High torque ripple can be observed with a 6/4 variable flux reluctance machine (VFRM). In order to minimize the torque ripple in VFRMs, this paper presents a harmonic injection method for 6/4 VFRMs with an open-winding configuration. By analyzing the impact of harmonics on VFRMs, the method involves detecting the third harmonic using a first-order low-pass filter (FLPF). Subsequently, the extracted harmonics are controlled and shifted to counteract the voltage harmonics in both inverters without inducing phase imbalance or overvoltage. With the proposed method, the torque ripple can be significantly reduced by about 50% under load conditions. The effectiveness of the harmonic injection method is validated through a prototype VFRM.

Variable Flux Reluctance Machines (VFRMs) face multiple interconnected challenges that limit their performance, particularly in high-performance applications such as electric vehicles (EVs), where smooth torque output and robust operation are critical. Chief among these challenges are complex inter-axis couplings, including cross-coupling in the dq-axis, differential term coupling in the d0-axis, and disturbances propagating from the 0-axis to the q-axis. Additionally, harmonic disturbances associated with torque ripple exacerbate performance issues, resulting in degraded dynamic behavior. These challenges hinder current loop controllers, preventing effective management of winding impedance voltage drops and inter-axis coupling terms without advanced decoupling strategies. To address these challenges, this paper proposes a novel integrated torque harmonic extended state observer (ITHESO) within a decoupled current control designed to ensure fast and accurate current tracking, system stability, and torque ripple reduction. The ITHESO identifies and compensates for total current disturbances, including harmonic components, through feed-forward compensation within the current loop. Furthermore, the influence of control parameters and the effects of parameter mismatches on stability, torque ripple reduction, and disturbance rejection are thoroughly analyzed. Experimental validations demonstrate that the proposed strategy significantly enhances torque dynamics and reduces torque ripple, outperforming the conventional Active Disturbance Rejection Control (ADRC), which does not explicitly address disturbances associated with torque ripple. These advancements position the VFRM with the ITHESO as a competitive option for high-performance EV propulsion systems, offering smooth operation, noise reduction, and reliable performance under varying speeds and loads.