yeah it's switching at 1khz. the motor is a 4 brush standard DC motor. the problem I am seeing is only at the current threshold needed for rotation. the pulses are not meeting that threshold so the motor is not turning but they are causing the unit to sing at 1khz. moving lightly above that threshold, the motor turns fine and the noise diminishes. So in layman's terms, at such large deadtimes the pulses don't supply enough current when ON to do anything but make the motor vibrate(and burn brushes). I am looking to smooth the pulsetrains out to an average DC level, the less deadtime/the more ON time, the higher the average DC level. It seems that inductors won't work properly with such high variations in pulses from what i can find. I'll have to experiment with caps on the outputs but I can't have too large a discharge time after the bridge turns off due to the need to reverse the motor. I could limit the lowest duty cycle to something over the current threshold but I really need it to go from 0-100% A snubber might work, that's in my Try This list.
also for more info, when switching into a direction, the PWM controller softstarts, or ramps up to the set speed over a couple of seconds to limit inrush current and the like.
:thumb: