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Published in IET Electric Power Applications
Received on 8th May 2012
Revised on 10th December 2012
Accepted on 18th December 2012
doi: 10.1049/iet-epa.2012.0140

ISSN 1751-8660

Modular stator switched reluctance motor for fault

tolerant drive systems
Mircea Ruba, Ioan-Adrian Viorel, Lornd Szab
Department of Electrical Machines and Drives, Technical University of Cluj-Napoca, 28, Memorandumului Street, 400114
Cluj-Napoca, Romania
E-mail: mircea.ruba@emd.utcluj.ro

Abstract: A modular stator switched reluctance motor (SRM) for fault tolerant drive systems is proposed. Owing to the particular
construction of the stator there is no mutual coupling between adjacent phases. Hence, the motor can work also when a part of the
coils is faulted and the faulted modules can be replaced without uncoupling the machine from the load or gearbox. The sizing
particularities are presented and the mathematical model of the motor is developed. The results obtained via nite element
analysis are compared with the analytical ones, and with that resulting after testing the constructed laboratory model. All
these prove that the proposed SRM can be used in safetycritical drives.

Introduction

This paper discusses the design, construction, simulation

and tests of a modular switched reluctance motor (SRM)
for fault tolerant drives application. Even if the squirrel
cage motor can be a competitor in the fault tolerant
drives domain, two main directions of research have
been followed up to now: permanent magnet (PM)
motors [1, 2] and fault tolerant SRMs. Each variant has
its advantages. Since the SRM can be constructed with
stator phase independent modules, as shown in this
paper, the research was carried out for it. The SRM
requires a specic electronic supply device, controlled
function of the rotor position and phase current. The
SRM is a low cost, simple and robust motor which has a
wide speed range and high starting torque [36]. Its most
attractive feature for fault-tolerant drives is the possibility
to construct a multi phase modular stator. Each stator
segment has a magnetically separated independent coil.
The modules can be replaced in case of winding faults
without uncoupling the motor from the load. To ensure
an adequate fault-tolerant behaviour the SRM should
have at minimum four phases. The designed and
constructed prototype has eight independent modules.
Their coils can be supplied separately or coupled
diametrically.
In this paper rstly the modular stator SRM is presented
and some design particularities are specied. The
mathematical model based on nite element analysis (FEA)
results is also detailed. Some simulations are presented in
the paper, in both normal and faulted conditions. Extensive
tests were conducted on the laboratory model and the
results stand by to conrm both the mathematical model,
and more importantly, adequate behaviour in faulted
conditions of the motor.
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doi: 10.1049/iet-epa.2012.0140

Modular stator SRM

Besides the fact that the stator is built of independent,

magnetically separated modules, the motor has noother
particularity. It can be adapted to a particular segmental
rotor topology [7, 8] to improve its performance. For the
moment, the main goal was to prove its fault tolerance, and
that it can be a competitive variant in the domain.
Different possible topologies of modular stator SRM were
analysed. For the sake of simplicity a variant with 8 stator
modules and 14 rotor poles was chosen for the study, as
depicted in Fig. 1.
Between the modules a non-magnetic spacer is placed to
ensure adequate shift of the modules and a good magnetic
separation. The coils are wound on the yoke of each
module. The machine has eight independent coils. One
phase is a compound of two coils from diametrically
opposed modules, connected in series or in parallel. Owing
to the specic construction there is no mutual coupling
between adjacent coils [9].
The adopted modular stator topology allows for an easy
and quite low cost manufacturing and ensures the
possibility of fast replacement of a damaged module in case
of coil failure.
The control system of the SRM is given in Fig. 2.
The design algorithm follows the usual sizing step of a
SRM [6, 1014] requiring a few particularities.
Once the design specications are given the designers have
to decide on the number of phases, adequate air-gap length
and shaft diameter. The stator design implies several
restrictions; the main ones are referring to the dimensions
of the modules, which must be correctly shifted between
them. As the aspect ratio, the air-gap ux density and
electric loading are chosen [14] the air-gap mean diameter
and the stack length can be calculated [13, 14].
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Fig. 3 Main dimensions of a stator segment

Fig. 1 Modular stator SRM

The dimensions of the stator module, Fig. 3, depend on the

air-gap mean diameter, imposed restrictions and coil
cross-section.
To achieve the required reliability in the case of faulted
coils it is necessary to increase the phase current. It means
that the coils must support the overrated currents. Once the
coils cross area is known the slot area will also depend on
the lling factor kll. By now all the dimensions of the
stator module and of inter-module spacer are calculated.
The rotor dimensions come next after the designer chooses
an adequate ratio between stator and rotor pole
circumferential length and rotor pole height [11, 13, 14].
The uxes through different parts of the iron core are
calculated by means of the magnetic equivalent circuit given
in Fig. 4 in order to check the iron core magnetic loading and
to calculate the torque, the core losses and the output power.
The corresponding equations of the magnetic reluctances
are given in Table 1, and the uxes are calculated by
solving the system of equations (1)

F + Fj Rm yokeS + Fs Rm leak1 = 0

F
+ Fj Rm yokeS + F ps1 Rm leak1

+Fss Rm leak1 + F ps2 Rm leak1 = 0

Fss Rm leak2 + 2 Rm g + Rm poleR + 2 Rm

Fj Fs F ps1 = 0

F ps2 Fj + Fs = 0

F ps1 Fss Fpr = 0

Fpr + Fss F ps2 = 0


poleR

Fpr = 0

(1)

Fig. 4 Equivalent magnetic circuit of the SRM

The main specications, dimensions and parameters of

sample SRM are given in Table 2.
The results obtained by analytical computations were
veried by means of two-dimensional (2D)-FEA. A
ux-linkage map is given in Fig. 5. It can be easily
observed that the ux paths are shorter than in a
conventional SRM.
The results computed by means of 2D-FEA were compared
with those obtained analytically. The two sets of results are
included in Table 3. As can be seen there is good
agreement between them.

Fig. 2 Control system of the SRM

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The iron losses in the proposed modular SRM were also
computed via FEA, by using the scalar iron losses function
of Flux 2D [15]. This precisely takes into account variation
of ux density at each time moment in all the dened
domains of the analysed machine. The computations
required several material dependent coefcients, as
hysteresis losses coefcient 388.244 Ws/T2/m3, the classical
losses coefcient (conductivity) 4 106 1//m, losses in
excess coefcient 1.689 W/m3(T/s)3/2 and some data
concerning the lamination stacks [16]. The program
computed the variation in time of the iron losses separately
in the stator and the rotor stack for a complete revolution of
the motor (see the plots in Fig. 6).
The computed mean values of the stator, the rotor iron core
losses were 45 and 29 W, respectively. By adding to these
losses the wire and the supplementary losses 0.72 efciency
was obtained.

Table 1 Magnetic reluctances of the MEC

Item

Formulae
yokeS

lcoil
h jS la m js

Rm

poleS

hm
bpS la ms

magnetic reluctance
of the rotor pole

Rm

poleR

hpR
bpR la mr

magnetic reluctance
of the rotor yoke

Rm

yokeR

bcR
h jR la m jr

magnetic reluctance
of the stator yoke

Rm

magnetic reluctance
of the stator pole

magnetic reluctance
of the air-gap
magnetic reluctance
of the leakage
region around the
upper side of the
coil
magnetic reluctance
of the leakage
region around the
lower side of the
coil

Rm
Rm

Rm

leak2

leak1

gx
bpS la m0

lcoil
hcoil la m0

1







=


hcoil / 3bcR + hlim /bcR la m0

Table 2 Main specifications, dimensions and parameters

Item

Symbol

Value, unit

rated voltage
rated output power
rated current
base speed
number of phases
stator and rotor poles
air-gap length
stack length
coil height
height of the stator module
module yoke height
outer diameter
rotor pole height
rotor yoke width
spacer width
stator pole width
rotor pole width

UN
P2N
IN
nN
m
QS, QR
g
la
hcoil
hm
hjS
DM
hpR
hjR
lD
bpS
bpR

300 V
350 W
6A
600 r/min
4
16, 14
0.5 mm
50 mm
19 mm
35 mm
11 mm
248.5 mm
26 mm
11 mm
11 mm
13 mm
13 mm

3 Mathematical model and the simulation

program
The 2D model of the machine is built by using Flux 2D
software. By means of this model the ux-current
characteristics are plotted for three distinctive rotor
positions (aligned, average and unaligned). A curve tting
method was used to approximate the ux-current
characteristics for all the other positions. The following
Fourier series approximation with three terms is proposed
for the phase ux linkage [17, 18]
C(i, u) = C0 + C1 cos (u) + C2 cos (2u)

(2)

where 0, 1 and 2 are obtained from the uxes in aligned

al, unaligned un and average av positions




C0 = 0.5 0.5 Cal + Cun + Cav



C1 = 0.5 Cal Cun




C2 = 0.5 0.5 Cal + Cun Cav

(3)

The non-linear ux-current characteristics in aligned and

average position can be estimated by using a ratio of
polynomial functions (3), the polynomial coefcients a, b,
c being obtained via curve tting
C=

i
a i2 + b i + c

(4)

The obtained ux-current characteristics were compared with

the ones calculated via 2D FEA, Fig. 7 [19].
For the ux linkage against current characteristic plotted
for the unaligned position, which is an almost linear
Table 3 Comparison between analytically and via 2D-FEA
calculated results at rated current
Item

Fig. 5 Flux-linkage map of the SRM, one phase supplied

IET Electr. Power Appl., 2013, Vol. 7, Iss. 3, pp. 159169
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Flux density in the:

stator yoke
stator pole
rotor yoke
rotor pole
air-gap
torque
output power

FEA

Analytically calculated

1.4 T
1.1 T
1.1 T
1.1 T
1.2 T
5.7 Nm
358 W

1.37 T
1.09 T
1.09 T
1.2 T
1.09 T
5.47 Nm
350 W

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Fig. 6 Iron losses computed by means of Flux 2D plotted against time

a Stator core
b Rotor core

Fig. 7 Phase ux-linkage curves against phase current

Fig. 8 3D plots against phase current and angular displacement

a Magnetic ux
b Torque
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Fig. 9 Main window of the Simulink model

function of the phase current, the estimation can be made as

the product of the unaligned phase inductance and the
phase current. As can be seen in Fig. 7 the characteristics
obtained via the proposed analytical model are in good
agreement with the ones obtained via FEA.
Based on this mathematical model, a 3D surface can be
developed to obtain ux variation function of the current

and the rotor position, Fig. 8a. The torque against the same
phase currents and rotor positions obtained via FEA is
given in Fig. 8b.
Based on the above mentioned ux and torque variations, a
MATLAB-Simulink simulation program was built, Fig. 9, to
analyse the dynamic behaviour of the modular stator SRM.
The advantage of such a simulation program is short

Fig. 10 Modular SRM block

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simulation time, compared with the Simulink coupled with
2D-FEA model [20].
The power converter block sends the voltage signals to
the modular SRM block which practically is the model of
the machine in study [21]. Its structure is given in Fig. 10.
The SRM model is based on the voltage equation
u = Rph i +

dC
dt

(5)

where u is the phase supply voltage and Rph the phase

resistance.
The magnetic ux in the energised coil results

C=


u Rph i dt

(6)

In the rst look-up table (containing the magnetic ux

variation against current and rotor position) a current
corresponding to the calculated ux and to the known rotor
position is obtained. This current and the same rotor
position are the inputs of the second look-up table (with
torque variation against current and rotor position) which
will return the corresponding torque for the given inputs.
The model also contains the mechanical system block. Its
inputs are the load and the electromagnetic torque. It
computes the speed and the angular displacement of the
machine based on torque equilibrium

dV 1

= T Tl Bi
dt
J

(7)

where T is the electromagnetic torque, J is the rotor inertia, Tl

is the load torque, Bi is the viscous friction coefcient and
is the angular velocity of the machine.

Results of dynamic simulations

The dynamic behaviour of the designed modular stator SRM

was checked under various working conditions. The focus
was laid on torque development capability of the machine
under diverse winding fault conditions. The following three
conditions of the SRM were analysed:
1. healthy machine
2. one coil opened
3. one phase opened.
In Fig. 11 the developed torque, the currents in the rst,
and, in the second coil of each phase are plotted for all the
conditions taken into study.
Even if a coil is faulted (Fig. 11b) 4 + 3 coils of the
machine are still working (86% of the windings). The
missing current in the faulted coil can be clearly observed.
The remaining coil of the phase is still contributing to
torque generation. Owing to the lower torque produced by
the faulted phase the torque ripples are greater than in the
case of the healthy machine (Fig. 11a). The mean torque in
this case is 4.95 Nm, 86% of the rated torque.
The most severe fault that the machine can overdrive is
when an entire phase of the machine is opened.
As can be seen in Table 4 the machine develops at least
75% of rated torque in all the considered conditions.
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Fig. 11 Results of dynamic simulations for different winding fault

conditions
a Healthy machine
b One opened coil
c One opened phase

The results given in Table 4, along with calculation of the

average torque, were also checked by using a coupled
Simulink-2D-FEA environment [20].
To emphasise the advantages of the proposed modular
SRM structure it was compared with an 8/6 poles classical
SRM having the same rated power and current, number
of phases, active stack length and outer diameter. The
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Table 4 Mean torques under the conditions in study

Table 5 Main results of the comparative study

Condition

Conditions

healthy machine
one opened coil
one opened phase

Mean torques [Nm] and

percentage of rated torque
5.7 (100%)
4.95 (86%)
4.25 (75%)

comparison was performed by means of FEA and of the

above mentioned co-simulation approach. All the
simulations were performed in identical conditions for both
motors. From the numerous results detailed in [14] here
only the ux-linkage map for the classical SRM, and the
results of the dynamic simulations for the same motor
having one opened coil are given (see Fig. 12).
Comparing Fig. 5 with Fig. 12a it can be observed that the
ux passes only through 1/4 of the iron core of the modular
SRM. As it has 14 poles on the rotor, against 6 on the
conventional SRM rotor it has 2.3 times more pulses/
revolution.
It should be of interest also to compare the iron core losses
in the two SRM variants in the discussion to see if the shorter
ux path of the modular SRM can compensate for the
increased frequency. By using the same scalar iron losses
function of Flux 2D detailed in Section 2 around 81 W total
iron core losses of the classical SRM were obtained. This
means that the iron core losses of the proposed modular
SRM are about 9% less as compared with the classical
variant.
Owing to less pulses/revolution of the classical variant its
torque ripples are greater (as can be observed by comparing
Fig. 11b with Fig. 12b), and accordingly its mean torque is
a little bit smaller than in the case of the proposed modular
SRM.
In Table 5 the comparison of the developed mean torques
for the two SRM variants is given.
As can be seen in all the conditions the modular SRM
develops greater torque. All these results highlight the
advantages of the proposed modular SRM.
The dynamic performances of the proposed machine were
also tested under constant speed and variable load conditions

healthy machine
one opened coil
one opened phase

Mean torques [Nm] and

percentage of rated torque
Modular SRM

Classical 8/6 SRM

5.7 (100%)
4.95 (86%)
4.25 (75%)

5.6 (100%)
4.6 (83%)
4 (72%)

by using the above mentioned coupled Simulink-2D-FEA

environment. The purpose of the simulations was to study
how the proposed SRM can tolerate the winding faults
when its torque generation capability is reduced according
to the data given in Table 5. The results obtained for the
healthy and the one opened coil condition are given in
Fig. 13.
As can be seen in Fig. 13b the healthy machine follows
closely the imposed speed at all the imposed load torques
because of correct settings of the closed-loop speed control
system. When the faults occur the current is raised up to 8A
in the healthy remaining coils, as was stated previously in
Section 2. When a coil is opened (the current pulses in the
rst coil of phase A are missing, Fig. 13c) the current in the
second coil of the same phase is increased. When the
imposed load torque is greater also the currents in the other
phases of the SRM are increased by the control system for
tolerating the winding fault. The proposed SRM can work
at the same speed and can develop the required load torque
despite one opened coil fault. The speed uctuations are
only a little bit increased, but the torque ripples are
signicant, mainly at higher torques, being the price to be
paid for tolerating the fault.

Laboratory tests

A laboratory model of the designed modular stator SRM was

constructed and tested.
The magnetic core of the modules was manufactured with
0.5 mm thick laminated sheets of M80050 A type. Each
stator module contains 100 laminations. The coil has 220

Fig. 12 Results of simulating an 8/6 poles classical SRM

a Flux-linkage map
b Results of dynamic simulations for one opened coil condition
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Fig. 13 Results of dynamic simulations for constant speed and variable load at diverse machine conditions
a Imposed speed and load torque proles
b Healthy machine
c One opened coil
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Fig. 14 Laboratory model

a Module with its coil
b Stator with all the modules
c Machine assembly

turns of enamelled copper wire of 0.95 mm diameter and it is

wound around the yoke of the module, as shown in Fig. 14a.
The modules are placed in the inner side of the housing, as
shown in Fig. 14b. The connection panels, the encoder, and
the cooling openings near the windings can be observed in
Fig. 14c.
The rst measurements were carried out for plotting the
ux-current-position characteristics of the built up machine.
These were compared with those obtained via numeric eld
computations, Fig. 15.
As can be seen the two sets of plots are quite close.
Consequently, the motor model based on three 2D-FEA
ux-current characteristics is pretty close to reality.
For studying different operating regimes of the machine a
laboratory test bench was built, Fig. 16.
The dSPACE 1104 rapid prototyping tool was used to
control the SRM. The width of the hysteresis band of the
current controllers was set to 0.75 A and the sampling
frequency of the dSPACE program was set to 10 kHz. The
load of the SRM was an induction machine. A data
acquisition board with eight current sensors (one for each

Fig. 15 Magnetic ux against current and rotor position plots

a Via FEM analysis
b By measurements

Fig. 16 Test bench

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coil) and a torque meter were also included in the test

bench. The power converter is built of four classical
H-bridge modules of 500 V and 25 A each.
As the available torque transducers were measuring only
the mean torque we were forced to use a hybrid estimation
method for obtaining the instantaneous torque [22]. This is
based on both measured data and results obtained via FEA.
Upon the method at the rst step during the measurements
the currents through each coil are acquired and saved in
les. At the second step the currents are loaded from these
les serving as input for a Simulink program in which the
Flux 2D model of the machine is embedded through the
Flux-to-Simulink link [20]. The model practically computes
at each time step instantaneous torque from the
instantaneous current via a precise model based approach.
As the FEA model of the motor was validated by laboratory
measurements the applied hybrid torque estimation seems to
be adequate for the given purpose.
The acquisition time of the tests was 0.03 s and the speed
was set at its rated value (600 r/min). Different variants of
the control systems were considered, as the ones given in
[3, 23, 24], but for the sake of simplicity and to avoid any
current control interference to the obtained motor
characteristics, a basic control system was considered. It
was set so as to ensure rated current in the coils of the
machine. The measurements were performed for the same
conditions as those carried out during the simulations. In
each case the speed, the currents and the mean torque of
the machine were measured. The results of the
measurements (the torque and the currents against time) are
given in Fig. 17.
As can be seen in the gures the results of the tests are quite
close to those obtained by means of simulations (Fig. 11). For
the healthy machine 5.32 Nm mean torque was measured.
This value is very close to both obtained via simulations
(5.57 N m) and analytical calculations (5.47 Nm). In
Table 5 the mean torques measured during the tests are
compared with those obtained by means of simulations.
Also, the efciency in different faulty conditions of the
machine should be of interest. Therefore it was computed as
the ratio of the output and input powers averaged for a
complete period at steady-state. The efciencies for the
three motor conditions taken into study are also included in
Table 6.
In all the faulty conditions taken into study the mean
torques obtained via simulations and measurements are
quite close. As the errors between the results obtained by
means of simulations and laboratory tests are signicantly
under 7% it can be stated that the model and the
simulations are covering the phenomena well.
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Table 6 Mean characteristics of the motor at different
conditions
Condition

healthy
machine
one
opened
coil
one
opened
phase

Mean torques [Nm] and relative error

between the results

Efficiency,

Obtained via
simulations

Measured

Relative
error, %

5.7

5.32

6.1

0.764

4.95

4.68

5.4

0.763

4.25

5.8

0.764

Conclusions

In this paper, a modular stator SRM was proposed for safety

critical applications where fault tolerance is one of the most
important criteria [25, 26]. The increased fault tolerance of
the machine was achieved by modular construction of the
stator. This enabled an increased independency of the
phases and shorter magnetic ux paths inside the machine.
The practical advantages of the proposed modular
construction are construction simplicity and the possibility
to replace a module having faulted coils without uncoupling
the machine from the load. Other advantages of the
proposed structure over its 8/6 poles classical counterpart
are the increased number of pulses per revolution (hence
smoother torque developed) and less iron losses because of
shorter magnetic ux paths.
The correctness of the design was checked by analytical
computations, numerical simulations and laboratory
measurements.
The fault tolerance of the SRM was proved both by means
of dynamic simulations and laboratory tests. The machine is
able to continue to work also under severe winding faults.
Of course, in such faulty conditions the torque ripples are
higher and the speed has to be reduced. Its efciency is not
reduced with increase of the number of opened coils.
Owing to its advantages the proposed segmental stator
SRM could be a real competitor of the machines used
currently in variable speed industrial drives intended for
safety critical applications.

Fig. 17 Results of the measurements

a Healthy machine
b One opened coil
c One phase opened

The work was partially nanced by the Romanian National

University Research Council (CNCSIS) Executive Unit
for Financing the Research, Development and Innovation in
Higher Education (UEFISCDI), project type PN-II-RU,
code TE_250, no 32/28.07.2010.

8
Regarding efciency it can be seen that it is not
signicantly modied because of the winding faults. This is
obvious since when a coil is opened both the current
through it and the torque developed during its conduction
period are also nil. Therefore both input and output powers
are diminished in the same ratio and the efciency remains
practically unchanged.
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Acknowledgment

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