The partnership between Marand Precision Engineering and the CSIRO through their Future Manufacturing National Research Flagship, is set to create new markets and opportunities for advanced manufacturing. It’s a partnership that was made possible by the Advanced Manufacturing CRC (AMCRC).
In 1996, CSIRO had a group that was successfully developing high torque high power compact electric machines. These were brushless rare earth permanent magnetic motors. As smart electric motors, brushless rare earth permanent magnetic motors are much more efficient than other types of electric machines. Typically, a brushless permanent magnetic machine of about two kilowatts could be 98% efficient. By way of contrast, a standard induction motor operates at about 70% efficiency. This makes the brushless rare earth permanent magnetic motor effective in situations where energy has to be used more efficiently, such as when it is coming from solar cells or batteries.
It is unusual for any machine of that size and power i.e 1800 W to have this level of efficiency. Potentially, the principle that underpins the technology can be used in any number of applications. So far, the most high profile application has been in the area of solar powered racing vehicles.
The CSIRO was approached by Aurora Solar to develop such a special motor for solar power electric racing. It was a spectacular success. Aurora won the Darwin to Adelaide world solar challenge in 1999, came second in 2001 and had subsequent impressive results. As a result, the CSIRO found itself in the unusual position where it was manufacturing smart electric motors for solar car racing teams around the world. However, the CSIRO is a research organisation, not a boutique manufacturer. It had to find an advanced manufacturer to commercialise its product.
Enter the Advanced Manufacturing CRC. About a year ago, it started providing the funding that facilitated the transfer of the expertise and technology across to Marand, a provider of high-quality precision tooling, machine tools and highly engineered automated production solutions across a range of industries including automotive, aerospace, rail, robotics and automation. However, up until now, it had not been in the business of manufacturing electric motors.
Marand had identified the permanent magnetic motor technology as an entry point into the growing alternative energy market, particularly in the automotive sector.
The AMCRC provided the funding for both Marand and CSIRO to enable the transfer of the technology, facilitating the commercialisation of the product.
Theoretically, these machines can also be used in tidal turbines, propulsion drives and side thrusters for large ships, washing machine motors, machine tool motors, electric power steering motors, computer hard disk drive motors and solar powered drone planes.
Marand however has identified the growing market of electric, solar and hybrid vehicles, integrating other applications into its manufacturing processes. Potentially, it is a market worth hundreds of millions of dollars.
Critically, Marand is taking the manufacturing to a new level. When the machines were being developed by CSIRO, they were all being built by hand. Marand however is introducing semi-automation into the manufacturing process.
At this stage, Marand has been selling the motor to CSIRO’s traditional solar customers but is now fielding inquiries about other applications.
The first machines are expected to roll off the production line in January.
These are expensive machines but the process of introducing automation will enable the price point to reduce and open new markets.
Marand’s commercial expertise, with the commercial backing from the Advanced Manufacturing CRC, is turning a scientific innovation into what is likely to become a booming market for advanced manufacturing.
