> Cogging in BLDC/PMSMs is because of square wave drive currents
>

Not exactly.  There are 2 things at play here.

1) Cogging is from the variable reluctance based on rotor angle.  It has
nothing to do w/ the drive waveform.  It exists even when the leads are
open circuited.  In simple terms, the magnet is getting closer/farther from
a pole that forms a magnetic short (low reluctance, similar to low
resistance).  It wasn't to 'roll downhill' and sit in a valley and get as
close to the metal as possible.

2) Torque ripple is torque (and thus power) ripple from a multitude of
factors.  Cogging may or may not affect torque ripple (it definitely adds
to it, but it may be deliberately cancelling a ripple from the drive
waveform giving something closer to a net constant.)  Sinusoidal vs
trapezoidal drive doesn't necessarily fix things either.  A motor designed
for trapezoidal drive will often have trapezoidal back-emf.  For a surface
magnet rotor, the magnets can be left flat on their face and the magnetic
field varies approximately trapezoidaly in the airgap (the airgap is
obviously varying) .  IIRC, Trapezoidal drive w/a trapezoidal back-emf can
produce a motor w/ fairly low torque ripple.  Similarly, a surface magnet
rotor thats been machined smooth will give more sinusoidal back emf and
when driven w/ sinusoidal drive will give very low torque ripple.
"Negligible" is a matter of opinion.  There are many research papers &
methods on how to reduce the remaining torque ripple even w/ sinusoidal
drive.  Some distort the flux distribution in the motor, some deliberately
distort the drive waveform.  High inertia loads are fairly insensitive.  It
can be a big problem with low inertia loads, backlash, systems w/
resonances, etc however.

There are lots of ways to shape the flux distribution in the airgap other
than just flat vs curved magnet surfaces.  There are buried magnet rotors,
saturatable pole tips, etc.  The thing to take away is that torque ripple
is complex and one type of drive waveform or the other isn't necessarily
better.  Its a system problem and a system solution is required.

Stephen
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