1. Introduction
The use of fault-tolerant electric systems becomes unavoidable in many critical applications where failures may endanger the safety of the user or machine. Therefore, it is essential to develop structures that are resistant to damage and capable of maintaining continuity of operation. Such solutions can be achieved by redundancy of system components, for example, a multichannel three-phase system, multiple independent power converters, etc. Although multiplying components may generate higher cost, it is worth it in terms of safety.
Multichannel machines are investigated in various areas such as aviation (More Electric Aircraft—MEA) [
1,
2,
3], the automotive industry (Electric Vehicles—EVs) [
4,
5,
6], the marine industry [
7], renewable energy resources (RESs) [
8,
9,
10,
11,
12], and military applications [
2]. In the literature, the MEA concept is the most popular in regard to multichannel machines.
An overview of electricity generation in aviation is widely presented in [
2]. The authors indicate that electric power systems are progressively replacing pneumatic, hydraulic, and mechanical power systems in MEA. Therefore, there is a need for on-board electric power generation. Over the years, reliability and power density have become more critical parameters. In [
13], it is mentioned that the Permanent Magnet Synchronous Generator (PMSG) is a primary power source for modern aircraft, both civilian (Airbus and Boeing) and military (Lockheed Martin). Since the complexity of the on-board power system and its load are high, the Permanent Magnet Synchronous Machine (PMSM) is the most suitable due to its good airworthiness, autonomous work, high power density, and robust design. The authors of [
1] also suggest that a favored choice for MEA applications is a dual or triple three-phase PMSM due to its balance between redundancy and complexity, while providing a balanced operation after a failure occurs. In addition to MEA, there are papers that consider the multichannel operation of EVs, since it is also essential to provide high reliability to both users and machines in the automotive field [
4,
5].
In addition to reliability and safety, ecology is also an essential aspect, as many countries are committed to reducing the emission of greenhouse gases [
8,
10,
12]. In the scientific literature, tremendous work has been conducted on the development of a reduction in gas emissions and fuel cost in MEA [
3]. The reduction in air pollution and the exhaustion of petroleum resources is also investigated in the area of EVs [
6]. In terms of RESs, the authors focus mainly on wind power generation [
9,
11,
12]. Recently, interest in generating energy from the movement of marine waves or marine currents, which is in an early stage of development, has been observed. Therefore, generators for use in the marine industry are investigated [
7,
8].
So far, a multichannel generator has not been widely investigated. There are a few papers on dual-channel generators or motors [
4,
5,
8,
9,
10,
14,
15,
16,
17]. The tests performed refer to dual-channel work under normal conditions [
4,
7,
8,
9,
10,
11,
12,
13,
18,
19] and include failures, such as operation during failure of one or both channels [
5,
14], short circuit [
9,
18], and open circuit [
4]. The starter/generator system [
3,
18,
20] is also investigated.
Researchers have analyzed reluctance generators [
14,
16,
17], brushless DC motors with permanent magnets [
5,
15], and PMSMs [
4,
7,
8,
9,
10,
11,
12,
13,
18,
19] in terms of multichannel operation. Recently, the type of generator that has been the most researched is the PMSG. Many authors in their work indicate that the PMSM is generally the preferred choice (over reluctance and induction machines) for various applications, because of its high power density, high efficiency, compact volume, and low maintenance costs, among others. Although the PMSMs have a lot of advantages, they are challenging in terms of reactive power, parallel operation, and fault tolerance [
2]. In [
1], it is said that in the PMSM, currents can flow in a failed lane even if it is disconnected from the power supply due to the presence of magnet-induced electromotive force (EMF). In such a case, at the design stage of the machine, the effects of a potential short circuit in the winding should be minimized by introducing, for example, thermal separation of the windings or increasing the hardiness of permanent magnets to the appearance of such a machine operating condition.
The diagnosis of generator operation and malfunctions is another important issue. There are different methods of diagnostics in terms of electric machines, and therefore, different diagnostic parameters can be used, for example, electric current, voltage, signal, temperature, noise, vibration, etc. [
21,
22,
23,
24,
25]. Harmonic analysis can, for example, provide information on the presence of anomalies in generator operation.
The aim of this work is to analyze properties of the prototype Multichannel Permanent Magnet Synchronous Generator (MCPMSG) prototype designed and constructed by the authors for critical applications. Various configurations of the generator channels, taking into account the improvement of the redundancy of the electricity generation system, were analyzed. There are few works on the MCPMSG. Furthermore, the existing works do not address the subject of the influence of the channel configuration on the MCPMSG properties. An original mathematical model was developed for the study of the MCPMSG operation. Under laboratory conditions, the influence of the channel configuration on the output parameters of the MCPMSG was verified. An original method for diagnosing the operation of individual channels of the MCPMSG was proposed by the authors. This diagnostic method based on a single voltage signal was tested under the conditions of numerical tests and laboratory tests. As part of these tests of the proposed diagnostic method, the capabilities of the prototype MCPMSG were used to analyze selected operating states of internal asymmetry. The advantage of the proposed diagnostic method is the control of the operating state of the channels both under load and in the de-energized state. The proposed diagnostic method for control of the individual channel requires measurement of only one voltage signal.
The paper consists of several sections. In
Section 2, design and configuration analysis of the MCPMSG is presented.
Section 3 contains the mathematical model of the tested MCPMSG. The operation of the MCPMSG with different sources of energy consumption is presented in
Section 4. In
Section 5, the proposed diagnostic method for the MCPMSG is discussed. The final
Section 6 contains a summary and conclusions.
6. Summary and Conclusions
This article proposes the use of the MCPMSG for safety critical applications. In comparison to classical solutions, the use of the MCPMSG allows us to obtain an improvement in the redundancy of the power generation system. The MCPMSG can work with one energy consumption system. In this case, the two channels are treated as redundant. The other option is to work with two independent energy-receiving sources. In both cases, the configuration of the channels is important since it affects the generator operation. The analysis of the MCPMSG properties in various channel configurations is possible due to the mathematical model developed by the authors. Regardless of the type of configuration of individual generator channels, their condition should be monitored in terms of correct operation. Conclusions were formulated on the basis of the tests that were carried out.
For the DCO it is preferred to use the configuration of the channels that are not magnetically coupled. This solution provides higher efficiency of energy conversion and balanced magnetic tension. In the DCO with magnetically coupled channels, in solitary operation or with various loads, the efficiency deteriorates due to the appearance of equalizing currents.
Numerical and laboratory tests have shown that there is more interaction between the DCO AC and the DCO BD channels in the DDCO mode. The change of the DCO AC load affected the operation of the DCO BD. This problem can be reduced by reducing the pitch of the distributed winding or by using a typical concentrated winding. The proposed method of diagnosing the operating state of the channels is based on harmonic analysis of the voltage signal. The appearance of the diagnostic harmonic component in the voltage signal indicates deviations from symmetric operation. The advantage of this approach is the ability to monitor channels in a non-current state. The proposed diagnostic method can also be used under practical conditions to assess machine quality. Even small differences in the values of induced voltages, phase resistances, etc., have an impact on the increase in the diagnostic frequency f1 of the diagnostic signal. The effects of damage to one of the channels are noticeable in the remaining efficient channels. This shows the high sensitivity of the proposed diagnostic method.
The validity of the proposed MCPMSG is verified by the experimental results.
The prototype, the extended mathematical model, and the proposed diagnostic method will allow for further testing of the MCPMSG, e.g., analysis of emergency states such as short circuits (e.g., one turn) in the windings of the band of a given channel.