With demand for electronics at an all-time high and a global supply shortage, the Semiconductor Equipment industry is busier than ever. Today’s modern wafer processing, automatic test and packaging system have a need for increased force density and high resolution move and hold steps. Highly precise, yet compact designs help enable inline process steps that are critical to higher throughput.

There are many needs for high precision BLDC electric motors in every stage of semiconductor production, from wafer processing all the way to inline testing. Motor selection is critical to system architecture, and factors in control methods, feedback requirements, and mechanical attributes.

Motors and actuators used for these applications are required to deliver cogless and absolute precision. Low profile motor architecture is ideal, because of the large internal aperture so optics or cabling can be routed through the middle. In addition to wafer positioning, precision motors are needed to direct optical systems, such as beam steering, with precision actuation to deliver precision to the micron level.

The continued use of Direct Drive solutions enables system-level advancements needed by semiconductor processing and test equipment.  Rapid and accurate movement defines the performance specifications.

Beyond zero cogging, ThinGap motor kits have near zero Eddy-current, low hysteresis, and a harmonic distortion of less than 1%, so torque output is directly proportional to current throughout the operating range. The resulting smooth motion, linear output, and low profile of ThinGap’s motor kits make them perfect for use in precision applications. Slotless motor kits with high torque, direct-drive capabilities are in many cases the ideal solution for semiconductor equipment.

ThinGap’s LS Series of slotless motor kits is an industry leader for applications requiring performance and efficiency. Standard LS motor kits range in size from 25 to 267 mm diameter and produce torque from 0.1 to 12.0 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.

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.

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.

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.