A Novel Current Solution for Torque Ripple Suppression of BLDCM With Minimal Rotor Eddy-Current Loss

In this paper, a novel current solution is proposed to suppress the electromagnetic torque ripple of brushless dc motor (BLDCM), and simultaneously minimize the rotor eddy-current loss to prevent thermal demagnetization of the permanent magnets. To determine the current solution, an optimizing problem of the rotor loss is developed, subjecting to the constraints of average torque and the sixth harmonic torque. Finite dc supply is also considered. In addition, an improved model of the rotor loss is proposed with a simpler expression of quadratic form, so that the problem can be solved analytically. A comparison with the square-wave and minimal-copper-loss current solutions is studied based on a 3.77 kW, 12000 r/min BLDCM, which indicates that the proposed solution performs as well as the two solutions in suppressing the torque ripple and producing stator losses, but the rotor loss can be significantly reduced by at least 86% and 35%, respectively. Precision of the rotor loss model and performance of the proposed solution are validated experimentally on the 3.77 kW BLDCM setup.