The ThinGap® Advantage

ThinGap’s patented electromotive coil technology improves motor performance by eliminating the need for wire-wound stators with slotted laminations. Instead, precision-machined copper sheets provide the coil with structure, replacing the copper magnet wire and slotted laminations used in conventional motors. This allows higher copper packing density and a higher ratio of copper to total coil volume, while virtually eliminating the magnetic detents (cogging) caused by slotted laminations.
ThinGap® motors offer the following advantages:
Higher Power Density
ThinGap motors lead the industry in power density, i.e. power (watts) / weight or volume ratio, allowing higher performance with a smaller motor. The electromotive coil design is lighter than conventional coils. The design of the coil allows high copper packing density and eliminates the need for slotted laminations. In turn, this eliminates eddy current and hysteresis losses caused by laminations. A solid steel ring fixed to the rotating magnet structure replaces the stationary slotted laminations. The eddy current losses in the coil are very low and easily controlled. This configuration increases motor efficiency, enabling higher shaft torque and horsepower.
High Efficiency
The efficiency of the motor is improved by eliminating the wire windings and iron core/slotted laminations that cause hysteresis and eddy current losses and lower efficiency and output power. Additionally, the ThinGap coil has very low resistance, substantially reducing i2R losses.
No Hysteresis Torque
By replacing the stationary laminated stack with a rotating solid steel return path hysteresis losses are eliminated. Since slotted laminations are unnecessary, the magnetic detents they cause are eliminated. This combination of features virtually eliminates cogging, in turn minimizing velocity and torque ripple.
No Cogging Torque
Eliminating slotted laminations eliminates cogging torque caused by slot interaction with magnets. Since the coils are constructed without iron, and all iron parts either rotate (i.e., brushless motor) or remain stationary (i.e., brush motor), cogging torque and hysterisis drag torque are virtually non-existent.
Very Low Starting Torque
Without cogging and hysterisis drag torque, starting torque is very low. Bearing drag is usually the only friction during starting. This is often desirable for wind power generation at low wind velocities.
No Radial Forces between Rotor and Stator
By replacing the stationary laminations with a rotating iron ring, radial magnetic pull between the rotor and stator becomes non-existent because now there is no iron in the coil assembly. This is especially important where magnetic pull between the rotor and stator causes rotor instability in critical applications.
Reduction of radial forces improves stability where air, magnetic, or oil film journal bearings with a low radial spring force constants are used.
Smooth and Quiet Operation
Harmonic variation of torque and voltage are reduced by eliminating lamination slots. Additionally, since an AC field does not exist in the iron components, AC excitation of acoustic noise from the iron is eliminated. The only detectable noise comes from bearings, air turbulence around the coil and vibration caused by non-sinusoidal current waveforms.
High Speed Brushless Coil
Low inductance windings are needed for high speed operation. Lower inductance allows the required voltage needed to drive the motor at speed to be lower. A low inductance winding also helps to reduce motor weight by allowing more magnetic poles(higher frequency) and less iron thickness. As a result, power density is improved.
Fast Response Brush Coil
With a low inductance coil in the brush motor, current responds quickly to sudden voltage swings. Torque builds as fast as the current rises in a rotor that has a very low inertia. As a result, rotor acceleration is doubly improved compared with conventional motors.
High Peak Torque
Very high ratios of peak to continuous torque are achievable because the torque constant does not change as current increases up to the peak current limit. This linearity between torque and current allows the motor to produce very high peak torque. With a conventional motor, no matter how much additional current is applied, when it reaches saturation it will not produce more torque.
Sinusoidal Back EMF Waveform
The motors contain very low voltage harmonics because of the precise location of the coil elements and inherent smoothing of the waveform due to the coil configuration in the air gap. This provides exceptionally smooth constant torque independent of rotor angle with sinusoidal drives and controllers. This characteristic is especially useful for slow-moving objects (e.g., telescopes, optical scanners, and robotics) and precision surface machining, where smooth motion control is crucial.
Enhanced Heat Dissipation
Both the interior and exterior surfaces of the coil are exposed to airflow, which dissipates more heat than slotted rotor coils. Conventional wire windings embedded in lamination stack slots have very little air flow on the coil surface, resulting in higher operating temperatures. With the same wattage in the ThinGap coil, the motor will have a lower temperature rise.

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