Abstract: A moving coil brushless motor including an actuator having a stator and a rotor. The stator includes a cylindrical array of permanent magnets. The rotor includes a coil assembly having a plurality of coils interposed between a stator back plate and the permanent magnet array. The coil assembly rotates relative to the array of permanent magnets. A center shaft is disposed to rotate about a longitudinal axis. A cylindrical transformer is disposed within an interior space circumscribed by the stator back plate and includes a primary side and a secondary side. The primary side includes a primary coil and the secondary side includes a secondary coil magnetically coupled to the primary coil. Primary electronics are in communication with secondary electronics attached to the center shaft. The secondary electronics are configured to receive power from the secondary coil and to provide current to the actuator.

Abstract: A printed coil assembly including a flexible dielectric material, a patterned top conductive layer formed on a top surface of the flexible dielectric material, and a patterned bottom conductive layer formed on a bottom surface of the flexible dielectric material. The patterned top conductive layer and the patterned bottom conductive layer form a plurality of printed coils arranged in a plurality of printed coil rollers concentrically arranged in a cylindrical shape. Each of the plurality of printed coils includes a top layer printed coil disposed within the patterned top conductive layer and a bottom layer printed coil disposed within the patterned bottom conductive layer. Coil pitches of the coils within each roller are chosen such that corresponding ones of the plurality of printed coils in adjacent rollers are axially aligned relative to a center of the cylindrical shape.

Abstract: A system and method for precisely applying threaded caps using a linear rotary actuator is provided. The method includes aligning the threaded cap with the threaded top of a container, soft landing the threaded cap in contact with the threaded top, aligning the ends of the threads, soft landing the threaded cap in contact with the threaded top, and snugging the threaded cap. The system includes a linear rotary actuator and a tool for driving and coupling to the threaded cap.

Abstract: A direct drive brushless motor including a plurality of rotational components and a plurality of non-rotational components. Ones of the pluralities of rotational and non-rotational components form a dual magnetic circuit. The plurality of rotational components includes a center rotation shaft circumscribed by a plurality of coils and a coil termination plate configured to support the plurality of coils. The plurality of non-rotational components includes a plurality of outer magnets arranged around the plurality of coils in a Halbach configuration and a plurality of inner magnets arranged in a Halbach configuration between the coils and the shaft. A flex cable having one or more leads provides electrical current to the plurality of coils without the use of brushes.

Abstract: A system and method for precisely inserting threaded fasteners using a linear rotary actuator. The method includes aligning the threaded fastener with the threaded hole, soft landing the threaded fastener in contact with the threaded hole, aligning the ends of the threads, soft landing the threaded fastener in contact with the threaded hole, and snugging the threaded fastener. Additional threaded fasteners may be inserted and snugged before a final torque specification is applied to each of the fasteners. The system includes a linear rotary actuator and a tool for driving and coupling to the threaded fastener.

Abstract: A prosthetic finger, comprising: a first axis of movement comprising a moving magnet; a second axis of movement comprising a moving coil, wherein the second axis is generally orthogonal to the first axis; and a third axis of movement comprising a moving magnet, wherein the third axis of movement is generally oriented in the same direction as the first axis of movement.

Abstract: A linear actuator, comprising a base housing, a top housing, and a piston assembly. The base housing may comprise at least one recess configured to restrain at least one magnet in three dimensions and a channel configured to receive a linear guide. The top housing may be fixedly attached to the base housing and may comprise at least one recess configured to restrain another at least one magnet in three dimensions. The piston assembly may comprise at least one coil bobbin, a shaft, a linear encoder scale, and a flex cable, wherein the piston assembly may be positioned between the base housing and the top housing.

Abstract: A linear actuator, comprising a base housing, a top housing, and a piston assembly. The base housing may comprise at least one recess configured to restrain at least one magnet in three dimensions and a channel configured to receive a linear guide. The top housing may be fixedly attached to the base housing and may comprise at least one recess configured to restrain another at least one magnet in three dimensions. The piston assembly may comprise at least one coil bobbin, a shaft, a linear encoder scale, and a flex cable, wherein the piston assembly may be positioned between the base housing and the top housing.

Abstract: A robotic finger, comprising: a first axis of movement comprising a moving magnet; a second axis of movement comprising a moving coil, wherein the second axis is generally orthogonal to the first axis; and a third axis of movement comprising a moving magnet, wherein the third axis of movement is generally oriented in the same direction as the first axis of movement.

Abstract: A programmable control system and related features and methods are provided for the operation an automated, actuator-based component inspection system. In one implementation, the invention can be characterized as an actuator control system comprising: a controller adapted to be coupled to and control an actuator including a probe moveable by the actuator about an axis in response to control signals from the controller; a user input device coupled to the controller and configured to receive inputs from a user to define an automated sequence of multiple locations of the probe and configured to cause an encoder measurement to be retrieved from the actuator; and the user input device further configured to receive a tolerance value from the user corresponding to the encoder measurement.

Abstract: A system for programming and controlling the movement of a probe of a voice coil actuator along a path includes a control module that is mounted on a voice coil actuator. Specifically, the control module is connected to a clock and to an encoder to selectively establish a plurality of sequential positions for the probe. Each position in this sequence is defined by a location on the path (translation and rotation), and a time at the location. More specifically, the control module includes a key pad for inputting data to identify each position and also, there is a display for providing a visual presentation of the data. In operation the plurality of sequential positions specify a work cycle for the probe and the voice coil actuator uses the input data to perform a series of work cycles.

Abstract: A linear actuator includes a plurality of magnetic plates and a ferrite core with a conductive cover which are mounted on the actuator body to generate a permanent magnetic field. The linear actuator also includes a metal bobbin which has an outer surface and which is formed with an aperture that defines an inner surface for the bobbin. Further, the bobbin is formed with a gap which extends along its length and which intersects the bobbin from its inner to its outer surface. An insulating insert is placed in the gap. Finally, a winding is wrapped around the outer surface of the bobbin to form an electromagnetic coil, and the coil on the bobbin is slidingly mounted on the actuator to receive the ferrite core through the bobbin's aperture. Electrical current can then be selectively applied to the winding to interact with the permanent magnetic field and thereby cause reciprocating motion of the coil.

Abstract: An electric voice coil actuator includes two coils slidingly mounted on a ferromagnetic housing. The coils, which are connected to each other in most applications, are mounted co-axially for linear reciprocal movement in respective magnetic fields. The north poles of a first pair of magnets are affixed to the housing to create the magnetic fields in which the first coil moves. The south poles of a second pair of magnets are affixed to the housing to create the magnetic fields in which the second coil moves. Alternately, the coils can move in the same magnetic field. Opposing poles of the pairs of magnets are affixed to the housing to prevent magnetic saturation of the housing. The coils are electrically connected to an electric current source to produce magnetic fields that interact with the magnetic fields of the magnets to cause movement of the coils. The electric current source may be electrically connected in parallel to each coil, to cause substantially identical movement of the coils.

Abstract: The, present invention is a gripper for use in combination with a machine for repositioning a component. Structurally, the present invention includes a housing formed with a chamber. A fixed-pole housing magnet is positioned inside of the chamber. A pair of grips are slidingly mounted for movement relative to the housing. Each grip is partially contained in the chamber and partially projects from the housing. An electromagnetic coil is attached to each grip. Functionally, the gripper is positioned with an assembly component between the grips. A separate electric current is then passed through each of the electromagnetic coils mounted on each of the respective grips. The electric current causes each electromagnetic coil to generate a magnetic field which interacts with the housing magnet. The interaction between the magnetic fields generated by the electromagnetic coils and the housing magnet creates a force on each grip, causing each grip to move translationally to hold, or squeeze, the component.

Abstract: A method for manufacturing a linear voice coil actuator, capable of continuously generating a one hundred kilogram force with less than two amperes of current, requires using a coil for generating an electrical field and an unsaturated permanent magnet circuit for generating a magnetic field. In the method of manufacture, a flat surface of the electrical coil is positioned parallel to a flat surface of the magnet to establish a gap therebetween. Before operating the actuator, when no current is running through the coil, a distance of approximately 0.75 mm is established across the gap. Subsequently, during operation of the actuator, when a current of less than approximately two amperes is driven through the coil, the electrical field generated by the coil interacts with the magnetic field of the magnet to generate as much as a 100 kg force on the coil.

Abstract: A controller for a voice coil actuator includes sensors that are connected with the actuator probe to monitor both the linear and angular position of the probe, as well as the axial and rotational forces on the probe. Using predetermined instructions, the probe can be controlled in either an open loop mode or in a closed loop feedback mode, for either static or dynamic operations. For static operations, the axial and rotational forces on the probe can be controlled by referencing set values for the forces which are to be applied to/by the probe. For dynamic operations, in addition to the axial and rotational forces on the probe, the linear and angular movements of the probe can be controlled. In the closed loop mode, linear and angular positions, velocities, and accelerations can be used for control.

Abstract: A method and device for moving a probe assembly into soft contact with a work surface includes initially placing the probe into an approach position. Advancement of the probe along a substantially perpendicular path toward the work surface is then controlled by applying a restraining force on the probe. This resisting force is decreased until the weight of the probe assembly just overcomes the static friction forces that are acting on the probe. After the static friction forces are overcome, the probe advances along a path toward the work surface. By monitoring this advancement, soft contact of the probe with the work surface can be determined when the velocity of the probe changes to zero. First, the position of the probe can be monitored to advance the probe along the path through a known travel distance. Second, the velocity of probe advancement can be monitored to indicate soft contact when velocity changes to zero.

Abstract: A thin film field effect transistor includes: a) a thin film channel region; b) a pair of opposing electrically conductive first and second source/drain regions adjacent the thin film channel region; c) a gate insulator and a gate positioned adjacent the thin film channel region for electrically energizing the channel region to switch on the thin film field effect transistor; d) the first source/drain region having a first thickness, the second source/drain region having a second thickness, the channel region having a third thickness; at least one of the first and second thicknesses being greater than the third thickness. Methods are disclosed for making thin field effect transistors.

Abstract: A linear voice coil actuator using a removable electromagnetic coil includes an electrically conductive wire wound on a plastic bobbin. The wire which is wrapped around the bobbin is connected to an external power source as the electromagnetic coil is attached to the linear voice coil actuator. Current applied from the external power source causes the electromagnetic coil to selectively generate a magnetic field and, in response to generation of the magnetic field, to move translationally within a fixed magnetic field. The translational movement of the coil moves a grip which is mounted on the coil to allow the grip to selectively position and manipulate objects and things.

Abstract: An in-line linear/rotary drive mechanism for a voice coil actuator includes an electro-magnetic drive motor having a rotatable drive shaft. Specifically, both the drive motor and its rotatable shaft are slidably mounted for translational movement on the housing of the actuator. An actuator probe is also slidably mounted on the actuator housing. Importantly, a bearing unit constrains the actuator probe to translational movement along a predetermined axis on the actuator housing. Further, a rotary-servo coupling selectively connects the rotatable drive shaft of the electro-magnetic drive motor with the actuator probe. Within this combination, the actuator probe moves in direct translation with the drive motor along the predetermined axis. Also, within this combination the actuator probe moves in rotation about the predetermined axis in response to the rotatable drive shaft.