condition monitoring and fault diagnosis. All
presented papers in this area aim to maximise the operating
reliability of the system within a low-cost strategy. Thus, for cost
reasons, the problem of defects in switches of ACDC converter
of the SHEVs drive train has not been deeply treated, despite the
importance and sensitivity of this component in the power supply
device of this kind of vehicle.
Recently, articial intelligent (AI)-based fault diagnosis seems to
be attractive and interesting, because it has some advantages
compared with other methods [18]. The AI-based method views
the whole system as a black box, whose inside details are not
cared about. This can avoid the problem of circuit system
modelling. There are varieties of AI classication methods
including support vector machines (SVMs), articial neural
networks (ANNs), K-nearest neighbour (KNN), etc. In many
classication applications, SVMs have proven to be highly
performing. However, one drawback of the SVM is its rather high
classication complexity which scales linearly with the number of
support vectors (SVs). This is due to the fact that for the
classication of one sample, the kernel function has to be
evaluated for all SVs. To speedup classication, different
approaches have been published, most of which try to reduce the
number of SVs. All these methods yield to a good speedup, but
are fairly complex and computationally expensive. Another
drawback of SVM is to be considered as hard to interpret [1922].
However, K-NN is used as an auxiliary classier to improve the
SVM performance, but it is also introduced as another prevalent
classication method. KNN has several main advantages:
simplicity,
effectiveness,
intuitiveness,
and
competitive
classication performance in many domains. It is robust to noisy
training data and it is effective if the training data is large. Despite
the advantages given above, KNN has a few limitations. KNN can
have poor run-time performance when the training data set is

IET Electr. Syst. Transp., 2016, Vol. 6, Iss. 2, pp. 96106

& The Institution of Engineering and Technology 2016

Fig. 1 Schematic diagram of a generator (G), three-phase full bridge rectier, three-phase full bridge inverter, and three-phase induction motor by application
in SHEV

Fig. 2 Experimental setup

large. It is very sensitive to irrelevant or redundant features because

all features contribute to the similarity and thus to the classication.
By careful feature selection or feature weighting, this can be avoided.
One disadvantage of the method is the fact that the distance-based
learning is not clear in the choice of its type and its attribute in
order to produce the best results. Another disadvantage is the
computation cost, which is quite high because we need to compute
the distance of each query instance for all training samples [2325].
In front of these methods, neural network (NN) is a good
classier, which has good performance in faults classication of
power electric circuits. In [26], the radial-basis-function NN is
adopted to perform fault detection of an induction motor drive
circuit. A back-propagation NN (BPNN) is presented in [27] to
diagnose faults of a three-phase inverter. In this example, over
95% classication accuracy is reported. In [28], a multi-layered
perceptron network is employed to classify open faults of a
simulated voltage source inverter. Another study of BPNN fault
classication application to multi-level inverter is described in
[29]. In some investigations, two or more NNs are integrated to
implement classication task, and this can improve the
classication performance of diagnostic system [3032].
This paper presents an ANN-based fault diagnosis method on
open-phase fault in switches of ACDC converter in an SHEV. A
new pattern has been identied for use in fault diagnosis. This
paper is organised as follows.
In Section 2, an introduction of faults structure in ACDC
converter is presented. Section 3, presents a simulation schematic,
where simulation and experimental results have been veried in

IET Electr. Syst. Transp., 2016, Vol. 6, Iss. 2, pp. 96106

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Section 4 with a proposed experimental setup. A new pattern is

identied in Section 5, by considering all effective parameters on
identied pattern. Finally, Section 6 presents an ANN-based fault
diagnosis of open-phase fault in switches of ACDC power
converter of SHEV. It is shown that ANN is able to fault
diagnosis by classifying the severity of faults in different speeds
and loads.

2 Introduction of faults structure in ACDC

converter under study
The schematic diagram of ACDC converter of power supply of the
SHEV studied in this paper is shown in Fig. 1. The six
thyristor-based switches, S1, S2, S3, S1, S2, and S3 are
introduced to create different types of faults. The presence of
capacitor between converter and inverter will compensate some of
Table 1 Rated characteristic of the used three-phase IM
power
frequency
voltage
speed, rpm
cos
number of poles
full-load current

0.75 kW
50 Hz
220 V
1440 min1
0.72
4
A

97

Fig. 3 MATLAB/SIMULINK simulation of a sample of SHEV

Fig. 4 Comparison of simulation and experimental results on DC-bus voltage and current, respectively
a DC-bus voltage under healthy mode operation of system-simulation result
b Experimental result
c DC-bus current under healthy mode operation of system-simulation results
d Experimental result
e FFT analysis on DC-bus current-healthy mode simulation and experimental result
f Faulty mode simulation and experimental result (switch S2 is opened)
g Zoom of faulty mode in frequencies 25, 75, and 125 Hz

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IET Electr. Syst. Transp., 2016, Vol. 6, Iss. 2, pp. 96106

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Fig. 5 Comparison between the DC-bus current under healthy and open-phase faulty state operations

the voltage drop and also harmonic changes under some types of
faults that lead to difculty in fault detection. This paper shows a
useful and new method to reach this goal.
In [3], we presented a complete introduction of ACDC converter
operation in healthy and faulty states. According to six switching
operations, 26 different states exist for consideration. These include
healthy and faulty conditions that can be classied in ve different
groups [3]. In group 1, the ACDC converter under health state
operation is considered. In group 2, an open-phase fault-assuming
failure in only one switch with six different states has been
investigated. Group 3 considers this fault under two different
switch failures. In groups 4 and 5, frequently, three and four
switches simultaneously under failure were considered. However,
in group 5, the power transferred to the motor is not enough to
operate under a full-load, but the motor is still supplied so can
continue its work.

Experimental setup

For data acquisition and simulation result verication, an

experimental setup is used as shown in Fig. 2. The main parts of
this experimental setup are described below. The main parameters
of the motor are presented in Table 1:
(i) Three phases full bridge ACDC converter.
(ii) PC, for data transfer and data analysis.
(iii) A system equipped with a data acquisition controller that it is able
to connect with dSPACE (DS1104card) for sampling the electrical data
at adjustable frequency. For advanced uses of the inputs and outputs, the
card has a digital signal processor subsystem slave to ensure the
measurement acquisition and generation of PWM signals.
(iv) The voltage inverter in the power circuit consists of three arms
of power switches. There are six SEMIKRON insulated gate bipolar
transistors ordered with drivers. This inverter includes

IET Electr. Syst. Transp., 2016, Vol. 6, Iss. 2, pp. 96106

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6(EPCOS-B43303-A0158-M90) parallel capacitor, 1500 F,

200 V, 25 A, between inverter input and DC-bus output.
(v) The three-phase induction motor. The parameters of the used
induction motor are shown in Table 1.
(vi) Electromagnetic brake.
(vii) DC power supply for electromagnetic brake.
(viii) Power network.

4
4.1

Experimental and simulation results extraction

Simulation study of ACDC converter operation

A simulation programme has been developed under MATLAB/

SIMULINK software as shown in Fig. 3. This part presents an
original and accurate result in ACDC converters, under healthy
and faulty operation modes.
The simulation results have been veried by experimental results
that will be discussed in the next part.
4.2 Experimental results and simulation results
verification
HEV fault detection and diagnosis require a deep knowledge of
system operation and fault detection techniques. Dependence and
effect of different parts of HEV-like generator, ACDC converter,
capacitor, inverter, and motor require high precision in fault
feature extraction to avoid errors in fault detection and diagnosis.
The existence of capacitor between ACDC converter and inverter
may lter the effect of some types of faults inside of after
capacitor, especially when faults are at minor levels. In this case,
the fault detection will become difcult. Moreover, because of the
vehicles movement, in part of the electric motor, it is under an
inherence vibration in addition to inherence asymmetries that
could appear during motor manufacturing. Therefore, the

99

Fig. 6 Identied pattern is independent of the capacitor size

a Consideration of the capacitor size inuence on a pattern identied under a healthy and a faulty condition operations of ACDC converter (switch S2 is opened)
b Consideration of load variations inuence on a pattern identied under faulty operation of ACDC converter (switch S2 is opened)
c Consideration of the speed variations inuence on a pattern identied under faulty operation of ACDC converter (switch S2 is opened)

waveforms of the motor and the other instruments occur with some
distortion. This leads to unreliable amplitude changes for fault
detection and diagnosis.

As we explained in [3], fast Fourier transform (FFT) is one of the

useful methods in steady state, even though it is not efcient for fault
detection in a transient condition. We justied that DC-bus current is
the best data for acquisition. DC-bus current carries valuable
information against the motor current, the motor voltage, and the
DC-bus voltage. These informationlet us to establish proper
pattern identication and fault diagnosis [3].
To verify the simulation result, two types of faults are considered:
Open-phase fault by considering one switch is opened, because
the signal variations are very small.
Open-phase fault by considering four switches are opened,
because the fault effect can be notable.

Fig. 7 Sample of a feed-forward ANN

100

Figs. 4ad show a comparison of simulation and experimental

results on DC-bus voltage and current, respectively. The FFT
analysis results on DC-bus current under healthy and faulty mode
operation of ACDC converter are presented in Figs. 4e and f. The
experimental results verify the simulation results. According to
satisfactory results on simulation validation, this software tool can
be used in total security to simulate more faulty conditions,
especially those which are difcult to perform experimentally.

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Fig. 8 Fault detection and implementation algorithm

Pattern identification

As mentioned in the previous section, the current IDC -bus can help us
to reach the goal easier and more accurately than other introduced
methods. By the use of the FFT on IDC -bus, we can have a
targeted comparison between healthy and faulty mode operations
for fault detection and diagnosis.
In [3], we have introduced a new pattern as (1)
fopen

phase fault

= (2k + 1) ff

(1)

where the thyristor-based ACDC converter works with different re

angles (a = 15 , a = 30 , and a = 45 ). This part of the present
paper will prove that thyristor operation in a = 0 (as operation in
diode condition) will lead to another new pattern. Each of the
faulty groups will lead to the presence of frequently harmonics in
ff/2, ( ff + ( ff/2)), (2ff + ( ff/2)) etc., in IDC-bus, compared with a
healthy mode. In Fig. 5, the comparison between IDC-bus under
healthy state operation and under open-phase fault by opening
switches in conditions of groups 2, 3, 4, and 5 is presented. The
amplitude of harmonic will decrease when the severity of fault
increases in groups 2, 3, 4, and 5, respectively. Note that, by
increasing the number of defective switches, the amount of
transferred power will decrease.
As a nal result, the new pattern can be considered as (2) for all
faulty states belong to different introduced groups
fopen

phase fault

(2k + 1) ff
2

(2)

where k = 0, 1, 2, 3, and ff is the index of fundamental

frequency.

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The important advantage of this pattern is the detection ability

under fault states of group 2, where just one switch is opened. At
this level of fault, it is expected that the fault should be detected
and the process should be started to avoid its progress to the other
groups.
5.1 Influence of the DC-bus capacitor variation on fault
signatures
In this part, the inuence of capacitor size variations because of
validation of our pattern has been considered. In this base, four
different levels of capacitor have been compared under healthy
and faulty operation conditions of the ACDC converter. In this
project, the nominal value of capacitor used is Cn = 9000 F,
because of the experimental facility. Cn/2, Cn/10, and Cn/100 are
different sizes chosen for the validation of the identied patterns
under faulty operation in comparison with healthy mode operation.
The results presented in Fig. 6a show that the identied pattern is
independent of the capacitor size, since the fault frequencies
appear as (2).
5.2

Influence of the load variation on fault signatures

One of the most important problems in any fault-diagnosis method is

the investigation of the load variation on the proposed indices.
Accurate fault detection is not possible without considering the
relations between indices, load variations, and types of the faults.
In this paper, the effects of the load variation on fault detection
under ve different states as no-load, load, load, load, and
full-load have been presented, and the results are shown in
Fig. 6b. The results show that the load variations do not have a
notable impact on the identied patterns.

101

Fig. 9 Pattern identication and fault diagnosis strategy

Fig. 10 Different positions of overlap between training data to ANN

a Position 1 (view from opposite 0)
b Position 2 (view from left 45)
c Position 3 (view from right 45)
d Position 4 (view from left 15)

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5.3

Influence of the speed variation on fault signatures

A speed variation operation is an important item in HEV application.

According to this application, at different speeds, this part considers
the identied pattern for ve different speeds, including 1000, 800,
600, 400, and 200 rpm under a healthy and a faulty operation mode.
The results are shown in Fig. 6c.
The results show that the speed variations do not have any impact
on the identied pattern.

ANN-based fault diagnosis

Recently, ANN-based methods have been used in fault detection and

diagnosis, increasingly. NNs offer a number of advantages,
including requiring less formal statistical training, ability to
implicitly detect complex non-linear relationships between
dependent and independent variables, ability to detect all possible
interactions between predictor variables, and the availability of
multiple training algorithms. Disadvantages include its black box
nature, its greater computational burden, predisposition to
over-tting, and its empirical nature of model development [33, 34].
The architecture of an NN species the arrangement of the neural
connection as well as the type of units characterised by an activation
function. The processing algorithm species how the neurons
calculate the output vector for any input vector given a set of
weights. The training algorithm species how the NN adapts its
weights w with all given input vectors, called training vectors.

Thus, the NN can acquire knowledge through the training algorithm

and stores this knowledge in synaptic weights. There are many types
of ANNs, but the most commonly used ones are the multi-layer
feed-forward networks. A sample scheme of a feed-forward ANN
(input, one hidden layer, and output layer) is shown in Fig. 7 [35].
In this paper, a three-layer feed-forward ANN has been used in
order to achieve a fault diagnosis and a classication.
The neurons are the building blocks of an ANN. As shown in
Fig 7, in general, there can be n inputs X = [x1, x2, , xn]T and k
neurons in the single layer of the ANN, where, in general k n
and an input is connected to each neuron (input) through the
appropriate weights. Each neuron performs the weighted sum of its
inputs plus the bias and applies this to its activation function. It
follows that there are k outputs y1 = [y11, y12, , y1k]T to the
ANN described by a single layer (where the index 1 in y1 outputs
on the rst layer are y11, y12, , y1k) and



y1 = F1 W1 X + B1

(3)

In this expression F1 is the activation matrix of this single layer,

which is a diagonal matrix with k elements, and which depends on
the net inputs to this layer







F 1 S 1 = diag f1 s1 , f1 s2 , . . . , f1 (sk )

(4)

where the elements are the activation functions of each of the k nodes,
which have been assumed to be equal, f11, = f12 = = f1k = f1, S1

Fig. 11 ANN training results for six iterations

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103

Fig. 12 ANN result for fault diagnosis of ACDC converter for four time repetitions

is the net vector, S1 = [s1, s2,, sk]T which contains the net inputs S1,
n

wij xj (t) + bi . Furthermore,
S2,, Sk to neurons 1, 2, , K, Si =
j=1

W1 is the weight matrix of the output layer, which due to the

specied architecture, must contain k rows and n columns

w1, 1
w2, 1

W1 =
.
.
wk, 1

w1, 2 . . . w1, n
w2, 2 . . . w2, n

.
.

.
.
wk, 2 . . . wk, n

(5)

A general wij is the weight from destination (recipient) node j to

source node i, where i = 1, 2,, k; j = 1, 2,, n and B1 is the bias
vector of the single layer, B1 = [b11, b12, , b1k]T, where b11, b12,
, b1k are the biases of nodes 1, 2,, k of the output layer,
respectively. An ANN with three layers can be developed with an
extension of the proposed equations.

104

6.1

Fault diagnosis algorithm and strategy

Fig. 8 presents a fault diagnosis and implementation algorithm used

for open-phase fault of ACDC converter, where [A] is the pattern
data matrix and includes all healthy and faulty states. Min_value is
the minimum value of matrix [A] in no-load and health state of
system operation. To make a generalisation of the algorithm
presented for all states, a margin is considered. Margin (e) is the
sum of Min_value amplitude and the maximum value (AFmax)
under a healthy and a full-load operation of the system. Similarly,
pattern identication and fault diagnosis strategy in ACDC
converter of SHEV is shown in Fig. 9.
6.2

Justification of ANN for using ACDC fault diagnosis

The different groups dened in Section 2 have been considered to

validate their non-linearity relations. According to this objective,
rst, all trained data (the new pattern value in no-load, 0.25-load,
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Table 2 ANN output results under different levels of ACDC switches open circuit in SHEV application (for ten sample tests)

1
2
3
4
5
6
7
8
9
10

Fault value

Load condition

Speed condition, rpm

Output 1

Output 2

Output 3

Output 4

Output 5

Detection

healthy mode
healthy mode
group2 S1
group2 S3
group3 S23
group3 S11
group4 S122
group4 S233
group5 S1223
group5 S1223

full-load
full-load
half-load
no-load
full-load
0.75-load
half-load
0.25-load
no-load
no-load

200
1000
400
600
800
1000
600
800
1000
800

0.981
1.001
0
0
0.0007
0.0013
0.0213
0.0013
0.0079
0

0.0001
0.0012
0.9841
0.964
0.0034
0
0.0004
0.0001
0
0.0019

0
0.0006
.0008
0.0023
0.95
0.964
0
0.0014
0.0015
0

0
0.0006
0.0002
0.0008
0.003
0.001
0.97
0.967
0.0001
0.0069

0.0042
0
0.0002
0.005
0.0005
0.0009
0.0058
0.0087
0.985
0.9945

T
T
T
T
T
T
T
T
T
T

half-load, 0.75-load, and full-load in different fault groups, different

speeds etc.) to ANN drawn in a three-dimensional mapping to clarify
their non-linearity as shown in Figs. 10ad. According to the
complexity and the non-linearity relationship between training data
and according to the power of ANN function to solve these types
of problems, we can justify the use of ANN for these non-linear
structures.

Finally, ANN has been used for open-phase fault diagnosis of

ACDC power converter. By help of the ANN, all possible states
of faults including different levels severity of the faults (faulty
states groups 2, 3, 4, and 5), different speeds (1000 rpm, 800, 600,
400, and 200 rpm), and different loads (full-load no-load), as it
is expected in the vehicle application, can be detected.

6.3

ANN training

After identication of a proper pattern and the justication of the use

of ANN, the next step is the ANN training. This helps us to know
about ANN function before its implementation. To ensure the
performance of the NN, we repeat it 20 times. The results show
97% accuracy in the ANN training. LevenbergMarquardt
algorithm, 100 epochs, 39 s training time in order to achieve the
fault diagnosis, and the training regression 0.978 are some of the
used ANN performances in one of the fault diagnosis effort based
on the ANN, for example. Fig. 11 shows the ANN training effort
for four repetitions. All four different levels of an open-circuit fault
mentioned in Section 2 are trained and were detected by the ANN.
Even after successful NN training, a test from some new data must
be done. Note that the new data for test-trained ANN should be about
20% of all used data. Fig. 12 shows the response of the trained ANN
to new faulty data for four test repetitions. The obtained response is
acceptable to implement the trained ANN in experimental work.
According to the diagnosis strategy, ve outputs in different
conditions of loads and speeds and in each introduced group in
Section 2 have been considered for used ANN in this paper. The
experimental results for ten different samples tests in different fault
severities condition and under speeds and loads variations are
visible in Table 2. For each faulty state, the output of ANN will be
1, and for the healthy state the output of the ANN will be 0.
These data can be used to evaluate the loss of performances of the
ACDC converter, that is, the value of state of health (SOH)AC/DC
(state of the health) and to achieve a fault-tolerant control strategy
as future plan of this paper.

Conclusion

In this paper, a fault detection and diagnosis in thyristor-based

ACDC converter with re angle = 0 have been studied. A new
(2k + 1) ff
as a
pattern, identied such that fopen phase fault =
2
pattern frequency, was introduced to aim ACDC converter
switches fault recognition for SHEV application. Many
experimentations were achieved to verify simulation results. On
this basis, ve groups of different states of ACDC converter
switches failures have been considered and difference of analysis
results are compared with group 1 (healthy state of operation) to
nd the feature leading to a new pattern in the faulty condition.
This result has been validated through theoretical simulations and
by experimental measurements. This allowed us to use the developed
simulation software tool to study the inuence of the capacitor size,
the load, and the speed variations on the identied pattern. The
obtained results show the success of this pattern.

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IET Electr. Syst. Transp., 2016, Vol. 6, Iss. 2, pp. 96106

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