Advanced Fault Classification in Induction Motors for Electric Vehicles Using A Stacking Ensemble Learning Approach

This study proposes an innovative stacking ensemble learning framework for classifying faults in induction motors utilized in Electric Vehicles (EVs). Employing a comprehensive dataset comprising motor data, such as speed, torque, current, and voltage, the analysis encompasses six distinct conditions: normal operating mode, over-voltage fault, under-voltage fault, overloading fault, phase-to-phase fault, and phase-to-ground fault. The proposed model integrates Gradient Boosting (GB), K-Nearest Neighbors (KNN), Gradient Boosting (XGBoost), Support Vector Machine (SVM), Decision Tree (DT), and Random Forest (RF) algorithms in a synergistic manner. The findings reveal that the RF–GB–DT–XGBoost combination achieves a remarkable accuracy of 98.53%, significantly surpassing other methods reported in the literature. Performance is evaluated through metrics including accuracy, precision, sensitivity, and F1-score, with results analyzed in comparison to practical applications and existing studies. Validated with real-world data, this study demonstrates that the proposed model offers a groundbreaking solution for predictive maintenance systems in the EV industry, exhibiting high generalization capacity despite complex operating conditions. This approach holds transformative potential for both academic research and industrial applications. The dataset used in this study was generated using a MATLAB 2018/Simulink-based Variable Frequency Drive (VFD) model that emulates real-world EV operating conditions rather than relying solely on laboratory data. This ensures that the developed model accurately reflects practical electric vehicle environments.