Multi-Objective Switching Frequency and Component Optimization in PAM-Based BLDC Motor Drives

This paper presents a practical, data-driven approach to optimizing Pulse-Amplitude Modulation (PAM) based Brushless DC (BLDC) motor drives. The proposed method assists designers in selecting the optimal switching frequency and component set by combining performance analysis with real-world component data. Unlike purely heuristic or trial-and-error design methods, it leverages a database of commercially available MOSFETs, inductors, and capacitors to evaluate electrical losses, cost, and size at the same time. Two case studies demonstrate how design priorities influence the optimization outcome. When cost, loss, and size are considered equally, the optimal switching frequency is found to be 22 kHz, resulting in 4.57 W of total losses. When efficiency and compactness are prioritized, the optimum frequency shifts to 33 kHz, reducing total losses to 3.33 W. These results demonstrate how database-supported, multi-objective optimization can simplify the design process, reduce thermal stress, and improve the overall performance of PAM-based BLDC motor drives.