I just wondered if you upgraded a 24v hub motor, say with a "no load" max speed of 18 mph to 36v. That would give a no load max speed of 27 mph. If you take the actual realistic speed range (say 7 mph to 15.5 mph), isn't the motor speed going to be well below it's optimum efficiency (especially at lower speeds) and potentially struggling and overheating up hills at 7 mph ?
IVery good point. 've converted several 24v bikes to 36v. They were all much better like that and their owners were very happy. The theory doesn't quite line up with practice. The higher power will keep the speed up on hills, which would get a lot better efficiency. There are a lot of special circumstances where efficiency could go down, but not for a normal rider on normal rides. It's a bit like how when you have a hilly ride, turning up the current to get more power can actually reduce your consumption because you get better efficiency on hills, so your motor runs cooler too.
About 12 years ago, I added a second motor to a bike I had that had a wattmeter attached to measure power, consumption, etc. I was surprised when using both motors instead of one, I used less battery for the trip down Ironbridge Gorge and back. It got me scratching my head a bit until I figured it out something like this. With one motor slogging up the hill at 7.5 mph, efficiency was about 50%, so I was using about 500w to get 250w useful power. With two motors, I was able to go 15 mph at 70% efficiency, so using about 700w to get 500w useful power. Therefore, I was using 40% extra power to get 100% extra speed, and the time I was using the power was only half as much. That's just for explanation. In practice the gain was only about 5% because there must be other factors involved.
What you suggested matters a lot when you do something like put a small high speed motor in say a road bike or similar with large wheels, then spend most of your time slogging up hills slowly. Even at moderate speeds, the controller would be maxing out most of the time, which would overheat it and cause it to cut out. A medium sized motor in a 20" wheel wouldn't suffer from that problem unless the rider is very heavy.