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A Review of Condition Monitoring of Permanent Magnet Synchronous Machines: Techniques, Challenges and Future Directions

Author

Listed:
  • Alexandros Sergakis

    (School of Electrical and Computer Engineering, Technical University of Crete, 731 00 Chania, Greece)

  • Marios Salinas

    (School of Electrical and Computer Engineering, Technical University of Crete, 731 00 Chania, Greece)

  • Nikolaos Gkiolekas

    (School of Electrical and Computer Engineering, Technical University of Crete, 731 00 Chania, Greece)

  • Konstantinos N. Gyftakis

    (School of Electrical and Computer Engineering, Technical University of Crete, 731 00 Chania, Greece)

Abstract

This paper focuses on the latest advancements in diagnosing faults in Permanent Magnet Synchronous Machines (PMSMs), with particular attention paid to demagnetization, inter-turn short circuits (ITSCs), and eccentricity faults. As PMSMs play an important role in electric vehicles, renewable energy systems and aerospace applications, ensuring their reliability is more important than ever. This work examines widely applied methods like Motor Current Signature Analysis (MCSA) and flux monitoring, alongside more recent approaches such as time-frequency analysis, observer-based techniques and machine learning strategies. These methods are discussed in terms of strengths/weaknesses, challenges and suitability for different operating conditions. The review also highlights the importance of experimental validations to connect theoretical research with real-world applications. By exploring potential synergies between these diagnostic methods, the paper outlines ways to improve fault detection accuracy and machine reliability. It concludes by identifying future research directions, such as developing real-time diagnostics, enhancing predictive maintenance and refining sensor and computational technologies, aiming to make PMSMs more robust and fault-tolerant in demanding environments. In addition, the discussion highlights how partial demagnetization or ITSC faults may propagate if not diagnosed promptly, necessitating scalable and efficient multi-physics approaches. Finally, emphasis is placed on bridging theoretical advancements with industrial-scale implementations to ensure seamless integration into existing machine drive systems.

Suggested Citation

  • Alexandros Sergakis & Marios Salinas & Nikolaos Gkiolekas & Konstantinos N. Gyftakis, 2025. "A Review of Condition Monitoring of Permanent Magnet Synchronous Machines: Techniques, Challenges and Future Directions," Energies, MDPI, vol. 18(5), pages 1-35, February.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:5:p:1177-:d:1601775
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    References listed on IDEAS

    as
    1. Zijian Liu & Pinjia Zhang & Shan He & Jin Huang, 2021. "A Review of Modeling and Diagnostic Techniques for Eccentricity Fault in Electric Machines," Energies, MDPI, vol. 14(14), pages 1-21, July.
    2. Waseem El Sayed & Mostafa Abd El Geliel & Ahmed Lotfy, 2020. "Fault Diagnosis of PMSG Stator Inter-Turn Fault Using Extended Kalman Filter and Unscented Kalman Filter," Energies, MDPI, vol. 13(11), pages 1-24, June.
    3. Lynn Verkroost & Joachim Druant & Hendrik Vansompel & Frederik De Belie & Peter Sergeant, 2019. "Performance Degradation of Surface PMSMs with Demagnetization Defect under Predictive Current Control," Energies, MDPI, vol. 12(5), pages 1-20, February.
    4. Zia Ullah & Bilal Ahmad Lodhi & Jin Hur, 2020. "Detection and Identification of Demagnetization and Bearing Faults in PMSM Using Transfer Learning-Based VGG," Energies, MDPI, vol. 13(15), pages 1-17, July.
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