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Blog Posts (11)
- PFA MAGNET WIRE
A new frontier for high performance stators Magnetic wire is a key component in various electronic products such as transformers, inductor coils, electromagnets, electric motors and generators. The latter are particularly important to the automotive industry, and the proper functioning of an electric motor for an electric car depends on the stator. All electric motors consist of a rotating part – the rotor –, a stationary part – the stator –, bearings, and a shaft . A review of several studies about electric motor failures resulted from the experience of manufacturers, repair centers and academic studies shows that the faults distribution percentage in electric motors is approximately 45% in the bearings, 35% in the stator, 10% in the rotor, and the remaining 10% in other components . This implies that one-third of all motor failures are to be attributed to stator failures, the most frequent cause being the breakage of its winding. The winding, comprised of a copper conductor with polymer insulation, is highly susceptible to electrical stresses, and mechanical and thermal loads; therefore, it is the most vulnerable component of the stator. Factors such as cracks, pores, wire oxidation, insulation damage, and permeability to gases and liquids can all diminish the dielectric properties of the polymer coating. . Undoubtedly, the thermal and chemical resistance of the wire is directly contingent on the selection of its insulation material. The most used insulation materials for wires include PI, PEI, PAI, and PPS. Additionally, new high-performance polymers such as PEEK and PFA have been recently introduced. Polyimides, which are applied using classic enameling technology, remain the most popular insulation material on the market due to their ability to provide a uniform coating. However, the primary issue with this technology is the use of highly toxic solvents, such as cresol, which can have adverse effects on both worker health and the environment. Consequently, finding an alternative technology for electric wire production is an urgent task. Nowadays, extrusion represents a promising alternative, as this method offers a wider range of applications. For example, it allows to apply polymers that are not suitable for the conventional enameling technology, such as PEEK, PPS, and PFA. PFA (perfluoroalkoxy) has great potential compared to other materials due to its excellent chemical resistance, which makes it suitable for use in aggressive environments. Moreover, PFA exhibits a higher resistance to partial discharges compared to common materials such as PEEK or PAI. Partial discharge is the main cause of wire insulation failure, which leads to the failure of the entire electric motor. Resistance to partial discharges is a crucial parameter to consider when designing high-voltage motors. Thus, PFA-coated wires have the potential to become a universal stator winding base for high-performance electric motors. However, the widespread use of PFA in magnet wire manufacture is limited by the difficulty of applying it to the wire due to its extremely poor adhesion to the copper surface. In order to overcome this challenge, Tre Tau Engineering developed the patented "DryCycle® technology" (patent EP 3518255B1), which allows most extrusion polymer grades to be applied to wires without the use of solvents, primers, or other copper processing. The DryCycle® process requires minimal polymer application and offers fast application times, making it both economical and environmentally friendly. This article presents the main properties of the resulting PFA wire, thus showing the wide range of possibilities and advantages of using this polymer in electric motor stators. The PFA coating was applied using the commercially available polymer Daikin AP-201. The tests were conducted in accordance with international standards IEC 60851-3, IEC 60851-5, and IEC 61934. In order to fully characterize all the properties of the wire, standard tests for magnetic wire were selected: adhesion, elongation, springback, BDV and PDIV tests. One of the non-standard test methods we used was to make hairpins and compare their electrical properties with those of the unformed samples. These characteristics were chosen to provide a comprehensive evaluation of the properties of the wire. + Adhesion: the ability of the wire to bend and stretch is a function of this factor. This is the major weakness of most fluoropolymer coatings. Tre Tau Engineering has been able to achieve strong adhesion without the need for additional primers or other fixing compounds. + Elongation: this is a measure of the tensile strength and yield strength of the wire and the resistance of the insulation to this kind of stretching. + Springback: an important parameter to create hairpins, it indicates the deflection of the wire when it is bent. + BDV and PDIV: crucial parameters to determine the electrical properties of a wire. BDV indicates the maximum discharge that the wire can withstand, PDIV indicates the inception voltage of partial discharge. Another important parameter in this study is RPDIV (initial voltage of repeated partial discharge). PDIV and RPDIV can be used to simulate the actual operation of the electric motor by predicting the possible moment of stator failure. PFA MAGN E W About Tau Tau is a technology company at the core of energy transition, decarbonization of energy and electrification of transport. Its patented technologies reconcile the necessity of sustainable, resource-minimizing manufacturing with the power, reliability and performance that electrification requires to enable smaller, greener, longer-lasting and more powerful motors, transformers and generators. Tau focuses on carbon-conscious protective coatings for high-performance and standard copper, aluminium and steel wires. Visit www.tau.group or follow Tau on Twitter and LinkedIn
- Tau Group concludes €9m series-B round to scale up production for e-mobility
The round, led by Solvay Ventures, is joined by existing investors including Finindus and happens in parallel with Tau Group’s commercial breakthrough with automotive customers Turin, Berlin, 1 February 2023 – Technology company Tau has concluded a series-B round raising €9 million with Solvay Ventures as a lead investor. Solvay Ventures is joined by existing shareholders including Finindus, a Belgium-based joint venture of ArcelorMittal and the Flemish Region, as well as management and private individuals. Tau has established itself as an innovative supplier to the automotive industry by setting a new global standard in winding wire for e-mobility. Its wire addresses the industry’s demand for the next generation of electric motors with a reduced carbon footprint, using less resources and improving the electric vehicles’ efficiency, range and recharge time, notably through superior resistance to partial discharge and accommodating voltages of 800V and higher. Recently, Tau reached an important commercial milestone when its wire products completed diligent validation processes of several automotive OEM and Tier 1 suppliers in Europe, Asia and North America. The company is currently ramping up capacity, providing early adopters with immediate competitive advantages, and is preparing industrial scale carbon-neutral winding wire production in Italy with the goal to start worldwide deliveries by 2024. “Through the use of specialty polymers, Tau’s innovative technology enables higher performance electric motors, key to the accelerating adoption of electric vehicles”, says Peter Vanlaeke, Partner at Solvay Ventures. “We are delighted to add Solvay Ventures as one of our key investors as we move into this new phase for our business. Strengthening the ties between the different parts of the value chain is critical to help accelerate solutions like Tau’s winding wire and the impact it will have on the energy transition”, says Francesco Taiariol, CEO and co-founder of Tau. “Since our initial investment mid 2021 we have seen excellent progress of this leading-edge technology towards full scale industrial manufacturing and market acceptance by world renowned automotive players. We are thrilled to have Solvay Ventures on board - adding more insights - to strengthen our network and to complement the existing core investors”, says Hans Maenhout, investment director of Finindus. About Tau Group Tau is a technology company at the core of energy transition, decarbonization of energy and electrification of transport. Its patented technologies reconcile the necessity of sustainable, resource-minimizing manufacturing with the power, reliability and performance that electrification requires to enable smaller, greener, longer-lasting and more powerful motors, transformers and generators. Tau focuses on carbon-conscious protective coatings for high-performance and standard copper, aluminium and steel wires. Visit www.tau.group or follow Tau on Twitter and LinkedIn About Solvay Ventures Solvay Ventures is the Venture Capital fund of Solvay. Solvay Ventures invests in breakthrough technologies in advanced materials, devices and business model innovation. Operating since 2005, Solvay Ventures is currently investing out of a €80 million global evergreen fund. Solvay Ventures targets early stage investment opportunities (Seed through Series B) with a focus on startups addressing better use of resources, energy transition, increased well-being, and digital age. Beyond capital, Solvay Ventures looks to leverage the resources at Solvay to help accelerate technology and market adoption. Visit www.solvay.com/en/innovation/solvay-ventures or follow Solvay on LinkedIn About Finindus Finindus is a Belgium-based investment company funded by ArcelorMittal and the Flemish Region and is linked to OCAS, a world class metal research centre with campuses in Zelzate and Zwijnaarde (Belgium). Finindus provides early stage and growth financing (both equity and debt) to innovative technology companies active in the field of materials (including material processing), sustainable manufacturing and industry 4.0. Finindus invests across Europe, with Flanders as a home base and sweet spot, and across the globe for investment opportunities in technologies at the centre of our core domains and in line with the strategic interests and areas of expertise of our shareholders. Visit www.finindus.be or follow Finindus on LinkedIn
- Tau brings the new electric motor technology to life
Tau paves the way for transport electrification at Coiltech Italia 2022, the international coil winding exhibition, held in Pordenone on September 28-29. Electric car manufacturers are racing to launch more advanced models at a rapid rate. Most importantly, industry experts are mastering innovative winding technologies for high voltage motors featuring high-power density. This helps to improve the electric vehicles’ efficiency, range and reduce recharge time. After successfully passing laboratory testing, Tau has now unveiled a new hairpin stator prototype for automotive e-traction developed in partnership with Additive Drives, a manufacturer of state-of-the-art e-motor components for mobility, automotive, industrial and racing sectors. One of the highlights of Tau winding wire is that it has all the characteristics that future mobility requires. Its partial discharge resistance and voltage resistance are 60% higher than that of competing products. In comparison to modern conductor solutions, the Tau wire delivers a higher power output and is suitable for applications above 800 volts. “We are proud to be partnering with Additive Drives to deliver our shared vision of the next level electric motor technology. At the current stage of pre-production development, we have a rare opportunity to shape decisions on product design and material sourcing based on our product performance. This milestone is of the utmost importance for Tau, now and in the future, as we want our magnet wire to play a key role in the energy transition”, said Filippo Veglia, co-founder and CSO of Tau. Tau’s magnet wire characteristics - electrical, mechanical and chemical - have been tested by FAPS and PEM Institutes in laboratory settings. Having successfully passed all tests, Tau further partnered with Additive Drives and built the first stator with Tau wire. This confirmed that Tau wire can be processed and allows for a smaller bending radius of the wire in the stator, lower friction, and a higher electrical fill factor. By rethinking traditional coating methods, Tau is leveraging the benefits that “from scratch” approach gives to put in place more sustainable practices. The DryCycle® solvent-free coating process significantly reduces any negative impact on the environment owing to the use of solid-state dry varnishes preventing VOC emissions. "We use only the materials we need and no more. Our one-layer insulation has already demonstrated very good mechanical robustness and superior dielectric strength, so we don't need to apply more polymer to obtain better results, which reduces not only the manufacturing cost but also carbon footprint. And we want to do much more than that. Our DryCycle coating is the only technology that allows 100% copper and thermoplastic polymer recycling - thus making our high-performance wire more environmentally friendly," added Veglia. The company will continue its partnership with Additive Drives to deliver an end-to-end e-motor solution that weighs less, consumes less energy and resources, and achieves the absolute maximum power density and range, Veglia said. To see the very latest technologies designed for the winding industry, visit Coiltech Deutschland 2023 in Ulm on March 29-30, where Tau will be exhibiting at Booth 7-D09. About Tau Tau is a technology company at the core of the electrification of transport and the decarbonization of energy. Its patented technologies reconcile the necessity of sustainable manufacturing with the power, reliability and performance that electrification requires to enable smaller, greener and more powerful motors, transformers and generators. Tau focuses on carbon-conscious protective coatings for high-performance and standard copper, aluminium and steel wires. Visit www.tau.group or follow Tau on Twitter and LinkedIn. About Coiltech Coiltech Italia is an annual international exhibition for the coil and winding industry that gives an excellent opportunity to keep up with the materials and methods innovation for further improvement of efficiency in production, distribution, transformation, and consumption of electrical energy. For more information visit https://www.quickfairs.net.
Other Pages (8)
- Tau Group | Tre Tau Engineering srl
ELECTRIFICATION MADE REAL WITH HIGH PERFORMANCE MAGNET WIRE At the very core of ELECTRIFICATION Tau Group is pioneering the production of sustainable, solvent-free, high-performance magnet wires and setting a new industry standard that enables the transition to electrification. As a core player in electrical machines, we are committed to accelerating the development of electric mobility for all modes of transportation, including cars, trucks, buses, ships, aircraft, and trains. Our driving force is innovation, and we are dedicated to creating cutting-edge solutions that pave the way for a sustainable future. Why TAU Solvents saved Litres of solvent saved per year by replacing ten traditional enamelling lines with DryCycle 297 THOUSAND Reduce waste Less scrap with our coating process 80 % | Raised Total equity investment so far 24 MILLION € We just MAKE IT HAPPEN DryCycle® is a new, sustainable and efficient way of enameling wire that minimizes carbon footprint and use of resources. Our innovative technology offers a solvent-free, dry process that outperforms traditional enameling, producing no CO2 emissions. With superior ease of operation, flexibility, and unit economics, DryCycle® is the future-proof solution for enameling wire. DryCycle® Our Solutions AUTOMOTIVE WIRE GRID WIRE STANDARD WIRE Powering EVERYTHING THAT MOVES Our cutting-edge solutions offer the power density, voltage and sustainability needed for electrification. By moving from fossil fuels to electricity, we can pave the way for a sustainable future, together. Environment The driving force behind of our success. Our core belief at Tau is that the environment and human progress can thrive as one, and we're committed to making that vision a reality. Our chemistry, mechanics, and data-driven approach to sustainability are transforming the environment one solution at a time. Our easy-to-use solutions make the world more eco-efficient, driven by our belief that the environment can thrive alongside human progress. Our Culture Latest News 17/05/23 PFA MAGNET WIRE 31/01/23 Tau Group concludes €9m series-B round to scale up production for e-mobility 28/09/22 Tau brings the new electric motor technology to life
- Contact | Tau Group
- Why Tau | Tau Group
2013 Tau was founded 2014 Invention of “DryCycle” 2015 Angel Investment 2017 First steel wire production line delivered 2018 Start of commercial steel wire production with Tau technology 2020 Series-A, investment from Altana Start of the JDA with Elantas 2021 ISO 9001certification 1.500t of Tau steel wire produced 2022 First IFRS group audit completed First motor (stator) built by a Tau customer with Tau automotive wire Italian plant kick-off for first industrial production unit Preliminary IATF 16949 automotive certification obtained Installed 2 new production lines 2023 Series- B1 led by Solvay Start of ISO 14001 certification process Faster and focused product development Greater customization to, and early detection of, client needs Tighter cost control and high margins Increased protection of intellectual property Raised Total equity investment so far 24 MILLION € Electrification. For Real. At Tau, we're pioneers in wire solutions, driving progress towards an electrified future. Since 2013, we've been revolutionizing the industry with innovative products and a passionate team of experts. Welcome to the core of E-MOBILITY OUR MISSION IS TO LEAD THE WAY We empower our stakeholders and society by providing innovative solutions that create value and build a world where resources are used efficiently and processes work to their full potential. IN THE PRODUCTION OF SUSTAINABLE, SOLVENT-FREE, HIGH-PERFORMANCE MAGNET WIRE AND TO ESTABLISH A NEW INDUSTRY STANDARD ENABLING THE TRANSITION TO ELECTRIFICATION. Tau’s vertical integration enables depth of solutions. ADVANCED CHEMISTRY OF COATING POLYMERS PROPRIETARY TECHNOLOGY FOR MANUFACTURING IN-HOUSE WIRE PRODUCTION END-CUSTOMER SALES OF WIRE Our vision and commitments. We believe that the environment can thrive alongside human progress. Our innovative solutions transform the world, one solution at a time, creating a sustainable future by promoting the efficient use of resources and optimizing process performance. We strive to foster a cleaner, healthier planet for generations to come, where electricity is the primary source of energy. At Tau, we are committed to leading the way in providing solutions that enable the transition from fossil fuels to electricity. Solvents saved Litres of solvent saved per year by replacing ten traditional enamelling lines with DryCycle 297 THOUSAND Get in contact Italy - Turin Tre Tau Engineering s.r.l. Lungo Dora Pietro Colletta 85 10153 Torino (TO) firstname.lastname@example.org Germany - Berlin TAU ACT GmbH Friedrichstraße 68, 10117 Berlin