!! MOTOR SMOKING!!

I have a Emad 36v 800w electric skateboard. The original board was missing from it when I bought it. So after some trials and tribulations. I found a controller that seemed to work pretty flawlessly. Until it didn't. I put 50 to 70 miles on it then something popped on it.

So I ordered another board. This one was different from all the others. No relay. Even if the controller didn't have reverse option. There was always at least 1 relay. Why is that? What is this controller using in place of relay? Is this better or worse? Because now my motor is overheating to the point of softening the paint on motor. Could this setup be what is causing that? Any info or tips with this would be greatly appreciated. Thank you in advance.

My board is simple.
3x 12v 22ah AMG in series
Motor Controller, DROK PWM DC... https://www.amazon.com/dp/B07B4B2X35?ref=ppx_pop_mob_ap_share
800w brushed

Welp it's shot. Luckily I have another motor identical.[

With as hot as it got. I'm thinking short? I forgot I did disassemble motor while waiting for new controller to clean the commutator. Maybe I pinched or smashed a wire on the board for the brushes..? Also noticed my batteries with the distance I traveled (2½-3 miles) are typically still at 80%. This time it drained them to 60%. Any thoughts?

Your new controller probably uses mosfets instead of a relay. Your motor might have a partial short from overheating and the insulation burning off of the coils. (you can see this in your third picture how they are black) This will make the motor overheat easier and be less efficient. Idk if the controller could have caused it but a $16 controller powering a 800w motor might be pushing it. or it could have happened from it being overloaded (like a steep hill or rough terrain).

The other possibility is overheating it caused the magnets to demagnetize. Once this happens, it will draw way more power and have less torque (but run faster with no load). The controller should ideally have some kind of current limiting to prevent cooking the motor. Even better if it has a temp sensor in the motor that rolls back power when it gets too hot.

Hard to say about the relay unless you trace things out. Most brushed motor controllers have a relay somewhere to prevent runaway motor if the FETs fry. Without that, it could get stuck on full throttle and have no way to stop other than disconnecting the battery. It's a safety feature.

I agree with fetcher, i got a e300 down my shed still runs real slow but it was been feed 60amp 16s on a brushed motor, i got a few miles from it but i pushed it for too long one day and she let the smoke out.

For a brushed setup it was mental brushed arced bright white and spun the wheel up and lifted front end plus im no small boy but as with all things on the ragged edge life was noy long but damn it was fun.

Ive got loads of parts around me enough to make a 90v 30kw ride but im tempted to just run with a kaabo wolf king gt and swap its battery and controller out and let it see if that sucker can get actually get me 88mph sparks an all.