Faculty of Technology, Engineering and the Environment

ENGINEERING, AUTOMOTIVE AND MOTORSPORTS NEWS BRIEF 2011

The automotive and motorsports industry is a vital element in the development of the UK economy and will undoubtedly continue to play a substantial role in the years to come. The industry boasts a combined turnover of £52 billion, employs more than 180,000 personnel and reports for the Motorsport Industry Association (MIA) and The Society of Motor Manufacturers and Traders (SMMT) who report that more than 30 companies manufacture one million automobiles and commercial vehicles in the UK.

Would it surprise you to learn that “As the UK rapidly accelerates to a developing links and partnerships the UK has more specialist sports fully fledged knowledge economy it is with local and global engineering car manufacturers than any other essential that academia is constantly organisations, professional bodies country in Europe? aware and working towards the and industry experts to develop the needs of traditional and emerging Engineers for the 21st Century.” • In the motorsports sector alone industries. It is essential that there are eight academic programmes, especially in teams based here, supported engineering, are tightly integrated with by more than 300 specialist the requirements of industry working companies who, between them, hand-in-hand to develop students who employ almost 50,000 people. will be the next generation of human • The UK motor industry is capital with the knowledge to tackle built on solid foundations and the technical challenges of the future. is looking forward to a strong Birmingham City University’s School of Parmjit Chima, Head of Engineering future. The sector is currently Engineering, Design and Manufacturing Design and Manufacturing Systems driving technological change Systems is rising to this challenge to increase fuel efficiency and develop alternative fuels to reduce CO2 emissions that will meet the governments global environmental agenda. Birmingham City University is at the fore when it comes to innovations and development in these increasingly important fields.

Parmjit Chima, Head of Engineering Birmingham City University’s Driftcar and Formula Student Car Design and Manufacturing Systems, says

LOW CARBON VEHICLE RESEARCH AND DEVELOPMENT Birmingham City University’s Low • Fuel Flexibility and Emissions symposium has regularly attracted Carbon Vehicle Group is participating Control of Heavy Diesel Engines an international audience and high in a number of low carbon vehicle • Optimal Control of Diesel Powertrain quality presentations from industry initiatives with industry and other Emissions using EGR and VGT and academia. A number of the research organisations within its • Advanced Model-Based Transient papers are given by former students Engine Research and Development EGR Control of the University’s unique Masters Laboratory. Ongoing research • Development of Electric level course in Automotive Calibration programmes within the Group include; Turbocharger for Improved and Control. Driveability • Development of a Hybrid Powertrain • Open ECU Development for Control Architecture Emissions Control • Development of an SCR Control System for Heavy Duty Diesel The School of Engineering, Design Engines and Manufacturing Systems hosted • Development of Safety Critical its fourth Advanced Powertrain Metrics for Powertrain Controls Control Symposium on 24 November 2010. Held every two years the Students working in University Engine Test cells A FORMULA STUDENT EXPERIENCE AT SILVERSTONE Our second year BSc Motorsports Course Director David Jones said gain the experience and understanding Technology students enjoyed a taste “...not only did the students get the of what it takes to design, build and of life in the fast lane when they opportunity to build and develop a race a car to exact regulations. Apart built and raced their own car at car as part of their degree course, from the networking aspect of the day, the legendary Silverstone track in they enjoyed first-hand experience all the students who attended got to Northamptonshire, UK. at one of the most famous race tracks race the car around Silverstone. in the world.” How many people can say they’ve It was the first time Birmingham sped around the home of the British City University had entered the Students also had the opportunity Grand Prix in a car they designed and prestigious Formula Student of being headhunted by the world’s built themselves?” said David. competition, organised by the Institute leading engineering brands who of Mechanical Engineers (IMechE), and attended the event looking for the Birmingham City University Formula Student Team at Silverstone July 2010, (l-r) Jack Woodhouse, David Jones (Course Director – with more than 2,000 students from graduate employees of the future. sitting down), James Harris, Martin Young (seated) David Parker 23 countries entering the contest this Marc Wood, Craig McKenzie and David Tulett “Ross Brawn, Principal Engineer for year, the competition was very stiff. the Mercedes F1 Team, is Patron of the IMechE uses the event to promote Formula Student programme, which excellence in engineering by gives you an idea of the sort of contacts challenging students to design, build, our students have had the opportunity develop, market and compete as a to make through the project.” team with a small single-seater racing “It’s the thing to do if you want to be car, which is then raced around the noticed by the motorsport industry and track.

SECOND CENTURY OF INNOVATION FOR REYNOLDS TECHNOLOGY LTD A passion for high-performance Over the years, the Reynolds brand has competitiveness, productivity and engineering, combined with the become an integral part of the cycling performance. A KTP achieves this knowledge and experience to meet industry and their products continue through the forming of a partnership and exceed varying customer needs, to set the standard in this and many between a business, an academic has given Reynolds Technology the other industries including aviation, institution (such as university, further edge for over 100 years. motorsports, sporting goods and education college or research and leisure. The planned collaboration will technology organisation), enabling The Birmingham-based company has take the company’s world renowned access to skills and expertise that recently started a short Knowledge unique materials and tubular expertise will help the business develop. Transfer Partnership (KTP) together with University design programme with Birmingham City The knowledge sought is embedded capabilities and develop new design University to support the company into the business from the knowledge services. These services are focused through a second century of Innovation. base (University) through a project, on opportunities associated with or projects, undertaken by a The new Research and Development Motorsport and high performance recently qualified person (known as programme provides the company engineering sectors. the Associate) who is recruited to with access to advanced 3D Design Knowledge Transfer Partnerships specifically work on the project. KTP systems, motorsports technologies (KTP) is a UK-wide programme programmes can vary in length from and expertise that are based at the enabling businesses to improve their six months to three years depending University. on the needs of the business and the desired outcomes. KTP enables new capability to be embedded into the business and continues to benefit a wide range of businesses across many sectors, including micro, SME and large businesses. The University’s School of Engineering, Design and Manufacturing Systems has KTP programmes running with Morgan Motor Company, STS Rail Ltd, Malthouse Engineering Ltd, (l-r) Paul Booth, Keith Noronha, Dr Tim Burden and Hadi Moztarzadeh – Members Reynolds Technology Ltd, J Banks Ltd of the Reynolds Technology and Birmingham City University’s KTP Team and Glasscoat International Ltd.

2 CAN YOU REALLY BUILD A PEDAL CAR BY HAND, IN ONE HOUR? Our students from the School of top pedal car drivers: Engineering, Design and Manufacturing Jes Featherstone of the European Systems proved that not only is it Championship Team car, Rob Fulford possible, but that they could build a of the British Championship Team quality vehicle that could hold its own car and Alan Goodman of the in a race. Goodmaniacs Team. Challenged by Channel Five’s The “What a ride and what a great team,” Gadget Show, the nine engineering he said, when the programme was students helped the programme’s four aired. “The build quality, the design pedal car built in an hour presenters, Suzi Perry, Jason Bradbury, and the hands-on driving characteristics Jon Bentley and , to make of The Gadget Show pedal car were sure they finished the task in time. bang on.” Once completed, their pedal car was Parmjit Chima, Head of the University’s put through its paces in a race against School of Engineering, Design and three other vehicles at the Birmingham Manufacturing Systems, said: “This Wheels track. was a fantastic effort by the engineering students, who all stepped up to the The finished article impressed Jason challenge to design and build a pedal Bradbury, who sat behind the wheel of The Gadget Show Presenter Suzi Perry, with race car in a tight schedule with great the pedal car and raced against three Birmingham City University Pedal Car Challenge Team enthusiasm and commitment.”

ENGINEERING RESEARCH AND DEVELOPMENT EXCITEMENT! The Directors of young Birmingham- sideways-on throughout the twisty supervisor, Paul Booth, the company based specialist motorsport business, circuit balancing power and grip has gained access to advanced Driftworks Ltd, have established a levels”. James Robinson says: “Power computer aided design tools and two-way relationship with Birmingham must be delivered effectively to the expertise, and has designed locally City University’s Faculty of Technology, road. Our engineering concentrates on engineered prototype Driftworks- Engineering and the Environment (TEE). suspension, steering control – together branded parts. with ‘sticky’ track day tyres.” Phil Morrison and James Robinson Phil Morrison says: “The University of Driftworks Ltd have helped The emphasis in Drifting performance team has helped with techniques provide our students with insights focuses on suspension components. enabling us to develop lightweight into how involvement in a specialist This led Driftworks into a Knowledge components that offer vital strength. motorsport, led them to develop a Transfer Partnership (KTP) with TEE. The KTP has enabled us to explore our successful business and enhanced The business supplies mostly Far own design ideas, materials and local their understanding of the distinctive East-sourced parts to a growing, supply sources.” engineering aspects of competition enthusiast community. Seeking both Birmingham City University ‘Drifting’ cars.* to control its supply-chain and add Motorsports Technology degree value to its business, with help from Phil Morrison explains: “Drifting is Course Director, David Jones, says: Birmingham City University, Driftworks now an international form of extreme “Driftworks is a home grown success is developing its own suspension arm motorsport. Big in Japan and the USA, story offering role models to inspire kits. Working with William Murray a it’s mushrooming across Europe with our students through combining KTP Associate (who has a postgraduate competitions at fully viewable sections technology with enterprise.” of regular racing circuits, such as engineering degree) and academic Silverstone. Drifting offers a lower cost form of motorsport.” With Driftworks’ own cars performing dominantly in three of Europe’s four drifting competitions, it’s now thriving international business has, through on-line marketing, led to the company

becoming an information-hub for Birmingham City University’s branded Driftcar Drifting. “Whilst power is a major aspect, * ‘Drifting’ was championed by legendary motorcyclist Kunimitsu Takahashi in the seventies, as a technique in Japanese touring car racing. Famous for hitting the corner apex at high speed in a rear wheel-drive car, competitions rely on the vehicle being Takahashi intentionally over steered, drifting through the turn whilst preserving control and high exit-speed.

3 EXPERTS FROM THE UNIVERSITY’S PTC ACADEMY ON AN EXCITING STEM CHALLENGE The British Science Festival staged design, to register interest in the in Birmingham saw experts from the Scalextric4Schools challenge. University’s PTC Academy working The partnership between PTC, the with school children and students Technology Enhancement Programme on an exciting hands-on engineering and Hornby offers participating challenge. schools and colleges workbooks and The School of Engineering, Design and video tutorial materials to support the Manufacturing Systems experts tested Scalextric4Schools curriculum. Student building their own Scalextric Car students to the hilt in a STEM (Science, The day-long Scalextric4Schools Technology, Engineering and Maths) workshops, at Millennium Point, The Birmingham City University workshop, which saw participants build see participating students build an PTC Academy was the first of what a Scalextric car in a race against time; entire slot car from a set of prepared has become a global network of participate in a Pro-E Wildfire 5 CAD Scalextric components, including a PTC academies and the workshops masterclass; assemble slot cars and motor, transmission, axles and wheels. are designed to support the national race them against each other. STEM agenda in secondary schools The teams are also shown how to Based on the Scalextric4Schools and colleges. design and make body and chassis initiative local schools and colleges components and the assembled cars The aim is to invigorate the interest from the region took part in the event. are then tested and made ready for of teenagers in the subject of The School of Engineering, Design track-competition. engineering and energise the teaching and Manufacturing Systems is a of the subject. The best performing racing car from regular host of miniature slot car each school group then compete Dr Tim Burden, coordinator of the races, organised as part of the popular against the clock to determine an PTC Academy, said: “We show Scalextric4Schools initiative. More than overall winner. The lucky winners are youngsters just how creative 20 secondary schools and colleges given the opportunity to participate engineering is while helping them in the West Midlands have already in full-scale off-road go-karting, to understand how digital designs contacted Birmingham City University as well as competing in the annual become real life products. Young and the University’s PTC Academy, Scalextric4Schools national designers with engineering skills which specialises in computer-aided competition. must be encouraged and nurtured.”

KNOWLEDGE TRANSFER SUPPORT LEADS TO IMPRESSIVE RESULTS FOR MIDLANDS-BASED AEROSPACE COMPANY A successful Knowledge Transfer The KTP programme also gave the Partnership (KTP) programme with supervisory team a valuable insight Bromford Industries has led to into how the impact of their knowledge all-round benefits for the company and skills could change and develop and Birmingham City University. a medium-sized business such as Bromford. It was introduced following the completion of a highly successful Gary said the programme enabled training programme to the staff at an Enterprise Resource Planning Hampson Aerospace Machining, which (ERP) system to be adopted, now operates as Bromford Industries, which underpinned the company’s by the Lean Manufacturing Team. commitment to the Aerospace Knowledge Transfer Partnership (KTP) Industry’s best practice and improved General Manager Gary Lowe was programme with Bromford Industries its overall quality, cost and delivery keen to build on the success and was performance. keen that a KTP programme with overall management and operational the University would improve the capabilities”. It also enabled a further refinement company’s operational processes, of the plant’s ‘Lean’ operations and information systems, and overall He said, “… it helped to improve process improvement capabilities, staff skills. manufacturing planning and control, which specifically led to a successful management information systems £600,000 expansion project of the He described the partnership with and skills at all staff levels, as well fabrication facilities and the securing the University as “valuable” and an as enable the expansion of fabrication of a significant new customer. “affordable resource for the future facilities, which in turn led to new development of the Bromford Group’s business”.

4 UNIVERSITY’S KNOWLEDGE TRANSFER PROGRAMMES WITH MORGAN ACKNOWLEDGED AS WEST MIDLANDS’ ‘BEST’ The acclaimed Morgan Motor firm was awarded a Lord Stafford Company and Birmingham City Award for Achievement in Innovation University celebrated their long during 2007, while the first and third standing partnership with an award Government-supported programmes for excellence during 2010. were graded as “outstanding” by the national panel. The second, longer The work between the prestigious KTP programme, which successfully Malvern-based car manufacturer increased the efficiency of Morgan’s and the University was recognised manufacturing processes, was also in the national Knowledge Transfer highly rated. The School is currently Partnership Awards after being working on the second phase named the North West regional development of the LIFECar project. winner for ‘Best Partnership’. Graduate Matthew Humphries, The accolade acknowledges the the University’s third KTP associate success of the latest of three KTP worked with Morgan to transfer programmes that were launched with design-based technology into the the Morgan Motor Company by the company, has since become the University’s Faculty of Technology, company’s chief designer. with Morgan to realise my designs Engineering and the Environment, in both concept and production led by academic supervisor He styled Morgan’s exclusive and vehicles.” Dr Mike Daniels. highly-acclaimed AeroMax model and subsequently designed Morgan’s Rebecca Garrod-Waters, “We’re delighted our Morgan environmentally-friendly performance Director of Innovation at Advantage partnership has been identified as the LIFECar concept. West Midlands (AWM), said: “It’s West Midlands’ best among the many fantastic news that the partnership successful KTPs in this region” he “The KTP provided an excellent between Morgan and Birmingham said. foundation for my career in a hugely City University has received this competitive industry,” he said. “It has The KTP programme between regional award. Innovation is key to been particularly rewarding to work the university and the 100-year-old driving the West Midlands economy.”

Morgan Motor Company - LifeCar II

5 LEADING POWERTRAIN SYMPOSIUM DELIVERS LATEST DEVELOPMENTS ON TOMORROW’S VEHICLES Global automotive experts converged on Birmingham City University during November 2010 for a symposium on the developments being made to “future-proof”motor vehicles.

The University’s fourth Advanced The vehicle is being developed with Parmjit Chima, Head of the Powertrain Control Symposium the University, which is co-ordinating University’s School of Engineering, attracted delegates from as far away a double graduate-associate KTP Design and Manufacturing Systems as Japan and India, whilst other major programme through collaboration said: “The symposium provided a UK companies from the automotive with Oxford and Cranfield universities, unique opportunity for the automotive world also attended. to develop Morgan’s LIFECar over industry to engage, disseminate and a three-year period. exchange information on powertrain The biennial event brought together control systems – a key driver in the experts in the field of engines, hybrid The keynote address was given by design of new automotive vehicles of vehicle and alternative fuels to discuss Dr Daryao Khatri, Vice President of the future.” the future of powertrain control, SAE India on ‘Emerging trends in which refers to the components that Engine Technology’. generate power and deliver it to the Symposium convener, Dr Manjit wheels while optimising fuel economy Srai, said: “The automotive industry and emissions. is facing huge challenges to reduce Delegates, including representatives engine emissions and increase fuel from Jaguar Land Rover, Morgan efficiency as global oil production Motor Company and Ricardo also begins to fall.” discussed alternative fuels, hybrid “The symposium brings together vehicles and safety critical systems. leading automotive manufacturers Charles Morgan, grandson of and companies developing new tools, the Founder of Morgan Motor technologies and systems to optimise Company, told participants about not only conventional petrol and diesel the anticipated launch of the powertrains but also explore emerging

LIFECarII in 2012. trends in alternative fuels and hybrid Charles Morgan, Morgan Motor Company vehicles.”

HELPING KART-ENTREPRENEUR INNOVATE

Birmingham City University’s enrolled undergraduate and Several WA31s were subsequently Motorsports Technology degree course postgraduate students studying built for on-track action. The design was the catalyst for a partnership a range of engineering courses also accounted for the installation of between its Faculty of Technology, including Automotive, Mechanical and low-CO2 emission power-train options Engineering and the Environment Motorsports Technology can sample such as diesel, electric and hybrid. and locally-based, specialist off-road an off-road rally driving experiences Walker-Adams is now working Karting company, Walker-Adams Ltd. and witness other motorsport on the WA200, a 4X4 race buggy Liaison between the University’s demonstrations. also developed through significant Dr Tim Burden and Steve Adams, of To support Steve Adams’ desire involvement from students, with Walker-Adams Ltd, enterprising boss, to develop new dimensions to his their access to digital design and led to the University’s Motorsports business through diversification into other advanced resources at their Society launch with a competition at kart design and manufacture, students nearby campus. Students have also their nearby off-road track. It is now became involved in manufacturing a undertaken part-time work maintaining one of the most popular, regional prototype known as ‘WA31’. Exhibited buggies and running track events. motorsport experience locations for at Autosport International 2009, WA200’s ongoing student projects corporate and private parties. WA31 featured modular space-frame include design work on suspension, The company now regularly hosts sections designed to separate, allowing brakes, gearbox, frame and a new low an annual Freshers’ motorsport ease-of-access to the power-train for carbon Utility Vehicle. The first public event at the start of the Academic the regular repair and maintenance viewing of the WA200 is planned for the year during September. Newly demanded by a kart’s punishing life. Birmingham City University Stand

6 REGION’S TOP AUTOMOTIVE COMPANIES LOOKING FORWARD TO NEW BUSINESS OPPORTUNITIES Some of the region’s top automotive technology partners and explore Rowan Crozier, Sales Director at supply chain companies are looking the potential of KTPs. contract presswork and stampings forward to new business opportunities specialist Brandauer, said the Autolink Rachel Eade, Automotive Cluster after an event, backed by Birmingham event was “essential” for meeting Manager for MAS-WM, said “the City University, was staged in the city. potential customers and suppliers. feedback from SMEs and car The seventh Autolink event saw more manufacturers had been extremely “It opens doors, reduces travel time than 25 Midland SMEs, including positive”. and, by booking the meeting in advance, Brandauer, Powertrain, Sorion and “Low carbon was also a major you know you are going to see the Servosteel, showcase their expertise talking point and there were plenty people you really want to,” he said. to car manufacturers, including Aston of discussions about how the supply “We made three excellent contacts on Martin, SAIC and BMW. chain can get involved and work the day which could well lead to new The Faculty of Technology, Engineering with academia to explore existing value added contracts.” and the Environment also took expertise,” she added. advantage of the prestigious business event to demonstrate the value of its Knowledge Transfer Partnerships (KTP) with industry – and to display its highly acclaimed Formula Student Racing Car. Students spoke with delegates about future careers in the automotive industry and many attendees said how pleased they were to see the next generation of motorsport and automotive engineers being nurtured in the West Midlands. Autolink, which was also supported by the Manufacturing Advisory Service Autolink 2010 (l-r) Rachel Eade (MAS-WM Auto), Tony Spillane (SAIC), Matt Clive (UKTI), Steve Hayes –West Midlands (MAS-WM) and UKTI, (Sorion), Rowan Crozier (Brandauer) and Tom McDermott (Birmingham City University) gave firms the opportunity to talk to

at Autosport International 2011, taking place at Birmingham’s NEC. During the past three years students studying on BEng and MSc courses in both Automotive and Mechanical Engineering and a number of International Exchange students from Germany and Spain have undertaken joint projects and work experience with the University and Walker-Adams Ltd. Other nationals in the team are from the UK, Romania and India. The powerful, off-road racing WA200 is particularly exciting since its platform is capable of being adapted for other off-road uses, such as forestry and for potential on-road use, as a ‘city-buggy’. The Faculty’s involvement with Walker-

Adams Ltd could help establish a new Walker-Adams Off-Road Buggy force in this specialist automotive sector.

7 BIRMINGHAM CITY UNIVERSITY’S SPECIALIST SUPPORT ENHANCES ENGINE DEVELOPMENT, RESEARCH AND SKILLS TRAINING FOR ROLLS-ROYCE Birmingham City University’s Faculty of Technology, Engineering and the Environment is enjoying a successful, prestigious partnership with the aerospace division of Rolls-Royce, based upon the specialist knowledge and track-record of Craig Chapman, Head of Knowledge Based Engineering (KBE) at the University’s School of Engineering, Design and Manufacturing Systems. The relationship, which dates back to 2008, began with an initial twelve-month Knowledge Based Partnership (KBP), which focused on modelling Rolls-Royce’s advanced engineering systems, to provide better understanding, knowledge and intelligence of those key systems. The KBP programme relied upon the involvement of Maria Nicastri, the KBP Associate, under the careful leadership of Craig Chapman and guidance of Ardavan Amini (University Lecturer). The KBP project resulted in many positive outcomes for Rolls-Royce in the understanding of the complex relationships between Key systems. Maria Nicastri has joined a growing number of researchers who have passed through Craig’s KBE lab to become permanent members of Rolls-Royce staff. Birmingham City University’s working relationship with Rolls-Royce was further enhanced through the support of Carl Barcock, Head of Design further modelling of key systems and research-focused activities, the Methods within Design Systems developing potential architectures Faculty’s KBE lab also embarked Engineering and Michael Moss, to enhance Rolls-Royce design on a programme of bespoke training Corporate Specialist Knowledge automation systems. To support this for Rolls-Royce’s senior management Management within Design Systems project, Steve Suman, a Birmingham and key engineering teams. All Engineering, when the University was City University graduate, was participants gained a CPS (Certificate selected to enter into a commercial, recruited as Research Associate, and for Professional Studies) in Knowledge research activity built around the investments made at Millennium Point Based Engineering which acted as £90m, Technology Strategy Board to develop the KBE lab in order to fully an important catalyst for stimulating funded Strategic Investment in Low support the Rolls-Royce research further discussion and meetings with Carbon Engine Technology (SILOET) initiatives. the University in order to identify Project, which continued the initial exciting new research initiatives. work of the KBP by investigating In addition to these impressive In the spirit of true collaboration, benefits have been mutually-shared between both parties and University CONTACT US students studying undergraduate or postgraduate courses, with KBE- For further information on the faculty’s Engineering, Automotive related modules, have the ability to and Motorsports portfolio, please contact us: visit the Rolls-Royce aerospace plant, Birmingham City University to see directly how KBE is being used to enhance the design of Jet engines. Faculty of Technology, Engineering and the Environment Millennium Point, Curzon Street, To obtain further details about Birmingham B4 7XG. the University’s Knowledge Based Engineering expertise, please contact T: 0121 331 5400 F: 0121 331 5401 [email protected] or call E: [email protected] W: www.bcu.ac.uk/tee 0121 331 5400. Alternatively, visit our website www.bcu.ac.uk/business

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