An intelligent sensorless control strategy for brushless DC motor (BDCM) is presented. The rotor position for making commutation is first roughly estimated by a proposed switching signal generation scheme using motor terminal voltages. Then an intelligent self-tuning strategy is developed to finely adjust the commutation instant for obtaining optimal torque generating capability. This is achieved by a simple but stable self-tuning algorithm to minimize winding currents at any instant. The effect of commutation instant on the BDCM operation capability is observed analytically and intuitively, and accordingly, the proposed self-tuning strategy is established. Effectiveness of the proposed method is demonstrated experimentally.