Magnetics Business & Technology - July/August 2021 - 13

FEATURE ARTICLE
re-processed into different forms which can be sold back into the
supply chain for rare earth magnets.
HyProMag's strategy as a company is to establish a recycling facility
at Tyseley in Birmingham. Product options being evaluated
include hydrogen decrepitated demagnetized powders suitable for
magnet producers, alloy ingot re-melted from HD powders suitable
for alloy feed or magnet production, anisotropic alloy powders for
bonded magnets and sintered NdFeB magnets as required by the
RaRE project for automotive applications. A key investor is Maginito
Limited, a subsidiary of Mkango Resources.
Unipart Powertrain Applications Ltd will lead the development of
manufacturing to automotive scale. Advanced Electric Machines
Research Ltd will lead the design and development of the motors.
Intelligent Lifecycle Solutions Ltd will pre-process computer
hard disk drives to remove the rare earth magnet containing components
from the waste which will be shipped to Hypromag for
removal of the rare earth magnets. University of Birmingham will
provide cast alloys, which will be fed into Hypromag to blend with
secondary materials to produce sintered magnets.
Octopus e-axle project
For more info, see www.bentleymotors.com, www.hypromag.com,
www.advancedelectricmachines.com.
technologies and cars changing faster than ever before, research
projects such as Octopus are crucial to deliver innovative technologies
and overcome challenges for the next generation of mobility
solutions. "
Key to this project also is Advanced Electric Machines Ltd. A commercial
spinout from Newcastle University, AEM is responsible for
motor manufacturing and systems assembly while its associated
company, Advanced Electric Machines Research Ltd, is handling
motor and transmission design.
" Having already worked closely with Bentley to successfully deliver
a proof of concept, we look forward to this new project to push
the performance, packaging and sustainability of electric vehicle
drives to a new level, removing the need for rare-earths and copper
and achieving the highest levels of system integration, " commented
Dr James Widmer, AEM Group CEO.
Another participant is Talga Technologies Ltd, responsible for 2D
materials development for next generation winding technologies.
It is a Cambridge-based research and development arm of graphene
supplier Talga Resources of Australia.
SSRD motor from AEM without rare-earth magnets
The second effort, also a three-year study begun last year, seeks
to transform electric vehicle powertrains by using a fully integrated,
free from rare-earth magnet e-axle that supports electric vehicle
architectures. Titled Octopus (Optimised Components, Test and
simulatiOn, toolkits for Powertrains which integrate Ultra highspeed
motor Solutions) it follows an initial 18-month investigation
that delivered a technological breakthrough in electric drive
systems for high-performance vehicles. The electric drive system
exceeded the latest permanent magnet motor performance while
simultaneously removing the need for both rare-earth magnets
and copper windings. Octopus proposes to take the motor, power
electronics and packaging transmission design, adding next generation
materials, manufacturing processes, simulation and test
cycles to deliver a full e-axle powertrain.
" Today, there remains challenges and package constraints on
the viability and flexibility of electric vehicle powertrains that are
able to fully support EV architectures, " commented Stefan Fischer,
director of powertrain engineering at Bentley. " With the industry,
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July/August 2021 * Magnetics Business & Technology 13
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