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In the square-wave voltage signal injection sensorless drive of the interior permanent-magnet synchronous machine, the injection voltage can be distorted by the inverter nonlinearity effects especially when the injection voltage is low. If that happens, a high-frequency (HF) current signal which contains the rotor position information could be also distorted, which directly leads to an error in the position estimation. This paper analyzes the effects of the inverter nonlinearity on injection voltage, on induced current ripple, and on the position estimation performance in sequence and proposes a voltage injection method to minimize the impact of the inverter nonlinearity by the regulation of the HF current ripple. By simulations and experiments, the performance of the proposed method has been verified. The experimental results show 19.7% reduction of position estimation error under 15% of rated voltage signal injection without increasing the current ripple at a certain operating condition. Moreover, the performance of position estimation is kept uniform regardless of the loading condition. [ABSTRACT FROM AUTHOR]