Case Studies

Maxi Muncher Garden Shredder

Rover Mowers Limited, part of the Australian GWA Group of Companies, engaged e3k in 1990 to design and develop the current 1.8 kW electric garden waste shredder now marketed as the "Maxi Muncher". Sales have surpassed expectations with the product continually being on back-order. The systematic development process consisted of initially bench marking competitive machinery from Germany, the USA, and from within Australia. Logical engineering development was undertaken to provide Rover with a superior product within budget.

Exhaust Powered Tipper for Pick-Up Trucks

Development of a novel collapsible textile bag for the Nathan Group was originally undertaken by e3k in 1987. This patented development overcame persistent problems with fabric crimping as it collapsed, and provided a faster lifting system for loads up to 1.5 tonnes on the tray of pick-up trucks. Following this development, innovation continued with the development of a newly patented, very compact bag system for the USA market in 1992. Development escalated in conjunction with the company Smartech Manufacturing Pty Ltd trading as Exhaust Power Industries, and Triple "M" Holdings Pty Ltd after 1993. Extensive design and development continued in 1995, including the development of a safety prop, development of higher lift capacity units, and extensive reliability testing, with Dr Duncan Gilmore being the Director of Research and Development. The unit was exhibited in a large Dallas Automotive Show in 1996.

Medical Drug Delivery Device

e3k worked with Vapotronics Ltd between 1993 and 1997 to research and develop the concepts and technology behind a very novel pulmonary drug delivery system which will find application in the asthma and quit-smoking markets. The work has involved extensive brainstorming to identify the most viable and cost effective technology suitable for the task. Initial experimental research and development has also been conducted together with the management of a broad group of medical consultants to the project. Initial device prototypes were constructed using rapid prototyping stereolithography technology. The company currently based in San Diego, USA, is raising capital for further global market development. Assistance was provided to raise initial finance and to present the product.

CSIRO Numbat Vehicle Development

CSIRO Division of Geomechanics undertook the development of a mobile vehicle able to proceed underground to investigate the aftermath of coal mine explosions and to look for human survivors. This robotic device consisted of a 6-wheeled electric vehicle constructed by Evans Deakin Industries Limited, electronic and computer control designed and constructed by CSIRO, and a robotic head designed and constructed by e3k. The robotic head contained three television cameras, lights, and a microphone. It pivoted on two axes on command from a control station on the surface of the mine. The successful prototype was tested extensively in the coal mines surrounding Ipswich and Central Queensland.

Computational Fluid Dynamics (CFD) HVAC Study of a Train Subway

e3k was recently engaged to undertake a computational fluid dynamics study of a new subway in India. The modelling was used to optimise tunnel ventilation to ensure operational air-conditioning in the event of a train failure mid-tunnel. The simulation included heat transfer to the ground and through tunnel walls. Traditionally this process had been an exercise based on in-house empirical data. Additionally, modelling was undertaken of a typical platform situation to enable optimisation of the station ventilation systems. Heat input from carriage brakes and air-conditioners was incorporated into the simulation

Optimisation of a Francis Turbine for Hydroelectric Power Generation

A comprehensive hydraulic design optimisation was undertaken for a customised 4MW low-head hydro installation in New Zealand. The study involved computational fluid dynamics (CFD) modelling of the water flow through the machine and application of hydraulic engineering principles. Cavitation performance was also examined. Modifications were made to the scroll case as well as to the runner blade profile to improve overall hydraulic performance. Engineering advice was provided on the specialised blade material. An absolute increase of approximately 5% in efficiency was attained as a result of the improved geometry.

Ocean Current Renewable Energy Generator

e3k was engaged in 2000 to carry out engineering research into the feasibility of using ocean currents to generate electricity. Early concepts were examined using scientific methods including mathematical modelling and computer simulation. Further concept development occurred and a novel concept-validation device was designed and tested in the Clarence River in Northern NSW in December 2003. Further engineering development by e3k equipped the device with Aquafoils using proven hydrofoil theory. In June 2004 the technology was accepted into the Australian Technology Showcase. The technology is now being commercialised by Atlantis Energy Ltd.

Cutting Performance of Lawn Mowers

Detailed product R&D was performed in 1996 on the Rover lawn mower range sold widely in Australia, and now exported to the USA and Germany. The aim was to identify improvements which would provide additional competitive advantage for this well known and well proven product. The project began by understanding the physical mechanisms and factors which were important to cutting performance. A theoretical analysis of the typical grass cutting action using CHAM Phoenics particle tracking software was performed prior to designing and manufacturing many experimental prototypes. The experimental tests included visualisation through clear acrylic windows on a lawn mower, strobe visualisation, hot wire anemometry, evaluation of grass cutting performance against a standard benchmark, noise measurements, and trials in New Zealand. Product development work continues with this company for customised European product including noise testing to 2002 Directives.

Technofast Industries Pty Ltd

e3k has been engaged periodically over 14 years to provide design input and testing expertise for this innovative hydraulically-actuated fastening device. e3k has provided extensive computerised Finite Element Analysis (FEA) and experimental stress analysis for a new product destined for the Japanese Nuclear Power Industry. Interaction with Japanese engineers in Toshiba plus the provision of drawings and summary reports on the design has followed. Development work continues with this company for European and US Markets. Technofast Industries Pty Ltd received an award for "Commercial Technology of the Year" at the Global Energy Awards in New York, 2004, and were finalists in the Science and Technology Category of the 2005 Premier of Queensland Smart Awards.

Evans Deakin Industries Ltd

e3k was engaged in April 1993 to develop a method of weighing oil and gas skids being fabricated by Evans Deakin for BHP Ltd at their Colmslie Works. These structures weighed up to 150 tonnes. Both weight and centre of gravity were to be measured. e3k developed a method which was acceptable to both Evans Deakin and BHP, and then proceeded to undertake the measurements. All work was undertaken within a fixed price budget and within a very strict timetable dictated by fabrication progress, and shipping dates.

Olympic Athlete Foot Force Sensor for Kayaks

When staff at e3k watched the achievements of Australia's kayakers at the Sydney Olympics, they felt a special sense of pride because of their own contribution to the teams' training efforts. The team of Andrew Trim and Daniel Collins gained a silver medal in the Men's K2-500 metre event, and Katrin Borchert in the Women's K1-500 metre event gained a bronze medal. These were among contestants whose training program had benefited from a device developed by e3k to provide information about the forces applied by athletes to the foot bars in their kayaks. This Foot Pad Sensor (featured in New Product Advantage - May 2000) enabled sports scientists to measure the timing between the upper body paddle action and the subsequent application of leg force through each stroke. According to David Aitken, Senior Sports Scientist at the Queensland Academy of Sport, the sensor was valuable in providing more information that could be used in training programs. "The information gained from the sensor adds to the coaches' knowledge and enables them to develop advanced biomechanical training programs for the kayakers," he said. The eight Foot Pressure Pad Sensors developed by e3k were initially used only by the Queensland Academy of Sport. However, in view of their contribution to advanced training they were later adopted by the Australian Institute of Sport.
In a field as competitive as an Olympics final, e3k was awarded a certificate of High Commendation in the Institution of Engineers Australia Queensland Division 2001 Excellence Awards, for the design and development of the sensor.

Simplot Australia Edgell Food Processing Division

e3k was engaged in 1997 to analyse the repeated failure of a scissor lift in a high speed food canning line. The lift was used to lower canned food from one conveyor to another. Pins linking the scissor arms were breaking every few weeks, halting production. Visual inspection revealed a process of fatigue, which was confirmed by mathematical analysis. The complete design was reviewed using Finite Element Stress analysis, modified, and a new lift placed back into service with no further failures being experienced.

Aircraft Tie Down Device

e3k was commissioned to design a flush-mounted anchor point (FMAP) at the Brisbane International Airport to be used mainly by Boeing, Airbus and McDonnell Douglas freighter aircraft. The work included innovative concept generation and Finite Element Analysis (FEA) of the device as well as the securing concrete slab. The device was successfully proof tested in situ.

Predictive Maintenance Systems

e3k has been involved with the commercialisation of novel on-line residual life predictive maintenance technology for machinery developed by the Department of Mechanical Engineering at Monash University, Melbourne Australia in conjunction with Bankers Trust Australia, and other investors. The system uses novel sensors and software to compute residual life for large machinery systems.

Computational Fluid Dynamics (CFD) Modelling of Building Fire.

A CFD study was undertaken on a well-publicised fatal building fire within a local accommodation complex. Results from the six-month long study were integrated into the police investigation enabling determination of cause and qualification of the overall building hazard. The same simulation technology has recently been successfully validated by e3k against experimental data in a full-scale mock building burn.

Rotec Design Ltd

e3k has worked regularly for the past 11 years to assist Rotec Design Ltd in the development of their "Freedom Air" two-stroke diesel engine concept. This work has extended from assistance at the early stage of initial fund raising, through to recent testing of prototype engines destined for a European engine manufacturer. The "Freedom Air" concept delivers substantial emissions and power to weight advantages over conventional four stroke diesel engines. Work conducted has included detailed computer modelling of emissions production within combustion cylinders, computational fluid dynamic studies of gas flows, and experimental verification and certification of engine performance.