Rica r do Qua do r te r ly r eview defence vehicle safety and service Innovative thinking enhances O celot T s e n i b r u Ricardo helps OpenHydro’s seabed radical renewable energy on the the on efficiency in cars, trucks, trains source become real source become Dr Thomas Weber, Thomas Dr of head How flywheels can boost Stored energy energy Stored Mercedes-Benz R&D Mercedes-Benz – and even elevators I nterview

Q4, 2009 AltErnAtivE tHinking ABout comPutEr modEling And SimulAtion

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© 2008 Hewlett-Packard Development Company Contents Ricardo Quarterly Review Q4, 2009

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News Features 04 Industry news 10 Protect and survive Honda prioritises hybrids over electrics; stop-start reaches In the unpredictable conditions of today’s counter- the scooter and motorcycle market; key carmakers work insurgency campaigns, all vehicles are targets and all need on thermal energy recovery; EV excitement brings energy- to be protected against explosive devices. This calls for a supply backlash; Porsche offers lithium ion battery option wholly new generation of military vehicles, as to save weight Farah Alkhalisi found out when she spoke to the Ricardo team developing the radical new Ocelot platform 28 Ricardo news SARTRE project aims to develop platooning technology; 16 Power from the bottom of the sea new transmission for Russia’s KATE; test facility upgrade OpenHydro’s mighty undersea turbines tap ocean currents for Chicago, and; new fuel efficient demonstrator vehicle to provide reliable renewable energy irrespective of for US Army the weather. Anthony Smith tells the story of Ricardo’s assistance in this remarkable programme Questions and answers 22 Flywheels for the future 06 The battery is the key technology High-speed flywheels are a cheap and efficient way to Daimler and Mercedes-Benz Cars research chief Thomas hybridise vehicles – yet until now their development has Weber gives a wide-ranging interview to Tony Lewin been hindered by the lack of suitable transmission systems. Jesse Crosse reports on ingenious developments at Ricardo that could have wide-ranging applications in public transport too

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" United Kingdom Editor: Tony Lewin Tel: +44 (0)1273 455611 Contributors: RQ magazine is printed on paper Ricardo contacts and locations: Farah Alkhalisi, Jesse Crosse, Anthony Smith certified as being in compliance www.ricardo.com/contacts TwoTone Media Ltd contacts: with the environmental and RQ subscriptions: www.ricardo.com/rq Anthony Smith: [email protected] social standards of the Forest Sales enquiries: [email protected] Tony Lewin: [email protected] Stewardship Council. Industry News

Honda prioritises hybrids

attery-powered cars will be concept, both using a hybrid drivetrain. conducting research on battery electric Blimited to city commuting duties A series production version of the CR-Z vehicles as short-distance commuter while hybrids will expand to become is expected in the first quarter of 2010; vehicles,” he said. mainstream transport, says Honda. the Skydeck is a show-only model. “We believe that Honda should Speaking at the 2009 Tokyo Motor Public attention, however, was most prioritise the more widespread use show, Honda president closely focused on a second concept, of gasoline-electric hybrid vehicles and CEO Takanobu Ito the EV-N. Styled as an affectionate at this stage in the advancement of introduced a near look back to the Honda N600 of the electromotive technologies,” he added. production-ready 1960s, the EV-N is a tiny four-seater Also displayed by Honda were the version of the powered by lithium ion batteries. Yet EV-Cub, an electric version of the classic compact CR-Z despite the positive reaction, Ito was light commuter bike, and the sports- hybrid sports quick to express caution about any tourer VFR1200, marking the return of coupé, as well production EV: “At this moment, the V4 engine and a world first in the as the six-seater considering the level of battery shape of a dual clutch transmission for Skydeck family performance, Honda is a motorcycle. station wagon

Honda Skydeck is a concept for a six-seater family hybrid xxxxxx

Hybrid power for hybrid trike Bridging the gap between equivalent performance to a the scooter and car worlds is conventional 500 cc motor. Peugeot’s HYbrid3 Evolution, a Three drive modes are offered: three-wheeler concept displayed zero-emission electric, gasoline at the Milan bike show in only and hybrid. In ZEV mode the November. range is 10 km, while as a hybrid The concept’s name refers the machine, assisted by a stop- not just to its configuration but start system, achieves 48 g/CO2 to its propulsion system: the per 100 km. 3 kW electric motors in each With no direct connection of the front wheel hubs are between the two power sources, supplemented by a supercharged the gasoline engine cannot 300 cc gasoline engine driving recharge the lithium ion traction the rear wheel. batteries. Instead, these rely The forced-induction unit gives on braking energy harvested 41 hp, says Peugeot, providing through the front wheel motors.

Porsche’s lithium ion Dana keeps batteries cool Kia’s first GDI engine Lightweight less effective Porsche is the first company Tesla’s 2010 Roadster Sport Kia has launched its first Engine technologies such as to offer a lithium ion starter incorporates a Dana heat gasoline direct injection engine variable valve lift are more battery. The unit, which is 10 exchanger system to keep its – a 2.4 litre four-cylinder – on the effective at reducing CO2 than kg lighter than a conventional traction batteries at optimum Korean market. The Theta II GDI lightweight construction, battery, is a €1900 option on temperature to help maximise develops 201 hp and is expected materials supplier ThyssenKrupp the new 911 GT3 and Boxster their operating life, while also to appear in Europe-bound Kia said at the end of its three-year

News in brief Spyder. assisting cabin climate control. products in 2011. InCar research programme.

4 RICARDO QUARTERLY REVIEW • Q4, 2009 Ricardo GM explores narrow hysteresis Quarterly SMA wire exhaust Review heat recovery stream The task of RQ is to highlight the latest thinking in automotive engineering and technology engine recovered worldwide – both within Ricardo and among waste heat electrical power other leading companies. By presenting an up-to-date mix of news, profiles and interviews with top business leaders we paint an interesting and exciting picture of R&D activity at a world-class automotive engineering services provider. It is a formula that has certainly been a hit with the worldwide automotive community: in the electric eight years since RQ was launched we have had to increase our print run to 14,000 copies generator to keep pace with the demand to read about Ricardo and its activities. Client confidentiality is of the utmost cooling air SMA engine importance to Ricardo, which means that we can only report on a small fraction of the work carried out by the company. So we are eneral Motors, freshly emerged energy capable of powering your especially grateful to those Ricardo customers Gfrom Chapter 11 bankruptcy, has vehicle’s stereo, power seats and air who have kindly agreed to co-operate with RQ received Federal research funding to conditioning,” said the company. and allow their programmes to be highlighted explore methods of capturing heat BMW, too, is working on thermal in print: without such help from customers energy wasted in the vehicle’s exhaust energy recovery and featured a it would not be possible to present such a fascinating insight into the way vehicles are and cooling system. thermo-electric generator system on conceived and developed. GM’s project involves shape memory its Vision EfficientDynamics showcar alloy (SMA), a material that shrinks as in September 2009. In contrast to the it is heated. This movement could be GM system, the BMW generator works company officials declined to go into used to generate electricity, says GM, on the Seebeck principle, which relies more detail. and the unit could be installed in the on the current generated between two Up to 27 per cent of the energy vehicle’s exhaust to drive an electric metal-based semi-conductors when the content in a vehicle’s fuel is wasted in generator and charge a battery. temperature changes between them. the form of heat escaping through the “The day is coming when the heat “This system alone generates exhaust system, according to EE-VERT, from your car’s engine exhaust is enough charge to power some of the a European programme to boost the captured and converted to mechanical auxiliary features,” said BMW, though energy efficiency of road vehicles. EV carbon footprint questioned

ith at least six major automakers higher overall CO2 emissions and oil necessitate extra generating capacity Wpreparing to release battery cars consumption. in national grid networks. T&E also for general sale and significant market Brussels-based research group warns that though high upfront costs take-up a real possibility, attention has Transport & Environment concludes will prevent large market take-up of begun to focus on the combined carbon that if the electricity comes from EVs, their low running costs could lead footprint of the cars and the electricity coal, then a modern hybrid car is to extra demand for car transport. grid which recharges them. better in terms of well-to-wheel CO2 Nevertheless, momentum in the WWF calculated that even with emissions, again recommending EV market is building up. Renault has an extreme EV take-up leading to 20 changes to taxation and emissions announced production sites for its million electric cars on Germany’s trading regimes. However, T&E says four commercial battery car designs roads by 2030, the reduction in there is “compelling evidence” that (though not yet hinting at prices or German CO2 emissions would electric cars offer a good opportunity ownership models) and Fisker has be under 2.5 per cent; the UK to store intermittent energy flows from selected the former GM plant at Environmental Transport Association renewable sources such as wave and Wilmington, Delaware, to build up to says that under the current EU wind. This may in turn help promote 100,000 units a year of its volume plug- emissions trading system, sales of such sources and raise the threshold in hybrid, set to cost under $40,000 electric cars are likely to result in at which mass EV take-up will after federal tax credits.

Fuel cell buses for Hamburg Stop-start scooter New electric standards Hamburg will welcome 10 new- Honda has brought the first Improved safety standards have generation Mercedes-Benz CITARO stop-start system to the just been published by the ISO for fuel cell hybrid buses in a major scooter market. Idle-stop on electric road vehicles. The two-part field trial next year. The fleet has 50 its new 125 cc PCX cuts the ISO 6469 specification is designed per cent lower fuel consumption, engine after 3 seconds, to help makers design fail-safe an operating range of up to 250 km saving 5 per cent in fuel vehicles and to inform safety and is quick to refuel at 700 bar. consumption. personnel and emergency services.

Q4, 2009 • RICARDO QUARTERLY REVIEW 5 RQ Interview – Dr Thomas Weber

“The key technology for the future is the battery” In charge of perhaps the most admired automotive R&D organisation in the world, Dr Thomas Weber is a passionate believer in the power of technology to safeguard the environment – and to bring Mercedes-Benz Cars’ CO2 average below 140 g/km by 2012. Tony Lewin spoke to him in London after the Frankfurt show, where zero-emission cars stole the limelight

Mercedes-Benz used to have one What do you see as the main options With our joint venture “Deutsche of the highest fleet CO2 averages in for future individual mobility? Accumotive” we are developing Europe. How successful have your Future mobility will be marked by a and producing our own lithium-ion new technologies been in reducing mix of three directions in terms of batteries and we will also sell them to this average? powertrains; the high-tech downsized third parties. At the end of last year our fleet average for combustion engines, second, hybrids At this year’s Frankfurt Autoshow we Mercedes-Benz Cars was 173 g/km; by and, third, zero emission vehicles with gave a concrete outlook on the future the middle of this year we had already battery and fuel cell. The electrification of hybridisation. We presented the reduced our average to about of powertrains will gain more and Vision S500 Plug-in Hybrid – the first 160 g/km. This demonstrates that our more importance. In this regard the “three-litre car” – in the premium class large investment in green technologies lithium ion battery will play a key which can drive for up to 30 kilometres and products is starting to pay off. role. The S400 Hybrid, which we have solely on electricity and therefore Sitting here now, I am certain that we brought to market this summer, is without producing any local emissions. will meet the really challenging future the first European hybrid and the first European CO2 targets for Mercedes- series production car equipped with Mercedes-Benz S400 Hybrid was the first Benz Cars. this innovative battery technology. production car to use a lithium ion battery

6 RICARDO QUARTERLY REVIEW • Q4, 2009 The efficient drive system enables future. Hybridisation, for example, the vehicle to achieve a certified offers huge additional potential consumption of only 3.2 litres of petrol for larger vehicles: so it will be per 100 kilometres. This technology necessary to go in such a direction. I’m offers great potential especially for convinced that all three technological larger cars. We are convinced that in a solutions will be important for the few years from now such a vehicle can future global success of automobile be on the road. manufacturers. Tailor-made solutions without compromises in terms of What about smaller cars? safety, comfort or fascination are our Electric drive with fuel cell and approach. especially battery are attractive options for urban compact vehicle Other carmakers have expressed concepts. London marks an important reservations, but you now have a fuel milestone for us, for we started our cell car in [small] series production. test fleet with 100 smart electric drive Do you see fuel cell technology here in 2007. And the feedback from overtaking battery technology? the customers was and still is great! It is not a question of “either or” Now we have taken the next step: – battery and fuel cell technology we just started series production of complement each other. Both are our two electric vehicles – the new electric drives – just the kind of energy smart electric drive and the Mercedes storage differs. For us the target zero B-Class with fuel cell in small volumes. emission driving is set; especially in E-drive vehicles are no longer science crowded cities zero emission vehicles fiction: the technology is now ready, will be needed in the long-term. But but before we can go into higher there are different ways to reach this production volumes some basic aim. Pure electric drive with battery conditions have to be clarified and and fuel cell is possible. And only implemented. One keyword here is the customer will decide, which of infrastructure – refuelling stations with both technologies fits his individual hydrogen and power charging stations. driving profile best. That is why we It’s time to act: we have to reinvent the are preparing a flexible architecture car, and if we manage to do it quickly based on a pure electric powertrain. and in a concerted manner, there will If the customer, say someone living be a positive future for the automotive in a metropolis like London, needs to industry as well as the industry as a go only 50 to let’s say 150 km per day, whole. It is an opportunity for all to get an electric vehicle with battery like out of the crisis even stronger. our smart electric drive is the perfect solution. But if the customer prefers Which of these technologies will be to drive longer distances, our B-Class the most important? with fuel cell fits best. It has a locally Individual mobility will become even emission-free range of about 400 km more diverse and complex in the and can be refuelled within minutes. “The electrification of powertrains will gain more and more importance. In this regard the lithium ion battery will play a key role”

Q4, 2009 • RICARDO QUARTERLY REVIEW 7 RQ Interview – Dr Thomas Weber

Are you looking at other battery Of course the battery needs to last technology. On our S400 Hybrid we technologies in addition to lithium ion? the whole lifecycle of the vehicle – have achieved a reduction in fuel We will concentrate on lithium ion hundreds of thousands of charge and consumption by about 25 per cent. technology. Its advantages are very discharge cycles and even when going But for pure electric vehicles you have compact dimensions, far superior from a fully charged battery to almost different battery requirements. In a performance compared to other zero each time. If you look at the early hybrid battery, it is the power output batteries, long service life and great hybrids they protected their batteries that is the decisive factor. For batteries reliability even at very low temperatures. by using less than half of the charge. used in electric vehicle applications, Its high level of safety is the equal of that But if you really want to achieve major the focus is on energy content. And the provided by today’s auto batteries. savings on the fuel economy side lithium ion technology offers solutions you need completely different cycles for both. What is the battery lifespan you are and charging requirements, and that targeting? will only be possible with lithium ion On combustion engines, is the development potential swinging back to gasoline? “In a hybrid battery, it is the power output that is the We believe we need both – diesel and decisive factor. For batteries used in electric vehicle gasoline - in our portfolio. Looking at applications, the focus is on energy content. And the European standards of 140 g/km CO2 in 2012 – and as an engineer, of the lithium ion technology offers solutions for both” course, looking ahead – I don’t think it

8 RICARDO QUARTERLY REVIEW • Q4, 2009 “This is the important message about transmissions: So there will be no DCT for your rear- drive models? the technology has to be perfected for hybrids. We won’t use DCT on rear-drive Hybrids are more influenced by the transmission cars because everything we need in terms of comfort, shifting speed and and the combinations within the transmission” sportiness can be addressed by our planetary automatic transmission. will be possible to reach this ambitious you have no real benefit. What we are target without a high market share of working on is a transmission with a The recently announced SLS super- diesel vehicles. The efficiency of diesel really wide range – and of course the sports car has rear drive and a double technology is still 20 per cent higher number of gears could be different. clutch transmission. Is that an than that of gasoline engines. And exception? our diesel success story – even in the Will the range be wider than the Yes, the SLS is a completely different US – speaks for itself. So we are well Porsche Panamera, where the DCT has story. It is an extreme sports car, prepared for the future, when it comes a spread of more than 10? hence different solutions had to be to diesel, gasoline, hybrid or emission That’s quite wide, but from our considered. free driving technologies. point of view not the limit. If we go in a downsizing direction for smaller So will other less extreme sports You have said that Mercedes-Benz vehicles, then the number of speeds versions, such as your AMG models, will meet the really stringent and the ratio range will be important use the wet-clutch planetary automatic European regulations for passenger- to further improve the fuel economy. that is already fitted to the SL? car CO2 emissions in the next five Short-term, we will improve the Yes, that’s right. These are really years. How important is transmission economy of our transmission by at expensive technologies we are talking design to the improvements you need least 2 to 3 per cent; in the next step we about. This is the important message to achieve? will also incorporate start-stop in the about transmissions: the technology On the transmission side it’s possible automatic transmission with additional has to be perfected for hybrids. to achieve between 5 and 10 per cent benefits for fuel efficiency. Hybrids are more influenced by the better fuel efficiency. We’re working on transmission and the combinations this at full speed. Our solution for front Why have automakers been so slow to within the transmission. wheel drive vehicles is double clutch bring in stop-start? – it’s more expensive than CVT, but The only reason why everyone is Dr Thomas Weber has been a member also superior to CVT. I can announce currently focusing start-stop on the of the board of management of that we will have such a (DCT) system manual transmission is that on an Daimler AG (formerly DaimlerChrysler) in our upcoming front wheel driven automatic it is necessary to electrify since 2003 and is responsible for compact cars – that’s the A-Class and the transmission on the pump side to group-wide research as well as the B-Class as well as further new models. maintain the oil pressure. In the long development of Mercedes-Benz Cars. run all Mercedes vehicles in Europe Born in 1954, he graduated in If your front-drive cars will have DCT, will be equipped with start-stop – mechanical engineering from Stuttgart what is your preferred transmission without exception. University in 1980 and joined solution for your RWD models? Daimler-Benz AG in 1987. After For rear wheel drive applications it You get better performance and a series of roles in engine is clear that we have already today lower fuel consumption with a dual development and the lightest and the most efficient clutch transmission – so will manual production he – and also the most cost-effective transmissions eventually disappear? took charge – transmission in the market: our No – cost-wise, manuals are good. And of the Rastatt seven-speed. We will advance this with younger drivers the emotional plant in 1999 technology and will soon come with feeling of shifting gears is still there. and oversaw further improvements, especially on We thought at one point in time that the launch of the the fuel economy side. It’s clear that we could completely switch over A-Class in 2002. if you are the leader in this field, you to automatic transmissions, but we want to stay at the top. concluded that it wouldn’t be possible for specific models. Will you incorporate stop-start and more speeds? But is it a declining market (for manual For the customer, seven speeds are transmissions)? better than six – so we could come to We thought the trend was approaching a situation where some people believe zero, but this is changing. There’s eight is better than seven. But speeds now a revival, driven first of all by are not what really matters: the most fuel consumption and now costs important driver is the spread of ratios. – especially as the alternatives are If you have an eight-speed with the becoming more expensive. same ratio range as a seven-speed, BlueZero concept (far left) uses same Are you developing your dual clutch architecture for EV, range-extender EV and transmission yourselves, or are you fuel cell EV drivelines; Smart Fortwo (left) is buying the system from a supplier? now produced in electric form We’re doing it in house. Ocelot

Protect and survive In the unpredictable conditions of today’s peacekeeping and counter-insurgency campaigns, all vehicles are targets and all need to be protected against bombs, mines and improvised explosive devices. This calls for a wholly new generation of military vehicles and, as Farah Alkhalisi reports, the Ocelot, developed by Ricardo and Force Protection Europe, brings fresh structural thinking for maximum occupant protection, robustness and versatility

10 RICARDO QUARTERLY REVIEW • Q4, 2009 ost light protected personnel ride and mobility tests. early next year. “When the Ministry vehicles in service with Ricardo’s many years of work on started talking about this programme,” Mmilitary forces around the the Land Rover Defender-based says Ricardo global vehicle product world are derived from existing WMIK (Weapons Mount Installation group director Graeme Rumbol, “they production platforms, often medium- Kit) vehicles for the UK Ministry of recognised that innovative thinking was duty 4x4 designs. Yet the unpredictable Defence, and on the Vixen upgrade required, and that they would consider conditions encountered in many programme for the so-called Snatch a clean-sheet design.” theatres of engagement are revealing Land Rovers, have provided invaluable the need for a new generation of vehicle experience in developing the Ocelot; A new type of warfare concepts, designed from first principles the programme has also confirmed The Snatch Land Rovers were originally to provide an architecture promising engineers’ suspicions that the existing developed for use in Northern high levels of crew protection and light protected patrol vehicle (LPPV) Ireland, explains Rumbol, where the ability to withstand the harshest platforms have now been developed to they mainly faced attack from small of environments. Responding to this their limits. A radical rethink was clearly bombs or handguns. However, in the call, Ricardo has been collaborating required to produce an LPPV suitable ongoing operations in Afghanistan, with the UK-based European arm of for modern conflict situations and the environment is very different; in Force Protection on the development peace-keeping duties. particular, there is no traditional front of the all-new Ocelot: indeed, the first This has been acknowledged by line. In an unpredictable insurgency war prototype has now started its formal the UK Ministry of Defence (MoD), such as this, all vehicles are targets and validation process involving handling, which is to assess the Ocelot prototype all need to be capable of withstanding

Q4, 2009 • RICARDO QUARTERLY REVIEW 11 Ocelot

The relationship between Ricardo and FPE

Ricardo has been working with South Carolina based Force Protection since late 2007 on enhancements to its Cougar product range (the Mastiff and Ridgback) and on the Wolfhound, a flatbed cargo-carrying version of the Mastiff being built for the UK MoD. “Force Protection come with very high credentials in terms of survivability and mine-blast protection, as they’ve made vehicles that are in service”, “Ocelot could in its basic form be just says Graeme Rumbol, Ricardo Global Vehicle Product Group Director. a utility truck with a flat bed and a Ricardo approached the recently- single radio; in other forms it could established Force Protection Europe division (FPE) with the Ocelot concept be a very advanced surveillance and in January 2009, and an agreement was reconnaissance vehicle that has camera reached the following month to develop the vehicle with FPE taking on the role technologies, thermal imaging, electronic of prime contractor for the UK LPPV jamming equipment and multiple radio programme and any other international markets that Ocelot might be targeted communications systems” at. This means FPE is responsible for Graeme Rumbol, Ricardo global vehicle product group director overall programme management, directing the programme operations, sustained blasts from mines, IEDs through narrow streets, it is not over- specific systems integration functions (improvised explosive devices or intimidating to civilians, and it enables and bespoke detailed design aspects roadside bombs) and other roadside troops to engage with local people and related to blast survivability. The IPR attacks. build more trusting relationships – part (Intellectual Property Rights) for Ocelot The British Army, explains Rumbol, of the so-called ’hearts and minds’ are jointly owned, with the core concept has “had to employ vehicles which will philosophy now seen as an important available to Ricardo to license to clients. patrol the front line, do reconnaissance aspect of peacekeeping duties. These “We chose to partner with Ricardo work at the front line, but which will qualities must not be lost in creating because of its reputation for world equally deliver logistics supply to the a new LPPV: despite the need for a class automotive excellence – and front line under the risk of attack.” The stronger, better-armoured vehicle particularly because of the recognition Army’s experiences in Afghanistan capable of carrying and supporting ever of this within the MoD,” says David have exposed the limitations of existing more heavy communications devices, Hind, Managing Director of FPE. vehicles; not only are they under electronic systems and other equipment, FPE has a base at Ricardo’s Midlands the constant threat of attack from it must not appear unduly threatening. Technical Centre, in offices previously insurgents and terrorists, they also used by BMW for the MINI programme need to cope with a wide variety of Essential structure and by the Ricardo2010 research unsurfaced terrains and an even greater Ocelot needed to be no more than and development venture with SAIC variation in climate, with conditions seven and a half tonnes in weight – (Shanghai Automotive Industry ranging from extreme heat to extreme light enough to be carried beneath a Corporation). This underscores the cold, and with deserts, mud and In the patrol vehicle Ocelot variant there is ongoing nature of the partnership mountains. seating for two crew and four dismounts between the two companies. Yet for all its shortcomings, the Land (right). The vehicle is powered by a Steyr Rover has its advantages: it is small 3.2 litre straight six diesel coupled to a and manoeuvrable enough to drive 6-speed transmission (far right)

12 RICARDO QUARTERLY REVIEW • Q4, 2009 “We came up with other equipment. Access is via large combining the V-shape rear doors, a pair of top hatches, or a with the vehicle chassis,” large commander’s door. The basic explains Rumbol. skateboard could support a variety “Combining those two of interchangeable pods, including elements, you get protection those for flatbed truck, reconnaissance for the vehicle that runs vehicle and ambulance configurations, from bumper to bumper. A and it does not intrude upon a flat- lot of the vehicles that are floored, roomy cabin. out there at the moment The pod is mounted to the skateboard have sacrificial zones where on hinges, and can be tilted and easily the protection stops, and removed by support engineers as they tend to be the bits that Rumbol explains: “We wanted to have a are blown off in a mine- vehicle that not only would allow people blast, so we wanted to to walk away in the event of a mine- protect the entire length of blast, but also one with an architecture the vehicle.” which allows it to potentially drive Rather than mounting away if it lost a wheel station; more the V onto a truck platform importantly, if the damage is major, we and then adding vulnerable could actually take the vehicle back, suspension and powertrain repair it, get it back on the road through components, or then wrapping changing out components.” the entire underbody in heavy Ocelot is in effect built from a armour, Ocelot’s whole powertrain, series of interchangeable modules. axles and all suspension components Within the skateboard, for example, except the torsion beams are housed the engine, transmission, exhaust, within the V-spine on the ‘skateboard‘. air intake and other core items are all Chinook helicopter – and no more than If one wheel is blown off, it can still mounted in a single sub-assembly on 2.1 metres wide, making it substantially drive away. a single frame, and can be removed smaller than the Mastiff and Ridgback whole and replaced by another in less armoured vehicles also currently in Ease of maintenance and modularity than an hour. Such modules have service. Its key structural configuration, The drawback of encapsulating all been created before in tanks, but though, has previously only been used the drivetrain components within the not wheeled vehicles: this flexibility, in much larger, heavier vehicles. V-spine is that they are then more combined with the protective benefits The core concept is based around difficult to reach and remove. “The of the skateboard, is what makes a V-shaped hull mounted along a only way we could credibly find a way Ocelot so unique, even if the V-shaped central spine, as pioneered and proven to have access to these components hull itself is not new. in a series of South African vehicles for maintenance and repair was to Aside from the mounting of the including the Casspir, Mamba and come in from the top,” says Rumbol, engine and transmission on the Buffel; the V shape disperses the force “so that’s how we introduced the idea skateboard, however, the packaging of a explosive blast. However, whereas of the hinged pod arrangement.” of the powertrain is all conventional. these heavy-duty vehicles had their Made from lightweight composite “Throughout this whole project, V-shape mounted onto conventional materials and fitted with super-thick we’ve tried to keep things simple”, truck-style components, which were laminated glass windows, the pod of says Rumbol. “It’s got to be proven to relatively unwieldy, Ocelot – an this initial Ocelot prototype is a cabin work very quickly, and it’s got to be altogether smaller, lighter vehicle – has seating six: driver and commander up fixable and repairable in very difficult its V at a steeper angle, integrated with front, plus four inward-facing seats conditions, at forward-operating bases a ‘pod’ (the cabin) and an armoured and a large compartment at the back with little or no infrastructure and no ‘skateboard’ chassis. to house communications devices and advanced workshops.”

Q4, 2009 • RICARDO QUARTERLY REVIEW 13 Ocelot

The Vixen programme “… a clear automotive electrical system … gives the vehicle what it will need to run. But on top of this there will then be an electronic architecture added to the vehicle, again depending on the customer” Graeme Rumbol, Ricardo global vehicle product group director

Powertrain and hardware expected to come under consideration For all the revolutionary qualities of for future upgrades and development the Ocelot’s structure , the powertrain of Ocelot. In the meantime, however, encased inside it is a known entity. The reliability and durability are crucial, and engine is a 3.2-litre straight-six Steyr only a powertrain system, long proven turbodiesel; this currently develops 150 to be robust in operation, can be fitted. kW but could be boosted to up to 200 kW, with substantial torque low-down Drivability and the user interface in the rev range for performance off Ocelot’s independent suspension the mark. Top speed is around 120 system is similarly simple to fix and km/h on good surfaces and, for use on repair, and well tried and tested for Ricardo is working to upgrade 100 of the poor terrain, a crawling function will durability. Power-assisted four-wheel British Army’s Snatch vehicles to Vixen be optimised; the cockpit could even steering aids manoeuvrability, along specification. The Vixen programme be outfitted with a hand-throttle to with the automatic transmission; all will address the Snatch’s shortcomings control very slow progress, depending remaining controls are driver-operated through the fitting of extra underbody on customer requirements. The six- and mechanical protection including a belly-plate speed ZF gearbox is fully automatic, Though Ricardo has extensively beneath the driver and commander, but featuring kick-down gearshifting; all researched drive-by-wire technology, as well as a comprehensive set of four wheels are driven, aided by locking this is still some way from fitment in enhancements to engine, suspension, front and rear differentials and a high/ Ocelot. “If we had three or four years to transmission and chassis. low ratio transfer box. develop and validate this vehicle, you Increasing the weight to 4.7 tonnes Ultimately, the Ocelot could feature could look at that sort of technology. has necessitated a more powerful hybrid technology; the V-spine is But we don’t, so the idea is to get a engine; Ricardo is increasing the swept compatible with a hybrid architecture, platform into service that could be volume from 2.5 to 2.8 litres, delivering and could easily house an integrated around 20 per cent more power. The starter-generator and technology manual transmission is replaced by an enabling the diesel engine to act as automatic, offering not only greater ease an electricity generator. As power of operation for the driver in difficult generation and the supply of electrical conditions but also promising better energy to power more complex reliability. equipment are an increasing concern The chassis receives a complete for the military, hybrid powertrains are overhaul, with extra stiffening throughout. The front axle is modified and the rear axle replaced completely with a unit supplied by Dynatrac; the all-new suspension, developed in- house by Ricardo, features new springs, dampers and Bilstein shock absorbers. The Ricardo-developed braking system, inspired by motorsport applications, uses components sourced from Alcon. The end result is a vehicle with a good 50 per cent of new component content compared to the Snatch – and, according to Ricardo Special Vehicles operations director Paul Tarry, only about 10 per cent of the mechanical parts of the original Land Rover. The core focus has been on crew protection, and the Vixen Land Rover now offers a good level of mine blast protection for an LPPV (Light Protection Patrol Vehicle) of this size and on this type of platform.

14 RICARDO QUARTERLY REVIEW • Q4, 2009 From WMIK to RWMIK+

The Vixen programme involves modifications originally developed by Ricardo for the RWMIK+. Ricardo has worked with the UK MoD for over ten years on its WMIK (Weapons Mount Installation Kit) programme; the RWMIK+, the latest development of the ‘R’ (Re-life) WMIK was first enlarged to 4.7 tonnes to accommodate new equipment, carry a four-man crew, and offer enhanced protection. It received automatic transmission and a bigger 2.8-litre engine, plus an improved armour package and rollover protection. As a result of this work, the MoD approached Ricardo with the contract to upgrade the Snatch Land Rovers. Ricardo has a contract to upgrade 68 vehicles to RWMIK+ specification, with a further 64 to follow next year. The company has also developed a safety upgrade and protection package for 200 in-service WMIKs, which can be fitted in the field.

upgraded over the time that the vehicle Rumbol, “a clean automotive electrical systems. There’s a whole host of would be used,” says Rumbol. system which gives the vehicle what different applications.” The electrical system, which needs it needs to run. But on top of this there to support items such as infra-red will then be an electronic architecture Progression and production night vision and navigation equipment. added to the vehicle, again depending Ricardo engineers are now fine tuning is more complex: final systems on the customer. Ocelot could in its the suspension to draw an acceptable integration is the responsibility of Force basic form be just a utility truck with balance between platform rigidity and Protection. “We’ve got to create about a flat bed and a single radio; in other ride comfort for occupants. Ocelot is 500 amps of power at 24 volts,” says forms it could be a very advanced also undergoing formal validation of its surveillance and reconnaissance handling, agility and mobility, with its vehicle that has camera stability, its braking, its obstacle-crossing technologies, and its off-road ability all being tested. thermal imaging, The British Ministry of Defence will electronic receive the first two prototypes for jamming evaluation at the end of January, and equipment and production – for this or other clients – is multiple radio scheduled to begin in the latter part of communications next year.

Q4, 2009 • RICARDO QUARTERLY REVIEW 15 Tidal energy Catching the tide From a promising start-up to an international leader in the field of tidal stream power in the space of just five years: that’s the remarkable achievement of Irish renewable energy company OpenHydro. Anthony Smith talks to Chief Executive James Ives about the company’s success, its co-operation with Ricardo and his strategy for the future

he sheer unrelenting inevitability rotates on its axis, there can be few in equity funding to support the of the sea and its tides has been earthly physical phenomena as fully development of its tidal energy T indelibly stamped on European predictable as the tide. business. culture for nearly a thousand years: It is perhaps surprising therefore that Following installation of the English legend even has it that King in comparison with less predictable company’s first 6 metre diameter Canute placed his throne on the beach sources such as wind, solar, and even turbine at the European Marine in an attempt to demonstrate to his over- wave energy generation, tidal energy Energy Centre (EMEC) in enthusiastic courtiers the limited powers has until recently been something of a Orkney off the Scottish coast of a mortal king; despite his commands neglected source of renewable power. in 2006, the company was to stop, the tide could not be prevented This was the opportunity spotted by the first to export tidal from advancing. Indeed, given that tidal the founding investors of OpenHydro generated electricity effects are created by the gravitational which, since its formation in late 2004, into the UK pull of the sun and moon as the planet has successfully raised €52 million national power

16 RICARDO QUARTERLY REVIEW • Q4, 2009 Catching the tide

Q4, 2009 • RICARDO QUARTERLY REVIEW 17 Tidal energy

grid. Since then it has designed and particular through the English Channel Ricardo assistance constructed turbines of up to 10 metres and around the north of Scotland provided to OpenHydro in diameter and is working towards These areas of highly focused implementation of a 16 metre unit; it flow are particularly attractive for the has developed and proven a fast and harvesting of tidal energy and, as economic method of deploying turbines Ives explains, candidate sites are in at depth, has created its own R&D and renewable energy terms comparatively manufacturing organisation, and is in easy to evaluate. “The beauty of tides the process of developing large-scale is that they are completely predictable tidal energy farms in Europe and North based on the movements of the earth, America for major energy companies. sun and moon. Unlike a candidate wind A former senior manager with farm site, where you may require two Accenture, as well as an engineering years of measured data in order to alumnus of Ricardo, James Ives was characterise its potential, tidal stream approached to become OpenHydro’s sites only ever require 28 days of data Chief Executive. In an interview for RQ, for an extremely reliable survey.” he explains the early development of With the exception of rare storm the company: “Our founding investors surges which might marginally amplify had been looking for potential tidal a given tide, a simple harmonic technologies and acquired the exclusive analysis of the data will show what rights to the Open-Centre Turbine the tide will do at the site over many technology from a US company. They decades to come. And as Ives asserts, were far-sighted enough to have the advantage of this in terms of the realised the fundamental potential of commercial attractiveness of power the system despite some of the teething generation is considerable: “Energy troubles reported by the previous from tidal farms can contribute owners of the technology. as base-load grid power with no “With the rights to the technology requirement for spinning reserve. For acquired, our founding investors less predictable sources of renewable needed to establish an organisation energy some form of backup is required to own and develop the technology, – be it from pumped storage or fossil and to exploit it internationally. This fuelled gas turbine capacity which can was the rationale for the creation of be drawn upon at short notice. This OpenHydro,” he continues. gives consequent additional value to In 2007 OpenHydro sought Ives was approached as the founding the power generated and hence the assistance from Ricardo to support Chief Executive for a number of market price that it can command. In the optimisation of its Open- reasons. Firstly he had a solid track addition to this inherent predictability, Centre Turbines using fluid and record in the energy sector from his the natural phase relationship between structural simulation. Engineers time at Accenture. He also had an even relatively close tidal sites means from Ricardo’s clean energy team excellent engineering background both that peak capacity of different sites used computational fluid dynamics from his studies at Loughborough can be highly complementary.” To (CFD) and finite element (FE) University and his time as a graduate illustrate this, the tidal peak at Dover at analysis techniques to simulate engineer with Ricardo. Finally, as a very the eastern end of the English channel the performance of the 6 metre keen sailing enthusiast and holder of a is approximately three and a half hours and 10 metre diameter turbines commercial MCA/DoT skipper’s licence, later than that around two hundred under a range of different operating he was aware of the unique challenges miles to the west at St Peter Port in the conditions. The CFD analyses were imposed by the sea. The significance Channel Islands. used to predict available driving of this marine experience is a quality generator torque under a range he repeatedly stresses: “One of the The Open-Centre Turbine concept of tidal stream velocities and flow critical success factors in developing There are some key advantages of directions, and also predict torque tidal power systems is having an Open-Centre Turbine technology and thrust loading distribution for understanding and an appreciation of compared to the perhaps more familiar the structural analysis of the turbine. the unique engineering requirements of axially mounted devices used in other The FE analysis was used to support the marine environment. This, coupled turbine applications. Firstly, the use of composite structural design and with a fundamentally very simple a permanent magnet generator built manufacturing process to ensure the technology and the exceptional pool of into the Open-Centre Turbine means structural reliability of the 10m device. in-house talent, has in my view been that there are absolutely no electrical This analysis process allowed Ricardo key to the success of OpenHydro to connections or sealing requirements for to provide OpenHydro with flow and date.” the running surfaces. The mechanical structural design recommendations and electrical design of each turbine on a number of key design areas Site development generator is thus extremely simple and for its seabed generator systems, Tidal sites are characterised by the the cost per installed unit of generating aimed at improving the efficiency geographical features that surround capacity can be kept comparatively low. of operation as well as supporting them. In Western Europe, for example, The void in the centre of the turbine improved overall system reliability. the North Sea acts as a tidal reservoir might at first sight appear at odds that focuses the tidal stream flows in with the objective of harnessing the

18 RICARDO QUARTERLY REVIEW • Q4, 2009 The OpenHydro installer barge moves the “One of the critical success factors in first 1 MW turbine into position at Nova developing tidal power systems is having Scotia Power’s tidal energy farm at the Bay of Fundy (above); an illustration of seabed an understanding and an appreciation of turbines as installed (below). the unique engineering requirements of maximum tidal flow energy within the turbine circumference. However, the marine environment” as James Ives points out, this serves James Ives, Chief Executive, OpenHydro an important role in a sub-sea environment: “We regard minimising the environmental impact of our systems as a top priority, and the open nature of the turbine is designed such that any debris or sea life – including marine mammals – can pass straight through the turbine without injury.” There is even evidence to prove this, too, as Ives reveals: “Our test installation at EMEC is constantly video monitored underwater and we have not observed any marine mammal incidents in over 3 years of testing.” In contrast to the wind energy sector, where economies of scale and environmental considerations increasingly favour a smaller number of ever larger, higher capacity units, OpenHydro feels that the optimal size of turbine for most sites is broadly within the scale of units already planned of up to 16 metres in diameter. “There are two factors that dictate the size of turbine preferred. The first is the physical parameters of the environment in which you are

Q4, 2009 • RICARDO QUARTERLY REVIEW 19 Tidal energy

A 1 MW turbine is prepared for shipping to Canada for installation at the Bay of Fundy (left); undersea video still from the 6m test installation at Orkney (right), and (below) James Ives speaking at the ceremony prior to installation of the first turbine for Nova Scotia Power Inc.

Installation and hot-swapping James Ives is particularly proud of the technology developed by the company for turbine deployment and replacement. The company is focused on minimising the number of operations carried out at sea. “We wanted to design the system so as to minimise the number of times the operator needs to interact with the device; we also strive to maximise the efficiency of the equipment required on site. If you’re looking to build a tidal energy farm on a commercial scale you need an installation process capable of deploying or swapping turbine units quickly.” OpenHydro has developed a process of swapping turbines such that each turbine, complete with its power connections and steel subsea base frame through which it is secured to the sea bed, can be installed or swapped in a single six hour tidal interval. The company has designed the world’s very first tidal turbine deployment barge, fully certified for operation by Bureau Veritas. Using this vessel, the company’s first ever subsea mounted “If you’re looking to build a tidal energy turbine assembly was installed at its Orkney test site at a depth of 35 metres farm on a commercial scale you need an of water in just twenty minutes. installation process capable of deploying Future prospects or swapping turbine units quickly” While OpenHydro’s growth has been James Ives, Chief Executive, OpenHydro phenomenal, Ives claims that this has operating. Typically a good, focused tidal stream site is in 30-60 metres of water. The size of turbine you can install is limited both by the clearance needed off the sea bed to a height at which the flow will have fully formed, and also by the overhead navigational clearance requirement based on the lowest point in the astronomic tidal cycle. “The second factor driving turbine size,” continues Ives, “is environmental and consenting limitations. In the wind industry consent is generally easier for a small number of larger turbines than a forest of smaller ones. In our case you can’t see or hear the turbines and they are deep enough to avoid shipping navigation. As such, most good tidal sites will economically and operationally favour larger numbers of modestly sized seabed-mounted turbines.”

20 RICARDO QUARTERLY REVIEW • Q4, 2009 being implemented by the company. “We have implemented a business-wide SAP system, not just in production but across the company from bought-in materials to human resources. We have also focused on manufacturing and supply-chain optimisation, and we now have many high-quality suppliers in low-cost regions – including China and South Africa, for example. Our aim in developing the business in this way is to prepare the company for rapid expansion: equipping it with the type of systems and infrastructure it will need at larger scale so that the growing pains that hold back so many otherwise promising technology businesses can be avoided.”

James Ives been precisely on target. “At each of our This success has been widely James Ives was appointed to the fundraising rounds we have projected recognised in the environmental and post of CEO, OpenHydro Group Ltd, our deliverables over the coming period renewable energy sectors. In the 2008 in 2004. Before this he was a senior and have always met or exceeded our UK Green Energy awards, OpenHydro manager in the Solution Engineering targets. We always believed that once won Best Renewable Innovation for its team of Accenture, serving clients we had developed and proven a stable first grid-connected installation at EMEC, including British Gas, EDF Energy and reliable technology at our test site and in 2009 it won two of the highly and the ESB. Following graduation at Orkney, we would see large-scale coveted Rushlight awards in the Marine from Loughborough University he utility interest in starting development of and Natural Energy categories. spent his early career with Ricardo plc tidal farms. We’re seeing that now with The growing maturity of OpenHydro’s working as a development engineer in our existing announced customers and technology is balanced by the the computer aided engineering and many on-going enquiries. professional infrastructure and processes software teams.

Ricardo and renewable energy

There’s no (typically sub 10 MW) and consequently patented hermetically sealed and doubt that we need to be manufactured at much magnetically coupled Kinergy have increased higher volumes than traditional power technology described on pages 22-27 our focus on station and distribution equipment. As of this issue of RQ which, in addition

supporting the an established designer and developer to use in vehicles of all sizes, is highly renewable energy of complex electro-mechanical attractive for application in local power sector over power systems from 1 kW to 10 MW, distribution systems. the past three renewable energy is a natural area for At a business level, our strategic years. There is Ricardo to be able to support clients consulting teams are also able to a clear global from our existing technology base. In support energy sector customers with imperative to deliver larger capacities wind energy in particular, customers a wide range of services in the planning “ of renewable energy using better are coming to Ricardo for drivetrain and implementation of their technology and more cost-effective technology and gearbox design and development developments through to engineering if climate change targets for reduced projects, whole device simulation and and commercial maturity. Together carbon dioxide emissions are to be met. loading analysis, and control systems with expertise in the development This translates into“ a major long-term design and development. of fuel cell systems, biofuels and driver for which the traditional energy In addition to wind, tidal and wave advanced combustion technology, we sector is not necessarily best placed to energy, Ricardo engineers from our can thus bring a wide range of support deliver the type of engineering support clean energy team are also to be found to companies such in the renewable needed by this rapidly developing supporting solar device engineering – energy sector whether they require sector. As OpenHydro demonstrates, not least for cost-reduction purposes strategic consulting, technology the renewable energy devices and – as well as Stirling cycle energy specific development or in-depth systems can be very different to generators and combined heat and design engineering support. Leading those of the traditional, large fossil- power systems. Again taking crucial automotive technology providers are fuelled electrical power station. A expertise from our automotive and thus extremely well placed to accelerate key differentiator in this respect is motorsport activity, we are also the development of renewable power that individual generators – even the developing technology for advanced systems. very largest wind turbines currently energy storage and buffering systems Giles Hundleby, Ricardo project proposed – are generally much smaller including, for example, Ricardo’s director, clean energy

Q4, 2009 • RICARDO QUARTERLY REVIEW 21 High-speed flywheels

The science of spin High-speed flywheels are a cheap and efficient way to hybridise systems from cars, elevators and industrial machinery to inter-city trains. Yet until now their development has been hindered by the lack of a robust way to transmit the power to and from them. Jesse Crosse reports on some ingenious new developments at Ricardo

esigning products which Recovering kinetic energy from comes to slow down, either through consume less energy has shot objects that have been accelerated, and frictional losses and aerodynamic drag D to the top of the agenda in this then re-using that energy, is one way when coasting, or heat when braking. energy-hungry world – not just in the of cutting consumption. For example, In electric vehicles, this energy automotive business but in any industry when a vehicle is accelerated from rest can easily be recovered and re-used delivering mechanical products which by the engine, the kinetic energy in that by using the electric drive motor do work for our benefit. vehicle is usually wasted when the time as a generator to slow the vehicle,

22 RICARDO QUARTERLY REVIEW • Q4, 2009 ”Recapturing up to 60 per cent of the energy available on each occasion, Kinergy technology fitted to a high speed train could deliver energy savings of the equivalent of about 75 litres of diesel for each station stop”

The science of spin generating electricity in the process. In also hugely effective energy storage for Formula One applications. As a cars, this electrical energy is typically devices. Decelerate a car by energising result of this work Ricardo has devised stored in a battery or ultra-capacitor a flywheel rather than wastefully using ‘Kinergy’, a compact, light weight, high- and then re-used when the driver wants the brakes and the energy it stores can speed, hermetically-sealed flywheel to accelerate again, whereas in rail be used the next time the driver wants energy storage system concept with applications electricity can be fed back to accelerate. a highly innovative and patented into the power distribution system via magnetic gearing and coupling the overhead catenary or conductor Hybrids, Formula One and flywheels mechanism. rails. However another and potentially Ricardo has substantial experience in Modern carbon fibre based flywheel much more cost-effective method, not flywheel hybrid system development. systems such as Kinergy can typically just for electric vehicles but for those It has investigated many different kinds operate at speeds of around 60,000 powered by traditional combustion of energy recovery technologies such rev/min. With consequent outer engines as well, is the flywheel. as ultra-capacitors, hydraulic systems, surface speeds of around Mach 2 a Flywheels make great children’s electric flywheels and mechanical vacuum is essential as friction from toys in the form of spinning tops, flywheels – including the engineering of any surrounding air would cause the gyroscopes and yo-yos, but they are kinetic energy recovery systems (KERS) carbon fibre to quickly overheat and

Q4, 2009 • RICARDO QUARTERLY REVIEW 23 High-speed flywheels

The Ricardo and ease of manufacture. A battery Kinergy high- has to be sized for energy capacity, speed, hermetically- power and the number of charge sealed flywheel and discharge cycles it can energy storage withstand. But with the Kinergy system concept, system, a continuously showing its variable transmission (CVT) patented magnetic determines power output gearing and coupling mechanism and the flywheel speed. Both can be optimised to achieve the balance of power and duration of output needed Although this approach is entirely mechanical, the flywheel can also be connected to an electric motor- generator and electrical system. It could also be connected to an hydraulic displacement unit rather than a CVT. Flywheels are extremely versatile devices. In a conventional car, they can be used to seamlessly feed power back into the powertrain, reducing the work done by the engine, saving fuel and reducing CO2 emissions. In a hybrid or electric vehicle, they reduce the drain on the battery, helping to extend the range. Decelerate a car by energising a flywheel There are less obvious uses too. rather than wastefully using the brakes Dual clutch transmissions (DCTs) are becoming more popular because the and the energy it stores can be used the lack of torque interruption provides next time the driver wants to accelerate the refinement of a torque converter automatic gearbox with the relative de-laminate. storage systems for use in industrial simplicity, efficiency and packaging The high power density and long- and construction equipment and benefits of a conventional manual life potential of Kinergy technology local electrical substations and power gearbox. The simpler alternative results from its inherent simplicity and distribution systems. to DCT, the automated manual effectiveness, avoiding the need for transmission (AMT), is much cheaper vacuum pumps and seals and offering Scaleable energy store to manufacture and equally efficient: a robust, compact and lightweight A flywheel is a relatively simple energy however, it suffers from torque package. The simplicity of its design store. It is scalable, modular and has a interruption during gearshifts, which also yields comparatively very low high power density, which means it can often led to poor levels of refinement projected production costs, thus absorb and release energy very quickly. in fully automatic mode. opening the door to a wide range of Unlike battery systems, with their much Ricardo has a patent pending on potential applications. higher energy density but much slower a flywheel system which can fill the The technology appears ideally ability to absorb and release it over torque gap as the gearbox shifts. “The suited for application in passenger time, modern flywheel systems are system is the same cost as a DCT and cars ranging from small, price- thus much closer to ultra-capacitors just as refined,” says Ricardo technical sensitive mass-market models to in operation, making them ideal for specialist, Andy Atkins. “However, large luxury SUVs, enabling the delivering short bursts of power, such because of the added hybrid function it effective hybridisation of a wide range as during acceleration. delivers a 20 per cent reduction in fuel of applications where conventional Flywheels are hence in effect a consumption as a bonus.” electro-chemical battery systems complementary technology to batteries would be prohibitively expensive. but in an electric hybrid powertrain High-energy applications Potential additional Kinergy they offer direct competition to ultra- Beyond the passenger automotive applications also include low-cost, capacitors, out-scoring them in terms sector, larger units are perfect for compact energy management and of cost, volume, weight, efficiency use in trucks, buses and passenger

24 RICARDO QUARTERLY REVIEW • Q4, 2009 wound onto a metallic hub or directly The Kinergy magnetic gear and coupling onto a shaft, these modern flywheels Stationary pole pieces embedded in spin in a vacuum, typically at speeds flywheel casing of around 60,000 rev/min. A vacuum is essential. With a surface speed of Mach Permanent magnets 2, friction from any surrounding air would cause the carbon fibre to quickly overheat and de-laminate. • Outer rotor attached to • external CVT system • Powertrain integration Flywheels are usually integrated • directly into a powertrain, one example being the rear axle of a rear • wheel-drive car. The Kinergy flywheel Inner rotor attached system incorporates a small Torotrak

to flywheel – can be t continuously variable transmission,

configured to rotate at • t through which torque passes to the up to 10x the speed of • flywheel from the driveline, then the outer rotor smoothly from the flywheel back into Direction of rotation the driveline whenever required. The huge rotational speed of the flywheel must be reduced before its power can be transmitted to the driveline. One trains which continually accelerate people on its downward journey could way of doing this is by conventional and stop. “Kinergy is tailor made for store enough energy in a flywheel to gears, but at those speeds there trains,” Atkins continues. “The braking allow a lighter passenger load to make are issues of frictional losses, wear, energy of a TGV or large express train the next upward trip for free. Yet, as lubrication, the transmission of represents a huge amount of energy. with any spectacular new technologies, vibration and foreign bodies finding For example, braking from full speed there are some myths surrounding their way between the gears. to rest, a modern high speed train flywheel systems mainly derived from Some of our original motorsport dissipates about 0.9 gigajoules, which old fashioned heavy steel flywheels. designs were like this, harvesting is the energy equivalent of 90 litres of Modern devices used in hybrid and delivering torque via gears, a diesel fuel. In this application, Kinergy drivetrains are quite different, explains system that, although acceptable, has flywheel systems would energise as Atkins. “As Kinergy shows, modern drawbacks for everyday use. A shaft the train brakes to a stop and give back high-speed flywheels can be very small leaving the vacuum chamber passes their energy as they help to accelerate and lightweight. Flywheels only need through a seal which inevitably leaks it away from the station. Recapturing to be heavy if they are spinning slowly. slightly. The faster the flywheel spins, up to 60 per cent of the energy The idea that they have a detrimental the more the seal leaks, necessitating available on each occasion, Kinergy effect on handling is also a myth; as you a vacuum pump to maintain the technology fitted to a high speed train increase the operating speed, inertia vacuum and introducing the need for could deliver energy savings of the and gyroscopic forces are reduced maintenance. So Ricardo came up equivalent of about 75 litres of diesel for a given energy storage capacity. with a better idea, a magnetic gear for each station stop. They have no more effect than taking a which allows torque to be transmitted Flywheels can improve the efficiency passenger out of a car.” from inside the vacuum without of elevators too. An elevator full of Manufactured from carbon fibre penetrating the seal.

Kinergy Flywheel System

Flywheel ▼ ▼ Coup ling ▼ ▼ CVT ▼ ▼ Drivetrain Housing

Vacuum

Vacuum pump management ▼ ▼ ▼ system Conventional high

▼ speed carbon-fibre flywheel system ▼ Rotating seals ▼

Flywheel ▼ ▼ Coupling ▼ ▼ CVT ▼ ▼ Drivetrain

Housing

Q4, 2009 • RICARDO QUARTERLY REVIEW 25 High-speed flywheels

on the output shaft of the flywheel is clearly important. Kinergy’s carbon rotating inside a cylindrical rotor on fibre flywheel has a margin of 12 times the power-take-off shaft. An array of the ultimate tensile strength (UTS), or permanent magnets is set into each in other words, it is being stressed to and it is the attraction between the one twelfth of the UTS of the carbon magnetic fields of these magnets that fibre material. The design is such that link the rotation of one shaft to another. failure modes can be detected by One inherent difficulty in engineering the automatic monitoring of out of this arrangement is achieving close balance vibration by bearing sensors, enough proximity of the magnets enabling safe shut down before further for the principle to work, given the consequential damage is caused. In the thickness of the casings. The peak field worst case, the external casing would in distance is at around a millimetre so any case contain any failure. the optimum distance between the The major challenges will come with two arrays of rotating magnets would mass production, says Atkins. “Although be around double this – not enough relatively cheap to make in principle, to maintain an acceptable air gap and winding the filament onto a bobbin casing thickness. But installing ferrous is relatively time consuming. This pins in the casing wall transmits the means that increasing volumes in the magnetic field and the wall effectively production process may be a challenge.” disappears, allowing acceptable air Yet Kinergy is cost effective and it gaps to be incorporated within a is estimated an entire unit integrated comfortable engineering tolerance. with a differential could be made for Efficiency is extremely high at more around $1500. The flywheel and CVT The magnetic gear can be configured than 99.9 per cent, and the system is represent about a third each of the to give a reduction of 10:1, so if the robust too. In the event of a serious cost, with the differential and other flywheel is revolving at 60,000 rev/min, torque spike, there are no gears to equipment making up the rest. The the output shaft can revolve at 6000 shear: instead the magnetic connection unit would be substituted for the rev/min, significantly reducing windage will slip and is quickly re-instated by standard differential so there are losses. Magnetic gears use permanent simply backing-off the torque. savings to be made there too. magnets to transmit torque through an Bearings are the only limiting factor airspace between two shafts, without Safety factor and in practice these will ultimately the need for mechanical contact Achieving a sufficiently high safety decide the service life of the unit. The Ricardo’s system comprises a rotor factor in such high-speed components current state of the art is to use ceramic

The Flybus research project

Following the public launch of savings of 20 per cent over the official or retrofitted to an existing vehicle to Kinergy, Ricardo aims to further UK bus test cycle,” explains Torotrak radically reduce fuel costs and CO2 develop this highly promising engineering director Roger Stone. emission levels, at modest cost – will technology and demonstrate its “In this initial project, the CVT and be particularly welcomed by bus benefits in applications through flywheel hybrid system will be applied companies, commercial vehicle fleet research collaborations with a to the vehicle’s driveline through operators, and government.” number of industrial partners. The the existing and previously unused first of these research collaborations, power take-off facility incorporated The KinerStor research project the FLYBUS project, will involve within the standard Allison automatic In a further research collaboration, Ricardo, Torotrak, Optare and Allison transmission. Further simulation Ricardo is leading the KinerStor Transmission. Part funded by the shows that an optimised system, project which aims to demonstrate UK Government’s Technology using a 110kW system with 1MJ the potential of using high speed Strategy Board, the FLYBUS will energy storage capacity, will produce flywheel technologies such as involve the development of a Ricardo further significant improvements in Kinergy, in delivering hybrid systems Kinergy flywheel energy storage fuel savings over the same test cycle.” with the potential for 30 per cent fuel device incorporating a Torotrak This project demonstrates the savings and equivalent reductions patented Continuously Variable practical potential of the application in CO2 emissions, at an on-cost of Transmission (CVT) for installation in of the Ricardo Kinergy based system below £1000 ($1600), thus enabling a demonstrator vehicle based on an incorporating its Torotrak CVT either the mass-market uptake of hybrid Optare Solo bus. “Simulation work in the design of a new vehicle or as vehicles in price sensitive vehicle by Torotrak, based on an Optare Solo a retrofit product to an existing fleet. applications. bus and using the readily available As Stone concludes: “Given the long The KinerStor project team 60kW system with 400kJ of energy service life of buses, the availability of aims to design, build and test a storage capacity proposed for this a simple hybrid system – one which number of prototype units such first demonstrator, produced fuel can be factory-fitted to new vehicles that on completion, the developed

26 RICARDO QUARTERLY REVIEW • Q4, 2009 balls and steel races: these already last hydrogen in a physical rather than a or railway substations, in particular for the life of the system. The only service chemical process”. example, mass transit and metro power requirement would be to reinstate the networks which are required to manage vacuum as the composite material used Many potential applications regenerative braking loads from rolling to make the flywheel seeks to balance The list of applications is extensive, stock being fed back into the conductor its own internal water content with the concludes Atkins, since flywheels rails or overhead lines.” atmosphere around it and water will are ideal for anything that involves “Ricardo’s Kinergy technology continue to ‘boil’ out for some time. intermittent flows of high power. is inherently cost-effective, robust, “This is all standard vacuum “Flywheels are particularly good for reliable and compact, giving it a huge engineering practice, though,” says vehicles that stop often – and the potential for many such applications. Atkins, “It’s a simple job which heavier the better,” he says. “So cars, Its highly compact size and light weight involves plugging in a vacuum line trucks, trains, trams, buses, materials also makes it an ideal candidate for during a routine service. If we didn’t handling machinery such as cranes aftermarket system integration without have the magnetic coupling, however, and elevators – and even White Van affecting the original equipment design, then we’d be doing that every couple Man, as it works brilliantly for delivery on anything that requires a pulse of of hours and you would need an on- vehicles! They’re also good for electrical energy.” he adds. board vacuum pump.” power management systems where Without any doubt, the future looks The rotating seals of a mechanically highly intermittent demands need to be good for flywheel technology. Proof geared system would also wear, so the smoothed, such as local distribution grid comes in the form of the enquiries that problem would get worse with time. are flooding in to the Ricardo offices Replacing these gears would involve as more people begin to understand a total break into the vacuum, with that, when it comes to reducing energy inevitable water ingress into the consumption, few devices are quite system and the pump would have so elegant in their simplicity, their to work a lot harder. efficiency and their cost To remove the need for any kind effectiveness too. of maintenance, Ricardo has also developed a solid state pump which would mean never having to do anything at all. Known as ‘getter’ technology, Atkins explains that The highly compact this currently highly confidential Kinergy system as technology is extremely promising: “it integrated into a absorbs just about everything except rear axle assembly.

technologies are ready for vehicle- systems, focusing on new material project’s structure will allow for based installation, testing and technologies including low-cost the development of common core- demonstration. With collaborators composite fibres and specialist technology solutions which can be including CTG, JCB, Land Rover, steels; continuously variable tailored to the individual needs of SKF, Torotrak and Williams Hybrid transmissions; bearing and coupling vehicle manufacturers. Power, KinerStor brings together design; drivetrain integration, and a critical mass of relevant skills volume vehicle manufacturing. The and expertise in specialist areas, including: advanced flywheel

Q4, 2009 • RICARDO QUARTERLY REVIEW 27 Ricardo News

Train now approaching icardo is leading a new EU project, of all the various functions. It would be capacity will also be utilised more RSARTRE, to develop and test driven by an experienced driver who efficiently. technology enabling vehicles to drive is thoroughly familiar with the route. “I do appreciate that many people automatically and in complete safety in Such lead vehicles might for example be feel this sounds like utopia”, says so-called road trains on motorways. This taxis, buses, inter-city coaches or trucks, Erik Coelingh, technical director of gives significant potential to improve and the each road train would consist active safety functions at Volvo Cars. traffic flow and journey times while of up to six to eight vehicles. Within a “However,” he adds, “this type of offering greater driver comfort, and few minutes of a car approaching and autonomous driving actually doesn’t reducing accidents, fuel consumption joining the road train, control would be require any hocus-pocus technology, and CO2 emissions. transferred to the lead vehicle, allowing and no investment in infrastructure. The name of this landmark project drivers to let go of the steering wheel Instead, the emphasis is on development stands for Safe Road Trains for the and spend time reading the morning and on adapting technology that is Environment. Part-funded by the paper, talking on the phone or watching already in existence. In addition, we European Commission under the the TV, while their cars drive themselves must carry out comprehensive testing to Framework 7 programme, SARTRE in complete safety – and also saving fuel. verify our high demands on safety.” comprises a collaboration between As each driver approaches his or her The SARTRE project will address the Ricardo in partnership with Idiada destination, control would once again three cornerstone transportation issues and Robotiker-Tecnalia of Spain, be resumed over the vehicle as it leaves of environment, safety and congestion, Institut für Kraftfahrwesen Aachen the convoy by exiting off to the side. yet at the same time it will also encourage (IKA) of Germany, and SP Technical The remaining vehicles in the road train driver acceptance through the prospect Research Institute of Sweden, Volvo Car would then automatically close the of increased “driver comfort”. Corporation and Volvo Technology also gap and continue on their way until the of Sweden. convoy splits up at the end of its shared The objectives of SARTRE may be SARTRE aims to encourage a step route. summarised as these: change in personal transport usage through the development of safe Many advantages • Defining a set of acceptable environmental road trains or platoons. The advantage of such road trains platooning strategies that will allow Systems will be developed in prototype is that, with the exception of the road trains to operate on public form that will facilitate the safe adoption professional lead vehicle driver, all highways without changes to the road of road trains on unmodified public the other drivers in the convoy have and roadside infrastructure highways with full interaction with non- time to get on with other business • Enhancing, developing and integrating platoon vehicles. while on the road. Road trains have the technologies for a prototype The ultimate vision of the project is to potential to increase safety and reduce platooning system such that the create systems that would enable, for environmental impact thanks to lower defined strategies can be assessed example, commuters to meet up with fuel consumption compared with cars under real world scenarios other cars as they join a motorway, and being driven individually. The reason • Demonstrating how the use of then form into a close-formation convoy is that the cars in the train are close to platoons can lead to environmental, travelling at normal speed. Each road each other, exploiting the resultant lower safety and congestion improvements train would have a lead vehicle that air drag. The energy saving is expected drives exactly as normal, with full control to be in the region of 20 per cent. Road

Russian transmission contract A major contract has been awarded concept demonstrator units, and to Ricardo by Moscow-based KATE has started preparation of a new LLC, to partner it in the development manufacturing facility in Kaliningrad of a new seven-speed automatic to support volume production. transmission. KATE, an independent KATE has sought the assistance company with a background in of Ricardo as a technology partner the development of automatic with extensive experience of transmission concepts, has selected by automotive transmission programme AvtoVAZ – Russia’s largest automaker delivery to help it complete the – to develop the new FT702 automatic design and development of the new transmission for use in Lada cars. This transmission. A strong working will be the first automatic transmission relationship has already been forged to be offered by AvtoVAZ and is aimed between KATE and Ricardo during a at helping broaden the appeal of the recent contract to review and optimise control software and calibration on the company’s products in the domestic the FT702 concept design. Building production programme. The objective Russian market, which increasingly on this, KATE has now confirmed is to develop a first derivative of the favours this type of transmission. Ricardo as its engineering partner for new transmission family for launch in a KATE has already built and tested mechanical design and development, Lada B/C class car in 2012.

28 RICARDO QUARTERLY REVIEW • Q4, 2009 Heavy duty emissions reduction An extensive study examining increasing the efficiency of heavy duty vehicles and off-road machines and cutting their emissions has been launched by the UK Government- backed Energy Technologies Institute (ETI). The study will evaluate heavy-duty vehicles (HDVs) such as coaches, buses and mining vehicles; it will determine drive-cycles establishing the types of usage patterns for each vehicle class, identify the potential efficiency improvement technologies and evaluate the benefits case for each one. Expected to run for nine months, the project will focus on the technologies which have the largest The road train is driven automatically by a professional driver in the lead vehicle such as potential to reduce CO2 emissions a truck or coach following a pre-defined route. The car’s navigation system will highlight and will be led by Ricardo and with the destination of nearby road trains that may be joined. Once accepted into the road train, the collaboration of Caterpillar and drivers are free to engage in other activities such as reading or making phone calls. As cars approach the junction at which they need to leave the highway, the driver re-takes control Rolls-Royce. The work will include a and moves away from the convoy – which then closes the space vacated. detailed analysis of the UK’s heavy- duty vehicle fleet in order to identify • Illustrating how a new business model industry and academia, with the aim of ways in which technological solutions can be used to encourage the use of encouraging the development of safe can increase the fleet’s efficiency and platoons. and environmentally effective road contribute to a reduction in liquid fuel trains,” explains Tom Robinson, SARTRE consumption. The first tests of a prototype system project co-ordinator, of Ricardo UK Ltd. The UK HDV fleet currently are expected to be carried out by the “By developing and implementing the consumes more than 13.5 billion SARTRE partners as early as 2011, with technology at a vehicle level, SARTRE litres of liquid fuel each year and the deployment of commercial systems aims to realise the potentially very contributes 8.96 per cent to overall expected within ten years. significant safety and environmental UK carbon emissions. According to “The SARTRE project brings benefits of road trains without the UK government sources, significant together a unique mix of technologies, need to invest in changes to road CO2 reductions across the entire HDV skills and expertise from European infrastructure.” fleet are therefore critical to achieving the overall UK target of an 80 per cent reduction by 2050. The FT702 transmission will be Lee Sykes. “This new project builds “Carbon reduction from heavy based on KATE’s original design upon an already well established and duty vehicles presents a significant concept. It will be an ultra-compact highly beneficial relationship between challenge”, said ETI chief executive unit, low in manufacturing cost. It has our companies.” Dr David Clarke. “Many of the current a 175 Nm torque capacity and with its “KATE’s Project FT702 is on a new options to reduce CO2 emissions from large ratio spread it avoids the need for scale for the Russian automotive light-duty vehicles are not feasible a torque converter, yielding efficiency sector and this is a new sort of project for heavy duty applications. Due to gains and further cost savings. Its in Russia”, added KATE LLC general the high energy usage, strategies attractive combination of features is director Mr Evgeny Novitskiy. “To reach such as electrification are unlikely to intended to make it a suitable basis series production in a high technology be successful, so the aim is to look at for a family of further derivatives and automotive sphere in today’s world ways of increasing the efficiency of applications in the future once this first it is essential to use the combined use of liquid fuels. Also, the vehicle project has been completed. efforts, knowledge and experience of types, applications and technologies “We are extremely pleased to have world-leading engineering companies. to improve efficiency are diverse, so been selected by KATE LLC as its We now have all the foundations to it is difficult to find a single universal engineering and technology partner on achieve successful results by mutual technological solution. This project the development of the FT702 seven- cooperation during the execution of the will allow us to identify potential speed automatic transmission,” said FT702 project. We are in for hard but technological solutions to increasing Ricardo global product group director interesting work and we’re happy that efficiency and reducing liquid fuel for transmission & driveline systems, Ricardo is with us.” consumption”.

Q4, 2009 • RICARDO QUARTERLY REVIEW 29 Capiton...

Ricardo News

Chicago testing upgrade icardo recently unveiled a Rsignificant enhancement of the company’s Chicago-based test facilities. The focus of this upgrade has been on the Constant Volume Sampling (CVS) systems, enabling the facility to provide certification testing of heavy duty engines, for both on- and off-highway applications, to the new EPA 40CFR Part 1065 procedure. Ricardo is one of the first laboratories outside the engine OEM sector capable of testing engines to this new improve the accuracy, repeatability infrastructure necessary for Part 1065 procedure, which applies to 2010 and and lab-to-lab variability of heavy duty testing”, explains Graham Weller later model years. The use of CVS is engine emissions measurements by (below), US product group director for widely seen in the United States as requiring several enhancements to the diesel projects, based at the Chicago representing the gold standard for test systems, along with calibration Technical Center. “This upgrade of heavy duty diesel engine emission and operating procedure changes. The our CVS systems testing and certification. The system mandated enhancements required represents a used by Ricardo is also similar to that for CVS tunnels in particular include substantial installed at the EPA engine testing modifications to allow operation at investment and facility in Ann Arbor, Michigan, both lower dilution ratios, which raise the demonstrates having been supplied by Horiba. concentration of the gases being Ricardo’s ongoing Measuring diesel engine exhaust measured. Tunnel heating is required commitment to our emissions levels is becoming to prevent condensation. Further clients in the North increasingly challenging due to the enhancements to calibration methods American heavy extremely low NOx and particulate and analyzer interference checks are duty engine market, matter limits required from 2010 also needed. even at this onwards. Through the Part 1065 “We’re pleased to have been among time of market procedure, the EPA has sought to the very first to invest in the testing uncertainty.”

Fuel-Efficient Vehicle for US Army Ricardo Inc has been awarded a performance of light tactical wheeled expertise to evaluate current and contract for the development of a vehicles. emerging technologies that can new vehicle under the Fuel Efficient “The FED project leverages improve fuel efficiency over the Ground Vehicle Demonstrator Ricardo’s experience and success entire vehicle. (FED) programme launched by in supporting the development of The effort drew upon the TARDEC, the US Army’s Tank a broad range of military vehicles company’s full range of automotive Automotive Research, Development over several years,” said Paul Luskin, systems expertise including and Engineering Center in Warren, Ricardo’s chief programme engineer compression-ignition engines, Michigan. for FED and vehicle engineering hybrid propulsion, transmission The FED programme, launched manager. “In particular, TARDEC and driveline systems, controls and in late 2008, has the overarching has recognized Ricardo’s role on electronics, thermal management, goals of improving military the Future Tactical Truck System chassis, suspension and structures. vehicle technology, reducing fuel (FTTS), in which we successfully Simulation results and innovative consumption on the battlefield, and implemented advanced technology systems engineering methodologies reducing the nation’s dependence into an innovative vehicle were used to develop vehicle on oil. Ricardo will apply its architecture.” concepts for demonstration. expertise in the development and The new contract award is for the Technologies were selected both manufacture of special vehicles and second phase of the programme, for their potential for immediate advanced automotive technology focusing on the detailed design of a implementation into the existing to create a demonstration vehicle demonstration vehicle. It builds upon fleets of military vehicles, and for the that maximises fuel economy while the initial phase in which Ricardo improvement of the next generation maintaining the capability and applied its systems engineering of vehicles under development.

30 RICARDO QUARTERLY REVIEW • Q4, 2009 Ricardo plc Seminars & Training Related to the automotive and clean energy industries

As a leading provider of technology, product innovation, engineering solutions and strategic consulting to the world’s automotive, transport and energy industries, Ricardo is uniquely placed to deliver topical, relevant and authoritative training at the leading edge of technology. All of these seminars will be held at Ricardo’s Shoreham Technical Centre in Shoreham-by-Sea, West Sussex, UK. Seminar programme: 17 Feb 2010 21 April 2010 Batteries for Automotive Applications Engine Design Training Course A one-day seminar discussing recent developments A one-day training course covering the fundamentals in battery technology for hybrids, plug-ins and electric of internal combustion engine design. Aimed at vehicles. Covers the latest in electric motive technology engineers in the automotive sector and those working and an overview of recent trends and advances in the automotive supplier base who need to know in battery pack technology, the key enabler of the the methodology and constraints of modern engine electrification of the vehicle network. design. 19-20 May 2010 9-10 Mar 2010 Digital Signal Processing for Scientists Diesel Engine Calibration and Engineers This two day seminar will cover the engine calibration process for diesel engines including the role of This one and a half day seminar provides a theoretical simulation in the calibration process, the advantages of and practical introduction to DSP from an automotive automated testing, the application of transient testing, engineering viewpoint. Content ranges from analysis of and the use of advanced tools for test bed and vehicle time and frequency domain data to the use of adaptive calibration activities. The particular challenge posed by filtering for active noise cancellation. diesel aftertreatment systems is also presented. 16 Jun 2010 16-17 Mar 2010 Crankcase Lubricants Diesel Particulate Filter Application and A one-day seminar discussing the features of crankcase Calibration lubricants, the latest developments and likely future requirements. Provides an insight into lubricant For more information This two day seminar provides detailed training on formulation and interaction with design and materials. about our current all aspects of DPF system calibration and validation. Includes discussion of how to formulate lubricants seminar programme The content includes system overview and to meet the challenges of increased drain intervals, or to discuss individual alternative layouts of aftertreatment and sensors; emissions control, engine wear protection, reduced fuel company-specific training calibration approaches for the major elements of DPF consumption and future engine design and materials. requirement, please system control strategies, i.e. thermal regeneration contact: management, soot load detection and DPF supervisor. [email protected].

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