Fault-Tolerant Control Method for Modular Four-Unit Permanent Magnet Synchronous Hub Machine Based on Current Reconstruction

This paper proposes a new modular four-unit permanent magnet synchronous hub machine (MF-PMSHM) with robust fault tolerance to enhance the operational reliability of electric vehicles (EVs). A new fault-tolerant control algorithm based on current reconstruction is proposed to address eight types of faults, including single-phase, two-phase, and three-phase open-circuit failures. The method aims to fully utilize the healthy windings, maximize torque output, and reduce copper losses. To validate the effectiveness of the proposed approach, a 1.1 kW laboratory prototype is used for comprehensive testing, with performance compared against traditional isolation algorithms. In addition to these benefits, the proposed system effectively mitigates the impact of unbalanced magnetic pull, which can improve the driving experience and safety of EVs.