Torque ripple control of brushless DC motors has been the persisting issue of the servo drive systems in which the speed fluctuation, vibration and acoustic noise should be minimized. In this paper, a novel approach to achieve the ripple-free torque control with maximum efficiency based on the d-q reference frame is presented and analyzed. The proposed approach can provide the optimized phase current waveforms over wide speed range incorporating cogging torque compensation without an access to the neutral point of the motor windings. Moreover, the undesirable errors caused by the assumptions such as 3 phase balance or symmetry of the phase back EMF between electrical cycles, which are related with the manufacturing imperfections, can be also eliminated. As a result, the proposed approach provides a simple and clear way to obtain the optimal motor excitation currents. A hysteresis current control system is employed to produce high-frequency electromagnetic torque ripples for compensation. The validity and applicability of the proposed control scheme to real situations are verified through the simulations and experimental results.