When performing weak flux control to drive a permanent-magnet synchronous motor at high speed, the efficiency is lowered because the copper loss increases as the negative D-axis current increases. In addition, if the overmodulation index is slightly lowered and driven without setting it to the maximum value, the phase current ripple reduction effect can be expected compared to the six-step control. Therefore, if the motor is operated at a current point that can minimize the sum of copper loss and iron loss, the motor can be driven with maximum efficiency. In addition, if the overmodulation index is slightly lower than that of the six-step control, the phase current ripple can be reduced. This paper proposes a method for finding an overmodulation index to maximize driving efficiency when driving a motor based on the magnetic flux–torque command. In addition, an algorithm for driving a motor with maximum efficiency by applying an optimal overmodulation index table is proposed. Based on the MATLAB Simulink simulation, the efficiency change characteristics according to the overmodulation index change are reviewed, and the efficiency improvement and current ripple reduction effects are verified through a dynamometer experiment.

In this study, a low-voltage three-phase inverter was used alongside a shunt resistor to measure the current. However, it is known that this type of inverter and shunt resistor system has a region where the measurement of current is impossible due to structural limitations. As a result, many studies have focused on this region through the use of additional algorithms. Most studies measured current by forcibly adjusting the PWM duty in order to measure the current at the region where it could not be sensed. However, unfortunately, the total harmonic distortion (THD) increases in the current due to PWM adjustment. This causes an increase in torque ripple and inverter control instability. Therefore, in this paper, current was measured using the Rds(on) value between the drain source resistor when MOSFET was turned on and the Kalman filter in a low-voltage three-phase inverter with a single shunt. Additionally, the value was verified via comparison with the values achieved when a Hall-type current sensor and single shunt were used. As a result, this study confirmed that the inverter with a single shunt performs the same as a Hall-type sensor at the region where current cannot be detected.