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.

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 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.