Competition in the professional imaging and industrial gimbal stabilizer market keeps rising. The customization capability of core power components has become key. It helps brands create product differentiation and break performance limits.

This case shares a full YAW/ROLL/PITCH three-axis hollow brushless gimbal motor solution customized by TSL for a professional stabilizer brand. It targets three common pain points. Standard models have fixed functions. Structural adaptation is difficult.

Closed-loop control integration has a high barrier. We provided a one-stop customized solution. It helped the client improve both product performance and commercial value.

Solemn statement: The design solution in this case has been officially approved by the customer for public release. We always fully respect our customers’ brand privacy and core technology NDAs. The motor structure and drive design are independently developed patented products of our company.

Customer Core Requirements

The client in this cooperation is a benchmark brand in professional imaging equipment and industrial stabilization systems. This project focused on the forward development of its new flagship three-axis handheld stabilizer and airborne gimbal products.

The core goal was to upgrade the customized core power motor. The aim was to solve common industry pain points in general stabilizers.

These include messy wiring, insufficient attitude control accuracy, and the difficulty of balancing lightweight design with high torque. The client wanted clear differentiation from similar products on the market. It also wanted to set a new performance benchmark for professional gimbal stabilizers.

Why Standard Motors Failed to Meet Customer Needs

The conflict between the client’s core needs and existing market solutions was concentrated in three dimensions.

Fixed Core Performance and Functions

General gimbal motors on the market usually only provide basic rotation. Model parameters are fixed. There is little room for differentiated customization. Under high-frequency attitude adjustment and long continuous operation in professional stabilizers, common problems appear.

These include large torque fluctuation, operation jitter, and excessive temperature rise. These problems directly affect image stability and service life. They cannot match the performance positioning of the client’s flagship product.

Neither standard products from leading overseas manufacturers nor regular models from domestic peers could provide differentiated tuning for the different load features and rotation angle needs of the YAW, ROLL, and PITCH axes. Overseas customized solutions were also far beyond the client’s complete machine cost budget. They had no commercial feasibility for mass production.

Poor Structural and Installation Adaptability

To ensure a compact whole-machine design and simplify internal wiring, the client clearly required a hollow brushless motor structure. This allowed video signal cables and power cables to pass through the motor center. It completely solved industry pain points such as messy external wiring, easy wear, and oversized product volume.

The client also raised two rigid structural requirements. First, the mounting holes and external dimensions of the motor had to fully match the client’s lightweight whole-machine design plan. Second, integrated space had to be reserved in advance for the encoder and matching housing.

One-Stop Supporting Needs Could Not Be Met

Traditional general gimbal motors mostly use open-loop control. They have no position feedback capability. To achieve high-precision closed-loop control, the client would need to select encoders and design matching housings by itself. Its R&D team would also need to complete complex structural adaptation, parameter tuning, and compatibility verification. This created a very high technical barrier.

Working with multiple suppliers separately would also increase the whole-machine BOM cost, assembly process complexity, and after-sales maintenance difficulty. This was completely against the client’s project expectations.

Therefore, the client raised a very clear core requirement. It wanted one-stop delivery of the motor body, encoder adaptation, and matching housing. The motor had to reserve a standard encoder mounting position. It had to support high-precision closed-loop control directly. The client did not want secondary structural modification or complex debugging.

This core need has almost no mature ready-to-use solution among general gimbal motor options on the market.

Our Customized Full-Solution Plan

For the client’s core pain points and personalized needs, the TSL motor R&D team created a customized YAW/ROLL/PITCH three-axis hollow brushless gimbal motor kit. We optimized it in performance, structure, and integrated support. It fully solved all of the client’s key requirements.

Differentiated Three-Axis Customization

We carried out one-to-one customized development for the YAW, ROLL, and PITCH axes of the stabilizer. Each axis has different load features, operating angles, and control needs. We used hollow brushless motor bodies. Through electromagnetic scheme optimization and precise dynamic balance control, we achieved ultra-smooth power output under all stabilizer operating conditions.

For the PITCH axis, we customized precise rotation control logic of 160° clockwise and 160° counterclockwise.

For the ROLL axis, we optimized a 320° rotation limit design. It includes 95° counterclockwise and 225° clockwise. For the YAW axis, we optimized a large-angle rotation limit design. The performance of all three axes precisely matched the stabilizer’s attitude control needs. It fully adapted to all-scenario anti-shake requirements in professional imaging.

Dedicated Structural Optimization

For the client’s key hollow-shaft wiring need, we broke the layout limits of conventional gimbal motors. We adopted a customized integrated hollow brushless structure. This created a full through-hole path at the motor center. It perfectly matched the client’s video signal cable and power cable routing needs.

All three-axis motors use a standardized double-row 2.0 pitch 3P pin design. Black electronic insulating adhesive is pre-applied at the stator winding soldering area for protection. The terminal layout fully matches the client’s wiring plan.

The whole machine uses a compact and lightweight design. It ensures high-precision smooth operation while meeting small-size installation needs. It also fits the lightweight and portable design trend of modern professional stabilizers.

Closed-Loop Control Integration

For the client’s core pain point of difficult encoder integration and high multi-supplier coordination costs, we provided a full-chain one-stop solution. It covered encoder adaptation, matching housing, and accessories.

The client did not need complex parameter tuning. It did not need to coordinate with multiple suppliers separately. It also did not need extra structural mold development. The solution was fully compatible with the client’s existing whole-machine design. It greatly shortened the client’s product R&D cycle. It also reduced R&D and supply chain management costs.

Implementation Value and Client Feedback

This customized three-axis hollow brushless gimbal motor kit has completed full-condition reliability testing. It has also achieved batch delivery. It perfectly fits all-scenario use requirements for the client’s professional stabilizer. It has received high recognition from the client.

Performance: The motor maintains stable operation under long-term high-frequency attitude adjustment and continuous running conditions. Its anti-shake accuracy and running smoothness greatly exceed the client’s expectations. The hollow brushless structure and precise dynamic balance optimization greatly improve motor service life. It meets the long-cycle and high-reliability use requirements of professional imaging equipment.

Cost: The integrated solution saved the client from extra encoder procurement, structural mold modification, and multi-supplier coordination. The whole-machine BOM cost and supply chain management cost were significantly reduced. At the same time, the customized sample fee can be fully refunded in the official batch order. This further reduced the client’s early-stage R&D investment.

Business value: The one-stop customized solution shortened the client’s whole-machine R&D cycle by more than 60%. It helped the client complete product development quickly and gain a differentiated competitive advantage in the professional stabilizer market. The fully flexible parameter customization also provided strong technical support for future product upgrades and iterations.

TSL Motor focuses on customized solutions for micro DC motors and gimbal motors. We have full-process independent R&D and production capabilities. Based on each client’s working conditions, structural limits, and performance targets, we provide one-stop customization services.

These cover requirement communication, solution design, mold development, sampling, and batch delivery. Our solutions cover professional imaging, drones, industrial automation, medical equipment, robotics, and many other motor customization fields.

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