ThinGap’s motor technology has been covered in a very informative article by our close business partner Sierramotion entitled “DIRECT DRIVE – AN ENGINEER’S GUIDE”.

The Applications Team at Sierramotion recently posted a blog on their company’s website where they outlined the desired motor performance in Direct Drive applications, focusing on characteristics such as zero-cogging, and large internal diameter.  While ThinGap was not mentioned by name (no vendors were), an image of the LS Series slotless motor kit was prominently shown.

One interesting excerpt from the post related to motors is sited below:

“The accurate definition of a motor has to do with its mechanism for generating torque or force and how many electromagnetic phases it has and how they are controlled/commutated. Electromagnetic (EM) torque/force production is derived from an interaction between two magnetic fields or through a change in reluctance or permeance with position/angle, (or some combination of these two main groups). There are four main electromagnetic motor types in use today; brush commutated DC or AC motors, electronically commutated Synchronous Permanent Magnet Motors (AKA Brushless DC), AC Induction Motors (AKA Asynchronous), and electronically commutated Variable Reluctance (AKA Switched Reluctance). Of course, there are hybrid combinations of these technologies also in use. There aren’t any new forms of EM torque generation, in spite of what you may read on the internet.”

To read the complete Sierramotion post, click here

ThinGap has made available two new variants of its successful LS Series of torque motor products: the LSO 225-51 and LSO 225-66. The new parts are 225 mm wide and either 51 or 66 mm tall, respectively. Using an outrunner architecture (where the rotor revolves on the outside, as opposed to the inside of the stator), the new motor kits offer a mechanical feature that is beneficial to applications needing outside rotation around a stationary center. Prior custom LSO models have been developed for use in gimbals and satellite-based laser communication systems.

Like other ThinGap motors, these outrunner motors provide the same cogless motion, high torque output and overall efficiency as the in-runner line of LS motor kits. As an example, the LSO 225-66’s continuous torque of 17.86 N-m and 1.315 N-m/√W motor constant. They also offer a stator with a thin radial cross-section and optimized permanent-magnet rotor. This results in a large aperture while being weight-optimized and low profile. The LSO 225-51 has a part set mass of just 2.4 kg and a 198 mm through hole, representing 88% of the part’s outer diameter (OD).

The LS Series of frameless motor has been built by ThinGap over the last five years and now offers more than 20 different models. They range in size from 25 mm up to 267 mm OD, and numerous axial heights, all providing highly scalable power and torque outputs.
Along with the two new LSO products detailed herein, the existing line of LS motors are in-runner types, as denoted by the product prefix of “LSI”.

ThinGap expects to release additional sizes to build out the LSO product line in 2022.

ThinGap participated in the 36th Space Symposium in Colorado Springs on August 24-26, 2021. The company was represented at the show by its CEO, John Baumann and Matt Panesis, its lead Applications Engineer. Additional members of ThinGap network of sales representatives were present at the show. In addition to meeting potential customers, domestic and international Space agencies, and industry partners, ThinGap proudly demonstrated a working unit of its recently released H-LSI 75-12, a turnkey Direct Drive Motor Assembly based on the company’s slotless motor technology.

John Baumann, ThinGap’s CEO, commented on the event, “After the last year and a half, it’s great to be back out on the road and meeting with customers, especially those in the critical Space sector. It was beneficial to not only meet with our customers and the Government sponsors, but also to network with industry partners and would-be collaborators.”

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 need in satellites and spacecraft. For vacuum-compatible motor kits, ThinGap will provide a custom variant of its commercial off-the-shelf motor. 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.

ThinGap has been covered in Surgical Robotics Technology as a leader regarding high-performance motor solutions for surgical robots.

Robert Mastromattei has showcased ThinGap’s frameless motors as being the ideal solution for high-precision surgical robotic applications in his latest publication on the website. After analyzing desired motor performance, focusing on characteristics such as zero-cogging, and large internal diameter, ThinGap’s LS series of motors are presented as the best solution for high-precision surgical applications.

Mastromattei details:

“A traditional frameless motor is shown below. The motor shown in Figure 2 is a slotless LS Series motor from ThinGap.  These motors have zero cogging and a large through hole. Km of these motors rivals some traditional slotted (or toothed) brushless permanent magnet motors.

Figure 2 Slotless Frameless Torque motor Example

Figure 3 below is a compact integrated Robot Joint for Surgical Robotics. It uses a frameless torque motor kit, high resolution medium accuracy absolute encoder on the input. It has a high ration zero backlash precision gear and a high accuracy absolute encoder on its output.”

Figure 3  Highly integrated Robot Joint

Source: Robert Mastromattei, Surgical Robotics Technology, July 2021. Link

ThinGap’s LS Series of slotless motor kits range in size from 25 to 267 mm outer diameter and continuous torque from 0.1 to 12.0 N-m. The LS motor offers torque performance equivalent to traditional frameless motor kits available on the market, unlike other slotless motor solutions which force a tradeoff between torque output and smoothness. With standard and modified standard configurations, the product line will cover voltages from 7-285 volts and current from 3-12 amps.

High performance motor kits used in Space has become ThinGap’s largest end-market in recent years. Reaction Wheel Assemblies (RWAs) used in Low-Earth Orbit (LEO) micro-satellites is one of the largest applications for the Company’s high-speed TG Series. The LS Series, like the model used in the OCI, is commonly used in advanced gimbal systems that require high amounts of torque, 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.

Government customers represent a small, but important, aspect of ThinGap’s motor development and production business targeted at aerospace, industrial, and medical applications. The delivery of motor kits to NASA adds to ThinGap’s long list of Government customers, including DARPA, US DOE, US Navy, US Air Force, and JPL.

“ThinGap considers it an honor to support NASA projects, both past and present. Our emphasis on engineered-solutions, performance and as a USA-source make us a perfect fit for important Government programs,” said John Baumann, ThinGap’s CEO.

ThinGap has made available a Direct Drive Motor assembly intended as a Technology Demonstrator and featuring LS Series of slotless motors. Using a low profile, 150 gram, 75 mm-OD motor kit, the new “H-LSI 75-12” includes ThinGap’s high-performance cogless motor, a precision bearing set, and a 20-bit absolute encoder from Renishaw. The part aims to demonstrate the superior performance of ThinGap’s motor technology and offers customers a chance to purchase the assembly as a test unit, demonstrator, in support of rapid prototyping, or even low-rate production applications needing a turnkey solution.

Most OEMs come to ThinGap in need of a motor kit, wanting to take advantage of the low profile, lightweight, large aperture, and frameless architecture that is ideal for deep system integration. Yet, the time and cost of engineering a housed solution are not lost on program managers and developers, so in some cases, the availability of a fully engineered, direct drive assembly provides a real advantage.

To learn more about the H-LSI 75-12, click here.

Today’s modern Robotic Systems and Collaborative Robots, including robotically assisted surgical-systems, require smooth precision motion in their robotic joints and end-effectors. Haptic systems require accurate torque feedback without mechanical disturbances to improve the human control experience. Multi-axis robots in manufacturing and semiconductor applications need low profile, frameless kits that fit inside articulating wrists, elbows, and shoulder axes while having high torque and low heat.

ThinGap’s motor kits have multiple important characteristics which make them highly effective for both haptic feedback and actuation applications. The linear torque output, little to no hysteretic drag, and ultra high magnetic efficiency of the ThinGap’s motor kits make them exceptional for Haptic feedback. At the same time, the motor kits provide zero-cogging for precise and smooth motion, a low profile and large through hole to assist with integration, and a lightweight motor kit with a high torque to weight ratio. All of these attributes make ThinGap motor kits a must-have for medical and robotic products.

With two lines of high performance slotless motors — both with space heritage, ThinGap’s patented technology is well suited for active control applications. The TG Series’ high-speed, high-efficiency is ideal for momentum-wheels in both RWA and CMG.  The LS Series’ high-torque, lower-speed precision movement is perfect for gimbal applications, like those in a CMG architecture and related Satcom and Optical applications.

Since 2015, ThinGap has shipped thousands of space-grade or MIL-STD rated motor parts for use in commercial satellites, UAV, military and commercial aircraft, and flight-grade NASA programs.  Using its proprietary design, very thin wire-wrapped stators and optimized permanent-magnet rotors, all ThinGap designs match the torque output of slotted motors while avoiding the cogging that plagues them. Cogging is an unwanted magnetic torque disturbance inherent in slotted motors.

ThinGap’s slotless architecture provides smooth motion that is critical to communication and optical systems that need precision aiming and pointing over long distances. The ring-shape mechanical design is a perfect form-factor for aerospace applications with their need for high efficiency, precision actuation, direct drive capability and open aperture.

With the release of the new LSI 25-16 and LSI 25-25, ThinGap has begun its expansion of the LSI line of motor kits with its new “Tall” options. These new motor kits will use the same outer diameter as the base motor kits in the line but will increase the axial height of the kits. This allows the motor kits to provide increased torque output while still maintaining a specific radial profile. The tall options for the motor kit should allow the LSI series to be an effective fit for applications with high torque requirements while still maintaining high performance, zero cogging, and high efficiency.

The addition of more “tall” options will continue in 2021 with the LSI 51 and LSI 59 receiving the next variants in Q1. Keep an eye out in the coming months for more information on these new motor kits