With the fast and aggressive build out of Space, namely the rapidly growing number of LEO constellations orbiting Earth, comes the pervasive need for free-space optical communications that allows space-to-space, space-to-air and space-to-ground connections. Point-to-point use of highly collimated light in high-bandwidth communication is critical to the utility of “mesh networks” connecting each spacecraft with each other and to the ground.

Space-rated gimbals used for Satcom and Optical systems need high torque actuation that allows for decisive move-and-hold positioning and smooth motion for long-range target lock. With size and weight constraints being a design objective for spacecraft, a large aperture, low-profile is ideal for deep integration and desired performance. Zero cogging and high linear torque output inherently come with the slotless architecture.

Multi-axial gimbaling mechanisms, like those used in Coarse and Fine Pointing Assemblies can leverage the benefits of high performance Ring Motors to directly drive movement and maintain position. Frameless motor kits offer the further ability integrate the actuation function as part of optimized systems. Optimized systems offering Size, Weight and Power (SWaP) savings, which is highly desirable in any kind of spacecraft application.

Other Space-systems, like larger gimbal-based Control Moment Gyroscopes (CMG) are used for Attitude Control in larger satellites requiring greater quantities of torque and precision. In some cases, to quickly and precisely move in both azimuth and elevation, and in other cases, to quickly compensate for external “tumbling” disturbances common in orbit.

ThinGap’s LS Series of slotless motor kits is an industry leader for gimbal applications requiring high performance and efficiency. Using a proprietary design, thin wire-wrapped stators and optimized permanent-magnet rotors, ThinGap provides that can match the torque output of slotted motors while avoiding the cogging that plagues them.

ThinGap’s LS line of slotless motor kits range in size from 25 to 267 mm diameter and torque from .1 to 12 N-m continuous. With standard and modified configurations, the product line will cover voltages from 24-400 volts and current from 1 to 100 amps. Hall devices and special configurations are also available.

To learn more about the LS Series, click here.

ThinGap will be participating in the 37th Space Symposium in Colorado Springs on April 4-7, 2022. The company will be represented at the show by CEO, John Baumann, and Lead Applications Engineer, Matthew Panesis. Also present at the show will be members of ThinGap network of sales representatives. Besides meeting with existing and potentially new customers, domestic and international space agencies, and industry partners, a working unit of ThinGap’s H-LSI 75-12 turnkey Direct Drive Motor Assembly (image) based on the company’s slotless motor technology will be demonstrated at the ESI Motion booth (booth #612).

Matthew Panesis, ThinGap’s Applications Engineer commented on the event, “With the recent launch of our new TGR Series of Reaction Wheel Assembly motor kits, the timing is perfect to update our business partners, as well as customers about this new space-rated offering. In addition, we’re proud that our colleagues at ESI Motion will be demonstrating our Direct Drive Motor Assembly being driven by their control electronics.”

ThinGap slotless motors are widely used in many space applications, including Reaction Wheels, Control Moment Gyroscopes, Gimbals, Point-and-Track Satcom, Pumps and other precision actuation functions needed in spacecraft. For vacuum-compatible motor kits, ThinGap can easily provide variants of its commercial off-the-shelf motors. With these modifications, the motor kits can address the need for various program specifications, including low outgassing materials, specialty electronics, and in some cases, redundant stator windings to provide mission-critical assurance.

Space Symposium, held at The Broadmoor in Colorado Springs, Colorado, USA, has brought together space leaders from around the world to discuss, address and plan for the future of space since the inaugural event in 1984. In recent years, the Space Foundation team has welcomed more than 14,000 people from around the world, including speakers, attendees, exhibitors, volunteers, educators, and students. Space Symposium has become widely known as the premier U.S. space policy and program forum for information on and interaction among all sectors of space.

Small form-factor and high inertia-to-weight ratio ideal for microsatellites

Today’s Low Earth Orbit (LEO) satellites, including “SmallSat” and “CubeSat” microsatellites require a range of critical functions to serve their mission as cost-effective spacecraft. One of the most important functions is Attitude Control, which enables high accuracy pointing capabilities.

Reaction Wheel Assemblies (RWA) are used for multi-axis Attitude Control. RWAs use multiple motors that each spin at varying speeds creating a change in kinetic energy in the desired axes. RWAs utilize optimized rotating inertia, speed, and torque to accomplish this.
Motors used in RWAs need to have the optimal balance between torque and inertia, with negligible rotational losses and smooth motion performance. Zero cogging is critical to achieving this smooth motion. Additionally, parts must be made with low-outgassing materials, have flight heritage, and be sourced from suppliers that can support space programs’ stringent requirements.

ThinGap has tuned its product offering of “air core” motors to meet the demands of this application. This moving magnet air-core motor lends itself to very low drag at high operating speeds, and a wide speed range with constant torque. ThinGap’s ironless stator puts all the magnetics (the heaviest part of the motor) in the rotor, maximizing the inertia for a given weight and size requirement. The reaction wheel’s necessary flywheel mass can be reduced, and sometimes fully incorporated into the rotor. The resulting package is lighter weight for the same momentum storage capacity.

Smooth operation is achieved through a zero cogging slotless design that maintains sinusoidal torque versus angle curves with total harmonic distortion of less than 0.5%. The precision wound coil results in a phase-to-phase balance within 1%. Hands down, ThinGap has the highest precision RWA motors available, yielding pure torque vector control, with very low losses and zero cogging.

Motor sizes range from 25mm to 250mm in diameter and axial heights as small as 22 mm, with through holes up to 80% of the outside diameter. Since 2015, ThinGap has shipped thousands of Space-grade or MIL-STD rated motor parts for use in commercial satellites, military and commercial aircraft, and flight-grade NASA programs.

ThinGap Motors Used For RWA Applications

To learn more about the TGR Series of motor kits, click here.

The use of gimbals is becoming pervasive in Low-Earth-Orbit (LEO) Satellites and even ground-based systems. A heavy reliance on gimbal-based systems is an important part of the Defense Agencies’ critical Intelligence, Surveillance and Reconnaissance (ISR) objectives. In addition to defense, there are emerging uses in communications, and remote imaging applications.

Satellites use Gimbals for communication in a similar method for pointing and positioning, with the gimbals acting as the turret and gimbal unit alone, and a device called a fast-steering mirror delivering fine precision control that ensures a reliable optical data connection between satellites, either between low Earth orbit and geostationary satellites and between low Earth orbit satellites.

Multiaxial gimbals require high performance motors to directly drive their movements and to hold position. Advanced space-rated gimbal systems, like those used in Control Moment Gyroscopes (CMG), require a large amount of torque. In some cases, to move in both azimuth and elevation quickly and precisely, and in others to quickly compensate for external “tumbling” disturbances common in orbit.

One of the largest use-cases for ThinGap’s slotless motors are Gimbals, so much so that it considers itself to be the performance leader in Gimbal motors. From handheld applications for action cameras to large platforms designed for satellite-to-satellite communication, the applications of gimbals are endless. By using an array of different sensors and motors to counteract movement, electrically controlled gimbals serve to keep platforms stable and focused. Last summer, ThinGap delivered a series of motor kits to NASA for use in a space-based gimbal application, which serves as a testament to the quality and processes at ThinGap.

Using its proprietary design, thin wire-wrapped stators, and optimized permanent-magnet rotors, ThinGap provides motors with specifications that can match the torque output of slotted motors while avoiding the cogging that plagues them. Ring motors are the perfect form factor for gimbals with their round shape, direct drive mounting capability and empty center.

ThinGap’s motor kits offer a large through hole, usually 65% of more of the device’s outer diameter (OD), due to its efficient mechanical design and optimized components. ThinGap’s LS line of slotless motor kits range in size from 25 to 267 mm diameter and torque from 0.1 to 12 N-m continuous. With standard and modified configurations, the product line will cover voltages from 24-400 volts and current from 1 to 100 amps. Hall devices and special configurations are also available.

To learn more about the LS Series, click here.

ThinGap has made available two new Space-rated frameless motor kits specifically designed for Reaction Wheel Assemblies (RWA) used to control small and miniaturized satellites. The new TGR 29-12 and TGR 45-20 are an extension of the widely used TG Series of aerospace motors supplied by ThinGap for nearly two decades.  The vacuum compatible parts are 29mm and 45mm wide, and 12mm and 20mm tall, respectively.

ThinGap’s patented motor architecture has inherent advantages in RWA and flywheel applications: an efficient ironless core, zero cogging stator, high torque capacity, dynamic responsiveness, and overall weight savings.

The “air core” architecture lends itself to very low drag at high operating speeds and cogless torque. The wave-wound design of the stator produces a sinusoidal Back-EMF with total harmonic distortion of less than 1%. The precision hand wound coil results in a phase-to-phase balance within 1 degree. In combination, these produce the highest precision RWA motors available which yields essentially pure torque vector control with very low losses and zero cogging.

The new TGR’s design puts all the magnetics (the heaviest part of the motor) in the rotor, maximizing the inertia for a given weight and size. The resulting package is lighter weight for the same momentum storage capacity, and because of no iron saturation in the stator, ThinGap’s peak torque capacity is much higher than a similar weight motor. This gives a high dynamic response significantly better than the competition at a lighter weight. The motors are also highly efficient (up to 95%) since the architecture lends itself to very low drag at high operating speeds.

The TGR 29-12’s offers a continuous torque of 0.012 N-m and 0.0054 N-m/√W motor constant. The TGR 45-20 offers a continuous torque of 0.075 N-m and 0.0197 N-m/√W motor constant. This allows the new TGR motor kits to offer more than double the torque of the closest competitor with minimal losses.

Prior TG Series models have been widely used in RWA systems. Sample quantities of the new TGR 29-12 and TGR 45-20 are available with a 12 week lead time.  Additional models of the TGR Series will include a 79 mm and 61 mm OD part set to be released later in 2022.

To learn more, click here.

ThinGap has continued the build-out the LS Series of slotless motor kits with release of the LSI 39 parts offering. The new LSI 39’s, with their small 39 mm (1.5 inch) outer diameter (OD), are targeted for use in robotics, gimbals and precision industrial applications, including semiconductor production and test equipment. Like all LSI products, they can also be modified for vacuum compatibility, as needed in Space-based systems.

The new LSI 39 motors are available in three different axial heights (10 mm, 17 mm, and 39 mm) and are zero cogging, low in profile and have a highly linear torque output. The motors are intended to fit between the existing LSI 25 and LSI 51 motor kits, and can deliver between 0.03 and 0.28 N-m of continuous torque at 6,400 RPM.

Low-rate product quantities of the new LSI 39 products will be shipped to customers in early February. Complete datasheets and CAD model are available at thingap.com for immediate design considerations.

To see the full LS Series of motor kits, click here.

Camarillo, CA (January 11, 2022) – ThinGap has delivered its latest large-size production unit, the LSO 393-31 motor kit to a commercial customer. The LSO 393-31 motor kit has an outer diameter (OD) of 393 mm and an axial height of 31 mm, providing a continuous torque output of 14.47 N-m, and a peak torque of 93.0 N-m.

With 20 years of experience in the design and production of its slotless motor kits, ThinGap is able to leverage proven analytical models and advanced design optimization that results in highly accurate transitions from predicted performance to test results. Furthermore, the process steps needed to produce motors of all sizes is highly scalable. ThinGap has shipped “large” class motors in the nominal sizes of 230-, 280-, 400-, 500-, and 600-mm OD, ranging in output of 10 to 400 kW of output energy.

Customers looking for unique and demanding performance requirements have repeatedly come to ThinGap for custom, application-specific, and modified-standard products to meeting their demanding applications. The recent repeated delivery of the LSO 393-31 is yet another example of this capability.

ThinGap has continued the build-out the LS Series of slotless motor kits with the latest release, three different LS “in-runner” frameless motor kits. The new LSI 39 products have an outer dimension (OD) of 39 mm or 1.5 inches, and are available in three different axial heights of 10 mm, 17 mm, and 39 mm. These motors are able to deliver between 0.033 and 0.279 N-m of continuous torque at 6,400 RPM. Much higher levels of peak torque are possible for shorter durations. Low rate product quantities of the new LSI 39 products will be shipped to customers in January 2022, and complete datasheets and CAD model are available for immediate design considerations.

Like all ThinGap motors, aside from being cogless, the stator windings are very thin and the rotor is optimized, resulting in a precision movement within a low-profile form factor with a very large through-hole. The LS line of torquer motors is being widely used in gimbals, optics, robotics and precision industrial applications that need cogless movement and are also looking for efficiency, low harmonic distortion, highly linear torque output and a compact form factor.

“The addition of a new smaller-sized set of motor to the LS Series really helps fill out the lower end of the product line,” said Joseph Kay, Director of Engineering at ThinGap. “We continue to establish ourselves as the market leader for slotless motor kits and assemblies, whether as part of our Standard Products or commonly modified-standard, and custom designs.”

This new variant of the LS fits in between the already established LSI 25 and LSI 51 motors sized motor sets and is part of the ongoing addition of variants within ThinGap’s LS product line. The LS Line of is ideally suited for smooth and precise motion in targeted applications in the typical aerospace, medical, precision industrial and communications markets. With OD sizes from as small as 25 mm and up to 267 mm, the LS line range in continuous torque from 0.1 N-m up to 12 N-m.

As a leading maker of high-performance motor kits used in a range of applications, ThinGap’s staff recently completed its annual IPC J-STD Training and Certification.

ThinGap is ISO 9001:2015 certified and supports customer-specific flow downs as part of program compliance and its Quality Management System. Industry-leading process and workmanship standards, such as IPC J-STD for soldering, are used throughout the production process. The annual training and certification of the J-STD is a key aspect of ThinGap’s quality control.

IPC is the global association that helps manufacturers and electronics industry suppliers build electronics and electronic components to higher standards. Like in years’ past, ThinGap production staff as well as quality control personnel underwent training to the IPC J-STD-001 specification. J-STD-001, is the Requirements for Soldered Electrical and Electronic Assemblies and the preeminent standard for electronics assembly manufacturing. The standard describes materials, methods, and verification criteria for producing a broad range of high-quality interconnections and emphasizes process control.

Workmanship standards, such as IPC J-STD and others like the American National Standards Institute or “ANSI” standards, are used throughout ThinGap’s production process. Furthermore, all documents and procedures are controlled by the Company’s Product Lifecycle Management (PLM) system.

ThinGap has a track record of supporting the exacting requirements for its base of Fortune 500 companies, Government customers including NASA, and regulatory specifications across multiple sectors, be it Space, Medical, Defense or Airborne.

ThinGap has delivered the first production units of its new LSI 267-58 motor kits to commercial customers. The new LSI 267-58 motor kit has an outer diameter (OD) of 267 mm and an axial height of 58 mm, nearly double that of its smaller counterpart motor, the LSI 267-32. The new LSI 267-58’s increase in axial height more than doubles the continuous torque output to 24.4 N-m, up from 11.5 from the LSI 267-32. In addition, peak torque has grown three-fold, from 68.1 N-m to 191.0 N-m.

The outer diameter of the LSI 267 motor kits is approximately 10.5 inches across, making it the same size as a small pizza. The LSI 267 kits are targeted at in gimbals and industrial applications that need cogless movement and are also looking for highly linear torque output, a low profile and a large through hole.

With OD sizes from as small as 25 mm and up to 267 mm, the LS line ranges in continuous torque from 0.1 N-m up to 24.0 N-m. Standard, modified-standard, and custom designs are available in both in-runner (rotor position relative to the stator) and out-runner configurations.