Enhanced battery charging efficiency using torque hysteresis controlled BLDC motor drive for electric vehicle

This research presents a novel, energy-efficient control strategy for brushless direct current (BLDC) motor drives, specifically designed to enhance battery usage in electric vehicle (EV) applications. The proposed approach integrates a current-blocking technique with an optimized torque hysteresis current controller to enhance both charging efficiency and torque response, which are critical parameters in EV power management. Unlike traditional motors, BLDC motors offer superior efficiency and reliability due to their brushless architecture and low mechanical wear. However, achieving optimal performance requires precise electronic control. In this work, a custom-designed BLDC motor with 40 stator slots and 48 rotor poles, powered by a 72 V supply and configured in a star connection, is analyzed. Electromagnetic modeling using Motor Solver software ensured minimal cogging torque and near-sinusoidal back electromotive force (EMF) characteristics, contributing to smoother operation. The starting torque was assessed across various rotor positions, with peak performance observed at a 90° magnet alignment. To validate the proposed control strategy, a comprehensive mathematical model of the BLDC drive was developed and simulated. The results demonstrate effective phase current regulation and improved dynamic torque behavior, confirming the suitability of the method for real-world EV integration. Overall, the proposed system supports enhanced energy utilization and contributes to the advancement of sustainable electric mobility.