RicardoFeature heading Quarterly Review Q4 2015

Interview: John Fuerst Delphi’s vice president of powertrain engineering Real driving A focus on the latest in technology, innovation and sustainability emissions How on-road measurement can bring credibility to official emissions certification Global challenge Ricardo celebrates 100 years with an ambitious round-the-world relay

Easy Riders The cruiser motorcycle phenomenon has always been hard for non-US bike manufacturers to crack. Ricardo Motorcycle gives crucial insights into what makes a cruiser irresistible to the American enthusiast Ricardo continues to push the boundaries of cost- effective hybridization and vehicle electrification

Ricardo is a leading force in hybrid system design, powertrain engineering and vehicle electronics • Reduced component costs With a broad spectrum of capabilities, a 2700-strong global team of specialists and a rich history in the • High synergies in powertrain research and development of ground-breaking technologies, we are positioned perfectly to collaborate on e  c i e n c y the rst-time application of ‘intelligent electri cation’ in diesel vehicles. • Mild hybridization at 48V The Advanced Diesel Electric Powertrain (ADEPT) project is a six-partner venture, bringing together scienti c, engineering and vehicle technology expertise to develop next-generation technology for a low-cost, low- • Reduced design complexities carbon diesel-electric hybrid passenger car, without compromising performance or driveability. • Cost-reducing advanced lead- Through extensive experience of hybrid systems and joined-up knowledge across engines, transmissions, carbon battery technology power electronics and e-machines, batteries and controls, we deliver on our promise to develop truly • Environmentally friendlier integrated vehicle solutions for our clients. switched reluctance motor- generator technology Find out more about ADEPT www.ricardo.com/adept Email: [email protected] Tel: +44 (0)1223 223200

Delivering Excellence Through Innovation & Technology www.ricardo.com 16

Contents Ricardo Quarterly Review.Review •Qx Q4 2011 2015

News Features Industry news...... 04 Easyxxxxxxxxx riders...... 10 Autumn motor shows with mixed Cruiser motorcycles are an American messages; concentrated solar fires up; xxxxxxxxxphenomenon that foreign...... manufacturersxx 08 xxxxxxxx future eco strategies outlined; autonomous don’t always understand. Ricardo driving gathers pace; smart lights for clever Motorcycle specialists explain to Jesse cities Crossexxxxxxxxx how to make a cruiser bike that’s xxxxxxxxxirresistible to US riders...... xx RQ viewpoint: xxxxxxxxx Chris Dodwell...... 07 Real driving Ricardo Energy & Environment’s emissionsxxxxxxxxx ...... 16 international director on the COP21 talks With exhaust pollutants now front-page in Paris and the need to put the promises news,xxxxxxx Anthony...... Smith reports on Ricardo’sxx xxxxxxxxxxx into practice ongoing projects for evaluating actual on- the-road emissions to ensure compliance with upcoming European RDE testing Ricardo news...... 28 regulations Ricardo helps FTS fast charge; JAC and Ricardo develop HyBoost for production; 22 helping Heathrow monitor black carbon; Round the world Ricardo continues to push the boundaries of cost- Network Rail approves Ricardo pantograph monitoring in 100 years...... 22 The Ricardo 100 Global Challenge celebrates the company’s centenary by linking all its effective hybridization and vehicle electrification worldwide locations in a global relay involving q & a Ricardo staff and Ricardo-developed Ricardo is a leading force in hybrid system design, powertrain engineering and vehicle electronics • Reduced component costs John Fuerst...... 08 vehicles. Tony Lewin hears the full story Delphi’s Vice President, Engineering Power With a broad spectrum of capabilities, a 2700-strong global team of specialists and a rich history in the • High synergies in powertrain Systems, gives Tony Lewin his take on the research and development of ground-breaking technologies, we are positioned perfectly to collaborate on e  c i e n c y future of engine control strategies, emissions the rst-time application of ‘intelligent electri cation’ in diesel vehicles. • Mild hybridization at 48V and electrification The Advanced Diesel Electric Powertrain (ADEPT) project is a six-partner venture, bringing together scienti c, engineering and vehicle technology expertise to develop next-generation technology for a low-cost, low- • Reduced design complexities carbon diesel-electric hybrid passenger car, without compromising performance or driveability. • Cost-reducing advanced lead- carbon battery technology Ricardo contacts and locations: The task of RQ is to highlight Client confidentiality is of the utmost importance Through extensive experience of hybrid systems and joined-up knowledge across engines, transmissions, www.ricardo.com/contacts the latest thinking in global to Ricardo, which means that we can only report power electronics and e-machines, batteries and controls, we deliver on our promise to develop truly • Environmentally friendlier RQ subscriptions: engineering and technology in the on a small fraction of the work carried out by the www.ricardo.com/rq integrated vehicle solutions for our clients. switched reluctance motor- transportation and clean energy company. So we are especially grateful to those Sales enquiries: sectors and related industries. Ricardo customers who have kindly agreed to [email protected] generator technology We aim to achieve this by presenting an up-to- co-operate with RQ and allow their programmes Head office: date mix of news, profiles and interviews with top to be highlighted in print: without such help from Ricardo plc, Shoreham-by-Sea, Conceived and produced Find out more about ADEPT West Sussex, BN43 5FG, for Ricardo by: business leaders, as well as in-depth features on customers it would not be possible to present such United Kingdom TwoTone Media Ltd programmes – both from within Ricardo and other a fascinating insight into the development of new Tel: +44 (0)1273 455611 Editor: Tony Lewin leading companies. products, technologies and innovations. www.ricardo.com/adept Contributors: Anthony Smith, Jesse Crosse RQ magazine is printed on paper TwoTone Media Ltd contacts: certified as being in compliance with the environmental and Anthony Smith: social standards of the Forest Email: [email protected] Tel: +44 (0)1223 223200 [email protected] Stewardship Council. Tony Lewin: [email protected] Delivering Excellence Through Innovation & Technology www.ricardo.com Industry News

Industry news The latest in technology, innovation and sustainability across world industries Mixed messages from Tokyo and LA

In the lull between September’s electric- displays and even movies across the intense Frankfurt show and next whole of its interior, even the seats. January’s Detroit, where a comeback Mercedes took the autonomous of heavy metal is expected, Tokyo and connectivity theme a big step further Los Angeles could only deliver mixed with its Vision Tokyo concept, and messages. Concrete engineering many producers boasted of significant innovation was thin on the ground in progress on the road to driverless Tokyo – instead, Japanese automakers’ travel. Significant, too, was Nissan’s IDS efforts revolved around leisure-friendly concept as the likely forerunner of the concepts such as the Nissan Teatro for next-generation Leaf EV. Dayz and tantalizing baby sports cars Across the Pacific, LA’s sunshine like the Toyota SFR and Yamaha’s Sports flushed out a rash of convertibles – the Mazda RX-Vision, Yamaha Sports Ride Ride concept, the latter using Gordon Range Rover Evoque, Mercedes SL, Mini Mazda continued to keep the rotary flame burning with its sinuous RX-Vision coupé (top) which is modelled around a front-mounted rotary engine of Murray’s innovative iStream structure. Cooper and the Fiat 124 Spider (now a unspecified capacity and design. Yet, says Mazda, the new unit will meet As its name suggests, Nissan’s Teatro clone of the Mazda MX-5) were the main current CO2 and emissions standards; further details are expected to follow. for Dayz is less a mode of transport, examples. But again, no clear technical Yamaha’s pint-sized Sports Ride concept (above) incorporates Gordon more a mobile entertainment module trend was discernible – in contrast to Murray’s latest iStream Carbon construction for a claimed kerb weight of for four people; particularly striking is 2015, when hydrogen fuel cell power under 750 kg, though the intended engine type was not specified. Two years ago Murray and Yamaha co-operated on the Motiv city hatchback. its ability to project colours, patterns, was the big talking point. Reversed heading... Citroën: clever suspension is backxxxxxxxxxxxxx

French automaker Citroën is to return to its roots as a provider in partnership with a French supplier and that it would remain of innovative, comfort-enhancing suspension systems. Next exclusive to Citroën to provide the pillowy ride associated with year will see the launch of an exclusive new type of suspension classic models of the marque. suitable for all upcoming models in the company’s portfolio, said Between now and 2020 Citroën will launch seven different CEO Linda Jackson. ‘silhouettes’ of models spanning the market from the A segment Speaking to correspondents in London, Jackson declined to to the C-D class, said Jackson, with models being developed for give technical details but said the new set-up had been developed worldwide rather than regional application.

4 RQ • Q4 • 2015 Industry News

Large-scale solar fired up News In brief parabolic mirrors track the sun to focus Highlighting the latest thinking in automotive reflected heat on a steel manifold carrying engineering and technology worldwide the Dowtherm A fluid, boosting it to 393 Picture: SENER Celsius; this heat can then be stored in InbriefCitroën subheading.... commits to on-road emissions the form of molten salt for later use in the xxxxxxxxxxPSA volume brand Citroën has become the first major turbines which convert it into electricity. carmaker to commit to independent testing of its models The opening of Noor comes against Inbriefand the publication subheading.... of real on-the-road driving emissions the backdrop of the UK Met Office Hadley (RDE).xxxxxxxxxx Working with Brussels-based NGO Transport Centre’s confirmation that human- & Environment, Citroën will publish real-world fuel Morocco has entered the solar super induced global warming has already Inbriefconsumption subheading.... figures from spring 2016 and begin to include league with the opening of the Noor 1 passed the 1 degree mark, and the NOxxxxxxxxxxx emission values from 2017 when Euro 6.2 comes in. concentrated solar power (CSP) plant near International Energy Agency’s assertion Ouarzazate. When all four phases of the that, despite the massive oil glut between InbriefNCAP to subheading.... test emergency braking plant are complete it will, at 580 MW, be the now and 2020, solar will be the world’s xxxxxxxxxxFrom early 2016 Euro NCAP will begin to include results largest CSP plant in the world. Crucially, by fastest growing energy source. of automatic emergency braking (AEB) tests in its vehicle employing a heat transfer solution it is able Solar and renewable start-ups around Inbriefsafety scores. subheading.... These new tests are the first in the world to store the energy it generates, enabling it the Mediterranean are benefiting toxxxxxxxxxx assess AEB and aim to distinguish between systems to power cities at night, too. The later Noor from the European Union’s SwitchMed that can help prevent car-to-car collisions and more 2 and 3 plants, set to open in 2017, will store programme, which aims to link and Inbriefsophisticated subheading.... setups also able to detect pedestrians. the heat energy for eight hours to allow full scale up the ideas of individual local Independentxxxxxxxxxx analysis of real world crash data in the UK 24/7 power supply. entrepreneurs, mainly in North Africa and and Germany indicates that the fitment of effective AEB Noor 1’s 500,000 twelve-metre high along the Middle Eastern coast. systems on passenger cars could prevent one in five fatal pedestrian collisions, says Euro NCAP. Castrol’s 90-second oil service Electrified performance Modestly billing its new system as the most significant oil BMW’s 199 hp S1000RR is highly respected as one of the fastest conventional change innovation in automotive history, Castrol claims superbikes on the planet. Nevertheless, BMW Motorrad head Stephan Schaller its Nexcel oil cell will allow both engine oil and filter to be was irked by just one point: the company’s modest C Evolution electric scooter changed, cleanly, in just 90 seconds. The Nexcel module could accelerate more quickly to 50 or 60 km/h. is the size of a car battery but can be made in different Schaller’s answer is the eRR shapes to suit underbonnet packaging requirements; it concept, presented at the EICMA contains both oil and filter, with the correct quantity of oil motorcycle show in Milan in being delivered to the sump during each change. When November. The chassis remains the next change is due, the oil is pumped back up and the that of the S1000RR, but the module, complete with filter, is sealed and sent off for gasoline powertrain is replaced re-refinement. by batteries and an electric motor. BMW is not saying any Mercedes finally opts for CO2 air conditioning more than that, but promises Following years of debate with the European authorities, to release full technical Daimler has announced that from 2017 its S- and E-Class details in the near future. models will be equipped with air conditioning systems using CO2 as a refrigerant. CO2 requires a pressure of 100 bar – ten times more than the current R134a, which will be excluded by a 2017 EU directive as above the new 150 GWP limit. Daimler earlier criticised the only other alternative refrigerant, R1234yf, after it failed Battery power raises its game flammability requirements in crash tests, deciding to The falling cost of batteries is making where they will be competitive against implement special inert gas protective systems in current them an increasingly viable solution for conventional back-up power generation. vehicle lines. balancing energy grids, according to a Tesla is already in the domestic new report from Lazard. This reduced energy storage market with its Centre airbag protects in side impacts cost will in its turn boost the take-up of Powerwall system, and in Germany ZF, which took over US-based safety equipment supplier intermittent renewable energy sources several companies including Daimler, TRW earlier this year, has developed a centre airbag to such as solar and wind, says the Levelized Sonnenbatterie and IBC Solar sell aid compliance with future side impact requirements, Cost of Storage Analysis. systems to service the country’s including upcoming protocols from Euro NCAP. Deploying This complex analysis, which also extensive microgeneration network. from the centre of the dashboard, the new airbag helps includes storage media such as Daimler is also a partner in the keep the driver in place when the impact is on his or her compressed air, flywheels, pumped hydro world’s largest second-use battery far side, and also reduces the risk of the driver hitting any and a variety of batteries, concludes that energy storage complex at Lünen, near front-seat passenger present. within five years the price of batteries Dortmund in Germany, initially using is likely to have fallen to the point batteries from the Smart microcar.

RQ • Q4 • 2015 5 Industry News

Future strategies unveiled

Environmental strategies announced recently by leading automakers give a clearer insight into the evolution of the car market over the next 10 to 35 years. Global number one, Toyota, declared a target of cutting vehicle emissions by 90 percent by 2050, which amounts to a virtual elimination of the internal combustion engine; the giant also said it would be selling 1.5 million hybrids and PHEVs by 2020, but made no mention of pure-battery EVs. Audi America president Scott Keogh declared that one quarter of annual Audi sales would be electric by 2025 – amounting to half a million vehicles – and GM North America for the new, fourth generation Toyota Prius (above). The 1.8 president Mark Reuss stressed the corporation’s “deep litre gasoline engine now boasts over 40 percent efficiency, a commitment” to EVs and the launch of the 320-km range Bolt dual cooling system speeds engine and cabin warm-up, and EV. Honda has promised a volume production PHEV spin-off mechanical losses in the transaxle and motor arrangement of its new Clarity fuel cell by 2018, and has committed to a are 20 percent lower – as are the electrical losses in the power “Green Path” programme to halve GHG emissions by 2050. control unit. While the standard battery is still NiMH, other More bullishly, Geely – which owns Volvo as well as the chemistries are expected to be offered later. London Taxi Company – says fully 90 percent of its production The outcome is an improvement in fuel efficiency and CO2 will be hybrids, PHEVs (at “standard prices”) and EVs by 2020, emissions to 70 g/km, the biggest single jump in the model’s and prominent start-ups such as Taiwan’s Thunder Power 17-year history. and the mysterious Faraday, promising seven model ranges, threaten to amplify Tesla’s disruption of the industry’s old EV Sales Forecast business order. 3.500 A study by Jato Dynamics confirms the trend, forecasting China 2.9m 5.5 million EV sales annually by 2025, of which the big winners 3.000 will be PHEVs at 3.3 m units. In addition, a two-year study 2.500 Europe 1.7m by the Union of Concerned Scientists in the US looked at the 1.500 Nissan Leaf and Tesla Model S and established that EVs emit 1.000 half of the lifecycle GHGs of gasoline cars over a 15-year, USA 805k

220,000 km service life, though their higher manufacturing 500 Japan 86k Korea 35k emissions mean they are actually less clean for the first six to – India 19k 16 months. 2015 – YTD 2016 2019 2022 2025 Full technical specifications have at last been announced Expected EV sales volume in 2016, 2019, 2022, 2025. 2015-YTD actual. Source: LMC Automotive

Autonomous driving gathers pace Europe, to generally positive reviews, and truck market leader Daimler has conducted the first public trail of its Highway Pilot on the A8 Autobahn near Stuttgart. Fitted to a series-production Actros, the Highway Pilot allows the truck to be driven legally on motorways in automated mode. An array of sensors and safety systems continuously monitors all around the vehicle, allowing it to keep in its lane and maintain the optimum distance from the traffic in front; lane-keeping, acceleration and emergency braking are all automated. In the initial demonstration by Daimler Trucks head Wolfgang Bernhard, however, manual control was resumed during roadworks sections and after exiting the motorway. A ‘Future of Driving’ survey of 7000 users conducted by Volvo revealed that while 70 percent of people wish to preserve the ability to drive manually, a similar proportion believe that automated cars should be allowed to break the speed limit to match the pace of other traffic. Audi continues to concentrate on high-speed racetrack Truck and car makers are hurrying to provide the first user- autonomous driving, recording “record times” at a track near accessible autonomous driving features suitable for use on public Barcelona, while Nissan has begun on-road trials of its automated roads. Tesla, thanks to an over-the-air software update, has been Leaf, and a prototype Peugeot completed a 580 km round trip from able to introduce the capability to owners in North America and Paris to Bordeaux entirely without driver involvement.

6 RQ • Q4 • 2015 Industry News

Solar Challenge Viewpoint Team Eindhoven’s Stella Lux added a new dimension to From climate pledges to the bi-annual World Solar Challenge across Australia from Darwin to Adelaide. Carrying two people, it covered the a low-carbon future complete 3022 km course on purely solar energy in 39 hours, Chris Dodwell – Ricardo Energy & Environment’s international director scoring 6044 person-km in the process and taking victory in the Cruiser class. The Cruiser class has been introduced to bridge the gap As this issue of RQ goes to press, between high end technology and everyday driving practicality, the 21st Conference of the Parties “Ricardo will work and the resultant cars are distinctly different – the winning (COP21) to the United Nations Stella Lux is a luxury four seater family car with a roomy trunk Framework Convention on Climate to support countries’ and comprehensive connectivity features. The winner of the Change is drawing to a close in Paris. high-end Challenger class, also from the Netherlands, was the Countries from around the world efforts to turn their Nuon Solar team’s Nuna 8, which completed the course in just have made a collective commitment action plans into under 38 hours, averaging almost 92 km/h. to limit the increase in global temperatures to less than 2° Celsius real, quantifiable and have set out their own targets, policies and actions to achieve achievements” this, framed as Intended Nationally Determined Contributions (INDCs). and, ideally, supported by appropriate In the run-up to COP21 there legislation. On these foundations must be was much focus on whether the built long-term, cost-effective mitigation aggregate impact of these INDCs strategies to deliver greenhouse gas would be enough to meet the agreed (GHG) emissions reductions, through photo: TU Eindhoven, Bart van Overbeeke Bart van TU Eindhoven, photo: temperature limit. The verdict is that national and sector plans aligned with they are the necessary first step development priorities. but they will be insufficient on their The next requirement is integrated own without more ambitious action adaptation planning – building long-term both before and after 2020. COP21 resilience to the impacts of climate Smart lights for is nonetheless a very significant change. Supporting all this, climate agreement: it is the first time that finance frameworks must match support the global community has aimed to needs against funding streams, and intelligent cities implement a legally binding declaration include strategies for how to arrange As conventional streetlights are replaced by low-energy, high- of intent to transition to a low carbon timely and effective access to them. reliability LED illumination, a major infrastructure change is now economy. Last, and by no means least: effective under way. Yet the next step – shown by supplier Continental And having secured this landmark measurement, reporting and verification at the ITS World Congress in Bordeaux in October – promises agreement, delivery is vital – the failure systems are vital in order to track an even greater revolution and stands to benefit not only to achieve agreed national INDCs could implementation and apply lessons pedestrians, cyclists and conventional cars, but also autonomous be disastrous to the prospects of any learned, thereby enhancing analytical vehicles and emergency services. progress in dealing with the economic capacity and understanding about So-called intelligent street lights have the potential to and social challenges posed by climate which policies work best and why – and “massively improve road safety”, says Continental’s Alfred change. informing future policy and practice. Waldhaeusl: “The use of LEDs means that the electronics required So, how can countries ensure they Success in any international for control, diagnostics, and communication are already present can turn their COP21 commitments endeavour of the scope of COP21 is never in the street lights.” not only into action, but also into guaranteed, but we at Ricardo will work Sensors can identify whether parking spaces in the vicinity of achievement? to support countries’ efforts to turn the light are occupied, and this information can be sent directly or For more than 20 years, Ricardo their action plans into real, quantifiable via the cloud to drivers who are looking for a parking space nearby. Energy & Environment has been achievements by the systematic Moving objects can also be detected, allowing brightness to be supporting developed and developing application of the five key pillars of INDC adjusted for pedestrians, cyclists or motorized traffic; the light countries in the design and implementation – as outlined here and could even be switched off entirely. implementation of national climate further explained in our recent white policies. Over the last year we have paper. helped nations with a combined COP21 may be less than perfect, but population of more than 500 million it offers a clear, agreed way forward, and people prepare their INDCs. Based on the failure to seize the opportunities it this broad experience, we believe the offers – given what is at stake – cannot COP21 commitments can be achieved to be countenanced. Ricardo, as ever, if actions are taken forward across five stands ready to help. distinct, but intrinsically linked, pillars: Firstly, political will and effective To request a download of the Ricardo Energy & governance will be needed to maintain Environment white paper ‘Implementing the Paris Climate Agreement: Turning Action Plans into momentum and ensure accountability Achievement’, visit: http://ee.ricardo.com/cms/ – overseen by capable institutions action-plans-into-achievement-white-paper/

RQ • Q4 • 2015 7 Interview: John Fuerst

INterview Command and control John Fuerst is Vice President Engineering, Powertrain Systems, at leading supplier Delphi. Tony Lewin hears his take on the future of engine control strategies, fuel injection, exhaust aftertreatment and electrification

What is the future for diesel in the light vehicle sector? injection systems. We also use advanced controls to develop We believe diesel has a strong future in the light-duty vehicle new combustion strategies. These include a stoichiometric sector. It offers low fuel consumption and CO2, along with combustion mode in a diesel engine to enable NOx reduction excellent performance and driveability that many customers with three-way catalysis at medium and high loads. One last favour. Emissions legislation around the world is increasing in example is a low-temperature gasoline combustion strategy we stringency through tighter standards and through expanded are developing that we call Gasoline Direct-injection Compression test cycles to prove compliance over a broad range of operating Ignition (GDCI) that offers diesel-like thermal efficiency through conditions. While diesel is one prerequisite for meeting compression ignition of gasoline over the full speed-load range of ambitious CO2 emission targets, innovations in both gasoline the engine. and diesel powertrains will continue to improve efficiency and reduce emissions while providing the performance that What further parameters can be sensed and controlled? customers expect. The list will continue to grow, as you would expect for an industry like ours that is constantly innovating. For example, we have What potential is there in the electronics to add even more developed a simple single wire circuit that we build into our sophisticated control strategies (that don’t involve cheating)? diesel fuel injectors to precisely measure the injector opening Electronic controls are key in today’s powertrains, and we expect and closing events by determining when the needle touches the the sophistication and influence of controls will continue to grow. injector lift stop or seat. This offers closed-loop control of all To leverage the influence that controls have, our electronic and injection events, especially important as combustion schemes software engineers at Delphi work closely with the technical continue to implement more multiple injections. It also allows teams developing our components in order to create high compensation over injector lifetime, and allows for corrections to performance system solutions. As such, Delphi has developed account for part-to-part variation. a new approach to control. Delphi’s Model Based Controls use physics-based models to provide a much faster response than Is control for the diesel lean NOx trap significantly can be achieved with today’s ‘look up’ type control methods. simpler than for SCR or both together? Model Based Controls anticipate where the control requirement is Control schemes are available for all three options you mentioned. going, removing latency so the optimum setting can be achieved Control of a lean NOx Trap (LNT) is more complex to implement more quickly, significantly reducing transient emissions and as it requires specific engine operating modes for the NOx providing more responsive driving. Model Based Controls are very regeneration (to restore the storage capacity) and for the well suited for the requirements of Real Driving Emissions to be desulphation (to remove sulphur contamination on the LNT). In implemented in Europe in 2017. contrast, SCR system control does not directly affect engine Another example is a new approach to sensor architecture: control strategy. Urea dosing level is determined to provide the our closed-loop control strategies for precisely delivering appropriate reductant concentration for NOx conversion without multiple small fuel pulses from our gasoline and diesel fuel producing ammonia breakthrough caused by overdosing. System

8 RQ • Q4 • 2015 Interview: John Fuerst

modelling is an essential factor for SCR system control, and electrification for many years to come, so that internal Delphi offers a unique ammonia sensor that enables closed-loop combustion engines will still be very important. Hybrid control of urea dosing based on direct ammonia measurement. electrification provides an interesting technical solution that SCR has become somewhat more popular than LNT recently. complements engines nicely and can offer significant CO2/ Combining both together is an option available in order to fuel consumption benefits. And we expect innovations in the meet increasingly stringent standards for some larger engines hybridization/electrification space to continue. Cost remains an producing higher NOx. Of course, this is the most complex issue. The technologies will continue to be available worldwide. scheme in terms of both mechanization and control. Variations due to size and region will occur depending on the existing legislated CO2 value, and cost-benefit of implementing How do multi-turbo installations impact on the different levels of electrification in order to meet legislation and design of the electronics? customer demands and expectations. Controller speed, drive capability and computing power continue to grow so that there are no issues supporting multiple turbos, Autonomous driving: how much does this add to the electronics as well as innovations that continue to evolve in areas like fuel requirement in terms of processing power, memory and cost? delivery, EGR, valvetrain, etc. The average car today has more than 100 microprocessors, 50 electronic control units, five miles of wiring and 100 million lines Diesel and gasoline injector design: what are the potential of code (NHTSA). That’s more than a Boeing 787 or a fighter jet. benefits of pushing pressures still higher? Where are the limits Delphi alone ships more than 20 billion lines of code per day. These and the trade-offs? numbers are expected to increase significantly in the future as Engines continue to have an appetite for increased fuel pressure more and more technology is added to the vehicle. This exchange to enable efficient combustion with low emissions. Increasing of high-speed data across vehicle domains is driving fundamental overall system configuration complexity, for example through more shifts in architectures – for the first time in years. Delphi has sophisticated boost and EGR delivery continues to show benefit developed a solution to address this increased complexity – a from higher fuel pressure. Of course, pressure is only one aspect. multi-domain controller that can process massive amounts of Delivery of multiple, small injection pulses with high resolution and content at very high processing speeds. close spacing capability is also important, for example. Our automotive grade multi-domain architecture provides a flexible solution that allows automakers to select functionality You have shown Skip Fire on a four-cylinder engine: how far can and optimize the computing power requirements to fit their this be extended? A V8 running on two, or cylinder shutdown on needs. Our advanced active safety technologies can be used to a three-cylinder? develop highly automated driving functions such as the real- In our view, advanced cylinder deactivation schemes can be highly world driving situations we demonstrated this year on the urban valuable. But it must be mechanized and controlled properly to streets of Las Vegas and the coast-to-coast automated drive. ensure excellent driveability and transient response. We recently invested in a company called Tula Technology that has developed Based in Luxembourg, John M Fuerst is VP Engineering, Powertrain Dynamic Skip Fire (DSF), a new method to implement and Systems at Delphi and a member of the Delphi Powertrain executive control cylinder deactivation. Instead of deactivating the same, leadership team, responsible for leading the global engineering and limited number of cylinders each time, DSF can deactivate any innovation process. Fuerst joined Delphi in 1983 as an engineer in number of cylinders each engine cycle. Torque demand primarily General Motors Rochester Products Division, moving outside the determines the average number of cylinders to fire. Choosing the company in 1997 before returning in 2001 as director of product specific cylinders to fire during each cycle is managed to avoid engineering. firing frequencies causing noise, vibration or harshness (NVH) problems. With DSF, any fractional number of cylinders can be fired on average. So, for example, a four-cylinder engine could fire 0 cylinders during deceleration, 0.8 cylinders on average at 20 percent load, 1.2 cylinders at 30 percent load, 2.8 cylinders at 70 “We believe diesel has a strong future in percent load, all the way up to all four cylinders when maximum torque is required. Modulating average cylinder firing fraction like the light-duty vehicle sector. It offers low this unthrottles the engine to reduce pumping losses and improves fuel consumption and CO2, along with in-cylinder thermodynamics for substantial C02/fuel consumption benefits. Tula has a demonstration vehicle delivering a 17 percent excellent performance and driveability” fuel improvement (EPA combined cycle) in a large SUV with a V8 engine. We are currently working with Tula to implement DSF in a turbocharged 1.8 litre GDi engine for which we are targeting 8 – 10 percent fuel consumption improvement. Results from this four- cylinder will be available in the second half of 2016.

Can the Skip Fire principle be applied to diesels? Dynamic Skip Fire can be expected to improve diesel performance. Throttling losses are not an issue for diesels, but DSF can still offer benefits through improved thermodynamics efficiency and aftertreatment optimization.

How do you see electrification rolling out across different vehicle types and sizes, and what will be the future for electric axles and wheel motor modules? We see hybridization to be the dominant means to incorporate

RQ • Q4 • 2015 9 Cruiser motorcycles

Easy 10 RQ • Q4 • 2015 Riders Cruiser motorcycles

Penetrating the big-capacity cruiser motorcycle market is something that bike manufacturers from outside the United States have traditionally found very difficult to achieve. But now the team at Ricardo Motorcycle has the know-how to help develop cruisers which American leisure motorcyclists will find irresistible. Jesse Crosse reports.

Several nations specialize in fine- considerable commercial opportunity handling sports bikes, other countries for global motorcycle manufacturers – have acknowledged expertise in rugged yet this is a market that has historically adventure bikes to tackle deserts and proven formidably difficult for outsiders trails; still more are masters in the art of to crack. making commuter mounts for traffic- For proof of how popular the cruiser clogged cities. But when it comes market is in the US, look no further than to heavyweight continent-crossing Sturgis, a small town located in Meade cruisers, laden with ornate equipment County, South Dakota. Sturgis is fairly and creature comforts, there is only one typical of its type, a mountain town and country with true credibility – the USA. ranch community sitting in the border The cruiser is uniquely American in lands between the Black Hills and the its origin – relaxed and comfortable, prairie. During most weeks of the year, with languorous power delivery and visitors driving through might find it oozing style. Its roots are set deep unremarkable. It has a population of in the heart of middle America and it just under 7000 and its fair share of represents a style of motorcycling stores, churches, restaurants and bars. that has endured from the 1930s to But in the first full week of August each this day. As such, it also represents a year, this small Midwestern community

Riders RQ • Q4 • 2015 11 Cruiser motorcycles

Ricardo Motorcycle

Ricardo Motorcycle was formed in 2014 to build on the success of Ricardo’s existing motorcycle division with the acquisition of UK consultancy Vepro Ltd. The new business unit also includes a Memorandum of Understanding with the Italian firm Exnovo Srl, taking the headcount of the group to nearly 130 people. With its unique skill set, Ricardo Motorcycle can offer the specialised expertise needed to handle full motorcycle design and development programmes. Vepro and Ricardo previously gained extensive experience in the US cruiser motorcycle market working together on iconic brands like Excelsior Henderson, Victory Motorcycles, Harley-Davidson Motorcycles and Indian Motorcycles, since acquired by Polaris. These are some of the greatest names in cruiser motorcycles, names which actually defined the genre.

undergoes a startling metamorphosis. focused – cruisers generally offer less on steeply banked wooden-boarded The Sturgis Motorcycle Rally is the performance, reduced cornering ability, circuits and for a time became the biggest of its kind in the world and and inferior low-speed manoeuvrability. highest-paid professional athletes, is remarkable not least because in Above all others, the air-cooled drawing the largest crowds in America. 2015 it swelled the population of the V-twin became the favourite engine Wall of Death riders defied gravity town to 790,000 in just a couple of configuration for both pre-war and and the unthinkable, blasting around days. First held in 1938, the economic post-war American-built motorcycles; vertical cylindrical walls to the delight of benefit the Rally brings to the State even from the very early days, large spectators. annually is around $800 million. The capacity engines, some as large as 1300 Outside sport and shows, sheer magnitude of the event serves to cc (79 cu in), were not uncommon. motorcycles became extensions of the define something else too: the scale of It is this engine configuration which rider’s personality, both a character America’s love for the motorcycle and presents one of the biggest challenges, statement and a fashion statement the many different forms that takes. a challenge which Ricardo Motorcycle is at the same time. Post-war, cruisers especially well equipped to meet. served as raw material for returning Distinctive in every sense Understanding the cruiser’s GIs in search of cheaper modes of Cruisers are a distinctive breed, with heritage helps explain why it is so transport. The GIs kept wartime Harley- a feet-forward, back-upright riding tough for a foreign nameplate to take Davidson and Indian motorcycles position; they are focused on delivering on the US domestic manufacturers going as best they could, stripping off an easy, relaxed riding experience with at their own game. From the 1920s damaged or broken components and smooth shifting and lots of low-end onwards, motorcycle enthusiasts replacing only those that were really torque taking precedence over high customised, raced and performed needed. Pretty soon, a new stripped- power. Providing such an easy style stunts on motorcycles while other back style of bike evolved: known as the of riding is not without its drawbacks, riders just enjoyed them for transport bobber, this style saw key components however, and in comparison with other and leisure. From around 1910 until like the frame, forks and engine remain more conventional motorcycles – the Great Depression in the 1930s, intact but the rest would be cut back, whether touring, sports or off-road ‘board trackers’ raced their bikes customised or removed altogether. From Bobber to Chopper In the 1960s the Chopper evolved, like the Bobber but with ‘chopped,’ modified frames and long, extended forks. A vocabulary evolved around them too, like “sissy bars” for the high backrests or “ape hangers” for the impossibly tall and sculpted handlebars. The chopper was immortalised in the film “Easy Rider” and became such an iconic style of motorcycle that manufacturers began producing their own, albeit less extreme, ready-to-ride versions. Throughout the 1940s, 1950s and 1960s the American motorcycle evolved into an art form and one that is deeply rooted in the country’s history and culture. During that time, a reversal took place, from form following function to the opposite, of function following form. A cruiser can be as practical or impractical as the owner wants, from a no-nonsense style icon to touring ‘baggers’ equipped with elaborate luggage pods or side bags.

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“Cruisers are a distinctive breed, with a feet-forward, back-upright riding position; they are focused on delivering an easy, relaxed riding experience with smooth shifting and lots of low-end torque taking precedence over high power”

The Sturgis By the 1980s foreign manufacturers during that time an array of styles have sensitivity; we understand the minute Motorcycle Rally (left) had already identified the scale of the evolved. The type of customer has details that are important to buyers, is the biggest of its kind in the world and potential business. By the late 1990s evolved too, one of the latest being the and that’s important,” he says. One demonstrates the cruisers would account for 60 percent ‘weekend warrior’ – someone who may of Wright’s prime recommendations renaissance of the US of the US motorcycle market and the spend weekdays toiling in the office to European or Asian manufacturers motorcycle market. The multi-award trend has continued – yet for a new and who at weekends wants to escape developing a product for the US cruiser winning Indian Scout motorcycle product to succeed, it has the rat race and take to the open road. market is to make use of American test motorcycle (above) a lot to live up to. Function is taken as a To that customer, the motorcycle is a riders during development, to be sure was the subject of a successful given in today’s hi-tech society, but an panacea for the stress of modern life, of achieving the right feel and riding collaboration authentic heritage ‘look’, with desirable an extension of personality, a style icon experience in the finished result. between Ricardo and accessories and the right handling and fashion accessory whose aesthetic The development of high-quality Vepro predating the formation of Ricardo feel, is the true key. A cruiser can be a appeal must hit the spot exactly to be accessories good enough to tempt Motorcycle (see also practical tool but, more importantly, it successful. even the diehard enthusiast should box on page 14) must be the stuff of legend. Neil Wright, former Vepro founder also be high on the agenda: Wright and managing director, and now Head believes these equipment lines form Cruisers: a 100-year of the Ricardo Motorcycle UK business a substantial chunk of the profit heritage unit, explains the intricacy of delivering centre for manufacturers of a cruiser. Thus the cruiser’s heritage can be products that the market will consider “We would never consider starting a traced back almost 100 years, and authentic. “We offer geographical project without a full definition of the

RQ • Q4 • 2015 13 Cruiser motorcycles

Case history: The rebirth of the Indian Motorcycle

Ricardo Motorcycle’s more recent experience of the competitor benchmarks using proven in the cruiser market dates back to the 1990s, Ricardo analytical and test techniques. and in 2003 Vepro and Ricardo were engaged The intake and exhaust systems were to work on a new cruiser platform from which carefully developed with the emphasis the “Indian Spirit” would be launched for the on acoustic quality. Ricardo acoustic 2006 model year. Two versions of the Spirit development techniques played a major part were to be powered by all-new 1667 cc, in honing this crucial aspect of the brand 55 degree V-twin engine driving through a character and an expert ‘listening panel’ six-speed gearbox and belt drive. Unusually, provided experienced subjective opinion. the technical development of the engine The parent company of the Indian brand went hand-in-hand with a powertrain styling went into Chapter 11 before the Spirit could exercise, something that was considered be launched, but in 2011 Vepro and Ricardo crucial to the bike’s success. were again asked to help with the rebirth of The programme included detailed the brand by its new owner, Polaris. The bike together on another Polaris brand, Victory analysis with full vehicle and powertrain in question was the Indian Scout, winner of Motorcycles. The successful working benchmarking, and with the focus on brand the Best Cruiser in both the Cycle World ‘Ten partnership between the two companies value, styling and design. The Ricardo- Best Bikes’, and the 2015 Motor Cycle News in these and other projects spanning more developed V-twin concept underwent full Awards, with MCN particularly praising the than a decade is what eventually led to the performance simulation and port design: free-revving V-twin engine and build quality. acquisition of Vepro by Ricardo to form this included modelling and test validation Vepro and Ricardo also worked Ricardo Motorcycle.

accessories planned for it,” he explains. to overhead camshaft types, so the “Overseas manufacturers have appearance of the cam cover, heads traditionally developed cruisers back at and barrels is crucial. A long primary base, then contracted US companies drive is preferable. Engine management to develop accessories afterwards. and electrical systems need to cope That approach can result in a lack of with plenty of low speed work, as well as integrated feel and there are frequently the addition of accessories like straight fit and finish issues which buyers are through pipes and aftermarket air sensitive to. Our approach is to develop filters. Gear ratios are important; a low accessories as part of the programme, first gear ratio is essential for parade achieving perfect integration of style work and there must be a belt-driven and colour matching of components.” final drive, never a shaft. The list of style-related ‘must-have’ New products: look, sound features is not endless but it is certainly and feel before technology long. That does not mean that good- When contemplating designing a quality engineering no longer counts, but new product from scratch, Wright is the balance between form and function adamant about the best approach: “It’s is quite different to what it might be for time to throw out the engineering rule a utilitarian scooter designed for a life book,” he says. “In this market, styling of commuting. So rigorous engineering and character rule. The engine look, practice must still be followed, beginning sound and feel is far more important with a full and detailed programme than the technical specification. Show of benchmarking including road and off engineering, but prioritise it over dynamometer testing. styling at your peril.” With cruisers, the normal sign- Listen to competitors off criteria for combustion stability, All aspects of key competitors’ gear shift quality, vibration and other engines are analysed, including NVH similar parameters take on a different performance, thermal performance perspective. Firing angle is critical to and sound quality. Vehicle performance achieve the ‘right’ sound. Cooling is benchmarking includes a full dynamic critical not just for full power, but for and performance evaluation taking ‘parade duty’ where the engine idles or in handling and brakes, an ergonomic runs at low speed for extended periods. assessment for both rider and Despite the obvious technical passenger, gear change evaluation, challenges, air cooling should still be refinement and rider experience. After considered over liquid cooling. Buyers that, performance and dynamic targets rate it as an authentic feature, along are set for the new product. with large displacements of up to 1800 cc. Benchmarking includes producing The market prefers pushrod engines CAD schemes of competitor

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motorcycles to allow accurate comparisons and the setting of objectives for the first concept. CAD schemes also make it possible to evaluate components for cost, complexity, manufacturing processes and their good and bad design points. Detailed studies follow on basic packaging, volumes and location for tanks and airbox as well as exhaust routing and the positioning of other key components. With the groundwork exhaustively covered, it is time to establish the architecture and spatial relationships. Defining the vehicle layout is one of the most exciting stages of designing a cruiser, because at that point the bike literally starts to take shape. The biggest priority at this stage is to evaluate aesthetic and market appeal, as well as functionality, service considerations, durability and manufacturability. Above all though, the key to developing a successful cruiser is to understand its cultural significance and the emotion that lies behind the hardware. The DNA of the genuine article is something the people at Ricardo Motorcycle have spent more than two decades unravelling. They have a deep understanding of what it takes to develop a successful cruiser and, with the massive engineering expertise of Ricardo to draw on, the teams are looking forward to helping others develop many more great American motorcycles in the future.

The importance of sound

A cruiser’s character comprises a complex Sound files are used to make subjective blend of attributes, one of which is the noise it judgements and this approach has the makes. “Sound quality is subjective,” explains advantage of excluding other factors that may Matt Maunder, Ricardo technical specialist, influence a road tester such as appearance, powertrain noise and vibration. “People have feel, smell or touch. ‘Blind’ evaluations of the an expectation of the way a product should sound files (to ensure there’s no subliminal sound based on their cultural awareness of it. brand-related bias) are made by a panel of “If we want to engineer to meet those expert listeners made up from the staff of both expectations then there are some additional the client and Ricardo Motorcycle. A sound steps required over and above what would be quality target is benchmarked against around done in a normal engineering programme,” six bikes, and the panellists score the sounds continues Maunder. “One of those would be the on a scale of one to 10, each describing their subjective evaluation of sounds by riding bikes, emotional responses in terms of feel and style. but there are disadvantages to that because Ricardo’s WAVE software is used to predict target sounds. WAVE is also used to develop the rider is exposed to plenty of other factors the all-important exhaust noise, which forms the muffler system and to modify the sound that can influence subjective judgement.” It’s a major part of a V-twin’s character. Those to match the targets. This modelling phase also impossible to evaluate machines back-to- predicted sounds can also be played back can involve hundreds of iterations, of which back when a new project is still at the concept to the panel and assessed subjectively, as perhaps two or three will be built and fitted to stage and no hardware exists, he notes. well as being compared directly with the production motorcycles.

RQ • Q4 • 2015 15 Real driving emissions

Getting ‘real’ about emissions testing In an extensive and ongoing research project, Ricardo has demonstrated processes for evaluating the aftertreatment technology options for diesel cars under the forthcoming European Real Driving Emissions (RDE) regulations – rules designed to ensure on-road compliance with published type approval data for fuel economy and emissions. Anthony Smith reports.

The late summer of 2015 will very Amid widespread calls for tighter probably be remembered as the point in regulation, it became increasingly clear time at which vehicle emissions testing that many outside the automotive – in particular of diesel cars – became industry – and a good few within it – the subject of widespread international were largely unaware that, following mainstream media, public and even many years in preparation, fundamental political debate. The immediate impetus changes affecting the type approval for this very public discourse was testing of new vehicles were on the undoubtedly prompted by the revelation verge of introduction. Most importantly by the EPA and CARB in the United of all, these new regulations will for States that so-called ‘defeat device’ the first time create a formal linkage software had been used to circumvent between testing and certification of new regulations on some diesel cars. vehicles on the road and testing carried However, the resulting outpouring of out in the laboratory. concern soon began to extend further. The overarching aim of this is to How fundamentally effective is the provide robust, reliable and directly vehicle type approval testing process? comparable data to inform the new- And why do street-level concentrations vehicle choices of consumers, providing of NO2 in the urban environment remain a link between the laboratory and persistently high? real-world driving at the same time as

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Getting ‘real’ about

ensuring that future improvements in requirements for diagnostics and re-escalated following the recession fuel economy and emissions implied durability have progressed in parallel of the early 1990s. This was also a by further tightening of regulatory with different strategies in different time when the ability to control the limits also correspond to equivalent regions, all based on a common test environment was comparatively improvements where it really matters – approach of known and repeatable lab- crude and test equipment lacked the on the public highway. based vehicle testing. sophistication of that available today. But to understand the complexity Type approval testing in Europe is Moreover, it has become ever more and scale of this impending change, it carried out in the laboratory over the apparent that the cycle itself is no longer is perhaps useful to consider first how so called New European Drive Cycle sufficiently representative of the wide regulations have evolved to date. (NEDC) in controlled conditions. Both range of driving conditions on the roads industry and regulators have realised of Europe. How did we get here? for some time that the process is not This has led to an increasing Emissions regulation around the globe sufficiently well-defined to ensure that divergence between officially quoted has progressed very significantly since the objectives of regulation are met NEDC test figures for fuel economy, the first rules were implemented in and have been engaged in discussions and those experienced by drivers. the 1960s in California and across to migrate to more representative The International Council on Clean the USA, with the overall goal of legislative approaches. Transportation, for example, has improving air quality and, later, reducing The NEDC was defined at a time when concluded, based on its own analysis, greenhouse gas emissions. The test CO2 emissions were not required to be that the difference between official cycles, emissions limits and associated recorded, and before fuel prices had laboratory and real-world fuel

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consumption and CO2 was around 7 percent in 2001, but had risen over four- fold to 30 percent in 2013. A new approach to type approval testing The automotive industry and regulators around the world have been responding to the requirement for more representative type approval data with the development over recent years of the World Harmonized Light Vehicles Test Procedure (WLTP). In Europe and some other regions, WLTP will replace the NEDC with the World Harmonized Light Vehicle Test Cycle (WLTC), a cycle designed to be more representative of the way that vehicles are used on the road. In particular, WLTC includes a much wider load and speed range and a significantly longer duration of test. It is understood that there is no current plan for WLTP to be adopted in the US, though the country’s regulators have adopted several drive cycles in an attempt to cover a wider range of operating conditions. In parallel, US For specific regulated emissions, limits the move is a complicated business regulators have created mechanisms will be set for the closely controlled requiring sophisticated and specialized to allow consumer fuel consumption laboratory-based WLTC testing, and equipment – in effect, recreating the labelling to be adapted and adjusted the laboratory limit value multiplied highly sophisticated and sensitive from the base legislated test cycle by a maximum permitted ‘Conformity measurement instrumentation of results. Factor’ (CF) under RDE road testing. laboratory equipment used in the WLTP also calls for the measurement temperature-controlled and vibration- of a greater range of pollutant emissions Phased introduction free environment of the laboratory and than have been mandated in previous CF values are greater than unity for a replicating it on the highway. regulations; more significantly, it will number of reasons. The intention is to The final specification of acceptable also require testing of vehicles for ‘Real provide a limit which reflects the innate Portable Emissions Monitoring Systems Driving Emissions’ (RDE). The principle variation of real-world driving behaviour, (PEMS) equipment is currently frozen of the RDE approach will be to create a and the ambient and topographical but is likely to require minor further fundamental link between the rigorously features of driving that can only be revision before implementation. The controlled chassis dyno-based partially normalized by the route allowable CFs have been agreed, certification test and real-world on- setting and processing tools. Moreover, however, by the European Commission road emissions control performance. measuring real-world emissions on at a meeting in Brussels on October 28;

CO2, PM and NOx: the diesel dilemma

The popularity of diesel cars in Europe has undoubtedly had a major PM10, another standard set for the protection of human health. impact in reducing both fleet-average and overall member-state CO2 However, the current issue of concern for air quality is roadside emissions, but the two principal pollutants of concern for this engine NO2 , an important component of which is likely to be derived from type have always been Particulate Matter (PM) and NOx. the oxidative catalysis that assists the very DPFs that have been so The very significant reduction of the first of these has arguably successfully deployed to control PM. The vehicle-level regulation been one of the great unsung successes of regulation since the of emissions of nitrogen oxides is currently framed in terms of NOx late 1990s. Emissions regulations for both light and heavy duty (the combination of NO and NO2) rather than individual species. vehicles now mandate the use of Diesel Particulate Filters (DPFs), This further complicates the situation in attempting to quantify which have proven highly effective in reducing diesel PM down to the benefits on local air quality, which sets limits for NO2. Moreover, levels indistinguishable from those of the cleanest forms of internal Ricardo experience is that different combustion systems and combustion engine. DPFs have a very strong reductive effect on PM catalysts have different engine-out NO2 and oxidative ‘abilities’. As and reduce emissions to the limits of detection. such it is not necessarily true that an engine emitting higher NOx has The full benefits of this technology will continue to be further higher NO2, or vice versa; the key to informed understanding is to appreciated as older vehicles leave the fleet, and the Ricardo obtain real-world data on vehicle emissions performance. understanding is that the reduction of vehicle PM emissions over time is being reflected in street-level air quality measurements. In the UK, We plan to make the issue of urban air quality the focus for example, there is full compliance with the European Limit Value for of a follow-up RQ feature in early 2016.

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European Commission data – found between on-highway measurements and laboratory type approval tests. On this basis, the currently proposed RDE testing process and its CFs represent a significant step forward in reducing the real-world emissions of new vehicles in Europe. The new regulatory regime will for the first time place a limit on real world emissions as well as providing a regulatory testing framework that is significantly more robust and more easily repeatable and compared than at present. The Ricardo RDE research project With the advent of such a fundamental shake-up in the manner in which vehicles are tested for type approval in Europe there is clearly an imperative for an independent powertrain expert such as Ricardo to be in a position to assist its clients in developing the next generation of RDE-compliant vehicles. For this reason, the company has these are now to be considered by the complained that this represented a been actively engaged in a research European Parliament and Council prior capitulation to industry, somewhat The final project in parallel with the development to final confirmation. spuriously claiming, for example, that it specification of of the new European RDE regulations. Portable Emissions Recognizing the technical challenge represented a 110 percent increase in Monitoring Systems While to an extent aiming at a moving of improving the real-world emissions allowable emissions from 2017 dropping (PEMS) used for RDE target in terms of the detail of the performance of currently produced to a 50 percent increase from 2020. testing is currently future test regime, this research aims to frozen but likely diesel cars in the short term, the This argument ignores the fact that until to require further establish a development process that is Commission has agreed to a two-stage now, type approval limits have applied revision before final capable of providing cost-effective yet implementation, with a maximum only to the laboratory test; on the implementation RDE-compliant diesel powertrain and CF of 2.1 applying for new models by public highway there was effectively no aftertreatment solutions. In planning September 2017, and for all new vehicles absolute limit. the research, Ricardo aimed to couple by September 2019. The second step As was pointed out in the its practical experience of PEMS testing will then follow with a CF of 1.5 by announcement of the new limits, the with its vehicle simulation capabilities in January 2020 for all new models, and allowed divergence represented by order to enable assessment of different applying to all new vehicles one year the initial 2017 CF is significantly less vehicle and aftertreatment systems later in 2021. than the current discrepancy – an over RDE-compliant cycles based on Some pressure groups immediately average of 400 percent, according to routes around the company’s Shoreham Technical Centre [see box on p21]. Two diesel vehicle types – a typical C-segment European hatchback and a small SUV – were the focus of the project. In addition to RDE testing, extensive use was made of Ricardo WAVE powertrain and V-SIM vehicle simulation software, using raw data generated from vehicle testing over the Ricardo RDE circuits. The engine used as the basis of the study was a 1.5 litre three-cylinder unit rated at 80 kW. For the purposes of a study based on WLTP requirements, the first task was to reduce engine-out emissions over a wider operating range than the baseline Euro 6/NEDC calibration. This was achieved through a WAVE study exploring EGR rate response at a range of operating points. Chemical kinetics aftertreatment models were applied to the engine- out feed-gas parameters resulting from the WAVE and V-SIM simulations for each vehicle type and for each air

RQ • Q4 • 2015 19 Real driving emissions system and aftertreatment package. Europe tightens diesel N0x regulations Air system options comprised high- 500500 pressure cooled EGR with a single-stage 500500 variable geometry turbocharger (VGT) and air-to-air charge air cooler, and an 450450 alternative based on high-plus-low- 400400 pressure EGR, with VGT and water-to- air charge air cooler. Aftertreatment 350350 technologies considered in the research 300 included a lean NOx trap (LNT), and 300 250250 active and passive selective catalytic 250250 reduction (SCR) and SCRF, where the 200 180 SCR washcoat is applied to the diesel 200 180 168168 EU N0x limit – mg/km particulate filter (DPF) as opposed to EU N0x limit – mg/km 150150 120 having a separate SCR brick. 120 Results data processing was based 100100 80 80 80 80 80 80 on analysis using the proposed EMROAD 50 and CLEAR data reduction algorithms 50 intended to assess PEMS test results. 0 0 While they are respectively based on 20002000 (Euro (Euro 3) 3) 20052005 (Euro (Euro 4) 4) 20092009 (Euro (Euro 5) 5) 20142014 (Euro (Euro 6) 6) 20172017 (Euro (Euro 6c) 6c)20202020 very different approaches – and it is likely that just one of them will be LaboratoryLaboratory test test limit limit – mg/km – mg/km (NEDC (NEDC to EURO to EURO 6/WLTC 6/WLTC introduced introduced from from Euro Euro 6c) 6c) selected for the final introduction of RDE RDERDE (on (onhighway) highway) limit limit – mg/km – mg/km regulations – both tools are intended to exclude abnormal outlier driving events Notes: NOx limits from date specified for new models, applies one year later for all new vehicles (with the exception of Euro 6c where this will follow two years later). RDE NOx limits are being applied for the first time in that would skew the emitted emissions Euro 6c – for direct comparison, European Commission data indicates that current models produce around four being assessed. times the current type approval limit (ie 320mg/km) in real driving conditions. Using this approach, it was possible to achieve a detailed review of the NOx control performance of the engine provide input to the data reduction business unit MD Ian Penny. “However, and aftertreatment systems of each tools, and the working assumption cost-effectiveness will be crucial. For different vehicle configuration, enabling for the legislated NOx limit employed many applications, it will be challenging an evaluation of the CF for each vehicle. was 80 mg/km (Euro 6). The detailed to meet future requirements with results of this research project are to be LNT aftertreatment alone, even when Initial results demonstrate presented at conference in mid-2016. combined with wide-range NOx control.” viable powertrain options “This research demonstrates that As a result, the majority of diesel Each engine-vehicle-aftertreatment a range of technological solutions are vehicles will feature ammonia-dosed configuration was simulated over the available to achieve likely future RDE SCR. For cars, SCRF gives the ability to NEDC and WLTC cycles in order to requirements,” explains Ricardo engines place the SCR functionality in a hotter

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position in the exhaust, giving the potential for higher efficiencies. “For Defining an RDE-compliant testing circuit this reason it is likely in the future that the majority of diesel cars will become The challenge in defining RDE is to capture variations, so of course no two RDE routes SCRF equipped, but for a few it may real and representative driving that can be or repeat runs around a single route will ever still make sense to opt for separate reliably measured without distortion due to be completely identical. This variability will SCR, particularly where it is combined unrepresentative behaviour. The industry help to increase robustness, whilst the strict with other technologies such as LNT,” and regulators have been working with this RDE test definitions will prevent random or adds Penny. complex challenge for a number of years. unrealistically severe driving inputs. Ricardo’s current understanding is that RDE Ricardo’s Shoreham Technical Centre Ongoing research and driving will be based on approximately equal provides an ideal location for the type of mixed future development sequential lengths of urban rural and motorway driving that is considered likely to form the Work continues on Ricardo’s RDE of at least 16 km respectively, each subject basis of RDE regulations; conditions include research project to evaluate a wider to specified upper and lower speeds, with a rural, urban, and fast highway roads, and a range of real world driving conditions cumulative test duration of 90-120 minutes range of gradients. As such, Ricardo has been and to select the most cost-effective and emissions averaged over the full test able to define an RDE route comprising all of the technology as well as considering further duration and distance. likely requirements within a 20 km radius of the vehicle classes and emissions legislation Due to the specific definitions of RDE, company’s technical centre. environments – such as US EPA LEVIII. In which is the consequence of these and many In addition to Ricardo’s own internal RDE parallel with this, Ricardo is also running other boundary conditions and the strict research project, this Shoreham-based RDE significantly more live PEMS tests for validation criteria demanded by the software route system is already being exploited by the commercial customers on an RDE- that processes the route and emissions data, company in its commercial work for automakers compliant circuit around the Shoreham It is a demanding task to generate a suitable wishing to evaluate on-highway emissions area, along with laboratory testing at the route for testing vehicles. Each RDE route will performance in a manner consistent with the newly commissioned Vehicle Emissions include local geographic and traffic density likely parameters of the future regulations. Research Centre (see RQ Q3 2015). With the parameters of the new European RDE regulations in the process of being finalized, automakers the RDE compliant circuit, as well as in RDE compliant hardware is made. now have a much clearer vision of the the laboratory environment of the highly test routes are As Europe moves towards likely to require requirements they will face for the type future-proofed VERC. approximately equal implementing a more relevant type approval of new vehicles between 2017 The second, and no less important, sequential lengths approval system for type approval and 2020. asset at the automakers’ disposal of urban, rural and with greater relevance to real-world motorway of at least And thanks to the preparatory is Ricardo’s RDE research: this has 16 km respectively, driving, Ricardo has ensured that research work put in place by Ricardo, delivered a comprehensive end-to- each subject to the toolkit is already in place to help automakers have two further crucial end simulation capability that is able specified upper and automakers develop fully compliant lower speeds, and enablers. The first is a state-of-the-art to assess different vehicle technology with a cumulative models both cost-effectively and within combination of physical vehicle testing packages for compliance under the new test duration of 90- the timescales expected of this most capability on the highway using PEMS on RDE regulations before a commitment to 120 minutes competitive of industries.

RQ • Q4 • 2015 21 Global challenge

A central feature of our 2015 centenary celebrations was this summer’s Ricardo 100 ROUND THE Global Challenge. With the ambitious aim of linking all Ricardo’s major facilities worldwide, teams of Ricardo engineers driving Ricardo-engineered vehicles spanning a century of automotive history WORLD took a special centenary baton from continent to continent, meeting more than half of Ricardo’s global workforce in the process. But it wasn’t all IN plain sailing, as Tony Lewin discovers

Like many ambitious ideas, the Ricardo 100 Global Challenge started out as a much more modest undertaking. In response to an in-house call for 100 suggestions of how to celebrate the company’s centenary (at that point still a couple of years down the line) YEARS Paul Trompeteler, a senior advanced

22 RQ • Q4 • 2015 Global challenge

Send-off: Mark technology development engineer the idea. As well as encouraging direct Sunshine State a series of US-based Garrett and Ricardo at the Shoreham technical centre, person-to-person contact between teams would then travel coast to STC staff at the start of the round-the- rashly put forward the idea of driving Ricardo staff on different continents, coast via the Chicago and Detroit world relay. Some of between Ricardo’s UK sites in vehicles the Challenge promised to bring a engineering centres, glimpsing the the Ricardo-inspired incorporating significant Ricardo much greater awareness of Ricardo Atlantic in New York before making vehicles taking part are (L to R): Le Zebre, engineering content. Pretty soon on social media; on the vehicle side the Washington DC in time for the July 4th Jaguar Syner-D, the idea had expanded to take in the travelling road show would both show Independence Day celebrations – the McLaren 12C, Jensen FF, Focus HyBoost, company’s European sites, too, as off the very latest products featuring crucial hard-point around which the Citroën Rosalie Trompeteler recalls: Ricardo engineering content and trip calendar had to revolve. “At first, people thought it was just highlight the most significant vehicles However on April 25th, just weeks an excuse for us to get our hands – many of them still in fine working before the scheduled start, the on the McLaren,” he jokes. “But we order – in Ricardo’s back-catalogue of devastating earthquake struck quickly realized that the idea had engineering milestones. Kathmandu. “Our route was set to go great potential, and that as well as right through Nepal, and then on to the the trip being valuable in building ties Earthquake forces a rethink Chinese border,” explains Trompeteler. between people working at our different Before long a basic route had been “The risk was too great, so we had to locations, we could perhaps also drop in drawn up, some 20 separate sectors rethink. Instead, the Indian leg of the on some of our customers en route.” taking the baton from the UK to relay would loop back from Himachal It was a concept that struck an Brussels, then to Germany and the Pradesh to return to Delhi.” From Delhi, immediate chord with chief operating Czech Republic; from Prague the one of the Indian team would board a officer Mark Garrett, says Trompeteler. crew would fly to Delhi in India, and flight to Shanghai and meet his Chinese “Mark immediately wanted to expand then teams of Indian engineers would counterparts there. it to the whole world: he said it was the cross the Himalayas to meet up with The extra slack now in the schedule perfect scalable idea.” the China team for the descent to made it easier on one level, however: Thus it was that planning began Shanghai. From the Chinese base the travel plans of senior Ricardo in earnest for what was now set to the relay would then cross to Japan executives could be more easily tied in become a round-the-world epic. Though and then across the Pacific to the with the progress of the baton around the logistics initially appeared daunting, group’s newest facility, the Santa the world, helping minimise the air there was no questioning the appeal of Clara campus in California. From the miles flown.

RQ • Q4 • 2015 23 Global challenge

ROUND THE First destination: Aachen Waved away by cheering staff on a WORLD slightly damp mid-May day, the lucky IN McLaren crew set off on the first leg of the marathon with the specially 100 honed cast aluminium Global 100 relay baton and the ceremonial flags safely YEARS stowed in the boot. The first call was 2 St Bede’s School in Redhill, followed 1 by McLaren Automotive’s futuristic factory near Woking; the next stop was Brands Hatch, where a wet track put the damper on any temptation to open up the car’s full quota of horsepower. And then it was across the Channel to 1 Mark Garrett is Brussels, where Ricardo is constantly the first to sign the banner that will active helping frame EU legislation. The 3 4 accompany the sector ended in Ricardo Deutschland’s teams around the nearest technical centre, in Aachen, world; 2 Stop-off at McLaren where the baton was ceremoniously Automotive, where handed over to the next crew. Ricardo-built V8 This set the pattern for the rest engines are installed; 3 Wet track spoils the of the European phase of the tour, fun at Brands Hatch; bringing the message to as many 4 Munich to Prague automotive establishments as 5 aboard the mighty six-cylinder BMW possible, and with a special emphasis K1600; on awakening the interest of students 5 Brussels, European in science, technology engineering Parliament; 6 Ricardo Aachen and maths STEM subjects. While the team handing over overall route and the timing hard points the baton to Ricardo had been mapped out in advance by Germany; 7 Ricardo Paul Trompeteler and Corin Wren, each Schechingen Ricardo centre on the itinerary was 6 7 Technical Centre; 8 Ricardo’s Prague responsible for arranging VIP meetings, engineering centre: local visits and local fund raising. signing the banner Despite careful planning, the climate is Martin Hill, Vice President; was not always on the side of the 9 Tatra Technical crews, and it was unfortunate that the Museum, admiring only motorcycle leg of the Challenge the V6 truck diesel – the 400-odd km from Munich to designed with 8 9 Ricardo in the 1980s Prague – should be accompanied by

18.5.2015 19.5.2015 20.5.2015 14.5.2015 Aachen-Schwabisch Schwäbisch Munich-Prague 28.5.2015 Shoreham-Aachen Gmünd Gmünd-Munich BMW K1600 GT, BMW Delhi McLaren 12C Audi S8 Audi S8 K1600 GTL Mahindra Scorpio x 2 Ricardo UK Ricardo Germany Ricardo Germany Ricardo Prague Ricardo India imeline

Highlights Highlights Highlights Highlights Highlights St Bede’s School, Nürburgring, Hockenheim, Schechingen Technical Praga automobile Shimla mountain city,

Challenge T McLaren Automotive, Mahle, Porsche & Centre museum, Zetor tractors River Sutlej, Kinner Brands Hatch, EU Mercedes museums Ricardo Connection Kailash, Indian Institute of Parliament Ricardo Connection Ricardo role in 6-cyl BMW Technology Ricardo Connection Ricardo software used engine; Praga used Ricardo Ricardo Connection Ricardo in NVH development of patents; Tatra V6 diesel Ricardo developed manufactures Audi S8 developed with Ricardo in dedicated transmission for McLaren V8 engines 1980s Scorpio SUV

24 RQ • Q4 • 2015 Global challenge

1 First stop in Asia some of the worst weather of the whole is Delhi, where tour. Undaunted, the enthusiastic crew the British High Commissioner powered their mighty BMW K1600s Sir James Bevan, – six-cylinder engines developed in President of Ricardo conjunction with Ricardo Motorcycles India, Mayank Agochiya, and Mark in Schwäbisch Gmünd – via a series Garrett sign the of fascinating stopovers towards the banner; Czech capital and the Prague Technical 2 The Ricardo India team with one of their Centre, where the British Deputy 1 2 Mahindra Scorpios; Ambassador was the guest of honour. 3 The specially-milled relay baton high in the Himalayas; By air to Asia 4 Shanghai and the The British High Commissioner and Qoros 3 crossover, his official New Delhi residence played on which Ricardo did NVH work; host to the first engagement in Asia, a 5 Yogesh Umberkar business networking event, following of the Ricardo India software team hands which the eight-strong Indian team the baton to the set out in two Mahindra Scorpios (with China team on the Ricardo transmissions) for Himachal waterfront of the Pradesh in the Himalayas, some 600 Huangpu River; 3 4 6 Ricardo Shanghai km distant and separated by daunting cake-cutting snake trails up hills – including a ceremony, with Asia MD Gary Tan and stretch which proclaims itself the Nick Burns (right), world’s most treacherous road. 3 grandson of Sir Harry With frequent stopovers to admire Ricardo; 7 Dodge Challenger the astonishing views at high altitudes with Ricardo- across to the Himalayas, the team designed Hemi V8 navigated many natural hazards as engine and crew members Jason well as finding time to visit schools and Matznick and Steven colleges before winding its way back to 5 6 Korsch at Bonneville Delhi almost a week later. Salt Flats, Utah, where Ricardo is in A member of the Indian team the diesel land speed accompanied the baton in its specially record books; made flight case for the trans- 8 Detroit Technical Center, where Himalayan hop to Shanghai and the design work on handover to the Chinese team, which Hummer models was completed took place on the waterfront of the Huangpa River opposite the famous Bund financial district. Here another historical encounter took place: Sir 7 8 Harry Ricardo’s grandson, Nick Burns,

4.6.2015 10.6.2015 13.6.2015 20.6.2015 22.6.2015 Shanghai Tokyo Santa Clara-Las Vegas Las Vegas–Denver Denver-Chicago Qoros 3 City SUV Jaguar Dodge Challenger Dodge Challenger Dodge Challenger Ricardo China Ricardo Japan Ricardo US Ricardo US Ricardo US

Highlights Highlights Highlights Highlights Highlights Huangpa River, Xitang Meiji Jingu shrines, Mazda NASA Ames Research Bonneville Salt Flats, NREL, Red Rocks water town, Zingdezen, Turnpike hillclimb, Mount Center, UC Davis, McLaren Abyss Canyon, Pikes Peak Amphiteatre, St Louis Changhi-Auto Co Fuji, Lake Ashi dealership, Sequoia Ricardo Connection Ricardo Connection Ricardo Connection National Park, Death Valley Bonneville is site of Ricardo Ricardo supports Ricardo carried out NVH Ricardo Connection diesel land speed records in renewable energy analysis for Qoros Ricardo assisted in 1936 and 2006 technologies development of Chrysler- Dodge Hemi V8

RQ • Q4 • 2015 25 Global challenge

ROUND THE just happened to be in town at the locations and sites of automotive taking part, and still more were able to same time and cut the blue and white significance such as Silverstone and appreciate the value of Ricardo’s 100- WORLD Ricardo cake at a special ceremony the BMW Mini factory in Oxford, the by year heritage and how its pioneering IN with Ricardo Asia head, Gary Tan. now much larger convoy conveying the philosophy is even more relevant in Now installed in the Qoros 3 City baton wound its way towards central today’s turbulent times. 100 SUV, for which Ricardo handled NVH London for the planned rendezvous Welcoming the relay party back to development, the China team spent with the oldest cars taking part in the Shoreham, Mark Garrett said that the YEARS nearly a week visiting customers and Challenge – the 1926 Le Zebre Z10, Challenge had been a remarkable and suppliers and exploring famous sites in designed by Sir Harry himself, and very appropriate celebration of the the region. Marketing director Fang Liu the 1934 Citroën Rosalie, the first achievements of the first century of was selected to take the baton onwards production diesel car thanks to its Ricardo. “It has done great credit to to Japan, where the Jaguar-based tour Ricardo-designed engine. the innovative engineering skills, hard took in not only the compulsory stop of A priority call was to pay homage to work and dedication of the company’s Mount Fuji but also the Mazda Turnpike Sir Harry’s childhood home in London’s employees, from Sir Harry himself to hill climb recently made famous when Bedford Square; this completed, the most recent of our apprentice and Motorhead Magazine closed it off for the century-spanning quartet [now graduate engineering recruits,” he told competitive timed runs. including the McLaren 12C and the the 200-strong reception. Jaguar SynerD research vehicle] “I would like to thank the US West to East: threaded their way through the city- participating teams for their UK North to South centre traffic to pay a number of visits generous commitment, and their With Yuji Yamamoto, head of to key sites, charities and schools and dedication to giving something back Ricardo’s Japanese business, having colleges. to the communities in which they accompanied the relay baton across The ceremonial return to the work through charity fundraising,” the Pacific, the US teams were ready Shoreham Technical Centre the he continued. “I am sure that Sir for their own high-mileage coast-to- following day was a spectacular affair, Harry would be very proud of the coast relay. Notable highlights en route with a welcome-back reception party achievements of the company he included the sky-high temperatures of 200 people assembled outside the formed one hundred years ago, and of Death Valley, the eerie expanse of building and Dr Camilla Bosanquet, of the spirit of enthusiasm, scientific Bonneville Salt Flats, scene of Ricardo Sir Harry’s daughter, riding in the inquiry and engineering innovation that world land speed record triumphs in back of the open-topped Le Zebre lives on in its employees today.” 1936 and 2006, and the famous Pikes for the official opening of the Vehicle Peak hill road, where brake tests on the Emissions Research Centre. Our thanks go to our partners Telefonica O2, Concirrus and Over-C for connectivity way down are compulsory. After stop- With record-breaker Richard technology that enabled the world to track the offs and team handovers in Las Vegas, Noble officiating, the ceremony was progress of the Global 100 in real time online. Denver, Chicago, Detroit and New York, a resounding success, and so too Thanks, too, to all the other partners and the baton returned to Washington was the Challenge that had just been customers who loaned us vehicles. DC for the flight back to Glasgow in completed. More than 70 people had Scotland. driven, navigated or accompanied the Linking a large number of UK relay baton on its travels, thousands Ricardo-group facilities, customer more saw and admired the vehicles

14.7.2015 7.7.2015 Leamington Spa – Harwell 20.7.2015 25.6.2015 Glasgow-Leamington Spa Jensen FF, Aston Martin, Harwell-Marble Arch Chicago-Detroit Volvo V60 DriveE Jaguar F-TYPE, Ford BMW i3 REX, McLaren Hummer H1 26.6.2015 Ricardo Energy & Escort Cosworth Ricardo Energy & Ricardo US Detroit-New York Environment, Scotland Ricardo MTC Environment

Highlights Highlights Highlights Highlights Highlights Tractor & Machinery Show, Nissan New York taxis Glasgow Science Centre, Trinity College Cambridge, Telefonica HQ, Gilmore Museum, Detroit Ricardo Connection Lakeland Museum, Ricardo Tank Museum, Silverstone, Westminster Recycling Tigers baseball Ricardo Inc assisted Rail Derby, AEA Warrington, Jaguar Land Rover Gaydon, project, Ricardo Board in development of Bentley Motors, Stratford Mini Oxford meeting Nissan New York Taxi for Ricardo Connection Ricardo Connection Ricardo Connection Tomorrow Calibration of DriveE Harry Ricardo studied Ricardo Energy & models; Ricardo Rail has engineering at Trinity Environment works with its HQ in Derby College; Ricardo companies Westminster on recycling developed drivelines for Jensen, Ford, Jaguar, and original BMW Mini

26 RQ • Q4 • 2015 Global challenge

1 Scott Hamilton 10 Chris Willett, and Susannah Telfer Stan Smith and Tom of Ricardo Energy & Collyer outside Sir Environment with Harry’s childhood Stephen Breslin, home in Bedford Chief Executive of Square, London, with Glasgow Science Jaguar Syner-D and Centre; Le Zebre, designed by 2 Outside Sir Harry; Ricardo Energy 11 Line-up outside & Environment’s Imperial War Glasgow offices, Museum: Citroën 1 2 3 ready for the journey Rosalie, the first south; diesel car, Le Zebre, 3 and 4 Jaguar Land Jaguar Syner-D and Rover headquarters McLaren; at Gaydon, with team 12 Last stop for members Adam the relay baton is Drury and Oliver Shoreham Technical Adams and Ricardo Centre, carried key account manager proudly by Dr Camilla Rob Stone; Bosanquet, Sir 5 6 5 The team arrives Harry’s daughter 4 at Ricardo Midlands Technical Centre, where staff turned out in force; 6 Flag-signing and handover at Ricardo Energy & Environment in Harwell; 7 Old Warden Airfield: Jensen FF and Aston 7 8 9 Martin V8 pose alongside a replica of the WW1 tank which gave Harry Ricardo his first taste of success; 8 Richard Ebsworth and Nicholas Brown with Stephen Laing, 10 Curator, at Gaydon Heritage Centre, with the Ford Escort RS Cosworth and its Ricardo-designed AWD drivetrain; 9 Ricardo Energy & Environment’s Marble Arch offices in central London; 11 12

23.7.2015 Raising money for good causes Marble Arch – Shoreham 28.7.2015 1926 Le Zebre Z10, 1934 Shoreham Many hundreds of Ricardo employees were involved in individual and Citroën Rosalie, McLaren, 1926 Le Zebre, Volvo team events – ranging from cycle marathons to sky-diving and mountain Jaguar SynerD XC60 electric project car climbing – to raise money for international and national charities. The Ricardo Shoreham Camilla Bosanquet original goal was to raise a total of £10,000, with the company promising to match this from its own budgets: in the event, more than £15,000 was raised by employees, bringing the overall contribution to charities to £30,000-plus. Highlights Highlights Among the dozens of charities supported were UNICEF, Aktion Familie, Bedford Square, Great Ceremonial opening Engineers without Borders, Cancer Research UK, Teach for India, and many Ormond St hospital, of Vehicle Emissions more notable worthy causes drawn from each country through which the Imperial War Museum Research Centre relay route passed. Ricardo Connection Ricardo Connection Separately, and as a further celebration of its 100 year anniversary, 13 Bedford Square is the Dr Camilla Bosanquet is Ricardo is establishing its Centenary Bursary initiative to provide financial birthplace of Sir Harry the daughter of Sir Harry support to students in greatest need, to further their education and to Ricardo; Le Zebre designed Ricardo encourage more young people to study STEM subjects. by Sir Harry; Rosalie with Ricardo engine was first diesel passenger car

RQ • Q4 • 2015 27 Ricardo News

Ricardo news Latest developments from around the global Ricardo organization Ricardo helps FTS fast charge

With increasing demand for fast, high- capacity – something that is particularly commutation protocols to link the multiple capacity electric vehicle (EV) charging, attractive as the intermittent renewable energy storage systems and power Future Transport Systems (FTS) has proportion of the generating mix increases. electronics on the E-STOR architecture. developed – with support from Ricardo Ricardo’s support for FTS has included Ricardo developed the TCP/Modbus, CAN, – a highly innovative and cost-effective the implementation of interface and RS 485 and Ethernet communications solution based on reusing EV batteries in a communication stacks to facilitate and selected the appropriate control ‘second life’ application. FTS application software. This included system hardware to implement the The E-STOR concept is a highly developing and testing the various E-STOR application software. innovative charging solution which provides The company’s expertise significantly improved functionality for the in embedded software and EV driver while also reducing peak demand hardware helped ensure a robust on the distribution network. It achieves product development cycle. these twin benefits by reusing EV batteries in a ‘second life’ application as an energy buffer for charging. This provides a robust and cost-effective solution that enables higher capacity EV fast-charging from a standard 3 kW electrical connection. In addition to avoiding incremental stress upon the local distribution network, E-STOR can also play an important role as part of a smart grid, in acting as a useful energy buffer to absorb surplus generating

A winning partnership Following a successful 2015 season, the Ricardo driveline package delivered to Greaves Motorsport is fully optimized and race-ready for 2016. With regulation changes expected for 2017, Ricardo is already in discussion with several teams in LM P1 and LM P2 to ensure it continues to be the partner of choice for the very best in endurance circuit racing. Rally renaissance in 2016 Elsewhere, Ricardo also marked its return to another motorsport arena with the announcement of the delivery to of a state-of-the-art ultra- lightweight and highly compact AWD transmission and driveline for a rally Fresh from celebrating its 2015 European Le Mans Series teams title, customer. An important milestone for Ricardo, this is the first support Greaves Motorsport permitted Ricardo to reveal its role in a transmission for rallying that the company has been able to announce since its highly and driveline partnership. successful collaboration on the Ford WRC Focus in 2010. Ricardo provided robust, ultra-reliable technology and support to the The first of many products that will once again see the company European Championship winning team. The collaboration between Ricardo supporting the world’s top rally teams, the new transmission is a and Greaves Motorsport goes back over eight years, with Ricardo being sequential five-speed unit with ratios optimized for gravel and asphalt. It responsible for the design, ongoing development and support throughout offers a class-leading balance of robustness and package, while achieving the season, for the complete driveline – connecting the clutch to the wheel the FIA requirements of the R5 championships for which it is intended. hubs, and including the transmission, visco-mechanical differential, clutch In close collaboration with the client’s rally team, the complete driveline shaft and drive shafts – of Greaves Motorsport’s LM P2 Gibson 015S 2015 system has been designed and developed by Ricardo at its Leamington UK championship-winning chassis. facility, including an extensive programme of physical testing.

28 RQ • Q4 • 2015 Ricardo News Natural gas heavy duty vehicle research Ricardo has been named as a key partner reduced greenhouse gas emissions, whilst in the European Commission’s Horizon also meeting current Euro VI emissions 2020 Green Vehicle Initiative project standards. The project aims to develop HDGAS – a project that aims to develop, technologies to address this need whilst demonstrate and optimize advanced also meeting or exceeding the latest powertrain concepts for dual-fuel and Euro VI regulated emissions standards, Heathrow monitors black carbon pure natural gas powered heavy duty as well as achieving CO2 or greenhouse vehicles. gas emissions reduction and in-use Ricardo Energy & Environment is working with Heathrow Long-haul trucks are an essential compliance under real-world driving Airport Ltd to monitor airborne black carbon in efforts element of the transportation mix of conditions. to enhance the airport network’s understanding of modern industrialized society. They are, Ricardo is one of 19 collaborating EU atmospheric particulate matter and to guide air quality however, inherently less amenable to the commercial and academic partners on the policy in the region. The new detection system provides type of electrification and hybridization HDGAS project. Particular areas of focus real-time measurements of the proportion of black strategies that are already contributing to for the company will be the development carbon produced by combustion. reduced carbon emissions and potential of engine and aftertreatment systems The project is the first of its kind outside of UK long-term sustainability for the light that offer the prospect of delivering real government-operated networks and will provide a greater vehicle sector. A key global imperative is driving emissions well below Euro VI limits depth of understanding for researchers and policy makers therefore the substantial improvement for heavy duty vehicles. Specifically, the to develop the best informed policies for air quality control of heavy vehicle engine efficiency and the aim of the new systems is to demonstrate across London and the wider region. reduction of environmental impact. improvements in the region of ten percent Black carbon contributes to atmospheric warming by The primary objectives of HDGAS are in torque, power, fuel efficiency and GHG reducing albedo - the ability of the earth to reflect sunlight to deliver improved fuel efficiency and emissions reduction. - when it deposits on snow and ice. There are currently no European or UK mandated limits or recommended targets that regulate concentrations of black carbon, and just 13 monitoring stations operate in the UK government JAC and Ricardo develop networks. With the deployment of the new monitoring system, ‘HyBoost’ to production Heathrow Airport Ltd now undertakes measurements of black carbon at two additional locations within its Anhui Jianghuai Automobile Group Co but with zero degradation of vehicle network. The newly installed analyzers are modified Ltd (JAC) and Ricardo are collaborating performance. Extensive NEDC testing versions of those employed by the UK Department for on a project to develop the Ricardo undertaken on the JAC mule vehicle Environment, Food and Rural Affairs, with enhanced HyBoost concept – a combination of low- during the concept phase of the analytical capacity for near-instantaneous particle cost technologies to deliver improved programme has served to verify that characterization. Black carbon measurements from the performance and fuel economy. the fuel economy targets are achievable network’s Oaks Road and Heathrow LHR2 stations are HyBoost is based on a downsized, highly without compromising driveability. now available to view in near-real-time on the Heathrow boosted turbocharged direct injection NVH has been an area of focus in the Airwatch Website: www.heathrowairwatch.org.uk. gasoline (TDGI) engine giving improved development of engine mounting fuel economy at low cost, and linked to strategies. Finally, the collaboration Former Volvo executive appointed 48V electrical architecture including is also extending to the detailed a belt starter generator (BSG), DC-DC development of control strategies Ricardo plc director converter and a lithium-ion battery for and software as part of the necessary Malin Persson has been appointed energy storage. powertrain systems validation. by Ricardo plc as a non-executive The HyBoost collaboration between director with effect from January. JAC and Ricardo began in mid 2015 She was employed by the Volvo and has already successfully passed its Group between 1995 and 2012 and ‘mule’ vehicle development gateway, a held roles including vice president major decision event for the programme. of corporate strategy and business The project team is now working to development, president and CEO of the research and productionize the HyBoost concept for a innovation company, Volvo Technology, and head of JAC vehicle intended for launch in the environmental affairs at Volvo Logistics. Chinese market. This launch vehicle Prior to joining Volvo, Ms Persson was responsible will see the 2.0 litre MPFI engine for transport and environmental technology replaced with a downsized gasoline development at the Swedish Office of Science and 1.5 litre TGDI unit and coupled with Technology in Brussels. She is an elected member of the 48V electrical system. the Royal Swedish Academy of Engineering Sciences With this combination of and is owner and CEO of Accuracy AB, a consultancy technologies, JAC and Ricardo are and engineering company. She has an MSc in Industrial aiming for a fuel economy improvement Engineering and Management from the Chalmers in the region of 30 percent in The original University of Technology in Gothenburg. comparison with current technology, HyBoost concept

RQ • Q4 • 2015 29 Ricardo News

Network Rail approves Ricardo pantograph monitoring

Main Line (WCML), one of the UK’s busiest mainline rail routes. During the trial the PanMon system proved capable of providing continuous and accurate measurements of pantograph uplift forces and defects – including chips, damaged end-horns and worn carbon strips – from trains passing at speeds of up to 200 km/h. The PanMon system is now designated for roll-out as a replacement for the current 30 year old Panchex system, which is reaching the end of its serviceable life. PanMon uses Sensys’ Automatic Pantograph Monitoring System (APMS) to provide high-definition images of each passing pantograph through a combination of radar, laser, video and photo technology, and an innovative new contact-less optical uplift monitoring system developed by Ricardo Rail in association with Italian-based optical monitoring specialists DMA S.r.l, Turin. High speed imagery Using specialist ‘pattern-recognition’ analysis software, the of a pantograph at Ricardo Rail’s ‘PanMon’ pantograph monitoring system has system automatically interprets the data to provide ongoing 192 km/h (far left); a Ricardo PanMon unit been formally approved by the UK’s railway infrastructure condition reports of each pantograph. This includes identifying is installed on the manager, Network Rail, for use across the national network. the remaining thickness of carbon strips, and any damage to West Coast Mainline Defective pantographs can inflict significant damage to the pantograph’s head, aerofoils or the end-horns, which can (below) overhead line equipment – in extreme cases leading to affect a vehicle’s ability to maintain de-wirement, requiring costly and time-consuming repairs good contact with overhead wires. The and causing significant delays to services. While both the system can also measure the uplift of pantographs – and the thin carbon strips they carry to draw the contact wire resulting from the force current from the overhead contact wire – are subjected to applied by the pantograph, as uplifts thorough manual inspections during scheduled maintenance exceeding specified limits can cause windows, defects can quickly accumulate. considerable damage. Remote monitoring technology such as PanMon enables “Getting new technology to work infrastructure owners to identify those vehicles operating on accurately and reliably in the rail the network that are at greater risk of inflicting damage to the environment can be challenging,” wires, often due to general wear and tear. PanMon can also help commented Network Rail’s Project Network Rail work with operators to take early preventative Manager for the PanMon trial at action and, ultimately, extend the life of both the wires and the Cheddington, Mike Dobbs. “But Ricardo pantograph equipment carried by the trains. Rail has worked closely with us during the trial to overcome the difficulties. I am Successful trial delighted that we are now able to start This decision to approve this Ricardo Rail system follows the the process of replacing our old Panchex successful completion of a two-year trial on the West Coast systems with a 21st-century solution.”

Ricardo motorcycle conference Following a very positive response to wide range of the most pressing engineering its inaugural event last year, Ricardo challenges facing the sector, including the Motorcycle held its second annual direction and trends for tomorrow’s two- conference in Milan on November 16th – a wheelers, future emissions legislation and one-day curtain-raiser for EICMA 2015, the the latest developments in rider assistance premier global trade show for two-wheeled systems. This year’s keynote address, on the transport. In excess of a hundred delegates, influential place of racing in the motorcycle including senior management, engineers industry, came from Jan Witteveen, and thought leaders from the world’s the engineering brain behind 23 world motorcycle industries, discussed current championship wins for Aprilia (Piaggio). trends and future drivers in the motorcycle There were also presentations from other and urban mobility sector – in the beautiful the Museo Nazionale della Scienza e della leading manufacturers and suppliers, and setting of the historic Sala del Cenacolo in Tecnologia Leonardo da Vinci. from leading academics and legislators in Milan’s museum of science and technology, The papers and Q&A sessions covered a the broad field.

30 RQ • Q4 • 2015 RICARDO TRAINING TECHNICAL TRAINING BY ENGINEERING EXPERTS Frequent courses o ered in a wide range of disciplines

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