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 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 linear actuator includes a magnet housing having first and second planar sides, a front plate and a rear plate, and a base plate covering a channel defined by the magnet housing. A first plurality of magnets is secured to the first planar side and a second plurality of magnets is secured to the second planar side. A linear guide slidably secured to an inner surface of the base plate. A piston assembly has a piston element attached to the linear guide. The piston assembly includes a shaft and a printed circuit board attached to the piston element. The printed circuit board defines a controller and a printed coil assembly. A flex cable is electrically connected to the printed circuit board. The piston assembly is disposed to move linearly during operation of the linear actuator.

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 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 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 stacked actuator system including a plurality of electromagnetic actuators operative to drive a piston shaft between extended and retracted positions. A plurality of electrical connectors and a plurality of signal lines are connected between the plurality of electromagnetic actuators and the plurality of electrical connectors. A system housing at least partially defines an interior volume containing the plurality of electromagnetic actuators. The system housing includes a plurality of apertures through which extends the piston shaft of each of the plurality of electromagnetic actuators. A controller is disposed within the interior volume and connected to the plurality of electrical connectors. The stacked actuator system may further include a base platform element upon which are mounted the plurality of electromagnetic actuators and the system housing. Each piston shaft may move between extended and retracted positions within a plane substantially parallel to the base platform element.

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: Disclosed herein are apparatus and methods for linear actuators that can deliver strokes and forces at different values. The linear actuators include both multi-coil and single-coil actuator designs. The linear actuators include a controller that is removably or permanently coupled to a piston assembly having any number of coils. An encoder may also be removably or permanently coupled to the piston assembly. The piston assembly, controller and encoder move as one unit during actuation of the linear actuator.

Abstract: A system, apparatus, and method for using a magnetic latch to maintain a desired force between a test-probe assembly and a surface of a component. The method includes moving the test-probe assembly into an approach position, the approach position being a predetermined distance from the surface of a component. The test-probe assembly is then moved from the approach position to the surface of a component pursuant to a soft landing procedure. The method further includes magnetically latching the test-probe assembly in contact with the surface of a component at a constant force. The moving coil of the actuator can be de-energized while the test-probe assembly performs measurements on the component. After the testing is completed, the moving coil is energized and the test-probe assembly is retracted away from the component. The applied force may be monitored based upon an output of a load cell responsive to a force exerted by the test-probe assembly.

Abstract: An electric motor including a coil assembly having a plurality of coils which may be arranged in the shape of a cylinder. The motor further includes a rotor including a plurality of outer magnets configured as a first Halbach cylinder surrounding the coil assembly. An outer magnet housing of the rotor is coupled to and surrounds the plurality of outer magnets. A plurality of inner magnets are arranged as a second Halbach cylinder with the coil assembly being interposed between the plurality of inner magnets and the plurality of outer magnets. An inner magnet housing is coupled to the plurality of inner magnets and surrounds an output shaft.

Abstract: An electric motor including a coil assembly having a plurality of coils which may be arranged in the shape of a cylinder. The motor further includes a rotor including a plurality of outer magnets configured as a first Halbach cylinder surrounding the coil assembly. An outer magnet housing of the rotor is coupled to and surrounds the plurality of outer magnets. A plurality of inner magnets are arranged as a second Halbach cylinder with the coil assembly being interposed between the plurality of inner magnets and the plurality of outer magnets. An inner magnet housing is coupled to the plurality of inner magnets and surrounds an output shaft.

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 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 direct drive motor for a robotic finger. The direct drive motor includes a plurality of outer magnets and a coil assembly including a plurality of coils surrounded by the plurality of outer magnets. The plurality of coils are configured to generate a magnetic field when current is conducted through them such that the coil assembly rotates relative to the plurality of outer magnets. The direct drive motor further includes a plurality of inner magnets surrounded by the plurality of coils and a core element surrounded by the plurality of inner magnets. A center rotation shaft is positioned within an interior space circumscribed by the core element.

Abstract: Disclosed herein are methods and systems for low cost linear actuators that can deliver strokes and forces at different values. The embodiments presented herein have parts and components that may be usable for both multi-coil and single-coil actuator designs. According to one embodiment, a magnet housing may removably or permanently coupled to a coil assembly having any number of coils. According to a further embodiment, an actuator housing may be coupled to a magnet housing having any number of magnets or coils.

Abstract: A linear actuator, comprising a base housing, a top housing, and a piston assembly. The base housing may include 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 include at least one recess configured to restrain another at least one magnet in three dimensions. The piston assembly may include 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.