Interview David Smith, CEO, Jaguar Land Rover Q4, 2008 Royal touch HRH The Duke of York opens new Ricardo Ricardo Quarterly review centre

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

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News Royal visit 04 Industry news 22 Shoreham Technical Centre Global business crisis brings electric cars into focus; GM, A major expansion to Ricardo’s UK headquarters was Ford play engine catch-up; PSA shows through-the-road opened by HRH The Duke of York in October. Anthony Smith hybrids; Toyota introduces stop-start; plastic mufflers that accompanied him as he toured exhibits demonstrating a save weight and space century of Ricardo innovation 24 Ricardo news Features China operation in major expansion; fuel efficient defence; Indian Tier 1 becomes Ricardo customer; new MD for Ricardo 08 Chery A5 hybrids Strategic Consulting; high-speed WAVE-RT offers real-time China’s biggest automaker turned to Ricardo for expertise simulation when it wanted to launch a range of hybrid models. John Challen discovers a remarkable programme which expanded Questions and answers to include full system design and integration – and even provision for the Olympic Games 06 Jaguar Land Rover CEO David Smith took command when Tata acquired the 16 Near-zero emission diesels British automakers in June, and immediately faced the global Once seen as the poor relation to gasoline, diesel is now financial crisis. Tony Lewin hears his thoughts about the in pole position as the clean fuel of the future – thanks to future Ricardo’s R&D. Jesse Crosse looks at the programmes and talks to the world-class engineers driving them

Head office: Conceived and produced for Ricardo by: Ricardo plc, Shoreham-by-Sea, TwoTone Media Ltd West Sussex, BN43 5FG, Editor: Tony Lewin United Kingdom Contributors: Tel: +44 (0)1273 455611 John Challen, Jesse Crosse, Ricardo contacts and locations: Anthony Smith, Andy Whittaker www.ricardo.com/contacts TwoTone Media Ltd contacts: RQ subscriptions: www.ricardo.com/rq Anthony Smith: [email protected] Sales enquiries: [email protected] Tony Lewin: [email protected] Industry News

Electrics get real as car sales collapse

n a quarter which has seen car Isales crash, automakers scale back production and the US Big Three brought to near bankruptcy, electric cars have become the hot ticket with the potential to re-animate disappearing consumer demand. BMW’s high-profile unveiling of the all-electric Mini E at the Los Angeles show in late November follows a season of electric car announcements, many of them concentrated at the Paris Thinking small: show in October. Perhaps the most significant from Big 3 play catch-up the industrial point of view was the Renault partner Nissan exhibited ocked by the turmoil of a production version of the Chevrolet its novel 2+1-seater Nuvu electric Rdisastrous year, the North Volt, due for its North American launch city car concept. Its plans are equally American organisations at GM and in 2010 and set to appear in Europe as ambitious and begin with a four- Ford have nevertheless been able an Opel the following year. seater car for lease in Japan and the to respond to changing Renault’s chief operating officer US in 2010. Mitsubishi, too, showed market conditions by Patrick Pelata went further than most a near-production version of its MiEV dramatically shifting in outlining his company’s ambitious hatchback, already on sale in Europe their engine production battery-car plans: a version of the with an underfloor gasoline engine. to four-cylinder units. Kangoo light commercial (shown as Pininfarina chairman Paolo GM plans to double the ZE Kangoo at Paris) will reach Pininfarina predicted the company’s its global production of consumers and business users through B-Zero electric hatchback would “make four-cylinder engines, leasing schemes in several countries waves in motoring circles.” A stylish, with most of the increase in 2010 and 2011. An electric version of premium five-door hatchback with going into the US. A new the Mégane-derived Fluence sedan will lithium polymer batteries supplied by plant in Flint, Michigan, will begin also appear in 2011, while the following French industrialist Group Bolloré, it will building the 1.4 litre units in 2010, year will see a purpose-designed, Clio- go on sale next year and could sell up to with turbo versions destined for the sized electric car. More than 100,000 15,000 units annually. Chevrolet Cruze and a non-turbo sales are expected in 2012, said Pelata. A host of battery-powered light serving as the range extender in the commercial vehicle designs bore Volt plug-in hybrid electric. witness to interest at every level, while Ford is migrating its gasoline two French specialists – engines to EcoBoost technology, maker Venturi and coachbuilder Heuliez beginning in 2010. This combination – each showed concepts making use of direct injection and turbocharging of Michelin’s innovative Active will power 80 per cent of the Wheel, which combines company’s North American line- steering, suspension, up by 2012, says Ford, when four- braking, drive and cylinder production capacity will be energy regeneration over one million units. within the diameter of Chrysler, cut loose from its the rim. technology-rich Mercedes former The main dissenter parent, is the smallest of the three, continues to be Honda, lacking in-house fuel-saving which insists battery technologies. It has been talking technologies are still not with several other automakers but Pininfarina B-Zero mature enough to allow electric has so far only announced licence- and (top) Mini E cars to be viable. production deals with Nissan.

Toyota’s first stop-start Volvo Trucks looks beyond Euro V Plastic mufflers save weight A new 1.33 litre gasoline engine New engines built in line with With a reduction in exhaust back is the first mainstream Toyota its eco principles will help pressure of 50 per cent as well as unit to feature stop-start. The Volvo reduce truck PM and half the weight and size, plastic four-cylinder engine will be smoke emissions beyond rear mufflers could be the future made in Wales and be fitted to the requirements of Euro V. for diesel cars. Extra benefits of the Auris, where it reduces CO2 Volvo’s technology centres on a the Woco muffler include the

News in brief emissions by 17 per cent. combination of SCR and EGR. deletion of external heat shields.

4 RICARDO QUARTERLY REVIEW • Q4, 2008 Ricardo Quarterly Review

The task of RQ is to highlight the latest thinking in automotive engineering and technology worldwide – both within Ricardo and among 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 Hybrid strategies come the worldwide automotive community: in the seven years since RQ was launched we have had to increase our print run to 14,000 copies into focus to keep pace with the demand to read about hree concept cars presented by PSA mode, the RC HYmotion4 concept Ricardo and its activities. Client confidentiality is of the utmost Tat the Paris show in October provide claims a top speed of 295 km/h and, importance to Ricardo, which means that pointers to possible future hybrid vehicle perhaps coincidentally, the same 109 we can only report on a small fraction of the production policies for the and g/km CO2 emissions as the Prologue. work carried out by the company. So we are Citroën brands. An intriguing fourth concept from especially grateful to those Ricardo customers who have kindly agreed to co-operate with RQ Citroën’s voluptuous Hypnos coupé PSA was the HYmotion3, a three- and allow their programmes to be highlighted and the Prologue HYmotion4 – a higher- wheeled scooter with a supercharged in print: without such help from customers architecture hatchback — from Peugeot 125 cc gasoline engine driving the rear it would not be possible to present such a share similar drive systems, with a front- wheel. The addition of 3 kW electric fascinating insight into the way vehicles are conceived and developed. mounted two-litre taking motors on the front wheels gives the drive to the front wheels via a six- the scooter hybrid capability and the Few technical details have been speed automated manual . distinction of being one of the few three- released, but the Insight is expected to In a move which may come to predict wheel-drive vehicles in existence. undercut current hybrids in price and to a broader future industry trend, both On a more serious note, Honda beat today’s 109 g/km Civic Hybrid on all-wheel-drive and hybrid operation are revealed its near-production global CO2 emissions. enabled by the addition of an electric volume hybrid, the Insight. Built on a rear axle, powered by a 200 Nm peak bespoke platform, the Insight combines Peugeot RC HYmotion4 (top) and Citroën Hypnos (below) through-the-road hybrid torque synchronous motor. a 1.3 litre gasoline engine with an concepts from PSA There is no mechanical connection updated IMA motor-generator between the axles: the link occurs sandwiched between the engine through the road surface. The more and transmission. The battery clearly sporty RC HYmotion4, seen as and power electronics are a stepping stone between previous packaged under supersports RC concepts and more the luggage practical models, has a similar compartment conceptual layout but reversed: the floor, leaving rear-mounted combustion engine – versatile gasoline this time – is complemented five-seat by an powering the front hatchback axle. Mustering a total of 313 hp in boost accommodation. Racing for the environment ager to prove that hybrid racer. The 908’s kinetic energy Etechnology is equally beneficial recovery system can deliver boost of in the world of motorsport, PSA 60 kW for 20 seconds per lap through a has developed energy-recovery gear-driven motor-generator, while the versions of its dominant Citroën C4 rally car has some 300 Nm boost C4 World Rally Car and the diesel- on tap through a rear-mounted 125 kW powered long-distance electric motor.

Green belt helps save CO2 Car talks to bike position and direction of travel of cars CO2 emissions reductions of up to 3 Honda is working on a series and motorcycles in relation to one g/km are claimed for a new Green of programmes to improve another. Motorcyclists receive alerts Runner timing belt developed by motorcycle safety by providing about vehicles approaching them, ContiTech AG. Fitted in place of a two-way communication between the warnings being given either conventional timing chain, the new bikes and surrounding vehicles. acoustically through an audio system belt can cut fuel consumption by The ASV-4 system uses wireless or on the head-up display on Honda’s 0.2 lit/100 km and reduce noise. communication to ascertain the special Communication helmet.

Q4, 2008 • RICARDO QUARTERLY REVIEW 5 RQ Interview – David Smith – Jaguar Land Rover

Are we likely, for instance, to see more growth at Jaguar and less at Land Safe pair of hands Rover as SUVs face difficulties in the David Smith slipped into the driving seat at Jaguar Land Rover market? just after its acquisition by Tata Motors in June, only to be faced They are different, but that’s not necessarily a logical conclusion. We’ve with the global financial crisis and collapsing sales. Tony Lewin seen big shifts in the premium segment asks him whether JLR’s big-car strategy will change as a result of for large luxury cars as well. I never view the industry’s general predicament this as a trade-off between Jaguar and Land Rover.

How is the Russian market performing for Jaguar Land Rover? Russia has slowed down very much in the last three or four weeks (since mid-October). It was extremely strong through the first part of the year; China has slowed down, though it is still significantly up year on year. Brazil is a market we’ve been doing very well in, but it has hit a more difficult period. Even in the Middle East, which is still relatively What is your relationship like with Tata, (finance minister) recently cut the rate strong, there have been some issues the owner of Jaguar Land Rover? How by 1.5 per cent. Do global rates also with consumer credit. Unfortunately, it is often do you see their top executives? need to fall to help Jaguar Land Rover’s a worldwide picture. The pattern is still developing, but business? normally I would see Ravi Kant [head of What we’re seeing is a global impact How much potential is there for Jaguar Tata Motors] every month, and Ratan on confidence. I don’t think there’s a in Russia? [Tata, chairman of Tata Group] has been market anywhere in the world where Jaguar has been successful this year, here three times [since the acquisition in we haven’t seen some kind of impact and in 2007 we sold about 1500 cars June]. from the credit crisis. It’s therefore there. Land Rover has grown rapidly; a more general problem; I’m not Jaguar has been slower and requires Are there now many Tata people expecting it to turn round overnight, but over time some different products. It’s within Jaguar Land Rover? How senior hopefully this [interest rate cuts] will beginning to develop now: the new are they? start the process. Jaguar XF works well in Russia and we There are none at all in management have the all wheel drive system on the positions. We have three experts who Do you see a pattern in this that would X-Type. About a third of the premium are helping us in three different areas: make you change Jaguar Land Rover’s sedan market is AWD. one in accounting, one in treasury and longer term strategy? one on the marketing side. They’re I don’t believe our main strategy will What can or should governments do to specifically helping us with the transition change, but what may obviously change aid the auto industry? and to get our Indian distribution started. over time are aspects of our volume Clearly, anything to increase demand balancing, portfolio and markets. It’s too is critical. We’ve had an interest rate You have been calling for interest early to tell while we’re in this turbulent cut and there is talk about a fiscal rate cuts, and the British Chancellor period. stimulation package – that will help.

6 RICARDO QUARTERLY REVIEW • Q4, 2008 Very specifically, changes to vehicle have to make the same improvements taxation – the German government has across the range, so the next generation just implemented actions to defer some of the larger vehicles will have to deliver of their changes for a couple of years, significant improvements as well. and we’re asking the British government to defer the new higher levels of taxation Do the bigger vehicles, with their due next April and to cancel or defer the higher prices, provide more scope for showroom tax. CO2 reductions? The technology that is going to deliver Overall, would you like to see a vehicle improvements in the bigger vehicles is taxation regime that is totally based on the same as that going into the smaller CO2 emissions? vehicles. 25 per cent is a reasonable We would like to see a lot more target for 2012 but as we go through the harmony within the European countries; rest of the decade we will need even unfortunately, we’re now seeing an Are you not confident about your own bigger improvements than that. increasing disharmony around taxation systems? regimes. We will have as good a set of techn- You are running a research programme ologies as our competitors – that’s what looking at advanced hybrid Would you be in favour of a unified I have to deliver. All I’m saying is that it’s powertrains for luxury vehicles. Will pan-European CO2 tax? unproven at the moment: we don’t have this work be incorporated into the new Absolutely, but that’s a dream. It will that many in the market, and we don’t XJ limousine due out next year? never happen, unfortunately. The know if customers will buy them. That’s fairly early technology at industry has pushed for this, but there’s the moment and needs a lot of no appetite [among member states] What kinds of technologies are you development, so it’s not going to be for tax harmonisation. The situation developing in order to achieve the 25 an early introduction in the XJ. We’ve is getting more and more chaotic. It per cent cut in CO2? been working on a roadmap across inhibits everybody’s business because There’s a mix of weight-saving all of the vehicles, so eventually we it makes it very difficult to plan when tax measures, improving aerodynamics, would think of introducing technologies rates and regimes are changing. reducing parasitic losses in the vehicle like that. But there’s a lot of work that as well as more efficient diesel and can be done in the shorter term just Are you confident you will get the petrol engines and new transmissions. improving the conventional technologies small-volume producer exemption – transmissions, power steering systems from the Commission’s CO2 fleet To sustain those reductions you will and so on. average proposals for 2012? have to add smaller models with much The proposed low volume exemption lower CO2 emissions. Has the LRX What about station wagons and the relates to manufacturers producing compact Land Rover been confirmed rumoured smaller sports car? less than 10,000 units per year. The for production? We’ve said we are not going to do an provision relating to Jaguar Land Rover No, we haven’t made any confirmation SUV, but I don’t think that rules out would regard us as a niche producer of production. Clearly, it’s an exciting having a kind of sports break. It isn’t and not provide us with an exemption, product proposition, which is why we something we’ve taken a decision on: but rather an option of a 25 per cent built the concept vehicle. It provides us we’re focused right now on developing reduction target on emissions. We’re with the opportunity to include a lot of the range that we’ve got. There are a OK with the revised proposals that the environmental innovation, but we’re still number of opportunities to invest in the French presidency is preparing: what is working on the business case for it. Jaguar brand beyond that [the current important is that we do have a package. range]. The worst result here is that nothing gets You are co-operating with Volvo on done, because that would create even lightweight architectures. When will Do you not need a Jaguar with a lower more uncertainty. we see this construction on a Land CO2 output and a lower price entry Rover SUV? point? Is that 25 per cent reduction I’m not going to comment on what’s We are going to have some very good achievable? going on with Volvo, but we have CO2 numbers when we launch our new It’s a stretch, but that’s the technology been working on light weight for many technologies in coming years. They we’re putting in place: we’re spending years and it is an important part of will deliver what we need to do to be about £800 million on it in the next few getting the CO2 reductions we need. competitive. years. One thing that nobody can predict We’re continuing to invest further in here is what the customer reaction lightweight technologies, and we are will be to this technology. At the end not the only people doing that. We’re David Smith became CEO of Jaguar of the day, if customers won’t buy into pursuing a number of research projects Land Rover in June after serving as some of the new technologies such as in that area. chief financial officer. Prior to that he the stop-start systems or the belt ISGs was director of finance and strategy for we will have to start incentivising it Do you see the time when it will be Ford of Europe and PAG and has been a and it becomes a much more difficult impossible to sell a vehicle which director of both Volvo and Aston Martin. proposition. emits, say, 350 grams per kilometre Born in Solihull, near Birmingham, in CO2? 1961, Smith holds an MA in economics But BMW customers have embraced I don’t think it will ever be impossible, from Cambridge University and an MBA these technologies enthusiastically. but it will become very rarefied. We will from Warwick University.

Q4, 2008 • RICARDO QUARTERLY REVIEW 7 Chery A5 hybrid

Great call from

For the development of China’s first hybrid vehicle, the country’s largest independent automaker, Chery Automobile, selected Ricardo as its engineering partner. John Challen reports on an exciting programme in which the team even had to overcome an unexpected extra challenge – the Olympic Games

eing asked to assist with the for control and electronics hardware into the driveline at a much earlier design and development of at the Ricardo Cambridge Technical stage, and few have yet reached models BChina’s first hybrid, to be based Centre. available in the showroom. on Chery’s new A5 sedan, was an Chery had decided it wanted to exciting prospect for Ricardo. Chery produce a mild hybrid car broadly The programme expands is China’s biggest independent similar in concept to the Honda Civic But, as the Ricardo team was soon to automaker, with an annual passenger Hybrid, remembers Edington, and discover, the scope of the programme car output close to 400,000 in 2007, and had already sketched what it would very quickly began to expand in an is ambitious to expand into Europe and ideally look like. “This architecture unexpected direction. “As the talks North America. was to form the basis of the Integrated progressed,” recalls Edington, “we Yet as can often be the case in the Starter Generator or ISG hybrid as it were asked by Chery to source a auto industry, the initial relationship will be marketed by Chery,” continues supplier for the battery, the motor, and between the two companies came Edington. “A second derivative would electronics within the hybrid system.” about through sheer good fortune. be a simpler micro-hybrid based on a Working with any new customer The first contact that was made was Belt Starter Generator, to be launched takes time and adjustment, and the via an email after an executive at the as the BSG hybrid.” Chinese car maker was certainly Chinese car manufacturer had seen a Essentially bolt-on in their application, no exception. “As one of the new Ricardo technical presentation. This belt-drive starter generators represent independent Chinese automakers, unconventional communication was a the first generation of micro-hybrid Chery was quite different to any taste of things to come. stop-start mechanisms and are company we had worked for “Someone from Chery got in already available on several European previously,” reveals Edington. touch with us, stating simply that the models, explains Edington. The more “There were cultural differences. company wanted to build a hybrid,” sophisticated crankshaft-mounted ISG, The processes and toolsets that we recalls Murray Edington, chief engineer by contrast, needs to be engineered had to work with were new, and the

8 RICARDO QUARTERLY REVIEW • Q4, 2008 A fleet of 50 Chery A5 BSG and ISG hybrids was used for transportation during the Beijing Olympic games and Paralympics. Driven by experienced Beijing geographical distance between the two companies was also a challenge.” taxi drivers, the cars The first phase of the four-year were working seven project involved a lot of supplier management. Edington: “We went to days a week, 24 hours companies such as Bosch and Valeo, a day, transferring but they were quoting big prices and long lead times. As a result, we made dignitaries and a counter-offer that led to Ricardo athletes. With each developing the power electronics hardware and the motor, as well as all of the ISG vehicles the control software and in addition, within six to eight months. Before accumulating being responsible for the successful we’d finished validating that vehicle, implementation of the entire hybrid we would be getting on with the next between 30,000 system in the vehicle. Chery originally generation of prototype, so there would and 40,000 km, not envisaged us co-ordinating the off-the- have been overlap.” shelf component supplies, but in the This is not the traditional way of a single fault was end we actually provided the technical working for Western carmakers; reported development expertise ourselves.” nevertheless, Chery’s process was seen as a way of shortening the Innovative thinking from the start timescales involved in the programme. The initial vehicles were produced very All agree that there were times when quickly, recalls Edington. “The plan was the approach was challenging, but it that we would get to mule vehicle phase nonetheless provided an impressive

Q4, 2008 • RICARDO QUARTERLY REVIEW 9 Chery A5 hybrid

China sourcing: Keeping the supply chain local

One of the most important priorities in producing this Chinese car was to keep it Chinese. This meant using local suppliers wherever possible, one key area being the motor. “We went to four or five motor suppliers and found that only a couple were suitable and had the capabilities that were needed,” remembers Edington. The company eventually chosen was Shanghai Ananda Drive Techniques. “We worked closely with the motor supplier during the design phase to design a motor that could be produced using processes and materials that were locally available, yet would deliver The fact that suppliers such as the required performance in the Bosch and Valeo were quoting vehicle. Edington needed to ensure that big prices and long lead times there was a Chinese link for each led to Ricardo developing the component in the hybrid system. “In the case of the battery, we power electronics hardware went to all of the suppliers that and the motor, as well as all Chery suggested and found that none of them had the capability the control software and, in to make the cell modules, relays, addition, being responsible for fuses and battery management system. In this case, we had to the successful implementation go abroad – to Johnson Controls/ of the entire hybrid system in SAFT – but even it has agreed to manufacture the packs in China.” the vehicle The Engine Management System (EMS) found on the means of delivering leapfrog of hardware functional and validation A5 hybrid was one component technology to the market.” testing. Flexibility was also key to the that could be taken almost off While Edington took responsibility for design to enable swift implementation the shelf. Technically a Bosch the project’s hardware needs, Russell and to cope with frequent change system, it is officially supplied Lewis, principal engineer for control requests. by the company’s joint venture software development, led the software On a parallel path the ISG control in China – United Automotive development team. Also based in application was being developed, using Electronic Systems. “We had to Cambridge, Lewis was able call upon – where possible – knowledge and work with them to implement a lot his own team as well as a number of expertise from previous Ricardo hybrid of the new hybrid functionality,” engineers sent directly from Chery HQ. research programmes such as HyTrans says Edington. “The pedal signal “Our first job was to create the and Efficient-C. For the software team comes into our control unit, software for a common platform for to achieve the original tight deadlines we split the demanded torque both the BSG and ISG programmes as with the required flexibility a model- between hybrid and engine, and well as a separate TCU (transmission based development approach was then the demanded engine torque control unit) project. We designed chosen, as Lewis explains: “Model- goes into the EMS. Although we a common platform so as to avoid based design gives you reduced time give the EMS a torque signal and redesigning the wheel three times,” to market and a much greater flexibility it delivers it, there is an enormous says Lewis. “The software that was than a conventional approach” amount of safety checking and developed was mostly written from Like Edington’s group, the software monitoring involved in a modern scratch. There were some off-the-shelf team would also have to cover new EMS. And when you implement components, but as we were trying ground. “Before this project, we hadn’t a hybrid system in a production to create a common platform, we had really executed a staged delivery application there is yet an extra to start with an almost blank sheet of programme over such a long period level of safety that you need.” paper.” of time. Our software process had One key requirement, says Lewis, previously been designed more for was to have a software package that a turnkey approach. On the Chery would also accommodate the needs hybrid project we had three distinct

10 RICARDO QUARTERLY REVIEW • Q4, 2008 powered by a new Chery engine, one of a family that the Chinese company Co-operation with Ricardo: has developed. We were meant to be the customer’s view comparing our hybrid vehicle with the base vehicle, but the base vehicle didn’t The success of the Beijing exist at that time. Furthermore, we had Olympic Trial operation a 1.3-litre engine in the A5 ISG hybrid attests to the special relationship and our baseline comparison was to be “and close collaboration between the standard 1.6-litre A5 saloon.” Chery and Ricardo. Without such a “In the final product, the motor is built committed and seasoned coach it into the flywheel. One of our early jobs would have been extremely difficult was to figure out how to gain enough for Chery to pull off this “Mission extra space between the engine and Impossible”. the gearbox to accommodate the motor Over the years we have developed without causing problems. Once we an open and trusting working had established how much the engine relationship the hard way, turning and transmission housing could be our collaboration into a truly moved from their original positions unprecedented win-win opportunity. within the engine bay, we were left with We have not only learned the best a small gap between the engine and the practices of hybrid electronic vehicle transmission that would allow space for development and automotive a motor.” electronics system development in Edington knew that the whole motor general, but we have also been able to could be squeezed into the gap, but train 24 young and aspiring engineers this meant the flywheel had to be in a world-class auto engineering redesigned to put the ISG rotor behind establishment like Ricardo. it, packaged together with the clutch, The year-long real-life working rotor position sensor, motor cooling experience abroad and the resultant jacket and starter motor ring gear. “The self-confidence gained by our hybrid initial plan was that Chery would do this team members are definitely non- aspect of the work, but ultimately it was duplicable assets for Chery, and we more effective for us to take this on for now see ourselves well positioned programme phases to support, and them.” as the leader of the pack in China’s there were differing specification nascent HEV market. requirements at each stage.” Supplier management Although the end result in the There were certain items, explains Working with suppliers from the US, market place is yet to be seen, this Lewis, that were developed on the EU and China was a big part of the learning experience is perhaps of still Chery programme for the full system programme for Edington. “There were greater significance for the long- implementation, that Ricardo’s control differences between suppliers in terms term future of Chery’s journey in the software team had not designed before of quality and their design capability. important strategic direction on a hybrid programme. “This included They are all different and trying to get of HEV development. end of line testing, fault diagnostics, them all together on one programme and European On-Board Diagnostics was a major challenge to overcome. Dr. Frank Liao, chief engineer for hybrid vehicle” (EOBD) that are needed for the ISG Supplier management thus became vehicle.” a very significant part of Ricardo’s development , Chery programme responsibilities. Early powertrain hurdles “What we have implemented is one example as the motor controller’s Another challenge that the Ricardo relatively state-of-the-art, but we digital signal processor (DSP), which is team faced was the fact that there recognised very early on that it was the latest generation industry standard, were no production examples of the vital not to undertake any undue automotive qualified part from Texas brand-new A5 that could be used for innovation or invention, or to become Instruments. comparison with the hybrid version. involved in debugging new products Edington admits the situation from suppliers. We wanted something Chery and Ricardo: a long-distance could have been worse: “Unlike that was up-to-date but it was relationship many Chinese vehicles, the A5 has important for it to be robust and to have There was plenty of interaction a completely bespoke body and is tried and tested parts.” Edington cites between Ricardo and Chery engineers, both in China and at Ricardo’s facility Chery A5 hybrids – fuel economy and performance in Cambridge. The initial focus of the compared with baseline gasoline A5 project was in the UK, where 12 to 15 Chery engineers joined Ricardo staff Chery A5 BSG Hyrbid Chery A5 ISG Hybrid to make a core team of around 30 Fuel economy improvement (NEDC) 5% 13% people. As the programme progressed, Maximum power increase As base vehicle 5% the vehicles became more numerous and more mature and Chery recruited Maximum torque increase As base vehicle 20% more people, the whole focus gradually 0-100 km/h acceleration time As base vehicle 10% faster moved across to China.

Q4, 2008 • RICARDO QUARTERLY REVIEW 11 Chery A5 hybrid

The Nickel Metal Hydride battery pack of the Chery A4 ISG hybrid (right) and integrated mild hybrid controller module

“Chery built the first vehicles with the parts that we shipped to them”, explains Edington. “Then, our team based in China debugged the vehicles, checked the wiring, ensured the system was installed correctly, even once dismantling the powertrain to ensure the motor was correctly fitted. When the team had finished, the first vehicle was shipped to us, and because they’d done such a good job, we were able to concentrate on installing and “We have not only learned the best commissioning our functional hardware module. Once the UK vehicle was practices of hybrid electronic vehicle working properly the Chery engineers development and automotive were able to build further working vehicles in China quickly and with a electronics system development in minimum of effort” general, but we have also been able to Olympic dreams train 24 young and aspiring engineers In the midst of all the negative press in a world-class auto engineering surrounding the air quality of Beijing, home to the 2008 Olympic Games, Dr. Frank Liao, establishment like Ricardo” Chery strove to be clean and green. chief engineer for hybrid vehicle development, Chery In the summer of 2007 the Chinese

12 RICARDO QUARTERLY REVIEW • Q4, 2008 Driving the A5 ISG Hybrid

It is easy to forget all preconceptions about Chinese cars when you see the Chery A5 hybrid. A unique body shape, as with many Japanese models, provides convincing evidence that the Chinese company is taking vehicle production more seriously than ever. Inside the car the layout of the controls is basic, but all of the switches are set out in a logical pattern. They are also built of good quality plastics, essential in a European market that ranks interior finish very highly. The Chery hybrid’s stop-start system works very effectively as you shift the car into neutral and release the clutch. Restart is effected as soon as the driver presses the clutch and engages gear. The downside of such a routine – as with many stop-start installations – is the time taken to use this procedure in busy urban traffic. Around the busy streets of Cambridge it was difficult to judge the outright performance, but the 1.3-litre A5 ISG hybrid demonstrated excellent launch characteristics and felt both responsive and smooth. The steering on the test car was nicely weighted and made manoeuvring around traffic straightforward. The simplicity of the display was also refreshing to see, and the overriding impression at the end of the test was that it felt like driving a Japanese or European product, as opposed to a Chinese car. This achievement alone will be a major help to Chery in fulfilling its export dreams. John Challen

carmaker was invited to supply a taxi “We had one problem with the able rapidly to eliminate many of the fleet of 50 hybrid A5s to the Games. motor inverter, and finding the solution possible causes of the problem and This news came out of the blue to the was like trying to find a needle in a identify the underlying problem – a tiny engineering team, which had not been haystack,” he recalls. “Several weeks integrated circuit in the control system expecting a significant extra package of before the date for the vehicles to be that was producing the wrong output work to be done in such a short space handed over to the Chinese government intermittently – and define a simple of time at short notice. Olympic committee, we had some but effective solution. The engineers in “There was a change of plan when serious issues with the semiconductor China were then able quickly to update the Olympics project was announced,” power switching devices that control the vehicle fleet in Beijing.” admits Edington. This change came the motor – about as big a challenge For Lewis’s software team, the during preparations for the design as you can get. I was in China, and on progress they had already made in validation phase, where a batch of cars my first day four of the first 12 cars implementing the common platform was being built for fleet testing. were affected. During the remainder of software meant things were a bit more “The situation was difficult as the the visit a couple more were showing straightforward. “We were due to finish cars and hardware we were working similar issues.” the common platform software around with had not been validated, but the By this stage of the project the the time of the Olympics date anyway,” Olympics was not a movable feast and Chinese company had enough faith he explains. “However, the team the timing was non-negotiable. It was in Ricardo to let Edington and his members developing the higher level a logistical and development challenge team get on with things. “It was a hybrid control strategy had a bigger for us, but it was our type of challenge big problem for Chery, but also a big challenge as they were due to deliver as it had filtered down from the problem for Ricardo and we were at a later date. This team had to really organisers of the Games to make them committed to fixing it. Due to our close pull the stops out to get the strategy more green. A second fleet of vehicles working relationship with the supplier functions implemented on time for the was built for the Olympics alongside the of the semiconductor power switching Olympics.” existing validation fleet. devices used (Semikron), we were During the entire period of the

Q4, 2008 • RICARDO QUARTERLY REVIEW 13 Chery A5 hybrid

“Substantial investment in recent years into the joint HEV [] development project with Ricardo has allowed Chery to acquire the technical capabilities of an independent, world- class HEV system and assure product development for the years ahead” Lu Jianhui, executive vice president, Chery

Games and paralympics there were system. Many other companies no problems at all with the fleet, says produce demonstrator vehicles that Edington. Driven by experienced have functionality only. When you Beijing taxi drivers, the cars were do a production product it is a very working seven days a week, 24 hours different challenge to that of a concept a day, transferring dignitaries and demonstrator. Other companies athletes. During this time not a single produce small fleets of vehicles, and fault was reported. This was quite an run no formal validation tests. The achievement with a fleet of vehicles Chery A5 ISG and BSG hybrids have which – despite significant fleet-specific been produced to the most stringent of validation testing – was in effect quality and safety standards.” midway between prototype and pre- Work is still continuing on the production status. software validation, but this is mainly In parallel with supporting the being run from China with approval Olympic fleet build, the original from Lewis and his team in the UK: validation activity continued unabated. “Chery engineers have taken on most Component-level validation of the of the validation work, which is what we system hardware including the trained them to do. They send us their battery pack and hybrid module test plans and subsequently the results, will support them for another 90 days, (environmental, thermal, electrical, which we then review.” after which our programme of work EMC) and vehicle (EMC, altitude, The programme is currently going comes to an end. This has been a climate, long distance and mixed into the confirmation prototype hugely successful programme for both mileage accumulation) have since been phase leading directly to the start of companies, delivering a major first for completed, requiring only minor tidy- production, meaning that the main China in the form of its first hybrids, ups for the final implementation. development work is done; but Ricardo including the pre-production fleet is nevertheless still in the position of which performed faultlessly throughout Lessons learned make Ricardo stronger design authority. This role means that the Olympics. The lessons learned Despite the many challenges that the company still has to push to ensure will be extremely valuable to all those the Ricardo team had to overcome, things are completed, and completed involved. In addition to the production- Edington believes that the company is correctly. ready hybrid vehicles, Chery now have now in a great position in the market. “The final phase is validation of the capability to develop HEV vehicles “Unlike many of our competitors we the production processes, working in their own right. This was an outcome have now completed a full production with a bug-free design. The official that Chery were very clearly focused on hybrid programme to production date for start of production is March from the outset.” quality and with a fully validated 2009,” explains Edington. “Then we “Substantial investment in recent

14 RICARDO QUARTERLY REVIEW • Q4, 2008 Ricardo establishes Global Hybrid Product Group

ecognising After completing his degree and PhD Rthe growing at Newcastle University in 1982, where importance of he specialised in power electronics hybrids in the and machine control, Thornton went automotive world, to work for the Northern Engineering Ricardo has Industries (NEI). and then moved to established the technical consultants PA Technology in Ricardo Global Cambridge, where he stayed for three Hybrid Product years. Group. Its director Thornton was involved from the will be Roger inception with an offshoot company Thornton, who called The Technology Partnership, has over 25 years’ Roger Thornton: The aim which formed a number of business of the Group is to provide a experience in focus for all the hybrid work groups including ‘Control’ which power electronics- across Ricardo focused on control systems and power based systems. electronics. “This is when I first got “The aim of the group is to provide involved in electric vehicles, working a focus for all the hybrid work being on the LA301, a very early electric car undertaken across the Ricardo designed for California. We thought we business,” explains Thornton. “We could do better than that [car].” want the Hybrid group to say, Ricardo There then followed a project does hybrids and this is the portal into with energy company Powergen, it. Whether the project is consultancy which subsequently grew into a joint or new product development, we are venture called Wavedriver. “They confident that we will be able to fulfil were interested in how to stimulate the needs of the client.” the electricity market, and our interest Thornton wants Ricardo, which was that the CARB mandates were already has well in excess of 100 being introduced in California, which hybrid projects to its credit, including meant EVs had to be produced,” says the Chery programmes, to be seen Thornton. Wavedriver developed as the prime-choice place to go for a range of innovative EV drive and hybrid development support. He charging system which were piloted on knows, however, that it will not be a range of vehicles. straightforward: “We need to be When the company was closed down drawing in new resources, but it’s not by Powergen in 1999 Thornton returned easy to recruit from the automotive briefly to TTP before establishing his industry because this is a new discipline own consultancy, which in turn led to and few people in the industry have contact with Ricardo. He has been a much experience in the types of permanent member of staff at Ricardo systems we are working with. It’s since 2006. unusual for example to find a power electronics specialist who has worked in auto industry for more than a few years.” years into the joint HEV development project with Ricardo has allowed Chery to acquire the technical capabilities of an independent, world-class HEV system and assure product development for the years ahead”, said Chery executive vice president Lu Jianhui. “We’re now the undisputed industrial leader in the field of Chinese HEV development, and our HEV team is among the best in China, even in the world.” Chery’s market impact and industrial influence in this strategically important direction would soon be felt not only in the Chinese market, but also aound the globe, he added.

Q4, 2008 • RICARDO QUARTERLY REVIEW 15 Diesel rules

16 RICARDO QUARTERLY REVIEW • Q4, 2008 Diesel

rulesIndeed, people are Ricardo’s biggest Diesel, once the poor relation to gasoline, is fast asset. In the last year a significant becoming the major powertrain force in world number of senior diesel engineers have joined Ricardo from leading automakers markets. The company’s diesel engineering teams and first-tier suppliers, and many others have now become the largest single business have returned to the company from employment elsewhere in the auto sector at Ricardo – and for the engineers involved, industry. life has never been busier. Jesse Crosse talks to Global customers the leadership team to find out why A number of major OEM customers are on the books, though the names sk most westerners what is the In the view of Ricardo’s global of these clients must clearly remain major challenge facing the world product group director for diesel, Ian confidential. Without exception, Atoday, and the chances are that Penny, it is no surprise that diesel however, all are looking to take the answer will be ‘global warming’. engines play a major part in Ricardo’s advantage of the global boom in the Ask again what they see as the principal activities. “Diesel is the single biggest diesel market and in most cases the causes of climate change, and many activity in our business. This will be rate of development is spectacular. “We will include the car high on the list of a record year, something which is have engineered EU5 solutions for a offenders. Yet huge strides in light duty reflected in a 25 per cent increase in number of customers, including any diesel development have revolutionised both people and facilities during the last associated DPF work,” says Penny. the European passenger car market 12 months.” The challenge in the EU, he continues, during the last 10 years, bringing the “is all about improving emissions and promise of greatly reduced fleet CO2 engineering for EU5 and EU6.” But emissions. Ricardo has wanted to move the game Until recently, the US has seemed like on further than just meeting regulated an impossible nut for diesel to crack – emissions standards. The aim is to but with volatile global fuel prices that deliver light duty diesel technology that looks set to change. Emerging markets can compete with gasoline on both with substantial urban pollution emissions and performance anywhere problems and the need to save in the world, including all US markets, energy in personal transport are also while beating gasoline hands down recognising the need for high-economy, when it comes to fuel economy. low-emissions solutions. Globally, The globalisation of diesel vehicles heavy duty diesels are quickly following is highlighted by a huge increase in the suit. The future for diesel power has number of the products OEMs have never looked better. in the pipeline. Such is the growth in

Q4, 2008 • RICARDO QUARTERLY REVIEW 17 Diesel rules

The Ricardo NZED engine has a two- stage sequential turbocharger system using two variable geometry turbochargers (VGTs) combined with an advanced EGR system.

penetration into the US market,” Penny “The aim is to deliver light duty continues. “We believe that 15 per cent diesel technology that can compete is possible during the next decade.” The expectation is for diesel with gasoline on both emissions and powertrains to percolate down from the performance anywhere in the world, heavy duty sector, eventually reaching the passenger car market in significant including all US markets, while numbers. “We are seeing a shift from beating gasoline hands down when the truck market into the car segment. It has already moved downwards from it comes to fuel economy” the six and seven-litre sector down Ian Penny, Ricardo to the four and five-litre litre sector – and is now dropping into the two to interest that Ricardo is investing more concerned about emissions while three litre class,” explains Penny. “US and more of its own resources into customers remained unimpressed due customers don’t necessarily want a advanced diesel research in order to to a plentiful supply of cheap gasoline. cheaper vehicle but they do want one maintain its leadership in the market. Now, with the recent wildly fluctuating that’s cheaper to run. In the future we fuel prices and increasing concerns for therefore expect a much greater overlap US diesel share may hit 15 per cent energy security, the need for restraint between US and European products.” The US market has become well known is becoming understood. “There have The cost of oil is clearly a major for its hostility towards diesel on more been a number of forecasts for anything driver, according to Penny. “Despite than one level; authorities have been between 15 and 30 per cent diesel recent events, fuel prices are expected

18 RICARDO QUARTERLY REVIEW • Q4, 2008 200 Starting point Engine out emissions 190 less than half of proposed EU 2014 NOx limit 180

170 ~90% NOx reduction

Emissions [g/km] engine-out with 5 ~ 10%

2 160 CO2 improvement CO 150 0.00 0.05 0.10 0.15 0.20 0.25 NOx Emissions [g/km]

disinterest to a very keen interest in And meeting that challenge means diesels as fuel prices climbed. Despite completely redesigning engines, the recent fall in fuel prices, let’s not particularly the air path, emissions forget that just six years ago the cost equipment and aftertreatment.” of gasoline was only around $1.50 Bar believes the German domestic and the highest we’ve seen was more market is moving towards SCR than $4. There’s not only concern from aftertreatment and is also heavily consumers who are worried about focused on economy. “The German the environment, but also from the market has always been green,” he regulatory bodies who are pushing says, “so there is a heavy emphasis for 35 mpg Corporate Average Fuel on CO2. We expect to see more micro Economy.” and mild hybrids entering the market Pinson sees trends evolving at first and manufacturers remain focused on hand. “There have been significant diesel.” announcements from OEMs regarding diesel power for the light truck Russia, China and India segment. Manufacturers are beginning As far as the rest of the world is to realise that diesel fits very well into concerned, diesel is pretty well their portfolios and that it is a very established in India, says Penny. “We cost-effective option. There have been are working on a number of engines around 60 announcements from OEMs for that market, ranging in capacity regarding passenger-carrying diesel from 500 cc to 1.2 litres, destined for light trucks and around 30 relating to a family of two- and three-wheeled diesel passenger cars.” vehicles. The engines range from a Despite its base being located in the simple mechanical injection, normally to return to higher levels in the long heart of Europe, Ricardo Deutschland aspirated, two-valve, single cylinder term. This factor, combined with an GmbH is also involved in the developing unit, right up to a four-valve common increasing public awareness of the need US market. “OEMs and Tier 1s are rail engine.” to reduce consumption of fossil fuels extremely busy in Germany,” says There is similar interest in Russia is driving people towards fuel-efficient director of light duty diesel, Frederic and China, says Penny, particularly in vehicles and generating more interest Bar, “and the US market is one of the the light truck sector. Particular interest in diesel.” reasons for this. The time to market is centres on two- to three-litre engines Penny also believes the depression shrinking and manufacturers no longer for pickups and small vans. Acceptance in the US car market should encourage have three to four years to develop new has also been high for diesels launched new diesel development rather than technology. The regulations are getting into the Australian market. hinder it. “You can’t cut costs and much tougher, specifications are On-highway heavy duty diesels survive. You have to invest your way out becoming much higher and available are following a similar trend to light of the problem with the right product, development time is getting shorter. duty. “In Europe there’s a drive for and the market for the low emission, Manufacturers do not have the resource emissions reduction and efficiency high fuel economy diesel is growing.” to keep up the pace, so they’re turning improvement in heavy duty with EU6,” to Ricardo for more help.” Penny continues, “and it’s much the Cost-effective option For the major players, the focus is same in North America with the US John Pinson, vice president of now almost entirely on the future. 2010 regulations on the way. There’s diesel engines at the Ricardo Detroit “Nobody is concerned about EU5 strong growth in Russia and China, Technology Campus, is keeping a any more – that work is finished. The with both markets moving towards EU watching brief on the US diesel market. biggest area of interest lies in what emissions standards and making large “We’ve seen a shift from relative follows that - the US regulations. investments.”

Q4, 2008 • RICARDO QUARTERLY REVIEW 19 Diesel rules

Off-highway is booming too 2004, extending to 2009. Within Tier 2 The Ricardo ECO-SPORT Running parallel to that, the off-highway there were originally 11 subsets called segment is booming too: diesels for Bins, with 1 representing the lowest In a parallel research programme construction equipment, agricultural (zero) emissions and the most polluting to its NZED engine initiative, and marine use all now need to fall being 11. The number of Bins has Ricardo produced a highly into line under fast-developing global subsequently been reduced to nine, convincing demonstration that emissions standards. “Despite the which still covers a wide range. using the latest available diesel recent downturn”, continues Penny, the Nevertheless, Penny and his team technologies it is possible to economy of emerging markets remains wanted to go further than just meeting create a performance diesel car a big-driver for that sort of equipment,” this most daunting of all US emissions with dramatically reduced CO2 says Penny. standards. They wanted to deliver emissions. Again, the Russian off-highway an engine with strong performance The Ricardo ECO-SPORT was market is growing with demand for and low fuel consumption as well based on a 1.9 litre, 150PS engine both upgrades and new engines. “That addressing the crucial CO2 issue – in taken from an Opel Vectra saloon particular off-highway market is seeing other words, truly an engine that can installed into a Speedster sports more growth than on-highway,” adds claim to be all things to all men. car. With modified pistons, Penny. “The growth of the economy Last year Ricardo showed a diesel upgraded fuel injectors and a is reflected in the increase in demand capable of meeting Tier 2 Bin 5, DPF, the engine was recalibrated for more construction equipment reflecting the US Federal fleet average. to allow for the much lower such as bulldozers, dumper trucks and Now, the project is being taken a step vehicle weight and performance diggers. Raw materials are in remote further to achieve Tier 2 Bin 2, just requirement. areas so there’s an increase in demand one stage above zero emissions and The ECO-SPORT provided for shipping and large marine diesel equivalent to California’s draconian impressive performance with engines and in fact this market is sold SULEV (super ultra low emission a 0-60mph acceleration time of out for several years.” vehicle) standard. less than seven seconds, and by Ricardo has strengthened its global The result was that Ricardo embarked implementing active control of presence to cope with the demand upon a new diesel engine project intake acoustics Ricardo was also and has technical centres in the UK, which is known internally as the “Near able to provide a sporty sound US, Germany, the Czech Republic and Zero Emission Diesel” (NZED). Brian quality to match this performance. China. Cooper, chief engineer of the NZED At the same time the demonstrator says: “Up until now, everybody in the delivered a mere 118g/km CO2 California – toughest of all industry believed achieving engine-out emissions, a full 42 per cent less But by far the toughest nut to emissions levels this low in a diesel was than the equivalent gasoline crack remains the region where impossible. Many of our customers are product. regulations are traditionally the most surprised that we are undertaking such Compliant with 2014 European demanding. California has severe air an ambitious research programme.” emissions regulations, the ECO- quality problems in the Los Angeles However, the company already has SPORT project was instrumental Metropolitan area which have earned prototypes of just such an engine in raising the profile of this form it the permission of the Federal installed in a donor D-segment car. of clean diesel application. Since Authorities to set its own emissions its completion many products standards. A revolution in diesel design? have been announced in this new California emissions regulations “There are three areas you can address market sector for diesel. are the most stringent in the world, to reduce diesel emissions,” explains and other US States have the option Matt Beasley, project director of of adopting them, or conforming diesel engines at Ricardo’s Shoreham to the Federal standards. The Technical Centre. The first is to improve current Federal standard the combustion system using the is known as Tier 2 very latest fuel injection technology. and took effect in The second is to use high-efficiency aftertreatment, and the third is to improve the air and EGR system.” The team decided to concentrate on the third option and, remarkably, the two-litre diesel engine has a virtually standard common-rail injection system. “We’ve not really done anything to the fuel system,” says Beasley. “We want to see how big an improvement we can get from just improving the air system. Then, when third- and ECO-ECOSPORTSPORT fourth-generation fuel systems arrive, we expect to see even greater improvements.” Ricardo’s approach was to follow its ECOSPORT

20 RICARDO QUARTERLY REVIEW • Q4, 2008

ECOSPORT

ECOSPORT Needless to say, so much complexity “We believe diesel has a long required an integrated approach to the term future because we have control system, whose management strategy plays a key role in the success shown that it’s possible for it of the engine. “There are far more to meet any standard” levers on the air system than usual,” confirms Beasley, “instead of two Ian Penny, Ricardo we have six, and each one has to be in the right place for each operating condition.” Emphasising the global Requirements: both doors 700mmapproach w x 300mm h taken at Ricardo, the bonnet logo plus text and graphic above 700mm w x 500mm h

boot requirs R logoaftertreatment and Ne0N 300mm x 300mm work was carried out in the US using parts supplied by Ricardo GmbH.

Outlook Elements of the NZED engine will be

SIZE 380mm X 100mm in production as early as 2012 and, although meeting Tier 2 Bin 2 levels, NZED the most important point is being able Near Zero Emissions Diesel to meet probable Tier 3 in the middle of the next decade. Ricardo’s NZED demonstrator vehicle. With the engine By then, Tier 2 Bin 2 will have become developing 160 horsepower and 400 Nm torque, its emissions the new fleet average standard across are staggeringly low and the engine delivers a fuel economy the US. Considering just how low improvement of 5 to 10 per cent emissions will eventually have to fall, it becomes obvious that despite an ‘ACTION’ engine technology roadmap, and fuel economy, while also offering a apparently extreme specification for standing for Advanced Combustion product with performance that is fun to the new diesel, Ricardo can hardly be Technology for Improved engine Out drive. This gives far more value to the accused of over-reacting. NOx. The NZED engine has a two-stage customer than simply having them pay Ian Penny is succinct in his summing sequential turbocharger system using for emissions reduction by filling the up of the story so far. “We wanted to two variable geometry turbochargers tailpipe with even more precious metal. take emissions completely out of the (VGT) combined with an advanced Using this system we can easily achieve debate as far as acceptance of the EGR system. A smaller VGT turbo gives EU6 without using a lean NOx trap.” diesel engine is concerned”. good transient response, but to achieve Through its NZED research a high rated power output there is also NZED Combustion – Ricardo programme Penny’s team has a larger, low-pressure VGT turbo. Both plays it cool demonstrated a clear path to achieving the air and exhaust paths can bypass The combustion strategy – Highly conformity with near zero US emissions the smaller unit when necessary. Pre-mixed Cool Combustion, or regulations by cleaning up engine-out With this approach, it is possible to HPCC – combines improved air/fuel emissions to unprecedented levels. At achieve much higher levels of EGR, mixing strategies with ultra-high EGR the same time the team has delivered while still maintaining lean combustion. delivery in order to reduce NOx. EGR an engine with an improved torque As a result, the engine develops 160 coolers, super-cooled using an external characteristic which further improves horsepower and 400 Nm torque, yet water coolant circuit, ensure a dense the diesel driving experience and has – produces staggeringly low emissions: low-temperature charge enters the crucially – a significant additional fuel engine-out NOx levels are 90 per cylinders. This cooling also makes it economy benefit. cent lower than the EU4 base engine. possible to achieve HPCC across a Together with next-generation fuel Moreover, the engine delivers a fuel much wider operating range. As ever, injection and aftertreatment systems, economy improvement of 5 to 10 per Ricardo software played a major part the technologies demonstrated cent, countering the received wisdom of in the development, a six-month WAVE offer a portfolio which, configured so many years that emissions reduction study being undertaken before the according to each individual product’s must be paid for in fuel efficiency. Using project started. This modelled the air requirements, is capable of delivering two VNT turbos does represent extra system and EGR, while VECTIS was the ultra-low emissions diesels cost, but the project is still at an early used to analyse combustion. demanded in the US in the decade stage. “The most important thing is to One approach investigated by ahead, as well as potential cost- understand what’s needed,” explains Ricardo comprised a mini diesel optimised CO2 reduction solutions for Beasley, “then we can modify the oxidation catalyst integrated into the EU6 and beyond in Europe. content. It may be, for example, that we exhaust manifold for ultra-fast light- As such, Penny is confident that end up with one variable and one fixed off, a main oxidation catalyst, and a his research team has demonstrated turbine.” combined lean NOx trap (LNT) and that there are no insurmountable “The other thing to remember,” diesel particulate filter (DPF) assembly. challenges for diesel in any part of the adds Cooper, “is that the technology Although that may sound like a positive world: “We believe diesel has a long we’re applying here provides a rare armoury of aftertreatment devices, the term future because we have shown example in which there is a genuine most significant gains are made at the that it’s possible for it to meet any synergy between emissions reduction engine-out stage. standard.”

Q4, 2008 • RICARDO QUARTERLY REVIEW 21 The Sir Harry Ricardo Centre for Innovation and Sustainable Transport

he Shoreham Technical Centre on the south coast of England T has been the home of Ricardo plc since 1919, when the original buildings were purpose built for the company – founded as Engine Patents Ltd just four years earlier in 1915. Yet this was not the first business connection that Harry (later Sir Harry) Ricardo had with the Shoreham area – in 1908 he collaborated as consulting engineer and designer with the Two Stroke Engine Company Ltd run by his cousin, Ralph Ricardo. In the hundred years that have followed, Ricardo plc has invested extensively both in facilities and in technological research. However, with the company’s more recent expansions in continental Europe, North America and Asia as well as elsewhere in the UK, there has been an emerging consensus that the Shoreham site too was in need of some significant investment. The resulting redevelopment emerged from an investment programme amounting to £6.4 million over the past year, part of a rolling three-year programme of £30m invested globally by the company in its worldwide technical centres. This investment has not, however, been at the expense of technological research; in its most recent financial year Ricardo has also increased its annual spend on advanced technology research programmes by 13.5 per cent to a total of £10.1m. The investment at Shoreham has included a total of 1,700 square metres of new buildings, A century of including design and engineering offices and test facilities. In addition to a new visitor reception area, the Sir Harry Ricardo Innovation and innovation Sustainable Transport Centre building – opened by HRH The Duke of York – Formally opened by His Royal Highness provides a focus for the display and The Duke of York on 23 October 2008, the communication of the very latest Sir Harry Ricardo Centre for Innovation and technologies and innovations of Ricardo and its research and engineering Sustainable Transport underscores Ricardo’s partners around the world. commitment to investment in the next generation of clean, sustainable and high Innovation – improving the breed To coincide with the launch of the new performance transport and clean energy facilities, Ricardo hosted a celebratory technologies. Anthony Smith reports event for customers and investors. The event included keynote speeches by Jan-Peter Onstwedder, project director, The London Accord, on the challenge of global climate change and investing for sustainability, and by Fumio Akikawa, head of product engineering for Mitsubishi Fuso, on the challenges facing the industry and near- to long- term approaches to sustainability. Visitors were provided with a comprehensive tour of the Shoreham

22 RICARDO QUARTERLY REVIEW • Q4, 2008 Sir Harry Ricardo Innovation & Sustainable Transport Centre at the Ricardo Shoreham Technical Centre

Technical Centre, with exhibits “Ricardo is just one Further exhibits and displays illustrating some of Ricardo’s latest focused on Ricardo’s expertise in areas research achievements. These included example of where including second-generation biofuels a demonstrator engine highlighting the UK has what I and clean energy projects, where Ricardo’s ‘Near Zero Emissions Diesel’ the company’s skills are increasingly (NZED) technology and Chery A5 would describe as in demand. Displays included work hybrid vehicles (described in the main global leadership” carried out for General Compression feature of this issue of RQ). HRH The Duke of York of the US on its ‘Dispatchable Wind’ Other displays included the energy concept and by Open Hydro of Ricardo ‘Drivewise’ vehicle, which power units – the world’s highest Europe on its tidal power generation demonstrates the company’s Torque specific power automotive diesel technology. Vectoring and steer-by-wire technology. engines – incorporate a Ricardo two- On opening the new facility HRH The This advanced chassis control system stage turbocharged low-compression Duke of York praised the company’s – which includes a mechanical back-up combustion and air management focus on technological development but steers fully electronically in normal system very similar to that of the and innovation: “Ricardo is just circumstances – provides considerable NZED engine. Similarly, the company’s one example of where the UK has safety enhancements in terms of experience in hybrid electric vehicles what I would describe as global improved handling performance, is now being used to great effect in leadership. It is through companies enabling the vehicle to execute helping leading Formula One teams and organisations like this that we can manoeuvres in the most challenging to develop Kinetic Energy Recovery maintain that edge – and that means of driving conditions. The two parts of Systems (KERS), as well as in advising that we can compete on the world the system operate in a fully integrated the sport’s governing body on future stage in terms of technology and manner such that the required regulations aimed at promoting energy manufacturing.” instantaneous yaw motion can be efficiency. Summarising the importance of the blended by both sub-systems – each of Ricardo’s long-standing leadership company’s commitment to investing which is, if necessary, also able to cover in the development of advanced diesel in world-class infrastructure and the for faults detected in the other. hybrids was also underscored with development of new technologies the display of some of its extremely and innovations, Ricardo CEO Dave High performance, high economy thought-provoking demonstrator Shemmans added: “Ricardo has from Some extremely high performance vehicles such as the i-MoGen mild its foundation been committed to the products were also on display, many of hybrid (2002), the HyTrans micro-hybrid development of new technologies which emphasised the strong synergies van (2004), and the 99 g/km Efficient-C and innovations powering all forms between Ricardo’s efforts to deliver vehicle (2006). This Citroën Berlingo- of transportation, and has been at the environmentally friendly vehicles for based demonstrator outperformed its very forefront of efforts to improve road use while also serving the needs of baseline counterpart while delivering fuel efficiency and reduce harmful performance products and the highest a 30 per cent improvement in fuel emissions. levels of competitive motor sport. economy. The effective targeting “The investments that the company These included a Bugatti Veyron, and successful execution of research has made both here at the Shoreham with its award-winning Ricardo seven- projects such as these has resulted in Technical Centre as well as at many speed dual clutch transmission, and the Ricardo becoming one of the world’s sites around the world, have enabled current international world diesel land most respected authorities on vehicle us to stay at the leading edge of speed record holding vehicle, the JCB electrification, with well in excess of a technology and help our customers and Dieselmax, powered by its Ricardo- hundred hybrid electric vehicle projects partners move towards a sustainable – developed engines. These impressive completed since 2000. and profitable – future.”

Q4, 2008 • RICARDO QUARTERLY REVIEW 23 Ricardo News

Fuel efficient defence icardo Inc has been awarded suspension Ra contract to optimise the fuel systems, body economy and performance of configurations future military ground vehicles. The and other vehicle project is part of the Fuel Efficient systems. TVFE ground vehicle Demonstrator (FED) focuses on programme launched by TARDEC, the integrating all US Army’s Tank Automotive Research, vehicle systems Development and Engineering Center to optimise fuel in Warren, Michigan. economy and The goal of the FED programme is performance. Ricardo to develop and define military vehicle expects to deliver the technologies that will reduce fuel first set of proposed consumption on the battlefield and vehicle configurations reduce the military’s dependence on oil. within nine months. The programme ultimately will result in “The FED project builds on Navistar a Humvee-size demonstration vehicle Defense’s Future Tactical Truck System that achieves significantly greater fuel (FTTS) demonstrator, a diesel-electric economy while maintaining tactical hybrid vehicle that was designed and of what TVFE predicted.” capability and performance. built for the Army using commercially The FED project will draw For the first phase of the project, available technology,“ explains Lou on Ricardo’s full range of Ricardo will apply its TVFETM modelling Infante, Ricardo, Inc. product group systems-engineering expertise, and simulation capabilities to director for vehicle engineering. “For encompassing compression- predict the performance of various the FTTS project, we used TVFE to ignition and hybrid propulsion, combinations of current and emerging select, integrate and optimise all the transmission and driveline technologies for the entire vehicle. vehicle systems, and when we built and systems, controls and electronics, These include conventional and tested the prototype, the fuel economy thermal management, suspension and hybrid drive systems, transmissions, improvement was within three per cent structures. Massive expansion in China icardo has announced a the establishment of a satellite test- Rsubstantial, two-phase based operation within the expanding development of its Shanghai- Anting ‘Auto City’ area to the west of based operations, underscoring the Shanghai. This area is already home company’s commitment to the fast- to significant automotive operations expanding Chinese automotive market. including the technical headquarters The first phase – completed with of Shanghai Automotive Industry the move to a new technical centre Corporation (SAIC) and the SAIC-VW – includes a tripling of the existing assembly plant. working area, with space for a staff of “With the two phases of expansion approximately 100 employees. currently taking place, Ricardo China This significant milestone in the is being transformed into a significant development of Ricardo’s Shanghai- regional product engineering and based operations will enable the development presence, capable new technical centre to focus on the of taking on the toughest product provision of high added-value services development challenges and delivering and projects for both Chinese and high quality services for its Chinese overseas clients, with approximately customers,” said Lee Sykes, executive 90 per cent of the team fulfilling vice president of Ricardo China. technical and engineering roles. The “These developments take Ricardo new Ricardo Shanghai technical centre beyond the level of an overseas is based in a central location, close to engineering provider,” added Sykes, the futuristic and highly prestigious “giving the company crucial critical Hi-Tech Park development at Caohejing mass as a local supplier of engineering – a convenient location for many of services in the Chinese market, with Ricardo’s customers and advanced the backup of the global resources of technology component and system Ricardo. As such we will be far better suppliers. placed to achieve our objectives for The second phase of development locally-based engineering recruitment – expected to be completed towards and further development of our the end of the year 2008 – envisages Chinese business.”

24 RICARDO QUARTERLY REVIEW • Q4, 2008 Ricardo helps leading Indian Tier 1 develop R&D capability Navistar Defense’s Future harda Motor Industries – a major years. These will include, for example, Tactical Truck System (FTTS) Sfirst-tier supplier to the Indian projections of the technology road demonstrator, developed automotive industry – has turned to maps of Sharda’s customer base with Ricardo. Ricardo for assistance in defining and estimations of the emerging and implementing an independent, engineering requirements likely to self-sustaining and state-of-the-art arise from this in terms of required product development capability. future product portfolios. Detailed Sharda, whose impressive organisational development and customer base includes both implementation plans will be indigenous automakers and the prepared for Sharda, which will regional operations of overseas focus on delivering the desired future manufacturers, has chosen to work product development capability with Ricardo to develop its research within a clearly defined time period and development strategy in support and against measurable outcomes. of Sharda’s growth objectives. The Sharda and Ricardo are planning programme of work, to be led by to collaborate in implementing Ricardo’s strategic consulting and the strategy. This will include Indian divisions, will address key comprehensive technology transfer levers for the development of a and engineering & testing support future independent state-of-the-art by Ricardo in the interim period until product development capability for Sharda has fully built up its research Sharda, including product strategy, and development capabilities. product development processes, Furthermore, in order to support infrastructure requirements, Sharda’s ongoing product engineering development tools and facilities requirements, Ricardo is also and the skills and core competence providing advanced Computer Aided requirements of the company’s staff. Engineering services. This will ensure In evaluating Sharda’s future that the company has access to the product strategy in particular, the technology it requires to meet its Research link Ricardo team will carry out a rigorous immediate programme needs – as analysis of the markets in which the well as having the long term plans in strengthened company operates and the drivers place to support its future strategic likely to act upon them in the coming product development aspirations. icardo UK Ltd has announced Rthat Mogan Heikal of the University of Brighton will become New MD for Ricardo the university’s Ricardo Professor of Automotive Engineering. The funding provided by Ricardo Strategic Consulting for the post stewardship of some key accounts. represents a three- Parker remains Chair of the RSC year extension to the advisory board and a board member company’s research of Ricardo plc. In parallel with this contract with the change Markus Doerr has assumed university and is the full responsibility for RSC as managing latest development director of this division of Ricardo plc. in the successful Doerr has been with Ricardo for industry-university five years, most recently as European partnership, which was established Steve Parker Markus Doerr managing director of RSC. He brings some 16 years ago. a wealth of expertise gained through Professor Andrew Lloyd, the n order for the Ricardo group to deep client engagements and Dean of the Faculty of Science and Iaccelerate the growth of the Ricardo interdivisional collaboration. Before Engineering at Brighton University, Strategic Consulting (RSC) division’s joining Ricardo, Doerr held positions said: “The sponsorship of Professor concept of deep content consultancy, with AT Kearney’s global automotive Heikal’s professorial chair marks Steve Parker has taken on a group- practice and Roland Berger Strategy the latest development in this long wide role to develop opportunities for Consultants; he also had industry and highly successful collaboration increased collaboration between the experience with Ford of Europe. Doerr’s with Ricardo. Support of this nature technical and strategic consultancy professional qualifications include a ensures our ability to attract and operations of the company. These combined master’s degree in business retain the very best academic talent include driving development and administration and mechanical to further our collaborative research implementation of Ricardo’s new engineering awarded by the Technical with industrial partners.” energy strategy and also enhancing University of Darmstadt.

Q4, 2008 • RICARDO QUARTERLY REVIEW 25 Capiton...

Ricardo News

Wave goes Real Time RT thus enables validation of strategies speeding up the process of global to perform close control of engine engine development.” performance during transients, and In its first release WAVE-RT will the accuracy of its airflow simulation support both gasoline and diesel allows development of concepts such engines, with turbochargers, as variable valve timing and lift control – intercoolers, and EGR circuits. It will be including more unusual examples such supported on numerous commercial as negative overlap for controlled auto- HiL systems from well-known vendors ignition or for camless engine control. such as ETAS, The MathWorks, and The fact that individual cylinders are Concurrent, and Ricardo Software aims separately represented also enables the to work with other HiL vendors in the development and validation of complex future to ensure support for additional control strategies such as closed-loop platforms. combustion control, fully accounting for variations between cylinders t the Ricardo Software European arising from the different air paths and A Users’ Conference held in Prague hence key associated variables such on November 18, WAVE-RT was as air mass and residuals or exhaust launched. The first real-time version temperature. of Ricardo’s leading WAVE engine “WAVE-RT is a major step forward simulation product, the new software for engine design,” explains Steve package is specifically designed to Sapsford, president of Ricardo enable highly accurate real-time Software. “It opens new avenues for simulation to become an embedded simulation-driven refinement and part of the engine management system optimisation of powertrain products development process. for the ultra-low emissions and fuel With wave propagation effects fully economy challenges of tomorrow. captured, the transient response of the The CAE process benefits are also model is much closer to that of the real extremely compelling, enabling much engine than would be the case with closer integration of activity between mean-value engine models typically powertrain and control engineers, used to date for this application. WAVE- holding the prospect of significantly Software for improved vehicle safety further new software package has been launched analysis through a model-based design approach A by the Ricardo Control & Electronics product that integrates tools for safety analysis and functional group. AutoFMEATM (Failure Mode Effects Analysis) is design, enabling engineers to incorporate safety and an engineering analysis tool designed to help ensure reliability during the specification and early design the safety and reliability of increasingly complex stages. The system performs a safety analysis at automotive systems and controls. each stage of the design cycle and verifies that safety Until now, safety and reliability analysis has largely functions operate properly. been an expensive and time-consuming manual AutoFMEATM is a powerful add-on to widely used process. Lengthy reviews were required at each MATLAB® Simulink®. It facilitates safety analysis design stage to reduce errors to an acceptable level. within the same environment used for design Propagating the safety analysis from stage to stage engineering. It can be applied to any system that can was difficult, requiring significant work to update the be modelled with Simulink. AutoFMEATM uses Markov manual safety analysis when changes occur. analysis to determine the probability of defined AutoFMEATM automates safety and reliability hazards occurring, based on user-defined failure rates.

26 RICARDO QUARTERLY REVIEW • Q4, 2008 Under the Patronage of H.H. General Sheikh Mohammed bin Zayed Al Nahyan Presented by Crown Prince of Abu Dhabi and Deputy Supreme Commander of the UAE Armed Forces Abu Dhabi, 19-21 January 2009 Abu Dhabi, 19-21 January 2009 www.WorldFutureEnergySummit.com www.WorldFutureEnergySummit.com

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4QFDJBMBVUPNPUJWFTFTTJPO r Dave Shemmans, CEO, Ricardo r Nobutaka Morimitsu, Project General Manager - BR Energy A airs Department, Toyota Motor Corporation r Jan-Olaf Willums, Think r John W Mogge Jr. Ph.D., A.I.A.,Senior Vice President, CH2M HILL r Dr. Antonia Terzi, Delft University of Technology

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Wind turbines Transferring expertise derived from Marine / tidal power generators Compressed air energy storage systems the automotive sector Flywheel energy storage systems Domestic CHP systems Ricardo’s rigorous approach to product development is already Fuel cells & hydrogen infrastructure nding applications in the clean energy sector. Batteries & electric inverters We are also undertaking projects with government agencies, Hybrid-systems for vehicles investors, utilities and energy companies. Application of bio-fuels Solar thermal electricity generation t Technical due diligence t Quality improvement, cost Contact t Technology roadmaps reduction, FMEA & design for Ricardo plc manufacture UK: Giles Hundleby t Product development planning +44 (0)1273 794328 t Design, design analysis, t Supply-chain organisation US: Pete Brown +1 734 3943750 prototyping t Validation & launch DE: Peter Feulner t Niche volume manufacturing +49 (0)7171 9821313 t Development testing Email: [email protected] & eld trialling

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