Since 1975 we supply the most modern inductive components, made in the Bavarian Forest.

When hearing “Bavarian Forest”, one thinks immediately about national park, mountain torrent, woods, nature, Bavarian traditions and quaint people. Exactly! But there is more to come:
Tauscher Transformatoren, a manufacturer of one of the most important electronic components of electrical engineering, the transformer, has its head quarter in the Bavarian Forest.

Our chance and strength is our regional connection.

For 16 years we produce stators for linear propulsion. The best-known ones are:

1995: Superman, California
1996: Tower of Terror, Australia
1998: Disney’s Californian Adventure
1999: Six Flag Magic Mountain
2000: U Shape, Rock’n Roller, Disneyland USA
2002: Rail Cab, Neue Bahntechnik, Universität Paderborn
2008: Ferrari Duelling Coaster Abu Dhabi

Performance characteristics of LSM propulsions

- wear-free, 10 million stress-runs
- compact construction of the stator, because of a special core construction, very high notch filling up to 60%
- magnetic impact over the whole construction-width
- completely capsuled setup (IP 68)
- solid mechanic conduct necessary
- secondary parts are used passively without any electric input
- forces up to 200 kN at 3000 A, speed up to 50 m/s (180 km/h)

Performance characteristics of SLIM propulsions

- no iron core
- weight 27 kg without cable
- length 1500 mm, thickness 20 mm
- thrust 8 kN/m
- brake force 14,7 kN/m

Technical data Roller Coaster California - Superman

- moved weights: 7000 kg
- max. speed: 45 m/s (=160 km/h)
- max. acceleration: 2g
- mechanic driver-input: 1,5 MW
- power of the frequency-inverter: 2500 kVA
- quote of permitted false-starts: 10 ppm
- Six Flags Magic Mountain Park

Within seven seconds, the 7t heavy vehicle is accelerated up to 160 km/h and shoots vertically up in the air. During the following free fall, the passengers are weightless for approximately six seconds.

For a railway application, inductive components often have to withstand difficult requirements:

The customer needs a choke for a railway application as auxiliary supply, which is arranged at the input of a converter. The device should be connected between a high voltage transformer and an inverter. The choke needs a construction that makes it perform as a booster choke and simultaneously limits the commutation currents of the rectifier. Furthermore, the device must be able to cope with a multitude of forces, that appear at such an application.

Due to a new design, we were able to find a proper solution for this application:

Due to a space saving construction, it was possible for us to redeem the limited requirements for space as well as the electrical requirements. The core is made of a thin tape magnetic core with optimisation of the air gap. The windings have low skin- and proximity losses. The mounting of the choke is designed for the difficult requirements of arrangement in trains. Like this, the choke is able to resist these mounting difficulties easily. It furthermore is able to deal properly with humidity, dirt, shocks and similar forces, that might affect the component in this field of application.

Technical data

Inductance: L > 375 µH
Frequency: 50 Hz
Current:
400 A @ 50 Hz,
30 A @ 2850 Hz
Weight: 70 kg
Dimensions:
370 mm x 330 mm x 250 mm
Art.: BV 2937006b

Toroidal transducing transformer for portable power supplies and application in US-trucks:

The customer needs a mobile power supply with 5 kW power, which has to be firmly integrated in the vehicle. The transformer has to be small, lightweight and low on hum noise and furthermore it needs to be able to generate the American net voltage by using the battery voltage. A toroidal transformer is the only suitable solution. It has to be implemented in the car body, best would be in a fitting potting. Due to this construction the transformer should be able to resist crash-tests without any problems. The connections preferably may only use a bit of space and they should be as small as possible. The efficiency of the transformer needs to be extremely high, but the short-circuit voltage on the other hand may not get too low because of this.

An optimised toroidal transformer served as a solution for this problem

We solved this customer problem with an optimised toroidal transformer, which is built with corded wire for the high current winding. The connection is done with a flat cable and standardised bushings. To increase the short-circuit voltage, we made a special construction of the primary- to the secondary winding.

Technical data

Primary:
42 VDC modulated to 60 Hz sinusoidal
Secondary:
120 - 0 - 120 V 20 A
Power: 5000 W
Dimensions:
Ø290 mm, height 120 mm
Weight: 30 kg
Art.: BV 1366005b

Potting of piezo ceramic actuators for rotor blades of a helicopter with electric flap drive:

The control is done by three flap modules attached to the backside edges of each rotor blade. The blades have integrated piezo ceramic actuators, which react with a change of length to variable electric voltages. Like this the rotor flaps are moved about 15 - 40 times per second.

Limit values are planned to be undercut even further in the future!

The primary goal of this innovative control method is to reduce the relatively high noises of the rotor blade peak vortex, which are system related for helicopters during the flight. Even though the limits are already underbid by today, the reduction should reach a level which is clearly below the limiting values of modern Eurocopter-helicopters.

Contemporary the vibrations, that have an effect on components and passengers, should be decreased remarkable. This will increase the flight comfort and the limit of performance of future helicopters. Furthermore the commercial usage of helicopters will benefit.

Technical data

Cast resin:
Tedistac D45003
Art.: BV 1559008

Auxiliary supply for Airbus A380 - in case of an emergency of vital importance:

In case of a failure of all propulsion units of an Airbus A380, the plane won’t have an electrical power supply anymore. This would lead to an air crash in no time. But thanks to modern technology, this can now be avoided. In case of complete failure, an airscrew is carted out and the airstream incites the airscrew and generates electricity.
This electricity has to be transformed and converted into the voltage which is required by the cockpit.


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Transformers and chokes, which are necessary in an emergency:

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To transform the generated electricity into the needed voltage for the cockpit, a converter is needed. Our chokes and transformers are components of this converter.

Ideally they are never deployed, in case of an emergency they are of absolute vital importance though.

 



Technical data

Inductance: 1,4 microH
Voltage: 250 mV
Frequency: 1 kHz
Weight: 178 g
Art.: BV 18049005

Transformation of small voltages to mains voltage - power transformer as photovoltaic application:

To transform the low voltage of photovoltaic cells to line voltage, our customer is in need of a transformer,
- which generates a sinusoidal wave without harmonics
- which is applicable in the outdoor area (rain, dirt)
- which can be exposed to high variations in temperature


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A potted toroidal transformer as ideal solution

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As a solution we developed a toroidal transformer, potted with polyurethane resin. The special characteristics of the used cast resin make sure, that the whole potting is extraordinary tearproof. Furthermore the housing rejects humidity and arranges the heat removal. The core consists of low-loss FeSi tape.
Additionally we mounted two smoothing chokes in the housing and around the toroidal transformer. The cores of these chokes are made of nanocrystalline materials.

 



Technical data

Power: 5000 VA
Input: 168 V
Output: 230 V 21,7 A
Short-circuit voltage: 1,5 %
Safety class: II
Protective class: IP 65
Art.: BV 2937002 - 005

Three-phase power choke for inverter test system:

For the operation with variable rotation speed of electric motors used in hybrid drives of vehicles, inverters are necessary. By using the direct current, inverters generate the output voltage, which is needed for the control of the electric motor. To test inverters, we developed a special test system. The harmonics of the inverter mounted in this system should be throttled with very low losses.


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A three-phase power choke with ferrite core for inverter:

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We construct a three-phase choke with a large ferrite core. The core losses are minimised by doing this. To also reduce the copper losses, we use special mid-frequency braid wires. On demand the connections can be fixed either at the front of the chokes or on top.

 



Technical data

Core: Ferrite N87
Winding: HF-Litze
Inductance: L = 3 x 0,20 mH
Current1: I1 = 250 A @ 2500 Hz
Current2: I2 = 25 A @ 10 kHz
Weight: ca. 95 kg
Dimensions: 500 x 250 x 510 mm
Art.: BV 2983054 - 055

Resonance converter with special water cooling - for potential-free power transfer:

Similar to its forerunner, this toroidal transformer was potted with a special epoxy cast resin, which has a very high heat conductivity of 1,26 W/mK. The generated heat is not only removed by the cast resin this time though, but additionally we implemented a special water cooling system. By means of two connectors the cooling water can be pumped through the transformer and thus it is possible to reach an optimal cooling for the device.
The winding is done with a very fine wiry HF-litz for a low Rac/Rdc factor. The core we used, consists of nanocrystalline material, known as VITROPerm, the same as we used for the forerunner. At a size of approximately 210 mm x 210 mm x 80 mm, the whole application only weighs around 9 kg. This toroidal transformer is also used as resonance converter in various battery test systems for potential-free power transfer.



Technical data

Power: 60000 VA
Primary: 700 V
Secondary: 880 V
Frequency: 10 kHz
Transformer with water cooling
Art.: 2983052

Linear positioning of modern surgery robots:

For the development of hand-held surgery robots in the medical technology, our customer is looking for stator coils with very small and over all very accurate dimensions.

These robots make a combination of robotics and computer-assisted navigation with manual methods possible. An optimisation of precise positioning during surgical interventions is enabled by working with modern technology.


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Stator coils with precise alignment to redeem the dimensions

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We solved the problem with nine interlinked stator coils, which are potted very precisely with special moulding tools. This made it possible, that we were able to redeem the required dimension tolerances of +/- 0,1 mm. The total dimensions of the component could not be bigger than 60 x 32,6 x 1,6 mm.

 



Technical data

Weight: 90 g
Art.: BV 3309001

Portable high current device to put locomotives in operation:

For the activation of locos, our customer is looking for an adjustable high current device to do converter tests. The devices needs to be portable and light in weight with carrying handles. The current needs to be adjustable from 0 to 1000 A without steps. Even though a measurement does not take a lot of time, the device should be safeguarded against longer operation times and short-circuits.


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A high current transformer, adjustable via a toroidal adjustable transformer

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As solution, we decided to build a high current transformer with 1000 A, which is controlled by a toroidal adjustable transformer. The high current transformer is equipped with a thermal protection, the adjustable transformer with an automatic fuse. The connections are made via high current bushings. The whole application is mounted in a housing with carrying handles and a control knob for the toroidal adjustable transformer on the front side.

 



Technical data

Power: 3000 VA
Current: 0 - 1000 A
Input voltage: 230 V
Weight: 30 kg
Art.: BV 29045001

Three-phase test equipment to test three-phase transformers:

Our customer is looking for three-phase test equipment, which is able to measure short-circuit currents up to I_K 578 A. Furthermore, it should be possible to test both one-phase or three-phase low voltage transformers up to 40 A permanent stress, and three-phase high voltage transformers up to 10 kV 2,5 A. As it also has to do tests with stators, the system needs a function, which enables a heating of stators up to 130°C with 100 A constant current. The input voltage needs to show an accuracy of +/- 0,5%.


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Complex construction to manufacture a modern three-phase test system

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The problem was solved with a complex construction and a combination of voltage regulator, variable ratio transformer, high voltage transformer and high current transformer. A three-step switch enables a shifting between high current, low voltage and high voltage. To examine values, several measurement instruments with digital monitoring were mounted, e.g. digital multimeters and temperature measurement devices. Furthermore the system has a digital interface (COM) to connect a computer.

 



Technical data

Components:
3-AC high voltage transformer,
3-AC high current transformer,
3-AC Low voltage transformer, voltage regulator, variable ratio transformer
built in a 3 x 19” control cabinet with chassis
High current assembly socket, LV- and HV-socket, Kill switch, 3 x 4-fold power strip, 5 digital measurement instruments,
digital interface (COM) for computer connection