I recently got some new "sealed" outrunner motors for my setup and noticed some strange things happening with the sensored setup. During the sensored RPM range, the motors run very noisy and when riding, there is a noticeable vibration until sensorless rpm is reached. I don't recall having this with the previous motors (Alien Power System) but I don't see anything wrong with the design of these new motors.
Analyzing the VESC signals, there is a lot more noise in the phase currents during the sensored operation. Also, feeling the torque of the motor in my hand, it is not a constant smooth torque but is instead choppy and segmented. There seem to be some dead zones based on the rotation position. If you guys have any idea what is causing this effect, I would love to know and try to fix it. See images below for captured data:
Let me know your thoughts.