ThinGap High Performance Motors

ThinGap specializes in the development and production of custom high performance brushless DC motors and generators. These machines utilize our ironless composite stator and lightweight high energy rotor technologies. We design and manufacture machines from 0.1 kW to 70 kW shaft power and are currently developing a series of new motors and generators for medical, aerospace, and industrial applications.

With either a new motor/generator design or modifications to a standard product, our team of specialists will create a solution that meets your application requirements. Our engineering toolbox includes years of experience, leading CAD and motor simulation software, as well as a fully instrumented test lab. With our full range of engineering design and application services we have created high quality special purpose machines for a wide range of applications.

Our motor engineering specialists apply proprietary analytical methods and a suite of development tools to accurately simulate the operating performance of all components, as well as the complete system, before any hardware is built. We use a variety of software and modeling packages including:

• SolidWorks for solid modeling and mechanical simulation
• JMAG for electromechanical and electromagnetic simulation
• MATLAB for numerical analysis and optimization
• LabView for testing and control

Final stages of motor/generator development include full machine analysis and characterization in our test lab. Contact us with your high performance motor, generator, and/or controller inquires.

Featured Products

TG Brushless Motor Series

• Highest power density motor design with high torque and inherent high speed capability
• Dual inside and outside rotating back iron
• Zero cogging, patented iron-less composite stator
• Available in frameless kit form or motor assembly with shaft and bearings
• Typically Hall effect sensors are pre-aligned and factory-installed, encoders option is available on some models
• Sizes from 25 mm to 1 meter, power levels range from Milli to Mega Watts
• 3 phase brush-less, precision sinusoidal waveform
• Fail-safe wrap available over rotor magnets for ultra reliability
• Fully encapsulated stator windings

LS Brushless Motor Series

• ThinGap’s LS line targets low speed, high precision applications such as gimbals, optics, and precision robotics.
  Highest torque density with high power capability. Low thermal resistance at any speed
• Smooth motion with zero cogging and ultra low torque ripple when paired with a sinusoidal drive
• High peak torque to continuous torque ratio
• Optimized for ultimate torque density
• Stationary lamination stack for typical bore mounting
• 3 phase brushless, sinusoidal waveforms < 1% THD
• Non-saturating facilitates very high peak torque (typically >4:1)
• Exceptionally large clear apertures
• Frame-less kit facilitates deep integration

Custom Motor Solutions

• A complete suite of software packages including advanced numerical analysis, magnetic 3D FEA, CAD packages, and proprietary tools allow for quick preliminary analysis and efficient “what if” trade studies
• Refined models allow seamless transition from specifications to hardware realization
• Typical design outputs fall within 5% of nominal specifications

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