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This paper presents a summary of a Honeywell collaborative IR&D project for development of a high-performance sensorless method for a Permanent Magnet Synchronous Motor (PMSM) based on Extended Kalman Filter (EKF). The parameters of a high speed 90kW industrial PMSM is employed for validating the proposed sensorless method through simulation. The simulation results demonstrate that the sensorless PMSM drive can work satisfactorily over the whole speed range with full torque and speed control accuracy. With the proposed flux linkage estimator, the new sensorless PMSM drive exhibits robustness against machine parameter variations. Good performance is obtained even when the stator resistance is changed by 200%, or the flux linkage is weakened by 20%. Detailed design and modeling of the sensorless PMSM drive are described in this paper.