Dual-Redundancy Electric Propulsion System for Electric Helicopters Based on Extended State Observer and Master–Slave Fault-Tolerant Control

To improve the reliability and fault tolerance of electric helicopter propulsion systems, this paper presents a master–slave fault-tolerant control method based on an extended state observer (ESO) for dual-redundant electric propulsion systems that addresses dynamic coupling disturbances. First, the control architecture puts the master motor in speed loop mode and puts the slave motor in torque loop mode with an ESO to estimate disturbances and compensate for mechanical coupling torque through feedforward control based on Lyapunov stability theory. Second, a least squares parameter identification method establishes a current-torque mapping model to ensure consistent dual-motor output. Then, fault-tolerant switching is implemented, transitioning from normal torque mode coordination to independent speed mode with adaptive PI adjustment during faults. Experimental validation shows that the total torque stabilizes at 240 N·m, and the synchronization error remains within ±0.5 N·m during normal operation. Under single-motor fault scenarios, the ESO detects disturbances within 15 ms with >95% accuracy. The system speed decreases to a minimum of 2280 rpm (5% deviation) and recovers within 3.5 s. Compared to traditional PI control, this method improves torque synchronization by 65.4%, speed stability by 62.6%, and dynamic response by 51.2%. Finally, the results validate that the method effectively suppresses coupling interference and meets aviation safety standards, providing reliable, fault-tolerant solutions for electric helicopter propulsion.