Severe Motor Chattering Problem?

[Ken McNeill]

I have a few bikes I built that I use for e-bike tours. When I built them in 2019, they worked great. But lately, one by one they have begun to severely chatter under load. The stuttering start has really been hard on clutches, even shearing an axle key. 100-200 miles if that. I have changed motors & controllers with no effect. Once it’s rolling, it’s silent and perfect.

I’ve attached a video of what I’m experiencing. I just replaced the clutch/gear assy in this motor. Could it be noisy electrical power from the controller? Hall sensor issue? Is it possible the CA3 is causing this? Could it be a noisy throttle signal?

CA3
40 amp Infineon Motor Controller -
EM3ev 48v 16ah Battery
MacMotor - Ebike Hub Motor For Sale | MAC

Video link -

 

[Ken McNeill]

Could be used as a screening test for potential new hires.
1. “What is wrong in this diagram?” Explain.
2. Please apply corrections to the diagram; include the wiring locations, colors and polarities, in your response.

Okay.. in my defense, by the time I got to the 4th diagram it was ‘margarita time’. I thought the colors balanced well there.

 

[Ken McNeill]

I opened my original drawing file. I must have noticed my error the next morning and made the correction. I’m gonna celebrate with a margarita.

Here’s the corrected one.

 

[Ken McNeill]

I still have yet to resolve my chattering issue. I’m appealing to those of you who have been extremely helpful thus far (thank you again). I ordered a new motor and new motor controller from MacMotor. I connected the throttle directly to the MC rather than using the Pass-Thru on my CAV3. Chatters really bad and is unusable. If I switch to my older (weakening) controller and only a slight noise while starting from a dead stop. Here’s a video.

MacMotor did send a programming cable. What might this cable be used for? It obviously connects direct to the MC 5-pin connector, and has a USB for a PC. Could the MC need to be programmed for compatibility with their own motor? Is there an application required?

Should I just scrap this set up and go with a Grin GMAC10T or MG62 and a Baserunner MC? MacMotor is no help whatsoever.