Design of a High-Efficiency Minimum-Torque-Ripple 12-V/1-kW Three-Phase BLDC Motor Drive System for Diesel Engine Emission Reductions

A 12-V motor drive system using an onboard battery is promising in vehicle applications, e.g., to rotate an air pump to adjust its air delivery to the burner, thereby providing autonomous exhaust temperature control for the conventional diesel engine vehicle. The 12-V/1-kW motor drive system proposed in this paper consists of a series-resonant LLC MOSFET full-bridge converter, which provides high-efficiency power transfer by implementing zero voltage switching and boosts the dc bus to ~300 V, and an insulated-gate bipolar transistor inverter, which provides the high-side phase currents to a 1-kW/6000-r/min brushless dc motor (BLDC). This design secures the high efficiency, low cost, and low volume. Meanwhile, with the variable output voltage of this dc/dc converter, this paper realizes a commutation torque-ripple reduction method, which will minimize the mechanical vibration. Experimental results on this prototype system demonstrate that: 1) the LLC dc/dc part efficiency is 97.6% with 92% of the inverter efficiency; and 2) the motor commutation torque ripple is reduced close to zero.