This paper describes a novel approach to monitoring the condition of small permanent-magnet synchronous motors (PMSM) operating under thermal stress. The approach begins with the estimation of temperature-dependent motor parameters from measurements of line voltages and currents. The parameters are then used to derive estimates of motor temperatures. Next, the electrically estimated temperatures are combined with a surface measurement of motor temperature and a dynamic thermal model of the motor to yield an observer that is a Kalman filter. The temperatures estimated by the observer are used for failure prevention. Finally, by modifying the observer, it is tuned to use the geometric properties of its innovation for failure detection. The innovation, that is, the difference between the thermally and electrically estimated temperatures, is monitored and compared against appropriate thresholds to detect failures. Failure detection is demonstrated experimentally, and shown to be capable of distinguishing the conditions of normal operation, and operation with obstructed cooling.
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