Expansion of Operating Speed Range of High-Speed BLDC Motor Using Hybrid PWM Switching Method Considering Dead Time

In vehicle electrical systems with limited battery power, the output torque and speed of high-speed brushless DC (BLDC) motors can decrease due to unstable and reduced supply voltage or manufacturing errors in the motor back electromotive force (EMF). This paper presents a method that can guarantee the output performance of an inverter through a control algorithm without a separate power supply system and DC-link voltage increase. The proposed control algorithm can increase the output torque and speed of a high-speed BLDC motor by using appropriate selection and change of the inverter's pulse width modulation (PWM) control method. In this paper, the operation and electrical characteristics of various PWM methods of BLDC motors are analyzed, and the optimal PWM method for improving the control performance of high-speed BLDC motors is presented. In addition, the relationship between the switching frequency, dead time, and voltage utilization was mathematically analyzed. Based on the results of this analysis, the proposed control algorithm automatically changes the PWM switching mode at the point where the output torque and speed need to be extended. The effectiveness and feasibility of the control method proposed in this paper is verified through the experimental results on the designed and manufactured high-speed BLDC motor system for vehicles.