Loud Noise on Acceleration in NEW Direct Drive Hub Motor (Video Included)

Jdana

New Member
Region
Canada
Can anyone help me diagnose this sound?

It only happens when accelerating. Metallic sound, almost like grinding gears. However this is a 2000 W (new) direct drive motor which should be gearless.

My current hypothesis is that my controller is square wave instead of sine. I was looking for a plug and play replacement online with a sinewave controller but didn't find anything yet.

Here is a link to the kit I purchased:

I am hoping some direct drive experts have a guess by the sound of the noise. Interested to hear your thoughts.

I love the idea of completely silent drive and would very much like this sound to go away.

Thanks in advance for your input!
 
Oh, Man! I thought I might have an easy our. You are going to have to take it apart. Canada is big. Which province? I am in the alternate CA, close to Windsor.
 
My current hypothesis is that my controller is square wave instead of sine.
I am hoping some direct drive experts

I'm no expert, but I think that your hypothesis is right.
I know that square wave controllers are noisier than sine wave for both the controller and motor.

When I had my firing order reversed on my geared hub motor, the noise sounded very mechanical, much like the sound of your motor.

The web site says it's a sine wave controller.
Looking at the controller, it looks like a POS. 😂

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It's simply not large enough to be a 45 amp controller.
This is a real 45 amp KT controller,..

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This is the 30 amp KT version,..


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Notice the extra large motor cable connector. Anything over 25 Amps has the bigger plug so that it doesn't melt.

Your motor connector cable looks like it has a 25 amp connector?




Screenshot_20240514-164047_DuckDuckGo.jpg



I think that you should buy a complete 25 amp sinewave KT-Conversion kit for about $250 and it will plug and play.

It will replace everything except your rear hub motor. (even the brake cut-off switches are different with three pin instead of two. Yellow vs Red connector)



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A hub motor cable connector only has a few standardized configurations.

Your hub motor should plug into and work with just about any controller if the plug fits.
There's always 9 pins. (10 if you have a temperature sensor output. Very rare.)
 
,.. Which province? I am in the alternate CA, close to Windsor.

I just happen to live in the alternate, CAD close to Windsor Ontario. 😂

,.. You are going to have to take it apart.

No he's not.
He mostly just needs to replace his cheesy controller.

Oh, Man! I thought I might have an easy our.


He can probably replace everything, including the brake levers, or the adapter interconnector, in less than an hour.


I will now reminisce about AHicks, who wanted to fill the world with KT controllers and displays that allow us all kinds of adjustability,..



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Or a Red-to-Yellow/Yellow-to-Red interconnector could fit the bill for the cutout levers.
View attachment 175860


I couldn't find the convertor and didn't want the extra 6", so I cut, soldered, and reconnected everything after I figured out the pin configuration,..


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If you could find an interconnector for my Julet/Tektro brake cut-off switch connector,. that would be Great !!

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