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Visit our new show at the NEC in June page 43 Down town Innovative thinking on subterranean cities »18

Careers section Future forming Driving change A new institution The upcoming GKN’s senior aiming to train developments engineer on the industry-ready in additive move to all-wheel engineering manufacturing »23 hybrid drive »28 graduates »52 For more news, jobs and products visit www.theengineer.co.uk

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inthisissue inouropinion Volume 296 Issue No.7863 | Established 1856

News Can you dig it? 05 Technology US plans to trial deep-hole There are some trends that always seem set waste disposal method to continue. General elections will keep getting more depressing than inspiring. Hollywood will 06 Technology Skeleton Technologies’ keep making superhero movies. And populations ultracapacitor set for space mission will keep moving from the country into cities. 10 Design Tiny antennas able to squeeze As the need to fi nd room for urban working and living intensifi es, it inevitably falls to onto computer chips could be built engineers to think up solutions. In the 1920s, 62 Digest This issue’s crossword, they built tall; and in some parts of the world plus a look through the archives they still do. Elsewhere, however, the pressures of city planning and sometimes unpleasant open-air environments are leading to an increasing interest in looking underground. Opinion In this issue’s cover feature (page 18), we take a look at some of 12 Viewpoint Neil Hopkinson on leaders the most innovative approaches to underground civil engineering in cities, from an inventive solution to an everyday problem in Tokyo; the 14 Mailbox Your letters to the editor and remarkably practical approach to planning in Helsinki, where the local views from www.theengineer.co.uk taste for an active lifestyle has to be balanced by the frostbite-inducing 16 Paul Jackson The future of the NHS weather for much of the year; and an ambitious plan for an inverted skyscraper underneath the most important public square in Mexico City. 28 Interview Rob Rickell, GKN Driveline Our Q&A (page 30) stays with the subterranean theme, taking us into the tunnels and caverns of CERN in France and Switzerland for a Features rare insight into the engineering, rather than the physics, of the Large Hadron Collider (LHC). Senior engineers answer our readers’ questions 18 Cover story Going underground to on how the LHC was upgraded to double its power, allowing it to resolve overcrowding issues in cities hopefully shed light on the most puzzling theories about the universe. 23 Additive manufacturing Production We come back to the surface for our interview (page 28), where the senior engineer of automotive technology provider GKN talks about how of entire electronic devices in one shot hybridisation is improving the capabilities 30 Q&A Large Hadron Collider The need to of road vehicles, including giving the 35 Pharma Healthcare manufacturers are fi nd room for urban performance of all-wheel drive without the “ increase in fuel consumption and emissions beginning to rethink process solutions working and living conventionally associated with them. 39 Drives and motors Siemens hopes to is intensifying Elsewhere, you can read about the shape introduce a hybrid passenger aircraft of things to come at the cutting edge of 3D printing from one of the main centres for its development, Prof Richard 43 Show previews The Engineer Hague’s labs at Nottingham University (page 23); the engineering Conference, TEDIS, Subcon and more consequences of the pharmaceutical sector’s shift towards more 52 Careers Graduate skills personalised medicine (page 35); and moves towards the development of hybrid passenger aircraft (page 39). A preview of what visitors to some Your number-one website for upcoming exhibitions can expect rounds off our May issue. engineering news, views, jobs and products theengineer.co.uk Stuart Nathan Features Editor [email protected]

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TE_0515 4 05/05/2015 11:03 Find the latest news, jobs & products at www.theengineer.co.uk news:technology

readmore online theengineer.co.uk

Aerospace ISS laser plan to clear space debris

Automotive Eye-inspired camera can work outdoors

Energy 3D-printed aerogels could aid storage

Manufacturing NUCLEAR ABB launches robot able to work US set to trial deep-hole alongside humans Electronics waste disposal method Brain-inspired computer memory Technique is said to be cheaper than the proposed mined repository consumes less energy

BY HELEN KNIGHT To ensure the waste is protected from leakage, Rail and marine A method to safely bury the world’s most highly corrosion or theft after it has been buried, the radioactive nuclear waste in holes 5km deep will be researchers have been developing two distinct Fresh approach to old tested in the US next year. The technique, developed sealing techniques, which they recently presented design marks rebirth in the UK by researchers at Sheffi eld University, at a conference held by the American Nuclear of B17 locomotive involves drilling a borehole around 0.6m wide Society in Charleston in the US. and 5km deep and lowering the waste into it. Firstly, the waste would be slowly lowered down Known as deep borehole disposal, or DBD, the the hole in metal containers, and then a specially Medical technique is much cheaper than the mined repository developed sealing and support matrix would be Software pins down proposed by the UK government for burying the poured in with it. country’s nuclear waste, according to its pioneer For ‘hot’ radioactive waste – that which gives off correct vertebra for Fergus Gibb, emeritus professor of petrology and heat of more than 190ºC as it decays – metal alloy surgery geochemistry at Sheffi eld University. shots that melt into a solder to seal the waste in the Each borehole would cost a few tens of millions casing would be used, said Gibb. Aerospace of dollars to drill, compared with hundreds of millions But for waste that does not give off as much heat, to tens of billions for a mined repository. Around six Gibb’s colleague, Dr Nick Collier, is developing a Reusable Vulcan boreholes would be enough to store all of the UK’s special type of cement that can be poured down the space rocket unveiled existing high-level waste, said Gibb, with each taking hole, which will not set until it reaches the bottom, less than fi ve years to drill, fi ll and seal. up to fi ve hours later. Manufacturing Deep borehole disposal should also be safer than a Once the waste has been sealed in position, mined repository, which at 500m deep would still be the hole is then fi lled above the disposal zone with Banks introduce within the zone of circulating ground water, meaning crushed granite, said Gibb. An electric heater is used funding for tooling any leakage caused by an earthquake, for example, to melt the granite, which is then cooled slowly to could potentially return to the surface, he said. allow it to re-crystalise, in a process known as rock “By going down several kilometres, it means the welding. “So we create a weld that is both continuous Civil disposal zone at the bottom of the borehole is in a with, and identical to, the host rock around the Automatic window geology that is below, and isolated from, the normal borehole,” he said. “This completely seals the hole, ground water,” he said. “So even if the waste just as if you’ve never drilled through it.” shade harnesses sun eventually leaks out of the containers into the The US trial, which is being run by Sandia National to keep buildings cool surrounding rock and water, it will never come Laboratories for the Department of Energy (DoE), will back to the surface; instead it will leak into waters take place at a yet-to-be-determined site in late 2016. Energy in the deep rocks that have been isolated from the If it proves successful, the DoE plans to build a surface waters for millions of years.” much smaller, 22cm-wide hole to dispose of small Study sheds light This should make it easier to gain public capsules of highly radioactive cesium and strontium on energy storage acceptance for a burial site, Gibb explained. being held at the Hanford nuclear facility in Although not a new idea, deep borehole disposal Washington State. has only been made possible by recent advances in drilling by the oil and gas and geothermal energy For news and jobs visit industries, he said. To comment visit theengineer.co.uk us at theengineer.co.uk

MAY 2015 | theEnGineeR | 5

TE_0515 5 05/05/2015 14:44 news:technology Find the latest news, jobs & products at www.theengineer.co.uk

SPACE TECHNOLOGY inbrief Surging forward More news daily at theengineer.co.uk ESA selects Skeleton Technologies’ ultracapacitor for space mission Powertrain partners BY JULIA PIERCE Mira and Samsung Techwin The European Space Agency (ESA) has chosen a are to work on battery and new ultracapacitor energy storage technology that powertrain systems for increases safety while reducing weight and costs automotive and off-road for a possible mission in 2018. hybrid and electric vehicles. Originally developed by Estonian start-up Samsung Techwin is a Skeleton Technologies for use in the motor industry, Samsung subsidiary that the technology is 60 times lighter and 30 times more develops energy and security

effi cient than the lithium-ion batteries it will replace, Airbus Defence and Space ESA 2015, systems. During a three- considerably reducing the amount of weight and year collaboration, they will room required for energy storage on a space vehicle. develop optimised systems While batteries can store more energy than ultra- for commercial, defence and capacitors, they are slow to charge and discharge niche vehicles, using Mira’s and lose 30 per cent of their energy through heat expertise in battery and alone. They also require frequent replacement. New technology increases safety powertrain design, validation Such an energy storage system is required by and testing, and Samsung’s spacecraft and satellites to provide surges of power undertaking further testing of the devices in space- manufacturing facilities. when required. Energy from the Sun is harvested like conditions, with high radiation and in a vacuum. using solar cells and is stored for when the vehicle The advantage of our ultracapacitor is that no Winging it moves to the dark side of a planetary object, away chemical reaction takes place when charging it, NASA and partners have from the Sun, where the power is used for tasks unlike with a lithium-ion battery, which can combust completed initial fl ight tests such as adjusting antennas and moving solar arrays. if it is faulty. With the Skeleton system, the ions of a new morphing wing Skeleton Technologies’ system uses patented are changing places in the electrodes, making it technology that could reduce nanoporous carbide-derived carbon (CDC), also a physical, not chemical reaction. This means we fuel costs, airframe weight known as curved graphene. They have also have no issues at all with, possible explosions.” and aircraft noise during developed a proprietary method for preparing As the ultracapacitors store energy in an electric takeoffs and landings. the ultracapacitors. fi eld rather than in a chemical reaction, they are NASA’s Armstrong Flight “We took a technology that was widely used highly effi cient at delivering sudden surges of energy Research Center in California in the motorsport and tier-one automotive market and can charge and discharge more than a million fl ew 22 research fl ights and deconstructed and reconstructed this for use in times, delivering signifi cantly more power for weight with experimental Adaptive space in, for instance, a high-radiation environment,” than batteries. With every pound of payload put Compliant Trailing Edge explained Oliver Ahlberg, Skeleton Technologies’ into space currently costing around €9,000 (£6,500), fl ight control surfaces, which general manager. adopting this technology is expected to achieve offer improvements over “Normally, our products have twice the energy and signifi cant effi ciency savings. conventional fl aps used four times the power of our competitors’ systems, but As well as the motor industry, the technology is on existing aircraft. the performance of this is even better. However, in also making inroads into use in the development of space, safety is a major concern. We are currently smart power grids. Explosive new research Research illustrating what ELECTRONICS happens when Lithium-ion batteries explode could help engineers improve their design and make them safer Star of the screen for transport and use. The study carried out by UCL, Team of UK researchers develops new class of ultra-thin displays ESRF, Imperial College London and the National BY JULIA PIERCE also used to create CDs and which is essential as, if the Physical Laboratory shows A team from Oxford University Blu-ray discs. image is too slow in refreshing, for the fi rst time how has created an entirely new class Dr Hosseini said: “The ultimate, it will cause the user nausea. internal structural damage of ultra-thin, ultra-high-resolution most diffi cult yet most exciting Importantly, it also does not to batteries evolves in real- displays with nanosecond access application of this is the building consume power when resting, time and how this can spread speed and no power consumption of a high-resolution nano-display. conserving battery life.” to neighbouring batteries. in static mode. “In, for instance, a Google The fi rst prototype displays The technology has a range of Glass device, you need to display are currently under development, Colour scheme applications in the rapidly growing a picture or video on a very small with a small working device set New research reveals the microdisplay market, and can be screen in front of you. This display to be completed within the next potential for graphene used in compact, projection-based must have a very high resolution 12 months. to help bring 3D colour displays such as those of emerging when magnifying the image.” One of the fi rst applications of holograms closer to fruition. near-eye applications. Hosseini continued: “On the display is likely to be in smart Led by Swinburne University Headed by Dr Peiman Hosseini Apple’s latest retina display jewellery that can change colour of Technology, Melbourne, of Oxford University’s Department system, one pixel equals 66 with a very pure brightness, and scientists have capitalised of Physics, the researchers’ micrometres. With our technology, Hosseini and his colleagues are on graphene’s properties and nano-display device utilises the whole picture must be only currently speaking with a major are confi dent of applications optical and electronic property 79 micrometres in size. brand to develop this. Other in fi elds such as optical data modulation in phase-change “Our device is also three times applications include security- storage and imaging. materials – materials that are the speed of existing technologies, tagging systems.

6 | theEnGineeR | MAY 2015

TE_0515 6 05/05/2015 18:24 TE_0515Bluebeam_FP_TE_0415.ps 7 1 05/05/201526/02/2015 11:0410:01 news:technology Find the latest news, jobs & products at www.theengineer.co.uk

The new valve LASERS design will not harm spacecraft Message in a bottle Plasma implants could help protect against potentially dangerous counterfeit goods

BY HELEN KNIGHT When these pulses, which An ultra-fast laser system that contain large amounts of energy, creates unique images within are focused onto a target material, glass bottles could protect the material converts it into consumers from potentially plasma in an ablative process, dangerous counterfeit goods. said Murray. The manufacturing platform, “Because of the tremendous dubbed ULPI (Ultrafast Laser amounts of energy involved, it Plasma Implantation), is causes [this plasma] to explode designed to create plasma that off the surface at high velocity, in is implanted into the glass to what looks like an aerosol spray,” generate individual patterns he explained. on the surface of the bottle. This plasma is then captured These could be used to in the glass bottle to become SPACE TECHNOLOGY identify individual bottles or implanted within the material, batches of alcoholic beverages, said Murray. pharmaceuticals or perfumes, “We are mixing up the target Cosmic event for according to its developer Dr and substrate material during this Matthew Murray, a research implantation process, and when fellow at Leeds University. we do that we create a unique AMRC design duo “Our aim is to create a environment that can’t be security measure that is in place replicated through any other Explosive-free valve design receives right from the moment that the kind of process,” he added. Space Propulsion Innovation Award glass comes out of the furnace, In this way, the system is able up to the point that it goes into to create unique optical signatures BY JULIA PIERCE Krumins, project engineer a customer’s home,” explained that can describe where or when A safer, pyrotechnic-free design for (design) at AMRC’s Design and Murray, who was recently a product was manufactured, and space valves from the Advanced Prototyping Group said: “The awarded the Royal Academy of by whom. Manufacturing Research Centre’s shape of the piston in a pyro Engineering ERA Foundation A spin-out company, (ARMC’s) Design and Prototyping valve is usually cylindrical and Entrepreneurs’ Award for the Ultramatis, has been created to Group has won the UK Space it has O-rings on it to create a technology, known as Alpin. commercialise the technology. Agency’s UK Space Propulsion better seal. To create the patterns, the Innovation Award. “While designing the permanent system uses a femtosecond laser, Sam Hyde and Valdis Krumins valve, we realised that there is a which creates a series of very For the latest jobs visit beat 14 fi nalists from leading mature solution in medical sector, short light pulses. theengineer.co.uk/jobs space science companies, design which does a somewhat similar agencies and university research task – a Luer slip connector that centres with their new design for is used to secure a needle on a AEROSPACE permanent valves – valves on a syringe,” Krumins explained. spacecraft that operate only once He continued: “Luer slip during a mission, after which they creates a good seal between Making light work remain open or closed. two tapered surfaces and does Currently, standard valves use a not require O-rings. It is a simpler A UK-based ‘airship’ company has pyrotechnic activator consisting of solution and has a larger contact received a €2.5m funding boost a small explosive charge to open surface area, which potentially or close valves permanently. creates a better seal. UK company Hybrid Air Vehicles has been awarded €2.5m However, fi ring creates gases, “Our concept is simpler (£1.8m) of European funding to refi ne the development of its particles, shocks and vibrations, and safer to assemble when ‘lighter-than-air’ hybrid aircraft technology. which can break welds and compared with existing pyro Based at Cardington in Bedfordshire, the company has been cause the satellite or rocket valves, which house a small refi ning its technology for a number of years and, following an to be damaged. charge of explosives. It is scalable abandoned project to develop a high-altitude reconnaissance The pair replaced the moving and can be used in almost any aircraft for the US military, is now working on a civil variant cylinder of the old valve with a application in which there is a of its technology. tapered cone and replaced the need for a valve that has to open According to the company, the funding – which has come explosives with a simple spring, or close permanently.” through the EU’s Smart, Green and Integrated Transport which is compressed and secured The pair plan to use their Societal Challenge programme (part of the Horizon 2020 seven by a piezoelectric trigger. £10,000 prize money to conduct year research programme) – will be used to continue work on When a current fl ows through a desktop study and to build a refi ning the civil variant, as well as to help develop a regulatory the trigger, it releases the spring, partial technical demonstrator framework for the vehicles. which pushes the valve into its for testing the critical parts of The company, which has also received £2.5m from Innovate new, permanent position. the concept. UK, a grant from the Regional Growth Fund and money from a The trigger returns to its Hyde added that he hopes number private investors including Bruce Dickinson, front man original position when the current the project marks the start start of of rock band Iron Maiden, is also looking to raise funds on is switched off and then prevents wider engagement between AMRC crowdfunding platform Crowdcube. JE the valve from moving back. and Britain’s space industry.

8 | theEnGineeR | MAY 2015

TE_0515 8 01/05/2015 11:34 Find the latest news, jobs & products at www.theengineer.co.uk news:technology

ENERGY All walks of life Pavegen set to provide London’s Canary Wharf with a sustainable energy boost

BY JULIA PIERCE Group to help small businesses A pilot project that is designed to set up pilot projects and grow. create electricity from the footfall With 100,000 commuters of commuters is set to be installed passing through Canary Wharf at London’s Canary Wharf this each day, the public spaces are summer, helping the district to be an ideal place to place the tiles in more sustainable while enabling order to gather footfall data as well vital data to be gathered on as generating renewable energy. visitors’ habits. “As well as generating energy, Pavegen’s fl ooring technology we can look at real-time analytics consists of slabs that are of footfall and where people go,” constructed from recycled rubber said Laurence Kemball-Cook, an The VCCO is part of Dstl’s Cyber and polymer concrete that convert industrial design engineer and Situational Awareness project the weight of a footstep into a graduate of Loughborough renewable electricity. University, who created Pavegen DEFENCE AND SECURITY When a slab is stepped on, it while researching kinetic off-grid defl ects the top sheet by 5mm, energy solutions in areas where and the movement is converted low-carbon technologies such as Operations centre set to electricity, which is delivered solar and wind are not practical. into a regulated 12V feed. “We can then do things such Unlike other energy-harvesting as targeting advertising,” he said. to protect key assets systems, Pavegen’s technology “We can see how the high street does not rely on piezoelectricity, is performing in real time.” Airbus takes charge of a system designed where energy spikes make it hard In a related development, a to shield the military against cyber attacks to give a constant fl ow of energy. recent collaboration with Samsung Each step on a Pavegen slab saw shoppers in Sandton City mall BY JASON FORD The VCCO project will show contains enough energy to power in Johannesburg using a 68-tile A system designed to verify and how virtual collaboration might an LED streetlamp for 30 seconds. walkway to power an interactive mitigate cyber attacks on military give commanders a better The energy conserved can also be screen, displaying real-time assets is being developed by understanding of how they are stored in lithium polymer batteries footfall data and providing a visual Airbus Group Innovations. being targeted by cyber enemies underneath the fl oor to be used at payback of the energy harvested Airbus Group Innovations will on the battlefi eld. a later date. from its monthly footfall rate of lead a 16-month study following Jones said: “If we think about The technology was a fi nalist two million footsteps. This power the award of £1.4m from the a distributed network… I’m likely in the Cognicity Challenge award, was then channelled to deprived Defence Science and Technology to have many cyber-security a scheme run by the Canary Wharf communities in South Africa. Laboratory (Dstl) to develop the operation centres or many pieces Virtual Cyber Centre of Operations of the jigsaw. How do I bring (VCCO), which is part of Dstl’s them all together? That’s what SENSORS Cyber Situational Awareness VCCO will do. It will sit in the research project. middle, [and] provide you with “Cyber situational awareness all the tools, all of the information Gate to success is a very diffi cult problem because, you’d expect to see in a physical in the modern era, we have very [cyber] security operations centre Rapid single-electron sensor developed in complex digital systems that are but in a virtual world,” he said. the UK holds promise for quantum devices interconnected,” said Dr Kevin “In this environment, I could Jones, research team leader also have experts ready wherever A European team in Cambridge has designed a sensor that – Cyber Operations, Airbus Group they are in the world to help me can detect the charge on a single electron in the fastest time Innovations. “I’m not just talking solve my problems in real time,” ever recorded. about information; I’m taking about Jones added. “The advantage here Researchers at the laboratory where the electron was assets – UAVs [unmanned aerial of a virtual environment is that discovered in the 19th century have designed a sensor vehicles] and ISTAR [intelligence, these people can come in to a live that can detect the charge of a single electron in less than surveillance, target acquisition, situation to a live cyber event and a microsecond. The sensor, which was designed at Cambridge and reconnaissance] assets. understand exactly what is going University’s Cavendish Laboratory, could be used in quantum “As they are interconnected on as if they are physically present computing to detect information stored in a single electron’s and highly complex, we have to in that room.” charge or spin, the team claims. be able to understand the whole The collaboration between Known as a gate sensor, the device gets its sensitivity domain, all of those assets within Airbus Group Innovations, MooD through coupling to a silicon nanotransistor that forces that domain and the types of International and Xuvasi follows electrons to fl ow effectively in single fi le, the team explained attack that people are going to initial research by each supplier, in Nature Communications. put against those types of assets.” previously funded through cyber- The new device is more compact and accurate than previous During the project, Airbus themed competitions run via Dstl’s gate sensors and the detection speed of around a nanosecond Group Innovations will work with Centre for Defence Enterprise. is the fastest obtained so far for this type of system. MooD International and Xuvasi Devices such as ultra-precise biosensors are all predicted to develop a 3D virtual world to to work by using the properties of individual electrons. SN enable collaboration and shared For the latest jobs visit situational awareness. theengineer.co.uk/jobs

MAY 2015 | theEnGineeR | 9

TE_0515 9 05/05/2015 14:45 news:design Find the latest news, jobs & products at www.theengineer.co.uk

MEDICAL Shoulder injuries hang by a thread Nanofi bre trials are set for later this year

BY HELEN KNIGHT Now the researchers have A nanofi bre thread designed for developed a technique to spin use in medical sutures could enter the fi bres onto a moving wire, clinical trials later this year in allowing them to stretch out very surgery to repair injured shoulders. long strands. “We can effectively The antennas can The thread, dubbed Bioyarn, make a ball of electrospun yarn,” be used in RFID has been developed with a novel said Chalkias. manufacturing technique by The technology is based on researchers at Oxford University. conventional electrospinning, in COMMUNICATIONS They hope to begin testing it which a solution is drawn through in surgery to repair torn tendons an electrically charged hollow in the rotator cuff. Around 40 per needle onto a grounded target, Antennas shrink to cent of surgeries on this painful in this case the wire. condition fail and the researchers As the solution is drawn hope that the thread will improve towards the wire, it stretches out fi t in computer chips the success rate. into a very fi ne fi bre. Then, as the Nanoscale fi bres are extremely wire moves past the needle, the Researchers utilise thin-fi lm materials porous and have a very high material attaches to it and is surface area by volume, making drawn along with it. BY HELEN KNIGHT is applied to them, are a type of them excellent candidates for “Since the fi bre does not stick Wireless antennas small enough dielectric, or insulating, material. use in surgical sutures, tissue fast to the wire, it can simply be to squeeze onto computer chips Piezoelectric thin fi lms are much scaffolds and wound dressings, peeled off using an automated could be built thanks to research more effi cient at storing energy according to Nikolaos Chalkias, machine,” explained Chalkias. at Cambridge University. within a certain volume than the senior technology transfer “We can then weave that thread The antennas – 10 to 100 dielectric materials conventionally manager at Isis Innovation, into fabrics or into medical device micrometres in size – could be used for mobile phone antennas, Oxford University’s technology materials like patches.” used in mobile phones, radio according to Amaratunga. commercialisation company. Thanks to their nanoscale frequency identifi cation (RFID) But the researchers found Until now, there has been dimensions, these patches tags and the so-called Internet of that at a certain frequency, the no way to reliably produce very can mimic the extracellular Things. The research is published materials also become effi cient long fi laments of the material, environment within human tissue, in Physical Review Letters. emitters of electromagnetic which would allow it to be woven meaning that they should help Antennas are designed to work radiation, thereby becoming into different types of fabric or support cell growth, according by converting electrical energy effective antennas. medical devices. to Chalkias. into electromagnetic, or radio, They attribute this to a process waves. These radio waves are then known as ‘symmetry breaking’ of AWARDS picked up and converted back into the device’s electric fi eld. electrical energy by an antenna on “This simply means that the receiving device. the energy of the electric fi eld But while the electronics used is changed in time or space,” African innovation in mobile devices are constantly said Amaratunga. shrinking, the antennas have By connecting only one end Engineers gain recognition in new event remained bulky in comparison, of the material to an electric signal said Gehan and leaving the Technologies developed by African engineers have been named as Amaratunga, other end free, fi nalists in the Royal Academy of Engineering’s newly launched Africa professor of Typical mobile the researchers Prize for Engineering Innovation. engineering phone antennas were able The prize – which is claimed to be Africa’s biggest award for at Cambridge “ to break the engineering innovation – was established to stimulate innovation in University, who occupy a quarter of symmetry of the Sub-Saharan Africa and covers all disciplines from mechanical, civil and led the research fi eld, generating computing to biomedical, oil and gas, mining and electronic engineering. team. “At the the device’s cover electromagnetic The four fi nalists include South African engineer Ernst Pretorius, moment, there radiation. who has developed a fence-mounted security that warns owners of fi res is no prospect of integrating “If you excite the material or intruders, and Tanzanian engineer Dr Askwar Hilonga, whose sand- the antenna onto a chip because from one end and leave the other based nanofi lter is able to remove a range of contaminants from water, it’s just too big,” he explained. “A end fl oating, then – as the energy rendering it safe to drink. typical antenna used in a mobile builds and cannot be returned to Another fi nalist is Zambian innovator Musenga Silwawa, whose phone occupies around one a supply through another contact fertiliser applicator offers an alternative to manual fertiliser application quarter of the device’s cover.” – it is released as electromagnetic for small-scale farmers. To overcome this, the waves,” he said. The overall winner – to be awarded £25,000 – will be chosen after the researchers investigated the use The work was carried out fi nalists present their engineering innovations and business plans to the of piezoelectric thin-fi lm materials alongside researchers from the judges at a ceremony in Cape Town later this year. JE such as gallium nitride and National Physical Laboratory gallium arsenide. These fi lms, (NPL) and Cambridge-based source.theengineer.co.uk which vibrate when a voltage company Antenova. For the latest products & services visit

10 | theEnGineeR | MAY 2015

TE_0515 10 06/05/2015 13:05 Who will make “searching for a signal” a thing of the past?

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TE_0515National Instruments_FP_TE_0515.ps 11 1 05/05/201520/04/2015 11:0512:12 viewpoint:neil hopkinson Follow the leader

Targeting specifi c leadership programmes at undergraduate level is necessary, says engineering professor Neil Hopkinson

e don’t just need more engineers in Some individuals was having leaders the UK – we need more engineering have what it with experience in both W leaders. And where better to fi nd takes to play a industry and research. them than among our undergraduates? There leadership role So what extra skills are now plenty of excellent initiatives to get do we need to provide schoolchildren interested in science and within a leadership engineering, and these are feeding through programme and how do to increasing applications at degree level. we identify the students Targeting more specifi c leadership programmes who will benefi t? At at undergraduate level is now needed. Those Sheffi eld, we defi ne the that walk through the doors of our universities attributes we want the signed up to a four-year master’s in engineering, SELA cohort to display are all high-quality candidates, destined for a now, the extra skills we great career. But also among them are some believe they will need exceptional individuals who have what it and how those will be takes to play a leadership role in the sector. taught. For example, we To be honest, these individuals might rise to believe our future leaders the top anyway – eventually. But as we know, need to be enterprising. the need for leadership is there; it makes sense For this, they need creativity, proactivity and to help them on their way as much as we can. Running leadership the ability to problem-solve. When being interviewed for the new Sheffi eld programmes is a sensible We look for evidence of this in a student’s Engineering Leadership Academy (SELA), one “ application to join SELA and in the interview. of our students described it perfectly. He said solution to help students Once selected, SELA provides training in that being part of SELA would get him on the these areas through the initial boot camp that motorway to a leadership role; without it, he’d to engage more easily students attend and two group projects they have to get there on the A-roads. undertake over the two years of the programme. SELA is the fi rst extra-curricular leadership don’t get experience of actually doing research We’ve identifi ed other leadership qualities in programme in a UK university to cover all until their fi nal-year dissertation project. The a similar way: good judgement; technical and the engineering disciplines – unashamedly SELA programme includes two summer work academic ability; the ability to inspire others, modelled on US initiatives such as the Gordon placements; these can be in research or industry. to create and communicate a compelling and Engineering Leadership Program at MIT. The needs of industry and academic purposeful vision of the future; fl exibility; self- The RAEng leadership awards also target engineering research are closely aligned. A awareness of your strengths and weaknesses undergraduates across the UK. This is an 2011 EPSRC/Cambridge University review and a willingness to learn; and fi nally personal excellent scheme but, necessarily, has a limited of international approaches to manufacturing vision, ambition and courage. SELA seeks reach. Running leadership programmes on research concluded that to compete globally to enhance these attributes through work campuses is a sensible solution to reach a the UK needs more engineering research placements, skills workshops, group projects, critical mass and to enable time-pressured leaders. The report looked at approaches to guest speakers and mentors. engineering students to engage more easily. manufacturing research in the US, Germany, Sheffi eld University may be the fi rst in It is also in our interest to do it – and by ‘our’, Japan, Sweden, China and Singapore that the UK to set up this kind of engineering I mean both UK plc and Sheffi eld University. were signifi cantly different to the UK and that leadership academy, but given the advantages We do believe the benefi ts to industry will be could offer competitive advantage. It found these schemes bring for all involved, don’t be enormous – helping it to identify exceptional the UK lagged behind these nations in aspects surprised to see other institutions follow suit. candidates and starting its leadership education including the importance placed on the role early. But there’s a benefi t to Sheffi eld’s Faculty of doctoral engineers in underpinning the Neil Hopkinson is professor of of Engineering as well. We want to be able to manufacturing research base. The report stated manufacturing engineering at Sheffi eld identify potential future leaders in engineering that without close interaction between the University and director of the Sheffi eld research and enable them to assess if studying research base and real-world manufacturing, Engineering Leadership Academy with us for a PhD is a worthwhile step for the UK would not be able to compete in the their career. Our undergraduates are taught by new science- and technology-based industries Join the debate at theengineer.co.uk academics who are active in research, but they of the future and that key to this interaction

12 | theEnGineeR | MAY 2015

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TE_0515 13 05/05/2015 14:12 mailbox For more news, views and information visit www.theengineer.co.uk

thehottopic What makes an engineering hero?

role in the invention of radar. Free thinking, Even architects are outstripping you Leslie but a team player, the drama showed him with Restoration Man etc, showing people Howard as far warmer than Turing and so a far better how to make something modern instead of played RJ role model. Pity someone couldn’t commission seemingly wallowing in the past. Mitchell a drama on the role of Tommy Flowers and his The boring presentation of engineers in The Post Offi ce team in the development of the fi rst in fi lm and media is because that’s the way First of computer, to counter the image of engineering you seem to the rest of the world. And little the Few conjured up by The Imitation Game. wonder when the best some engineers can Anonymous do is tediously slag off the higher-education system and art students, who do a damn site Victims of your own success once again, better job of selling their profession than as it’s the engineer’s accomplishments that engineers do engineering. are celebrated rather than their characters. David Redfern What you need is XGineers or Strictly Come Engineering to promote your image as team Two brilliant depictions include: The people, not loners. And I am serious here, Challenger Disaster, following Richard the technology engineers are promoted as Feynman’s quest to get to the truth, and The characters and quirky individuals with cult Wind Rises. The latter is a Japanese animation followings – the late Steve Jobs being the depicting the life of a talented aeronautical best technology ‘engineer’ at the PR craft. engineer, Jiro Horikoshi, who was the key Although, to be fair, mechanical engineering driver behind the design of what became always had the guy who presented Traction the Mitsubishi Zero in WWII. It shows hours Our piece on recent depictions of Engine and Industrial Chimney Weekly on the of thought and draughting required at the engineers on stage and screen generated BBC for years, and most of you gathered round expense of a personal life. It includes a gritty lively debate and some suggestions the telly agreeing that “them were the days”. depiction of how he had to navigate his way No wonder the youth of today aren’t through internal and world politics to achieve What about Alan Turing in The Imitation interested in engineering, while there are his personal goal of perfect fl ight. There is Game: again portrayed as a lone genius glamorous and interesting things such as memorable scene where he convinces his responsible for creating the Bombe, when in abseiling or base jumping off the biggest team of the possibility, even with the restricted fact he worked on a team developing an bridge in the world you have just constructed; resources available at war time. A fi lm quite original Polish invention. And there was engineers would rather discuss rivets or welds unlike any most mentioned in these pages. Castles in the Sky, depicting Watson-Watt’s or something equally tedious. Andrew Codd

inyouropinion

Divestmentdiscussion •I was reading recently (assuming it is •The problem with remote locations is the Our poll on the Guardian’s campaign correct) that our government is still spending inherent risk in getting the waste to them. to persuade charities to divest from billions each year, searching for oil. This would Editor petrochemical interests promoted perhaps be better spent on renewables. With oil some strong feelings. being a large and integral part of the economies •Such fi nal disposal of these materials may •It is not really investing. The only money that of so many countries, I would have thought a well be considered a mistake in the future reaches the company is during an IPO. After slow gradual natural decline in usage and share when they can be used as fuel in new reactor that, the ‘invested’ money goes to another prices, as renewables take over, would be the designs. The total quantities are quite small; as gambler (i.e. an investor). In my humble safest scenario – rather than trying to change was said, above six 60cm boreholes is enough opinion, better investments would be in cost things too quickly by making oil a dirty word. for Britain’s stockpile of these materials. savings – insulation of buildings, for example. If David Hogan Roger surplus money needs to be parked somewhere to prevent it being taken by government, there •And yet when I tried to bury all that old are probably better places than engaging in the Nuclearsafety asbestos off my garage roof in a ditch behind snowball system called the stock exchange. A recent news story about a method of Sainsbury’s, I got a £400 fi ne and was bound Ralf Muller disposing of nuclear waste in 5km-deep over by the magistrate. As usual, it’s one rule holes attracted a few suggestions. for Sandia National Laboratories and one rule •The only effect of divesting is to give people for the rest of us. a warm feeling that they’ve done something. •This sounds like a really cost-effective way Prof John Fortescue Maybe then they won’t have to worry about to dispose of nuclear waste. (Hopefully, though, the damage they cause to the environment valuable spent fuel won’t be disposed of, but •Why dispose of it at all when the new when they burn the oil. It’s not going to will be recycled). Existing disposal concepts generation of molten salt reactors where this affect the oil majors, and if it did Gazprom are always opposed by locals, even if proven ‘waste’ is actually the fuel is just around the and Aramco etc would be more than happy to to be safe. This could also be done in very corner. Sounds silly to go to this much trouble boost supply. At best, it achieves nothing. At remote locations where there are no locals; to throw away a valuable fuel resource, and the worst, its a distraction from the efforts we all somewhere like St Kilda, or even using an new reactors are so safe, I would not hesitate

need to make to reduce CO2 emissions. oil platform. to move in down the road from one. Alex Alex James Stewart

14 | theEnGineeR | MAY 2015

TE_0515 14 05/05/2015 11:30 thesecretengineer

Engineering didn’t have much of a mention in the run-up to the election – perhaps because it’s one thing the parties agree on

I suspect that, no Looking back, the politicos are fond of matter wherever in the having their photo taken in engineering world it is you’re reading environments but they then usually talk this, you will know that in about non-engineering issues. Generally this the UK Her Majesty’s Parliament has been is the latest embarrassment to befall their formally (although sadly not literally) dissolved own party; be it a senior member going off and the bun fi ght for power has run its course. message, some newly discovered hole in their I thought I would take a look at what the policies or, in the case of UKIP, a candidate major parties are offering for us engineers. being expelled for unsavoury views…again. A quick search of “[political party] policy So our choice of party comes down to engineering” revealed that they are all either our in-built leanings or matters outside concerned about the number of young of our profession, but this need not be an people entering our profession and each has entirely bad thing. If the parties are generally their own idea regarding how to combat it. in agreement, then why not try to get them Interestingly, none of the solutions are working together to implement all of their actually driven by pure political ideology. I ideas to help us out? We could lobby our had hoped to fi nd that the Tories would be institutes to lobby whichever shower actually snatching children’s dinner money, Labour ends up in power and then, even if we don’t confi scating the gold of the nobility and the get much, at least we will get something. Liberals doing whatever it is that Liberals are supposed to do – but no. It all actually seems sensible if universally lacklustre and devoid of a grand vision. Of course, it could be that they are all spending their time on lesser matters such as the economy and employment? The fi rst thing that springs to mind is that as engineers there is no one party offering us anything substantial. They all make the right noises but we are obviously not the section FAULHABER CR of the electorate being targeted. In fact, the impression is that they see what we bring to our country and economy as being of no interest to any of the electorate whatsoever. Parilamentary copyright images are reproduced with the permission of Parliament More bite Join the debate at www.theengineer.co.uk for high power

Jobsalaries a conservative take on the future where any applications We received several opinions on an signifi cant engineering-related impact on the article about reports showing the planet is curtailed. Another approach to the number of engineering jobs in the concern with ‘fragility’ may be to consider UK rising, but salaries stalling that it is a refl ection of our leaders’ inability 3890…CR to ‘boldy go’ anywhere over the past 25 years DC-Micromotors series •I think we need to be careful of opinions since the break-up of the Soviet Union, which or ‘analyses’ such as those that Lucy Care was seen as giving them the freedom to do so. • Enormous continuous torque up to 224 offers regarding the supposed fragility of our Paul Reeves mNm, considerably higher in short-time ‘interdependent world’. The example given of operation the 2008 fi nancial crash (which she admits was It doesn’t pay if you tell anyone how things • • Various voltage types from 18 to 48 V only partly triggered by ‘interdependence’) and work. People will still believe in double-dip the perception that we have a fragile society curves of the stock market as the cause of • Optimally adapted for combination with may sound modern. Also ‘systems’ types of everything. If you see something coming, FAULHABER precision gearheads and analysis are obviously attractive to engineers prepare yourself. Keep some cash in the house encoders (who then naturally offer themselves as experts for when this bank or that bank has a computer to solve these problems) because few others glitch and no ATM works. Keep your money in supposedly can. This still forgets that other different banks. In volatile times, anything can moral cultural and political issues are not so and will happen. You need to have a buffer or susceptible to these kinds of analysis. I don’t storage to cover shortages, just like a good totally reject some of the above analysis, but I circuit has capacitors and coils to remove the think that by highlighting the assumed ‘fragility’ volatility and provide a stable power supply. of society as a ‘system’ we can quickly end up It’s called risk management. Distributed exclusively in the UK by with a fatalistic approach to the future, close to Anonymous the greens, whereby things are best largely left alone – or only changed in small incremental Have your say, visit us at EMS ways. Bold, ambitious experimentation then www.ems-limited.co.uk goes out of the window and we end up with theengineer.co.uk

WE CREATE MOTION

TE_0515 15 05/05/2015 11:30 the Paul Jackson column A real transformation

A few examples of modern engineering paint a very promising picture of the future of our health service

For the past month or so disease and really save lives. Then there’s the we’ve heard seemingly endless toothbrush that can analyse DNA to detect the discussions about the NHS, from onset of cancer or diagnose Alzheimer’s disease. what’s devolved and what isn’t to That’s the type of innovation that has the potential current challenges and promises to transform how health professionals monitor and for the future. While talk continues screen patients. around top-down reorganisation That transformation is also being seen in terms of and the funding crisis, a quiet what is available over the counter. Now on sale in the engineering revolution is going UK is a DIY HIV test that is reportedly easy to use and on. A number of things have gives results in 15 minutes. Latest research estimates struck me recently as showing the way in which that around 26,000 people in the UK are unaware they our health service will actually be transformed. have HIV, so again you can suppose that ultimately At University College Hospital not far from the this too will save lives. EngineeringUK offi ces, an apparently small change The new, state-of-the-art South Glasgow University to the doors to wards highlights the potential impact Hospital boasts some of the latest innovations in of innovative approaches to signifi cant problems. The patient care. I was most interested, however, to learn ‘hygiene handle’, as I believe it’s called, automatically about the new members of the workforce operating dispenses alcohol gel when you hold it to open the in underground tunnels, not least because they’re not door. A small change that can stop the spread of human. The hospital has a fl eet of more than 20 ‘robot porters’ transporting linen, food, medical supplies and I was most interested to waste around the hospital. These autonomous vehicles are not the driverless “learn about the new members cars that we might generally associate with the term, of the workforce operating in but they are working in our hospitals right now and in spite of the current price tag they are no doubt underground tunnels, not least destined to become much more commonplace. because they’re not human This is not only what modern medicine looks like; it is a refl ection of the possibilities offered by modern engineering. These examples effectively paint a picture of the future, where our health service is viewed in terms of modernisation and real life applications, investment and transformation, rather than the rhetoric we’ve all been hearing. These are all great, but I wonder whether smarter procurement is the missing tool that could transform extraordinary innovations in one or two places into a globally relevant powerhouse for growth. Robots on the ward: the shape of hospital Paul Jackson is chief porters to come? executive of EngineeringUK

16 | theEnGineeR | MAY 2015

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Street Crane FP TE 0515 ps 1 30/04/2015 16:20 TE_0515 17 05/05/2015 11:07 feature:civil engineering

The only

Culture is replete with the concept of way is civilisations living underground. It crops up in everything from HG Wells to Elizabeth Beresford. Of course, Wells’ underground dwellers were mutated cannibals and Beresford’s were pointy-nosed down mammals with an excellent grasp of English and an ecological bent, but the Could underground exploration and exploitation of the realm below the surface engineering help solve cities’ has been a trope for decades. Now, the lure of subterranean space is growing, especially in cities overcrowding problems? where land is at a premium and building becomes ever-more diffi cult. Stuart Nathan reports And while travelling underground is

18 | theEnGineeR | MAY 2015

TE_0515 18 06/05/2015 11:43 feature:civil engineering

Square deal: the top glass plate would be able to host anything from ice skating rinks to political protests

part of everyday life for millions in cities around the world, other uses for panel on the kiosk; the mechanism then works in reverse, locating the underground space are becoming ever-more innovative; and more may fi led bike and bringing it back to street level; this takes an average of 13 well be to come. The challenge for engineers will be how to construct seconds. The store can hold mountain bikes, electric bikes and bikes with these underground spaces, make them suitable for the uses earmarked front baskets or rear child seats. for them and maintain the conditions inside them to keep their contents “It’s a formidable space-saving technique – imagine how much area and users safe and comfortable. would be needed on the surface for a bike park to hold 144 bicycles,” said There are many reasons you might want to go underground. Space is Haan Admiraal, chair of the underground space committee (ITACUS) of an obvious example. In crowded established cityscapes such as London or international tunnelling and underground space association ITA-AITES New York, or the chaotic, fast-growing cities of India and East Asia, there at a recent seminar on underground engineering at the Institution of Civil just isn’t much space on the surface. Taking a small ground footprint and Engineers in London. It is built with a proprietary system developed by building upwards into a skyscraper, the choice for maximising space since Giken that uses interlinking piles, pressed into the ground hydraulically to the 1920s, has its limitations. In many cities, the planning regimes are form the walls of the silo; the void is then excavated up to this wall. This increasingly frowning on ever-higher skyscrapers, and even in the Middle is a low-noise, vibration-free, seismically safe system that causes minimal East and East Asia, where it seems easier to get permission to build high, disruption to neighbours when installed, developed for the crowded, there’s a practical limit to how high you can go. Hollowing out the space earthquake-prone region, and is also used for other types of construction. under the ground could be a way to get around these problems, as it gives For some applications, underground may just be the best environment. more scope to expand laterally, rather than linearly. Go wide, not deep. ITACUS vice-chair Antonia Comaro gave the examples of museums and Another factor might be an inhospitable outdoor environment. In art galleries. “Architects and engineers spend an inordinate amount of Canada, the northern states of the US, Scandinavia and Eastern Europe, effort, time and money to design iconic, beautiful buildings, and quite the winters are so bitterly cold that building underground, where the rightly,” she said. “But then they have to spend even more effort and environment is stable and insulated by the surrounding soil and rock, is money to devise ways to protect the priceless artworks they are to hold an attractive prospect. Similarly, nearer the Equator, subterranean spaces from sunlight and changes in the environment. The Paris Louvre had the could offer an escape from steamy humidity; and in heavily industrialised idea to put its lobby underground, with the famous glass pyramid as its cities with air quality problems, it could be easier to guarantee a healthy, entrance; but it might well be that below ground would be the best place breathable environment underground. for the entire institution, and other galleries where light- and moisture- But sometimes it’s just a matter of space. In Tokyo, for example, sensitive objects are going to be on display. You are starting from a bicycle parking has been taken underground using a system devised by default position of no light – the effort is spent on bringing it in and engineering fi rm Giken Seisakusho, which can store 144 bikes in a space controlling it, not keeping it out – and the insulating effects of soil just 7m wide. Bikes are becoming more popular in urban Japan, where and rock help keep the environment very stable.” air quality from traffi c is a serious issue. But parking them is a perennial This is one of the rationales behind one of the world’s most intriguing problem. Giken’s solution, an anti-seismic parking system, takes the bikes plans for a large building: the Earthscraper, which has been designed underground and out of the way, with only a deposit system at the surface. for a specifi c location in Mexico City by architecture practice BNKER Under the ground is a cylindrical silo some 11m deep and 8m Arquitectura (pleasingly, the company name in English is said as across that holds a racking system, arranged radially around a central ‘Bunker Architecture’). Best described as an underground skyscraper, mechanism that incorporates a lift system and a robotic placing machine the Earthscraper has museum space as an integral part of its concept. that whisks bikes from the street-level kiosk (it’s this that is 7m wide; the This is partly owing to its location. kiosk doesn’t cover the whole area of the shaft throat). Originally devised as an entry for an architecture competition, Each user’s bike is equipped with an ID tag attached to its front Earthscaper is designed for the city’s largest public square – and, forks, with owners holding a matching smartcard. To use the system, the indeed, one of the world’s largest – the Plaza de la Constitucion, known bike’s front wheel is pushed into a slot on the surface kiosk; the placing as Zocalo. Bordered by the city’s cathedral, the National Palace and the mechanism grabs onto it, whisks it down into the silo and fi les it into one city government buildings, Zocalo is a square 240m on each side, giving of the radial slots. To retrieve the bike, the owner holds the card up to a it a total area of 57,600m2. It is a ceremonial space with a fl agpole at its ->

MAY 2015 | theEnGineeR | 19

TE_0515 19 06/05/2015 11:43 feature:civil engineering

centre that is raised every morning and lowered every night, and is a “greater investment in structure” than a skyscraper, making it about signifi cant area in Mexico City’s public life. 30 per cent more expensive. The cost would require government Which makes it slightly incongruous that the plan for the Earthscraper intervention, with tax breaks for developers similar to those that helped involves digging it up; especially as Mexico City has a long history, being fi nance the new buildings on London’s Isle of Dogs. the site of Tenochtitlan, the capital of the Mexica and Aztec civilisations, For the moment, however, the Earthscraper remains an intriguing and a correspondingly rich archaeological record, parts of which would and ingenious concept, a potential space to be watched. For real be showed off in the structure’s museum space. However, the land underground activity, a city much further north shows a way forward. pressure on the city is extreme. “New infrastructure, offi ce, retail and One of the biggest stumbling blocks with building underground is what’s already there. Whether it’s the basements of buildings, sewerage systems, In creating a electrical infrastructure or existing tunnels pleasant environment for roads, subways and underground “ railways, cities without an underground underground, we hope hinterland of some sort are rare. “You need to have accurate and reliable surveys of to convince the sceptics the existing situation,” said Martin Knights, of our scheme’s viability senior vice-president for earth engineering at contractor CH2MHill, “and some sort of Esteban Suarez, BNKR overarching plan of what else you want to fi t in and how it’s supposed to be used.” living space is required but no empty plots Leading the way in this respect is the are available,” said BNKR founder and chief Finnish capital of Helsinki, where the local executive offi cer Esteban Suarez. “Federal population love outdoor life but, for most of and local laws prohibit demolishing historic the year, can’t indulge in it without risking buildings and, even if this was so, height frostbite. The city has an underground regulations limit new structures to eight masterplan that governs all of its stories. So we have a massive programme of subterranean activities, which are extensive: hundreds of thousands of square meters and underneath its central park can be found nowhere to put it. This means the only way a 100-yard-long lake that can hold nine to go is down.” million gallons (41 million litres) of icy Baltic Earthscraper is designed to be “the water, which is used to cool the city in the antagonist of the skyscraper”. It is an summer (when temperatures can reach inverted pyramid 300m deep – as deep as 30°C). Conversely, the city also has a huge the Shard in London is high – whose base underground heat pump system, which would occupy almost the entire area of recovers thermal energy from wastewater Zolcalo apart from the roads around the and diverts it into domestic district heating. edge. The base would be covered with Elsewhere under the city is a running a thick glass sheet to allow Zocalo to still circuit, an ice-hockey hall, the Itäkeskus be utilised for its current uses, while still swimming pool, the Temppeliaukio Church allowing light to penetrate into the void at and a shopping centre. A series of light the centre of the structure, which will act wells dotted around the surface light up the like an enormous lightwell for the structures subterranean spaces, whose volume adds arranged around the walls of the pyramid. up to some nine million cubic metres, with The pyramidal form is not coincidental. If 400 separate facilities linked by tunnels, and it were housed in a simple vertical shaft, the the master plan has another 100 locations walls would tend to cave in and would need earmarked for future resources. There are enormous supporting structures to prevent also plans for an 80km undersea tunnel a catastrophic collapse. Sloping the walls linking Oulo in northern Finland with inwards on all sides means they are more Helsinki, to create an economic ‘twin town’. self-supporting, Suarez explained. It’s also But in many cities, the main reason to go a matter of concern that Mexico City is in underground is the same as it has been for an active earthquake zone, but again the more than a century: to get roads off the pyramid is a logical choice. “Because its surface, relieve congestion and open up structure must already resist the lateral surface ground for new uses. One example forces of the surrounding earth, it would is Boston, Massachusetts, where a project be especially strong against the lateral forces known as Central Artery Tunnel or the of an earthquake,” Suarez said. ‘Big Dig’ took an elevated highway that With the ‘buildings’ sections of the Into the deep: underground space can include was considered a blight to the city below Earthscraper lining the walls of the pit, swimming pools, bike stores and churches ground and constructed a new tunnel natural light can penetrate down into its under the harbour. Further west, Seattle, depths, although the plans include a fi bre-optic system to illuminate the Washington, is attempting to bury an the Alaskan Way overpass, which is deepest levels; vents in the top sheet would also allow natural ventilation. old and decaying. This is not going well, with the tunnel boring machine “We hope that in creating a pleasant environment underground we stuck 10 per cent of the way through a 1.7-mile dig for more than a year. would convince sceptics of the viability of our scheme,” Suarez said. In the UK, meanwhile, two major tunnelling projects could transform The fl oors nearest the surface would be museum space, with retail west and south London beyond recognition. CH2MHill is involved developments below that, then residential, and offi ce space at the bottom. with feasibility studies to turn the Hammersmith Flyover into a tunnel. The top glass plate – which we hope will be frosted in some way or only Another study is looking at the possibility of burying the South Circular the boldest would walk across it – would be able to host anything from Road. In a £30bn project that includes a tunnel on the North Circular at Christmas skating rinks to major artistic performances, religious gatherings Brent Cross aimed at improving facilities for cyclists and pedestrians at and political protests. “It preserves the iconic presence of the city square ground level while also improving air quality as London’s population and and the existing hierarchy of the buildings that surround it,” said Suarez. therefore its traffi c continue to increase. In engineering terms, one of the biggest challenges would be water. The lowest 165m of the pit would be below Mexico City’s water table, and therefore effectively fl oating on mud. This would necessitate a For more on this story visit www.theengineer.co.uk

20 | theEnGineeR | MAY 2015

TE_0515 20 06/05/2015 11:43 Inductive Position Sensors

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TE_0515 22 06/05/2015 12:58 feature:additive manufacturing Added functionality UK-led advances in 3D printing could one day lead to techniques able to produce entire electronic devices in one shot. Jon Excell reports

Light fantastic: using two-photon lithography to print nanostructures

t’s fair to say that over the past few years much of the hype surrounding 3D printing Ihas given way to a more considered and sensible notion of where the technology fi ts in. While not so long ago some warned that so-called additive techniques would usurp incumbent manufacturing processes, today printers will produce fully functional Loughborough University’s Additive they are increasingly seen as complementary: components from multiple materials, both Manufacturing research group, which has another tool in the toolbox. metals and plastics. It sounds fanciful, but the itself made a number of signifi cant advances, But according to Prof Richard Hague, group has already made signifi cant progress including the development of software aimed at director of the EPSRC centre for additive and such techniques could, it is believed, helping designers to exploit the full advantages manufacturing, fundamental breakthroughs one day enable manufacturers to print entire of additive techniques. are on the horizon that could ultimately help electronic devices – such as mobile phones – But the feel and purpose of the Nottingham realise some of the more exotic predictions in one go. facility is very different. that have been made for the technology. “We’re not just making clever shapes but Where the Loughborough lab was home Based at Nottingham University, Hague’s we’re making them do something.” he told The to a large group of engineers and numerous 70-strong team of researchers is making Engineer. “We’re looking at next-generation chunks of recognisably industrial equipment, something of a name for itself in one of multifunctional additive manufacturing, not just Hague’s current home looks more like a additive’s most exciting vanguards: the fi eld printing single materials but putting conductives pure science lab. Mechanical engineers are of multifunctional 3D printing, or 4D printing or pharmaceuticals in the structure.” outnumbered by white-coated chemists and as it’s sometimes called. Hague and his group have a long track physicists, while the benches and worktops While existing systems typically use just record in the fi eld. Before setting up the EPSRC are adorned with a variety of unusual one material, the idea is that multifunctional centre just more than two years ago, he led looking experimental systems. ->

MAY 2015 | theEnGineeR | 23

TE_0515 23 06/05/2015 12:55 feature:additive manufacturing

A multi-material jetting ahead in a PixDro printer It is, said Hague, “a very different beast” and With jetting Much of the group’s research is based the result of a deliberate decision to step back around advanced jetting technologies rather from the industrial coal face and concentrate “technology, you can than the powder-based sintering techniques instead on advancing the underlying materials more familiar to industry. “With powder-based science, something that he feels has been selectively deposit technology, you’re basically laying a whole lacking in the past, and that has potentially different materials layer of powder, and there’s no differentiation held back the technology. “People working in of materials on that layer,” explained Hague. industry are doing really great stuff but I think Prof Richard Hague “With jetting, you can selectively deposit historically there hasn’t been enough science different materials.” and basic understanding,” he said. terms of the basic processes themselves all The advantages are obvious, but one of the Hague admits that stepping down the the IP is held overseas. One of the reasons we key challenges is actually getting the material so-called Technology Readiness Levels (TRLs) wanted to go down the TRLs was to develop out of the jetting head. The water-like viscosity to focus on technology with less immediate our own IP for the UK, exploit that and take required to achieve this, explained Hague, commercial relevance is an unconventional it forward, and then canter back up the TRLs means that conventional polymers, for instance, move, but believes that in the long term the later on.” are unsuitable. The group therefore spends a benefi ts for the technology, and for the UK, Showing The Engineer around his state-of- lot of time tweaking the properties of materials: could be signifi cant. the-art lab, Hague’s breezy enthusiasm makes one of the reasons there are so many chemists “A lot of the original systems – it sound like it’s going to be a walk in the park. in the department. stereolithography, etc – were developed in “Build a structure, build a function, print it all in Another potential solution to this problem companies and all the development and IP was one go and off you trot,” he said. The reality is is a technique known as reactive jetting, which, held by those companies,” he said. “Universities that his team is entering largely unchartered rather than jetting polymers directly, enables would buy the systems, work on new materials, territory, and there are some major technical them to be created at the point of deposition. clever designs and all that kind of stuff, but in challenges ahead. “Because some polymers are too viscous ->

indepth It’s not all about jetting

Using a technique known as two-photon possible to produce nanoscale structures at lithography, the Nottingham team hopes high resolution in comparison with standard -> to pioneer the production of nanoscale additive manufacturing methods. multifunctional components. This is challenging in its own right. But the Tucked away in a quiet side room team has also thrown optical tweezers into of Hague’s laboratory, a technique is the mix, essentially a laser-based technology under development that could enable the that can be used to place individual particles production of functional 3D components at particular sites and tailor the properties in that are smaller than a grain of sand. specifi c areas of the structure. “For instance,” Like conventional stereolithography, said Hague, “by embedding gold and silver the process, which is known as two-photon particles in a particular area, you can tailor lithography, uses light to cure a liquid resin. conductivity to make devices such as sensors.” However, in this case the resin is engineered so Able to produce structures as small that the curing reaction can only be kicked off as 150nm, the system is expected to by two photons of light. This enables extreme have applications in areas such as optics, levels of precision and, Hague said, makes it metamaterials and biological constructs. A 3D-printed multi-material demonstration component

24 | theEnGineeR | MAY 2015

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TE_0515 25 06/05/2015 12:21 feature:additive manufacturing

indepth Drug delivery

The pharmaceutical industry is eyeing up Hague, is very interested in the 3D printing the potential of multifunctional printing. of drugs. “At the moment, drugs are banged Despite the fundamental nature of the out in the gazillions and you might want to team’s work, there is nevertheless a high do lower volumes or localised production,” level of industrial interest, and some of it from he explained. What’s more, multifunctional quite unexpected quarters. Indeed, while the techniques could also enable the properties centre’s focus on printed electronics remains of drugs to be altered. “You might also want a major driver, it is also undertaking work for to have different drugs at different places the pharmaceuticals industry, which, said within the pill that elute at a different rate.”

The Jetx3D suspended in a carrier solvent, can print it is actually jetting the actual different bulk metal and so conductivity materials is not compromised and from each of no secondary processing its six heads is required.” But despite the primary focus on exotic techniques such as this, Hague is also keen to build on his group’s hard-won expertise in more established areas of additive technology. To this end, he and a number of colleagues have established Added Scientifi c, a spin-out company aimed at helping organisations without their own corporate research laboratories to build up their competence in additive techniques. Since its launch, and in stark contrast to the diffi culties Hague had enthusing industry about additive earlier in his career, the company has been Currently, all the equipped with 128 nozzles and can jet a range inundated with work. “The kind of companies of materials, including conductive materials we work with now – 10 years ago I would have printed electronics stuff such as silver and other metals that are bitten your hand off,” he said. “We’re fl ooded “ deposited within a carrier material. with companies, and we don’t want to turn is done with nano-fl akes It is a unique piece of equipment, said away the industrial interest. We want to have Hague, literally the only one of its kind in the industrial interest so we can take through of silver that are loaded the world, and it’s expected to help drive the multifunctional stuff in into a carrier material some major breakthroughs in multifunctional a few year’s time.” printing. However, the team is now excitedly This high level of interest is a sure sign Prof Richard Hague awaiting the arrival of an even more advanced that additive is becoming more and more of piece of equipment that will take the ability to a mainstream process. when polymers [you can’t melt them and then jet metal to the next level. But is it really any closer to becoming jet them], you might want to jet the monomers, The Metaljet machine, which is being the silver-bullet process that some claim which are often very fl uid. You can jet two developed for the group by Dutch mechatronics will fundamentally reshape manufacturing? monomers and a catalyst and at the point at specialist Demcon, is based on technology “I would like to say that 3D printing could where they drop together you can get in-situ developed by yet another Dutch fi rm, Océ, be used for everything,” said Hague, “and we polymerisation,” Hague explained. a jetting specialist owned by Canon. Océ’s push at a research level that we want to use Meanwhile, the quest for new ‘jettable’ technology centres around a highly innovative [it] to do everything. But in reality you’re going materials is a painstaking and complex process drop-on-demand print head that works at up to have to do some post-processing and some in which different formulations are trialled and to 1,800°C and is capable of directly depositing joining with other technology. Generally, qualifi ed on a range of systems of increasing high-temperature metallics in 3D. additive will be a tool in the toolbox and it cost and complexity before fi nally being trusted Able to jet different metals from its four won’t be used to make absolutely everything on what’s currently the lab’s ultimate machine: a printheads, the new system is the fi rst of its of every component ever – we will be able to multifunctional £1m testbed known as Jetx3D. kind in the world, and, according to Hague, make systems on these additive processes but Purpose built for the centre by Dutch inkjet represents a major step towards the dream of whether everything in the phone, car or plane specialist Roth and Rau, the machine, known 3D printing real electronic devices. “Currently, be 3D printed? Probably not. It’s going to be internally as ‘The Toucan’, is effectively all of the printed electronics stuff is done with used where appropriate.” a 3D adaptation of technology originally nano-fl akes of silver that are loaded into a developed for 2D-printed electronics. Specially carrier material that you deposit and then For more on this story visit commissioned by Hague’s team, the system evaporate off the carrier materials. This is very www.theengineer.co.uk has six piezo-electric print heads each different. Instead of depositing particles

26 | theEnGineeR | MAY 2015

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TE_0515 27 06/05/2015 10:43 interview:rob rickell Driving force

rob Rob Rickell is at the helm of a company that has rickell grown into an automotive business supplying President, complete all-wheel drives. Stuart Nathan reports GKN Driveline t is a fact that in the all the constant-velocity joints of conventional engine driving the engineering sector, you’re all the cars in the world – which front or rear axle and are looking I only known if you sell direct is quite an achievement, of course for an electric axle to drive the to the public. The vast array of – but we’ve now grown much other wheels. This is becoming an companies in the supply chain are, more into an automotive company increasingly important subdivision with a few exceptions, unknown supplying complete all-wheel drives of the all-wheel-drive segment, to the general public unless they and hybrid and electric systems. which is itself becoming much are a major local employer. For “Across all the divisions more important.” companies whose contributions – automotive aerospace and land For most of its existence, are important to the product systems, which is systems such four-wheel-drive (or all-wheel- known by the public, this can as agricultural but also buses – drive – AWD – as GKN prefers to be a source of frustration. the move into hybridisation is call it) has been a rather niche “We’re defi nitely trying to be very important.” area for automotive, limited better known,” said Rob Rickell, Propulsion is a novel area to speciality vehicles such president of GKN Driveline. “It has for the company, according to as off-roaders and agricultural Education real advantages, especially when Rickell. Previously, vehicles. Its rise in popularity • Lincoln College of you’re trying to be more active in GKN’s powder has coincided with the launch Technology – OND in the recruitment fi eld.” metallurgy of premium-positioned sports Engineering GKN is, Rickel admits, not a division – utility vehicles (SUVs). As AWD • Trent Polytechnic – BEng well-known name. Despite this, which is conventionally needs Mechanical Engineering it is a major player in the its lead for big, powerful • Loughborough University engineering supply additive engines, it is – MEng Engineering design chain, especially in often seen as a ‘problem’ part Career Fantastic four: AWD for today’s • Since joining GKN in 1984 has until recently been a automotive as a product engineer in niche area for automotive sector, with Birmingham, UK, Rickell the cliché has worked on a variety of of the projects at the company’s fuel- facilities in the UK, Italy, guzzling, and Lohmar, Germany, and fume-spouting managed GKN Driveline’s ‘Chelsea Tractor’ cluttering up global Toyota account. the streets and making everyone • Previously, he was senior automotive and in the vicinity choke. vice-president of global aerospace. The But hybridisation is changing engineering for GKN. He company has manufacture all that, Rickell explained. GKN’s has played a key role in some 50,000 processes – provided e-axle technology, which it ensuring the sustainable employees in more some components pioneered on Porsche’s 918 growth of GKN through than 30 countries, for internal combustion supercar and BMW’s i8 hybrid the development of although it is engines (ICEs), but the saloon, is designed to give countertrack constant- headquartered Driveline division had always vehicles AWD capability while velocity-joint technologies; in the UK. been more involved with the minimising emissions. being a key infl uencer in “We supply components or drivetrain downstream of the E-axle vehicles have electric the decision to grow the complete systems to pretty much engine. What changed all that motors on the axles that the AWD business; and every car maker in the world,” was the advent of hybridisation. ICE doesn’t drive. “The control positioning GKN as an Rickell said. “This is an area that’s actively strategy and software, which we e-drive hybrid electric In recent years, the automotive looking for different solutions to also developed ourselves, gives systems developer. sector has seen some changes for the ones that were on the market,” you the optimum option for the • Rickell is a fellow of the GKN. “What we’re very proud of Rickell said. “For us, that meant situation,” Rickell said. “When Institution of Mechanical in the last few years is [not only] the development of electric axles you’re setting off, it’ll often just Engineers and the Royal that we have really moved from in one- and two-speed options, engage the e-axle, because the Academy of Engineering. being a mechanical engineering and what we call our e-axle electric motor has good torque company, supplying about half of solution where you have a at low revolutions per minute.

28 | theEnGineeR | MAY 2015

TE_0515 28 06/05/2015 12:56 interview

But if you accelerate hard, then to be the ICE will cut in; if you’re driving clear that in slippery road conditions you’ll this sort of have both systems together for intelligent tech, with the handling.” the control strategies But in the city, the system you need, is fairly high-tech, comes into its own and could so it is going to add value to the banish the Chelsea Tractor vehicle. We have a project with stereotype for good. “In normal Peugeot and Citroën with an done with a Wheel deal: GKN pioneered driving conditions, you’d probably e-axle on the back of a mid-range transmission using a its e-axle technology on use all-electric mode, and if you’re front-wheel-drive model. Front- lightweight synchroniser, not a Porsche’s 918 supercar in the city where pollution and wheel drive is the most cost- dual clutch; any gaps in the torque particulates are an issue you can effective way to build a volume are fi lled using the ICE so it’s very automotive sector,” he said. “In set it to drive purely on electric. car these days, but there are also smooth,” he said. “The driver can’t high-strength steel, you can make That’s one of the options on the more rear-wheel-drive platforms feel the shift.” high-strength steel components dash. Those sorts of options give coming through.” GKN is also looking at in seconds. You need to spend you the best of all worlds; handling, Car makers are keen to adopt lightweight materials, where money and invest in a transfer safety and zero emissions.” this technology because it helps there is commonality between press, but for high volumes that Development on such systems keep their ranges broad, Rickell its automotive and aerospace investment makes sense.” is normally in close co-operation explained. “It allows them to have divisions. “Automotive is the In the meantime, GKN is still with the vehicle manufacturer. vehicles with higher carrying largest part of our business trying to boost its profi le. “We “The best systems are always capacity, larger vehicles and and it’s very important to us; about have worked with one or two key collaborative. With Porsche 918, more sporty vehicles, but still half of what we do is in automotive. universities; we’re also actively we were the preferred technology have the emissions profi le to But 30 per cent is in aerospace: involved in sponsoring Formula partners; similarly with the BMW meet regulations. It’s a solution we’re the world-leading supplier Student, which we see as an i8,” Rickell said. they need to maintain their range.” for carbon-fi bre components for excellent way of demonstrating The systems have some One technology Rickell aircraft and we supply all the our technologies and working common components, such is particularly proud of is the major companies. We’re proud closely with fi nal-year students as actuators, electronics and two-speed e-axle on the Porsche of that because we can meet – we’d like to do even more,” control software, but GKN is not 918 and BMW i8. the requirements of that sector Rickell said. developing an off-the-shelf system “Normally, electric drives in structures and aero engines.” “We’d probably not be able for manufacturers to drop into disconnect between 120km/hr In the automotive sector, to visit every university, but cheaper cars. “We have to be cost and 150km/hr, but the two-speed lightweighting for GKN centres we’d like to do more with the competitive, especially as you go system allows it to be used all the around high-strength steels and key universities for automotive into higher volumes. But we have way up to motorway speed. It’s pressure die-cast aluminium; and aerospace, such as Cranfi eld, magnesium is making inroads Warwick and Bath, and one or two in the sector at the high end others with regards to materials We have worked with one or two for thin-walled housings, but tech and additive manufacturing.” key universities; we’re also sponsoring aluminium is still preferred, Rickell “ said. “For carbon-fi bre, the cycle For more news, comment Formula Student, which is an excellent times still aren’t fast enough to meet the 500,000 components & features visit way of demonstrating our technologies per year rates needed in the theengineer.co.uk

MAY 2015 | theEnGineeR | 29

TE_0515 29 06/05/2015 12:56 Q&A:Large Hadron Collider

Hard hitting Experts answer questions on the world’s most powerful particle accelerator. Stuart Nathan reports

he world’s biggest physics experiment, the Large Hadron As the design of the LHC started way back in 1984 and Collider (LHC) at CERN, straddling the French-Swiss border, since then many improvements have been made in the Tis about to begin its second round of experiments since fi elds of engineering and science and physics, if you had the its original start-up in 2008. Now colliding particles at twice the opportunity do you feel that you could drastically improve speed as it did before, the LHC teams now hope to uncover the the design of the LHC using newer materials and processes? mysteries of dark matter and energy, which are believed to hold And what would the changes be? And fi nally what would you galaxies together and power the accelerating expansion of the predict any such upgrades or changes in design would yield universe. The LHC and its detectors had to be considerably in terms of results? upgraded to make these experiments possible. Here, CERN’s JT: The fi rst concept of the LHC effectively dates back from the engineers talk about how the upgrades were made, how the 1980s; nevertheless, the design of its main systems continued engineering enables the exploration of new physics and what up to the end of the 1990s, giving the opportunity to integrate might be next for large physics experimentation. technical developments occurring in between. Also, at the time of its initial concept, in some areas, such as computing, the expected Jean-Philippe Tock (JT), senior LHC engineer improvements in terms of performance were taken into account, Francesco Pietropaolo (FP), neutrino physicist building on future improvements (Moore’s law).

30 | theEnGineeRtheEnGineeR | NOVEMBERMAY 2015 2013

TE_0515 30 06/05/2015 12:34 Q&A:Large Hadron Collider

2. The FCC (Future Circular Collider study) is a study for post-LHC particle accelerator options with an energy of about one order of magnitude higher. High-fi eld superconducting magnets are a key technology for the successor of the LHC. Low-temperature

superconductors (LTSs) such as Nb3Sn and HTSs are considered. Are there any changes in the physical forces that the structures that make up the LHC experience as a result of the Main: preparing upgrade? If so, what reinforcement was necessary, where was to weld on the this applied and how? LHC beamline JT: During the fi rst run of operation, so before the fi rst long Right: ‘beam shutdown (LS1) that took place in 2013–14, the LHC was run splash’ in the at a maximum energy of 8TeV centre of mass. It is now running CMS (above) and at 13TeV centre of mass, so about double. To achieve this, the ATLAS (below) current in the LHC superconducting dipole magnets has been detectors increased from 6,700A to 11,000A. At a fi rst approximation, the electromagnetic forces are increasing proportionally to the square In terms of superconducting magnets, the main LHC of the current, so almost three times larger. components, it is correct that new materials have appeared The LHC was designed to operate at 14TeV centre of mass since then. Niobium-titanium alloy (NbTi) is used for the LHC corresponding to a current of almost 12,000A. So there was no superconducting magnets. Since then, for example, Niobium- need to reinforce its structures except the LHC splices (electrical

tin (Nb3Sn) is used as well, a superconductor having higher joints). The LS1 was triggered by the need to consolidate more performance than NbTi. Also high-temperature superconductors than 10,000 splices between the superconducting magnets. They (HTSs) are emerging. were both consolidated electrically and mechanically to withstand It would not be effi cient to change all LHC magnets. safely the higher current. Nevertheless, CERN plans to take advantage of the enhanced performance of the superconductors in two ways: How do you design a detector for particles that barely 1. The HL-LHC (High Luminosity LHC project) is an upgrade interact with matter, if they exist at all? of the LHC machine to increase the total number of collisions FP: The most elusive particles presently known are the (luminosity) by a factor 10 in order to further increase its discovery neutrinos. The study of their properties will allow us to gain potential beyond 2020. This improvement can be obtained by a better understanding and possibly to extend the knowledge

replacing some LHC NbTi magnets with Nb3Sn ones. of the present standard model of elementary particles. -> MAY 2015 | theEnGineeR | 31

TE_0515 31 06/05/2015 12:34 Q&A:Large Hadron Collider

Above: physics at the LHC depends on precise engineering Below: the LHC control room awaits results on the fi rst runs post restart

The neutrinos have a tiny mass “and they interact with the ordinary matter only though the ‘weak force’ Francesco Pietropaolo

~1018 neutrinos per day and serve multi-kilotonne detectors located at distances from the production target ranging from few hundred meters to several hundred kilometres. Only a few neutrino interactions per day are recorded in these detectors. Most of the time, neutrinos interact with ordinary matter, transforming into the lepton partner and transferring energy to the target nucleus. Hence a neutrino detector needs to be able to fully reconstruct the products of the interactions in The neutrinos are the neutral partners of the charged leptons order to infer the nature of the parent neutrino. This is usually (electron/muon/tau), they have a very tiny mass (actually close to done employing ‘imaging’ detectors able to provide a 3D picture zero) and they interact with the ordinary matter only through the of any event, with high granularity (~mm) and with excellent ‘week force’. They are diffi cult to detect as they can travel, at the ‘calorimetric’ response, to accurately measure the direction, the speed of light, practically unperturbed over very long distances energy and the kind of all particles produced in the interaction. even in dense media such as the Earth (mean free path of more Examples include the Water Cherenchov detector adopted than 109km) or the Sun. by the 50ktonne SuperKamiokande experiment in Japan, the As a consequence, ‘neutrino’ experiments have to rely on Liquid Argon Time Projection Chamber (1ktonne ICARUS huge multi-kilotonne detectors coupled with very intense neutrino experiment in Europe), the Photographic nuclear emulsions beams, which can be either artifi cial (produced as from particle (2ktonne OPERA/Europe) and the Sampling Calorimeter approach accelerators or at nuclear reactors) or natural (from the nuclear adopted in the US by the Minos and the Nova collaborations. fusion in the Sun, or from cosmic rays interacting in Earth’s Given the extremely week neutrino interaction rate, these atmosphere). Artifi cial neutrino beams are available in Europe huge detectors are generally located deep underground, well (CERN), the US (FNAL) and Japan (KEK, T2K). They produce shielded from the cosmic rays, which can possibly mimic

32 | theEnGineeR | MAY 2015

TE_0515 32 06/05/2015 12:34 Q&A:Large Hadron Collider

neutrino interactions, by several kilometres of overburden rock. The latter feature allows us to use these large detectors CERN is already undertaking a as observatory of other very rare events such as the proton design study for the post-LHC particle decay (related to the ordinary matter stability) or even other “ unexpected phenomena. accelerator at the high-energy frontier What changes needed to be made to CERN’s accelerators Jean-Philippe Tock to provide particles with the appropriate energy? JT: The fi rst LHC long shutdown started in February 2013. development programmes that would be required to build a future It was triggered by the need to consolidate the 13kA splices circular collider. between the superconducting magnets to allow the LHC to For example, the eight Tesla dipole magnets that are used to reach safely its design energy of 14TeV centre of mass. steer the 7TeV beam along the 27km circumference of the LHC The consolidation of the LHC superconducting circuits were would need to be replaced by 16 or 20 Tesla magnets to reach carried out in the frame of the SMACC (Superconducting Magnets the energy of 50TeV per beam in a ring of, respectively, 100km And Circuits Consolidation) project. It has principally covered the or 80km in length. consolidation of the 10,170 13kA splices but also other activities linked to the superconducting magnets such as the exchange of 18 main cryomagnets, the installation of the additional safety- relief devices, the repair of known helium leaks and other consolidation activities. In addition, the quench protection system of the LHC’s superconducting magnets was also improved. Also, the cryogenics systems that are keeping the superconducting magnets at 1.9K has been maintained and its control systems have been upgraded.

Would CERN be able to manage research at any higher energy, if the next round of experiments indicates that this might be necessary? If so, how might this be accomplished? JT: CERN is already undertaking a design study for the post-LHC particle accelerator at the high-energy frontier: the FCC (Future Circular Collider) study. It is exploring the potential of hadron and lepton circular colliders, performing an in-depth analysis of infrastructure and operation concepts and considering the technology research and

Above: the upgrade of the LHC doubled the energy available for experiments Below: welding around the LHC’s superconducting magnet channels

MAY 2015 | theEnGineeR | 33

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TE_0515Omega_FP_TE_0515.ps 34 1 05/05/201509/04/2015 12:2315:07 feature:food, drink and pharma Getting personal As healthcare providers move towards personalised medicine, manufacturers are beginning to rethink their process solutions. Evelyn Adams reports

Storing huge amounts of data on health conditions has also become easier, and the world is far better connected on mobile platforms. Combined, these factors are changing the way healthcare is delivered. “One major area of development is in companion diagnostics, which are used to identify the patients who will respond to a particular treatment,” said Richard Alldred, head of innovation at the Centre for Process Innovation (CPI). “A good example of the evolution of stratifi ed therapies is in breast cancer treatment, where genetic data is being used to identify patient groups likely to respond to particular treatment regimens.” The drive towards personal healthcare means the way medicines are being manufactured is also changing. There has been a shift away from creating small molecules to one in which treatments are a combination of small molecules and cell and gene therapies. To produce these personalised drugs cost effectively, engineers are looking at ways to replace ineffi cient large-scale batch production with investment in new technologies, such as continuous manufacturing. Batch production and the centralised manufacturing systems are slow paced, inventory heavy and increasingly considered to be infl exible and unsustainable. What the industry needs now is a real-time demand-based supply chain. “Continuous manufacturing will undoubtedly be a major factor that can bring about change,” said Alldred. “It is likely to be the key to solving many of the manufacturing issues by enabling intensifi cation, plant fl exibility and improved control over product quality and characteristics.” But some believe the manufacturing industry isn’t moving fast enough. “While demand for personalised medicines has increased fairly dramatically in recent years, when seen within the context of the entire healthcare market it is still in its infancy,” said Alan Johnston, pharmaceutical and life sciences business manager of Siemens. “Some illions of people are taking medication that does nothing to of the industry’s processes would benefi t from optimisation strategies treat their symptoms. Recent studies suggest many of the most as technology has moved on since they were originally designed.” M popular drugs on the market help only a fraction of the people Alldred added: “The industry needs to fi nd more effi cient, cheaper who use them. But this could be about to change. and faster ways of discovering and developing new drugs and needs to Medicine is starting to get personal, and patients are increasingly fi nd better and more fl exible ways to manufacture successful treatments. demanding customised treatments with better results and fewer side A particular area that will need to be addressed is how an increasingly effects. The trend has largely been driven by improvements in genome diverse portfolio of personalised and stratifi ed therapies are regulated; sequencing, which has become much cheaper and more effective. current processes are not well suited to this.” ->

MAY 2015 | theEnGineeR | 35

TE_0515 35 06/05/2015 15:25 feature:food, drink and pharma

Popping pills: most popular drugs help Continuous only a fraction of the manufacturing people using them “ supports a cleaner and more fl exible process and can optimise capital costs Alan Johnston, Siemens

3D printing to provide a solutions. Last year, the University of Central Lancashire (UCLan) fi led a patent application for a system that uses a 3D printer to ‘print’ a tablet of medicine with realistic quantities that can be taken by a patient. The printer can replicate drugs already available in pharmacies and hospitals, but can also tailor medicines directly to an individual patient’s needs. This technology will potentially reduce the cost of manufacturing tablets for individual patients. Dr Mohamed Albed Alhnan from the School of Pharmacy and Biomedical Sciences alongside his team developed a drug- polymer fi lament system that can replace the original fi laments in a 3D printer. The team discovered that the new pharmaceutical ‘ink’ allowed them to print a challenging tablet design with signifi cant improvement of appearance and high accuracy of tablet weight and dose. “In my view, the future will see an explosion in the number and diversity of therapies available. Many of these will have been developed for very specifi c, often small, patient cohorts,” said Alldred. “There will be a corresponding increase in the type of facilities used to Johnston believes there are four key challenges in rolling out manufacture medicines from large plants much like those of today to personalised medicine to the wider public; tackling effi ciency issues smaller, fl exible units and even small-scale, fully enclosed, bench-top during the production process; getting companies to be bold in production units. introducing change within a highly regulated healthcare environment; “A potential scenario will be that a patient attends a surgery, a number dealing with the increased costs involved with personalised medicines; of rapid diagnostic tests are applied to determine the best treatment, and introducing completely new process technologies. which is then manufactured and formulated in a fully enclosed, small- He also believes continuous manufacturing may help address some scale manufacturing unit located close to the patient.” While a heavily of these challenges. “It can drive a marked increase in product quality regulated healthcare industry fi nds it harder to embrace change, Alldred consistency and help reduce both manufacturing costs and inventories,” believes the benefi ts of personalised medicines will spur more action in said Johnston. “It also supports a sustainable, cleaner and more fl exible the coming years. process and can optimise capital costs such as reducing inventory. Finally, it supports real-time process analysis and product release, for For more on this story visit www.theengineer.co.uk instance through a ‘quality by design’ strategic approach.” Manufacturers are beginning to adapt. For instance, research on continuous solid-dosage manufacturing has already been transferred from university-based research groups to the pharmaceutical industry. One project involves researchers at Rutgers, the State University of New Jersey, in the Engineering Research Center for Structured Organic Particulate Systems (C-SOPS), who have been working on a continuous direct compaction tableting process. The technology replaces the traditional multi-stage batch process by integrating feeders, mills, blenders and a press into a single process. Janssen Pharmaceutica constructed a line based on this design, to help speed up manufacturing for personlised drugs. And the trend is set to continue, according to Alldred. “The industry is increasingly investing in the development of personalised and stratifi ed therapies and adopting business models less reliant on the blockbuster drug model.” Some groups are looking towards technologies such as

36 | theEnGineeR | MAY 2015

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TE_0515 38 05/05/2015 14:08 feature:drives and motors Silent fl i g h t Siemens and Airbus are on a mission to introduce hybrid aircraft that can carry up to 90 passengers by 2035. Helen Knight reports

Hybrid hopes: the lightweight electric motor generates 200kW

magine living next to an airport where the A hybrid design would allow aircraft to when distributing the propulsion system aircraft are taking off and landing all night, receive an additional power boost from the around the aircraft, added Anton, including I but you never hear a thing? battery during take-off and climb. Not only the location of the propellers themselves. That is the promise of hybrid aircraft, in would this reduce the size of the engine “So, for example, there is an electric aircraft which a small jet engine is combined with needed for cruising, when the power demand called the e-Genius [developed by researchers a battery and an electric motor to drive the is much lower, but it would also allow it to at the Institute of Aircraft Design at Stuttgart propellers. Such aircraft could also consume up operate constantly at its most effi cient speed, University], where the propeller is on top of the to 50 per cent less fuel, according to Siemens. according to Anton. stabiliser at the tail of the aircraft,” said Anton. The company, which is working with Airbus, “Overall, we would expect a reduction “This is very good from the point of view ultimately hopes to launch 90-seater civilian of fuel consumption of 25 per cent,” he said. of propeller effi ciency, and also allows the hybrid-electric aircraft into the skies by 2035. The motor also has a rotational speed of 2,500 propeller to be larger than normal and turn But the technology must fi rst be proven revolutions per minute, allowing it to drive the more slowly, which also makes it much more on smaller aircraft. To this end, Siemens has propellers directly. This offers greater fl exibility effi cient.” This could reduce fuel consumption recently developed an electric motor with a by a further 25 per cent, he explained. weight of 50kg and a continuous power output What’s more, larger propellers that of 260kW – enough to fl y a four-seater aircraft There is an electric turn more slowly are much quieter than with a take-off weight of two tonnes, when aircraft called e-Genius, conventional designs, Anton added. “So if used in conjunction with a small jet engine. “ you start purely electrically, and only switch The motor has a power-to-weight ratio of where the propeller is on the combustion engine after some time, 5kW/kg, said Frank Anton, head of electric on top of the stabiliser you will have no noise from the battery, and aircraft at Siemens. “That is a factor of fi ve only a little propeller noise, which you can higher than a normal industrial motor.” Frank Anton, Siemens reduce by turning the propeller more slowly,” ->

MAY 2015 | theEnGineeR | 39

TE_0515 39 05/05/2015 18:19 feature:drives and motors

Motor ahead: Siemens used Then again, while simulation tools to design “you are improving the the synchronous device magnetics, you need to carry stronger forces, so you need more material Frank Anton, Siemens

he said. “In this way, you can make a really very quiet aircraft.” To design the synchronous motor, the company used advanced simulation tools, allowing its engineers to trade off improvements in one aspect of its operation with compromises in other areas. “So while you are optimising the magnetics, you have to think about how you can cool them, and if you optimise the cooling, you need more space so you have to compromise on the magnetics,” Anton said. “And then again while you are improving the magnetics you need to carry stronger forces, so you need more material, and the motor becomes heavier, so then again you have to work on the mechanics, on the structural analysis.” University. “It is very encouraging to see of the European Commission-funded Clean To reduce the weight of the motor, the large manufacturers taking an interest in Sky programme. device’s four permanent magnets are arranged more electric technology,” he said. “Clearly The researchers are also working on a next to each other in such a way as to ensure they are making signifi cant developments.” number of other projects to develop more that the orientation of each fi eld is in a different A great deal of work is going on among the electric aircraft. One way in which electric direction. This arrangement, known as a research community and industry to improve motors can be used to reduce fuel consumption Halbach Array, allows the magnetic fl ux the power densities of electric motors, said and emissions, for example, is while aircraft are to be directed so as to achieve the highest Gerada. “High power density and torque still on the ground. power output with minimal use of material. density are critical, because you can save Working with aerospace component To reduce the weight of the motor’s cooling material and get more power,” he said. “And manufacturers Honeywell and Safran, the systems, the company also used direct-cooled for any transportation system, any weight researchers have developed an electric motor conductors. Any heat lost from the copper saved is less fuel spent.” that is integrated into one wheel on each of an conductors is discharged directly into an To this end, he and his colleagues have aircraft’s main landing gear, to provide power electrically non-conductive cooling liquid, developed a motor with a power density during taxiing on the runway. The system, such as silicone oil. of approximately 30kW/kg. The motor known as EGTS, is powered by the aircraft’s The motor appears to have a good power was developed for use as an electric starter- auxiliary power unit (APU). density, according to Christopher Gerada, generator in a project with French business Gerada and his team are also working with professor of electric machines at Nottingham jet manufacturer Dassault Aviation, as part Safran on a future version of the ETGS system. “Today, most movement on the ground is powered through the main engines, but these are designed to operate at 30,000–40,000ft,” said Gerada. The higher air density on the ground, coupled with the fact that the engines are only operating at idle speed when moving around the runway, means that they are working very ineffi ciently. “So they are wasting fuel, and making noise and pollution on the ground,” he said. “With the forecast increase in air traffi c over the coming years, trying to reduce emissions while the aircraft is on the ground and maneuvering is quite critical.” Having a motor integrated into the wheel of the aircraft, and powered by the APU, can reduce fuel consumption and pollution levels signifi cantly, he added. Ultimately then, the next generation of high-density electric motors could allow aircraft to move around much more quietly and cleanly – both on the ground and in the air. Silent treatment: the aim is For more on this story visit create a very www.theengineer.co.uk quiet aircraft

40 | theEnGineeR | MAY 2015

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TE_0515 42 06/05/2015 11:15 show preview:TEDIS A showcase for design professionals The Engineer Design & Innovation Show 2015 will feature high-end products and services, as well as components, materials and more

unning from 2–4 June at the printing, to the components, materials and NEC in Birmingham, The Engineer innovative technologies that go into these Elesa: T119 RDesign & Innovation Show (TEDIS) next-generation products. Elesa will be showcasing a few of its many has been established to showcase everything Exhibitors at TEDIS 2015 are set to include new products including the PR-CH fl ush that an engineering designer needs to do Warwick Manufacturing Group, Proto Labs, pull handles, which save time and money their job: everything from high-end products JMP (a division of SAS Software), Panasonic on assembly of the sheet-metal lift-off and services used to realise their concepts, Electric Works, Laser Lines, Spaceclaim panels and doors commonly used on such as new design software and 3D Corporation and Tharsus. machinery of many types to cover equipment as a protective element. They are suitable for machine access panels Innovation hub and advisory EIA on topics including skills, innovation, and guarding – as well as for maintenance drop-in centres access to fi nance and building business in doors covering internal mechanisms or export markets. electrics – so preventing unauthorised Special features this year include an advisory Meanwhile, the Innovation Hub will personal interaction with dangerous drop-in centre where visitors will be able to provide a showcase for some of the products moving parts or electrical systems. get help with issues relating to their business and technologies that are shaping the future and an Innovation Hub that will give visitors of manufacturing. Panasonic Electric Works UK: T132 the chance to talk to companies that have Participants are set to include The Panasonic Electric Works UK will show successfully built their business. Proving Factory, Reaction Engines, The its newest additions and technological The drop-in centres will give small National Graphene Institute at Manchester innovations including two production and medium-sized (SMEs) direct access University, and the team behind the wheels methods for 3D-moulded circuit solutions to expert advice from the organisations that will hopefully propel Bloodhound SSC known as MIPTEC and LDS. Other including the Business Growth Service, the into the record books later this year (covered innovations on show will include the High Value Manufacturing Catapult and the in detail on p84). company’s next-generation MOSFET technology relays in its ultra-small TSON package and the HE series PCB relays that could eliminate small contactor needs and costly wiring installations.

Eplan: T4 EPLAN is an electrical engineering design programme (CAE), offering innovative options for the planning, documentation and management of electrical design projects. The EPLAN ‘platform’ supports interdisciplinary work, from fl uid and process engineering to harness and enclosure design.

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TE_0515 44 06/05/2015 12:14 show preview:The Engineer Conference A celebration of innovation The Engineer Conference 2015 will provide a stage for some of the country’s best engineers and most exciting projects

rom the Rosetta mission and the UK’s are dominating industry debate: new aircraft carriers to Industry 4.0 from Industry 4.0 to the welcome, Fand the rise of reshoring, The Engineer and much trumpeted, phenomenon Conference 2015 boasts an unmissable mix of reshoring. of inspiring projects and industry big hitters. Thanks to presentations Since its launch in 2013, the conference has from ADS Group and the recently provided a platform for some of the UK’s top launched Proving Factory, there engineers and some of its most exciting and will also be plenty of useful advice to innovative engineering projects. This year’s small and medium-sized enterprises instalment promises to be better than ever. (SMEs) on how to engage with Running from 2–4 of June at the NEC in OEMs, as well as fi rst-hand Birmingham, the 2015 conference features accounts from small companies Flying solo: hear three streams covering the latest thinking and – such as Magna Parva – that have how engineers the most exciting UK developments from the managed to attract interest from the have recreated worlds of engineering design, manufacturing UK’s biggest hitters. the legendary and supply chain management. On the technology side, there’s Bugatti 100P As always, throughout the event there will plenty of emphasis on the ever- be a major focus on some of the key issues that popular topic of 3D printing, with Prof Richard applications of composites and the innovations Hague, one of the UK’s leading experts in the in lightweighting that are helping some of our fi eld, making a welcome return alongside some biggest sectors lead the world. As always, there will fascinating real-world case studies from teams As always, the conference will also shine the be a major focus on the at Renishaw and BAE Systems spotlight on some of the UK’s most challenging “ We will also be taking a look at the way and inspiring projects. key issues dominating new materials are affecting the design and David Downs, the engineering director manufacturing worlds: from the untapped of the Aircraft Carrier Alliance (and regular industry debate potential of graphene to the various blogger for The Engineer), will be talking about the challenges of building the In depth: UK’s new Queen Elizabeth (QE) delegates -class aircraft carriers, while Ian will hear Costello, deputy engineering about the manager for Rosetta at Airbus production Space & Defence, will be talking of the QE to us about the UK’s role in last carrier year’s astonishing comet landing. We are also particularly looking forward to hearing from UK engineer John Lawson about how he and an international group of like-minded enthusiasts have recreated the only aircraft built by legendary car designer Ettore Bugatti. Other presenters over the course of the three days will include: Dick Elsy, chief executive offi er of the High Value Manufacturing Catapult, AMRC programme manager Dr Peter Osborne and Simon Black, senior manager of body structures at Jaguar Land Rover. The Engineer Conference runs alongside Subcon, The Advanced Manufacturing Show, and The Engineer Design & Innovation Show.

MAY 2015 | theEnGineeR | 45

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TE_0515 46 07/05/2015 10:11 show preview:subcon A focus for UK manufacturing This year’s Subcon show will feature a range of new and returning exhibitors – more than three quarters of which will be UK based

ore than 300 of the world’s leading subcontractors will be showcasing M their capabilities at Subcon from 2–4 June at the NEC in Birmingham. Subcon provides the UK’s foremost showcase of companies offering contract and subcontract manufacturing services and will run alongside the Advanced Manufacturing Show The Engineer Design & Innovation Show. The increasingly buoyant manufacturing sector is refl ected in the growing strength of the Subcon show, which this year features many new and returning exhibitors. Subcon is the UK’s only event that is completely focused on contract and subcontract manufacturing, including machining, moulding, fabrication, electronics assembly, fi nishing and treatments. The solid core of the Subcon show is its UK exhibitors, who make up more than three quarters of the exhibitors. Subcon also offers access to global markets, with 15 overseas countries represented in 2015, including pavilions for Denmark, Portugal, Italy, Hungary, China, India, Spain, Ukraine, Latvia and Taiwan, as well as individual exhibitors from Belgium, the US, Greece, Slovenia and the Republic of Ireland. Exhibitors include the Midlands Assembly Network, Lipco, WEC Group, Tata Steel, Gee Graphite, Tridan, Muller England and Mini Gears. See below for profi les of some of this At the show: Darian will launch its sheet year’s key exhibitors. metal and plate fabrication service

Mini Gears: S42 manufacturers, a design agency and academic partner Warwick Mini Gears will highlight its recently added large turning and milling Manufacturing Group and offers customers a single point of contact capacity. Just installed is a Leadwell LTC 35C turning centre with a to their engineering requirements, removing costs, reducing lead times huge torque and turning diameter up to 420mm. and delivering world-class complex parts. Based in Stockport and employing more than 80 people, the Working across 12 state-of-the-art factories, the collective has multi-award-winning company is often associated with small created an enviable reputation for providing a total manufacturing components and gears due to the ‘Mini Gears’ name. However, over solution, from initial prototyping, fabrication and precision machining the last three years the company has moved into aircraft seating to chemical etching, injection moulding and PCB development. components, the nuclear industry and specialist parts often machined The MAN line-up consists of Advanced Chemical Etching, Alucast, in exotic materials for the oil and gas industry. Barkley Plastics, Brandauer, Grove Design, Mec Com, Muller Holdings, PP Electrical Systems and SMT Developments. Darian: S130 Darian will be launching its sheet metal and plate fabrication service. Timsons Engineering: S112 The company supplies machined grey iron and steel castings, pressure Timsons Engineering offers a one-stop shop for all subcontract die castings, forgings, CNC-machined items, pressings and stampings engineering services, including both foundry and machining services, to the UK and German market, and this is now complemented by the which it offers on a complete supply or individual basis. new addition to its product range. At Subcon 2015, it is launching a mechanical and electrical fi tting service, with a huge fi tting area of more than 2,500m2 as well as a The Midlands Assembly Network: S442 maximum crane capacity of 30 tonnes, with an under hook height The Midlands Assembly Network (MAN) features eight subcontract of up to 4.7m.

MAY 2015 | theEnGineeR |47

TE_0515 47 06/05/2015 13:24 show preview:AMS Staying ahead of the game This year’s Advanced Manufacturing Show is set to highlight the critical technologies that UK companies need to invest in

ollowing its successful launch in 2013, the Advanced highlighting the technologies that UK companies need to stay ahead of Manufacturing Show (AMS) returns to the NEC on 2–4 June. the game in international markets. F Featuring more than 50 manufacturers and suppliers of Nigel Atherton, managing director of XYZ Machine Tools, said: “We had advanced production engineering technology, the exhibition will a very positive response at the Advanced Manufacturing Show in 2013 and highlight the critical advanced manufacturing technologies that UK this encouraged us to rebook for 2015, when we will have new products to companies need to invest in, in order to stay ahead of the game in show, such as the innovative XYZ 2-OP portable vertical machining centre.” international markets. Alongside XYZ, other exhibitors will include Matsuura, Delcam, These include machining and turning centres, sheet-metal working, Renishaw, Hexagon Metrology, FARO, Kasto, Trumpf, Vero and OGP. This metrology, tooling, workholding and CAD/CAM software. The show free event runs alongside Subcon, The Engineer Design & Innovation will feature live machining demonstrations and new product launches Show and The Engineer conference.

Left: XYZ will show the 2-OP vertical machining centre Right: FARO is set to present the Freestyle3D scanner

AMS exhibitors will be showing off a wide range of different Zoller: A126 manufacturing technologies from the latest CNC machines Zoller UK will be demonstrating a range of pre-setters to suit all and tooling to measurement systems and the latest CAM budgets and situations. Whatever the user’s individual requirement software. Here’s a fl avour of what visitors can expect to see: the Venturion is available in an optimum confi guration. The Venturion is able to accommodate large, heavy tools while maintaining the highest- XYZ: A106 precision demands, making it suitable for CNC production situations. XYZ Machine Tools will be demonstrating a wide range of machines with particular focus on the productivity gains that can be achieved by Vero Software: A26–4 introducing the XYZ 2-OP to your production mix. Visitors will have the Vero will be demonstrating latest releases of its three core CAD/CAM opportunity to witness the potential time savings and cost reductions brands: VISI, Edgecam and Radan. Visitors will be able to see how possible through the implementation of this new portable vertical Edgecam can be used to create optimised toolpaths; they will learn machining centre. about the latest enhancements to VISI (the company’s mould and die solution); and they will see fi rst hand the 180 items of new functionality Aberlink: A129 in Vero’s Radan software. Aberlink Innovative Metrology will have an advanced new shop-fl oor vision measuring system making a debut at Advanced Manufacturing. FARO: A37 Featuring Aberlink’s powerful vision software, plus a host of easy-to- FARO UK will be giving an Advanced Manufacturing Show debut to the use inspection tools, the innovative new Aberlink machine is designed company’s new FARO Freestyle3D. This handheld laser scanner is the to deliver high levels of accuracy, faster component throughput and only industrial-grade handheld device that allows users to scan almost enhanced ease of use. any sort of surface in nearly any kind of environment.

48 | theEnGineeR | MAY 2015

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TE_0515 49 05/05/2015 15:14 show preview:PDM PDM celebrates 10th anniversary The Plastics Design and Moulding Exhibition and Conference 2015 has already attracted more than 100 exhibiting companies

he Plastics Design and Moulding Theatre ticket: Exhibition and Conference (PDM15) is a two-day Tcelebrating its 10th anniversary as the UK’s conference will premier annual event for the plastics industry. run alongside Returning to the Telford International the exhibition Centre on 16–17 June, the event will be co- located with the second Plastics Recycling Expo and the new Plastics Packaging Show, and has already attracted more than 100 exhibiting companies. Major names from every part of the UK plastics community have confi rmed their presence at PDM15, including Distrupol, Plastribution, Negri Bossi, Premier Moulding Machinery, Billion UK, BMB Plastics Machinery, Kuka Robotics, Luxus, Mouldshop, Rutland Plastics and Chess Plastics. Companies exhibiting at PDM for the fi rst time in 2015 include Igus UK, Cad2parts, South West Polymer Supplies, Hotset UK and Kongskilde UK. Other exhibitors will include product design companies, rotational and blow moulding machinery suppliers, toolmakers, rapid prototyping specialists, moulders and mouldmakers, masterbatch specialists, software suppliers and materials testing specialists. Exhibitor highlights include Rainford Precision, which will be exhibiting its drilling products for truly hard materials, and Renishaw, A conference will focus on the UK’s only manufacturer of metal-based some the industry’s most topical additive manufacturing machines that print “ metal parts, which will be showcasing its issues including skills shortages collaboration with bicycle company Empire Cycles on the world’s fi rst 3D-printed metal practice and assessment of joint integrity’ by Running alongside PDM, the Plastics bike frame. Farshad Salamat-Zadeh, chartered polymer Recycling Expo (PRE) exhibition and Elsehwhere, TRUMPF laser metal and adhesive engineer and senior project conference will bring together key players in deposition welding (LMD) will provide a leader at TWI order to learn, network and capitalise on the quick and economical solution to modifying • ‘Failure in polymer products – it doesn’t just business opportunities plastic recycling offers. or re-manufacturing a mould tool. This is a happen’ by Justin Taylor, principal consultant, Over two days, the PRE conference will surface treatment process that adds a layer or ipolytech, Telford explore how the industry can boost plastics layers of material onto the substrate. The laser • Material innovations in injection moulding recycling, as well as the use of recycled melts a pool of metal on the surface and metal by Dr Mark Barnett, head of Warwick plastics. Speakers include sustainability powder is deposited through a nozzle into that Scientifi c Services experts working for major brands including pool, creating a new surface. There will also be a number of ‘shop-fl oor’ Unilever, IKEA and Marks & Spencer. Alongside the exhibition, a two-day sessions for engineers, providing practical Exhibitors already confi rmed for PRE conference will focus on a range of the expertise in areas such as moulding techniques include Axion Recycling, Biffa Polymers, industry’s most topical issues including skills and machine care. Cherry Plastics, CK Compounds, Impact shortages, EU membership, sustainable design, A popular feature of previous shows that Air Systems, Plasgran, Moulding Solutions, automotive lightweighting and 3D printing. returns for 2015 is the Plastics Consultancy STEINERT Elektromagnetbau GmbH and Highlights include: Network’s Plastics Surgery. Visitors are invited Veka Recycling. • ‘An overview of the UK auto industry’ by Luke to bring along questions that they may have To register to attend PDM15, please visit: Hampton, supply chain director at the Society relating to plastics design and moulding and www.pdmevent.com. of Motor Manufacturers and Traders (SMMT) PCN’s consultants will be on hand to offer Registration will also allow free access to • ‘Plastics, lightweighting saviour; welding of effective, creative and cost-effective advice the co-located Plastics Recycling Expo and automotive plastics components. Best and solutions. the Plastics Packaging Show.

50 | theEnGineeR | MAY 2015

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TE_0515 51 05/05/2015 14:33 careers:graduate skills Lessons learned A new university has been proposed that aims to create a supply of work-ready engineers to support local companies in Herefordshire

New take on teaching: programme; this is when we do the second law NMITE will eschew a of thermodynamics’, the teaching is done by traditional programme putting a problem on the table and using various of engineering lectures engineering tools to try to fi nd the solution.” This approach is inspired largely by Olin College of Engineering in the US, a small private university founded in the 1990s that focuses solely on producing the leading engineering innovators of tomorrow. It’s a highly selective institution that’s been dubbed one of the 25 ‘New Ivy League’ colleges and reached number three in one league table of US engineering schools last year. The hope is that NMITE can emulate this success in a way that both produces higher- calibre engineering graduates and attracts more people to the profession. “If you’re going to try to tackle the numbers, you have to look at new ways to engage people in the profession,” said Karen Usher, NMITE’s other co-team leader. “Getting an opportunity to work for months if not years in an industry sector where you’re actually learning by working on problems in that industry hooks men and women into the sector and the profession… The engagement with that sector, the real understanding of what it is and what the work is about, changes how you think about the job hunt. It makes it more appealing... and you’re more engaged with the choice.” The aim is also to use the broader curriculum to show students the sheer breadth of ways engineering can be applied in the real he engineering skills problem isn’t a six-month work placement and an additional world, which, said Usher, could be particularly going away. Despite the efforts of taught curriculum covering non-engineering effective in encouraging women to start Tvarious outreach programmes, publicity subjects including arts and humanities to engineering careers. campaigns and government initiatives, the promote critical thinking and cultural awareness. “Part of engineering could be working number of businesses complaining about the “Universities’ fundamental purpose is to for Oxfam and working with women’s quality and quantity of engineering graduates teach you how to think,” said David Sheppard, microbusinesses to help them design new remains stubbornly high. [water] pumps. [Demonstrating this is about] While the number of engineering students opening up and helping them to understand has grown in line with the wider take-up of If you’re going to try that the career of engineering is about problem higher education, the latest skills survey from to tackle the numbers, solving, people management [as well as] the the Institution of Engineering and Technology “ application of technical engineering.” (IET) found around 40 per cent of engineering you have to look at new Although it’s not obvious how studying fi rms struggle to recruit graduate engineers, English literature will open women’s eyes to the with 54 per cent saying graduate skill levels ways to engage people variety of the profession, the model has certainly did not meet reasonable expectations. in the profession worked for Olin, where 50 per cent of students So is it time for a revolution in the way are female compared with the average of around we teach engineering in the UK? A group Karen Usher, NMITE 16 per cent in UK engineering departments. proposing to build the UK’s fi rst new university Usher said this is down to establishing a in 30 years believes so and plans to initiate just co-leader of NMITE’s development team. “Being culture in which women feel welcome but that. Called the New Model in Technology & a fully rounded engineer is not just a matter of also about broadening the admissions process. Engineering (NMITE), the private university understanding the physics and maths… To be As such, NMITE plans to recruit students aims to create a supply of work-ready a really effective, innovative, problem-solving without A-level maths and/or physics (subjects engineers to support local engineering fi rms in engineer, you need a broader base on which in which women are minorities) and give its planned home in Herefordshire from 2017. to operate. Most of the problems coming down them adequate support to study the topics Although it is being advised by Bristol and the track are going to need an interdisciplinary in remedial classes. “Why could we not look at Warwick universities, NMITE will eschew a approach and that’s what we’re doing. a young woman, for example, who has studied traditional programme of engineering lectures. “But the teaching is also informed by biology, history and English and say if she’s got Instead it will teach students through a series industrial partners providing you with real the right grit and passion and she’s prepared of real-world problems supplied by businesses, problems. So rather than say ‘it’s week 13 of the to engage with the maths that’s needed, could

52 | theEnGineeR | MAY 2015

TE_0515 52 06/05/2015 11:52 careers:graduate skills

she not pursue engineering?” said Usher. Some traditionalists might be horrifi ed by this idea. Grand challenges require a whole spectrum of They might also be unsurprised to know that people from researchers to technicians, but day-to-day the neither of the people proposing this model “ have previous experience of engineering or commodity projects require different engineers engineering education in the UK (Usher is a human resources professional and Sheppard is a Elena Rodriguez-Falcon, Sheffi eld University retired marketer and management consultant). The idea for NMITE arose not from a desire do this with working hours and holidays closer ultimately it wasn’t sustainable, said Hobbs. “It to reform how engineers are educated, but from to those of a conventional company than a was really diffi cult to get people from a non-A- a local working group hoping to improve the term-based university, a move that will be level background up to speed in three years… economy of Herefordshire. As the county is one helped by the fact its lecturers won’t be We had people who found it wasn’t for them of the few in England not home to a university, balancing teaching with their own research. because it was a very technical degree.” the group decided founding one would increase It will also have the added bonus of drawing Perhaps the biggest question remains the local skills base and attract investment up a curriculum from scratch rather than whether this kind of curriculum will produce and young people to the area. As many local accommodating the existing interests of its staff, the type of engineers the UK needs. Education, businesses specialise in technology, particular in according to Elena Rodriguez-Falcon, professor after all, is not the same as training. It arguably the defence, agriculture and low-carbon sectors, of enterprise and engineering education at shouldn’t be the job of universities to produce it was felt an engineering university would be Sheffi eld University.“We are trying to develop ‘oven-ready’ workers with the employability particularly benefi cial and the group set about an interdisciplinary approach to learning and skills equivalent to several years’ experience investigating the best way to create one. teaching but we haven’t got there yet,” she said. on the job, but rather engineers with a deep Despite this lack of direct educational The problem might come not from the understanding of fundamental principles that experience among NMITE’s founders, the public teaching itself but the need for engineering they can apply to a range of technical problems. reaction from the existing university sector has degrees to be accredited by a professional If companies want engineers trained in the been positive. True, Warwick and Bristol are institution in order to count towards an practical aspects of their particular line of work, only advising NMITE at this time and have engineer’s chartership. “These guys will be they should arguably hire more apprentices and not yet agreed to award degrees for the new starting at a disadvantage because you can’t sponsor their part-time university study. institution, as has been incorrectly reported. get accreditation, generally, until you have “Current knowledge is very important but Indeed, a spokesperson for Warwick said the some graduates, which gives you a three- or innovation is occurring at a speed that has university couldn’t yet comment on the viability four-year run-in before you can say ‘this is an never happened before,” said Rodriguez-Falcon. of the venture. (A spokesperson for Bristol was accredited programme’,” said Hobbs. “We’re training engineers for jobs that don’t willing to be interviewed but was unavailable “The barrier for a lot of existing courses exist yet that will use tools that haven’t been before the deadline of this article). However, the is that if you want to make a radical change invented. So the most important thing is that fact that both universities were prominently to your curriculum you have go through the they have the principles and the mindset to involved in NMITE’s launch announcement accrediting bodies, and they have a reputation tackle problems they haven’t even imagined.” suggests they are confi dent enough in its for being very conservative and fi ercely This doesn’t mean, however, that practical proposals to be publicly associated with them. protective of their discipline, making sure you assignments based on current real problems Other academics The Engineer spoke to have particular subjects included.” However, from industry can’t form the basis of study at were similarly positive about the idea and the this doesn’t mean that NMITE faces an degree level. Indeed, project-based learning source of its inspiration, Olin College. “It’s a insurmountable task. “Actually, if you look at the is very common even at the most academic very interesting idea to shake things around [accreditation] literature… it’s extremely broad universities. What an increase in this type of a bit as the UK engineering curriculum on and doesn’t go down to a very detailed level,” study may do is produce a type of engineer that the whole is quite traditional, said Catherine added Hobbs. “If I were them, I would be trying is more focused on specifi c company problems Hobbs, head of department for engineering at to work with the accrediting bodies now.” rather than the biggest engineering problems of the University of the West of England (UWE). Recruiting students without A-level maths our age, but ones that are no less important to “I can understand how their aim to appeal or physics will also inevitably create extra UK industry. “Grand challenges such as energy more widely could be achieved by this really diffi culties that can really only be addressed and water require a whole spectrum of people quite different take on engineering curriculum.” by investing heavily in a high ratio of staff to from in-depth researchers to technicians, One issue with teaching engineers to degree students. And even then, there’s no guarantee but day-to-day commodity projects require level while introducing both more practical it will work. UWE, for example, used to accept different engineers,” said Rodriguez-Falcon. skills and a broader range of academic subjects non-maths students onto its robotics degree and Ultimately, the UK’s engineering skills issue will simply be fi tting it all in. NMITE plans to as a result recruited more creative people, but isn’t going to be solved by any single measure because the sector doesn’t require a single type of engineer. It needs more people to come through the apprentice route who know a company’s working practices inside out by the time they study degree-level engineering. It needs more top academic graduates to tackle complex technical and system-wide problems for the country’s most innovative fi rms. And it needs engineers who are prepared to go into small and medium-sized companies in quiet, rural locations such as Herefordshire, bringing new energy and ways of thinking with them. “Everybody’s been saying this for more than a decade: the curriculum needs more women, it needs to be modernised, it needs to be more interdisciplinary and it needs additional skills to make young people more employable,” said Usher. “This is a once-in-a-lifetime opportunity to bring industry and academia together, strip curriculum apart and say ‘how can we build a modern, sector-focused curriculum that’s fi t for purpose and has the necessary quality?’”

MAY 2015 | theEnGineeR | 53

TE_0515 53 06/05/2015 11:52 Find the latest jobs at www.theengineerjobs.co.uk careers To advertise, contact Mauro Marenghi t:020 7970 4187 e: [email protected]

Spellman High Voltage Electronics Corporation is the world’s leading high voltage power supply manufacturer serving the medical, analytical, industrial, commercial, telecommunication and scientifi c communities. Find our more information from our FULLY-FUNDED SCHOLARSHIPS website: www.spellmanhv.com INDUSTRIAL ENGINEER The role is pro-active in facilitating the continuous improvement of production processes effectiveness and effi ciency. You will work closely with the Manufacturing Engineering Manager Engineering Doctorate (EngD) to consolidate the link between Production, Product Design and Test Equipment Design teams. Key Responsibilities in Composites Manufacture • Ensure Lean thinking, Cellular manufacture, single piece fl ow, visual management and pull systems are utilised wherever possible • Introduce new tooling/jigs/fi xtures or assembly aids to ensure the most effi cient production x Run by the EPSRC-funded Centre for methods are employed • Continually review production assembly drawings and work instructions to ensure they refl ect Doctoral Training in Composites Manufacture, the most effi cient production processes and methods and tooling available. • Ensure all assembly and test processes utilise Poka-Yoke error proofi ng techniques a collaboration led by the University of Bristol wherever possible • Use our NCR database to gather and analyse data (via liaison with Quality Department) to drive ‘In-house’ process improvements and kaizen events x Developing elite Research Engineers ready to • Support Manufacturing Engineering Manager in liaison with Test Equipment Design team to take on key leadership positions in industry ensure the Test Strategy suits production needs and new test equipment is designed with Poka-Yoke in mind and manufactured in a way that is repeatable, maintainable and robust enough for production use. x Industry-based and industry-led EngD Preferred Education/Experience Degree/HND in Production Engineering or closely related discipline. research projects, directly addressing the Minimum 2 years’ experience in a Production Engineering role or closely related discipline. If you are interested in this position please send your CV to Mrs Hazel Reed Human Resources Manager. sponsor’s commercial research priorities Spellman High Voltage Electronics Ltd, Broomers Hill Park, Broomers Hill, Pulborough, West Sussex RH 20 2RY Email: [email protected] or telephone for more information on 01798 877014. x Programme of bespoke, Masters-level technical units and business skills training to underpin research TRAINER/ASSESSOR We are currently recruiting to a number IN ENGINEERING of exciting new projects with sponsors including FORMAX, Hexcel, Ketonex, £19,679 – £30,475 per annum Ref: TAEng LMAT and Rolls-Royce. Due to the expansion of our engineering provision we require a Trainer/Assessor to join our existing team. You will be required to assess young people and adults completing apprenticeship programmes as well as deliver training to support these programmes. This will involve delivery at college and on employer premises, so you must be prepared to travel. You should be A1 Assessor qualified (or equivalent /working towards) and ideally qualified to at least HNC Level in an engineering discipline. This is an exciting opportunity to join us in Dudley Advance, our new centre for Advanced Manufacturing and Engineering Technologies. To apply visit www.dudleycol.ac.uk Closing date: 21 May 2015 x Ongoing recruitment and flexible start dates A teaching qualification would be an advantage or a commitment to undertake this within the first year of employment is essential. x Scholarships: £20k p.a. plus fees for 4 years All successful applicants will need to undertake an enhanced disclosure and barring service check and children and adults barred list checks where the applicant will be employed in a regulated activity.

Dudley College is an equal For further informaƟon please visit our website opportunities employer and welcomes applicants from cimcomp.ac.uk/IDC all backgrounds, including disabled, and black and ethnic minority applicants.

hands-on thinking since 1862 dudleycol.ac.uk

54 | theEnGineeR |MAY 2015

TE_0515 54 07/05/2015 13:18 Follow us on : @TheEngineerJobs Connect with us on : The EngineerJobs careers

WHERE INNOVATION BEGINS FUTURE MANUFACTURING ENGINEERING OPPORTUNITIES West Midlands (Relocation Offered) It begins with a blank canvas, the drive to power the world’s finest vehicles and a passion to build the most advanced engine manufacturing programmes. It begins with you.

jlrenginecareers.com

MAY 2015 | theEnGineeR | 55

TE_0515 55 07/05/2015 12:35 Find the latest jobs at www.theengineerjobs.co.uk careers To advertise, contact Mauro Marenghi t:020 7970 4187 e: [email protected]

Build your career with Eaton, and build the Power of Perspectives.

Diversity at Eaton is the rich range of differences that make each of us unique. Recognizing, valuing and fully leveraging our different perspectives makes us powerful.

Learn more and apply for opportunities at www.eaton.com/careers.

Eaton is a global power management Our products and the employees company. We help customers who design and build them are part manage power, so buildings, of making a difference in the world airplanes, trucks, cars, machinery every day. If you’re ready to do and entire businesses can do more something that matters, to do it well while consuming less energy. As and to be encouraged and rewarded an integrated global company, we for doing it, then Eaton is the place CTGWPKƂGFKPQWTEQOOKVOGPVVQ for you. powering business worldwide.

Rail Safety/Reliability Engineers

Risktec Solutions is one of the UKs leading science or equivalent. They would ideally have engineering consultancies in safety, risk between 2 and 5 years experience in the Rail TÜV Rheinland Group® management and training and is part of the global Industry in a System Assurance, Safety, Reliability TÜV Rheinland Group. We have an expanding rail or Systems Engineering role and will be a member business and are seeking to increase our team of a relevant professional institute, either already ZLWKKLJKO\PRWLYDWHGG\QDPLFDQGLQÀXHQWLDO chartered or working towards it. Candidates should individuals who are interested in developing their have awareness of HAZOP, HAZID, FME(C)A, RBDs, career with us. )5$&$6DVVHVVPHQWVDQGLQGXVWU\VSHFL¿FGLUHFWLYHV We work with a wide spectrum of clients including regulations and standards such as EN 50126, EN National Regulators, Infrastructure Managers, Train 7HFKQLFDO6SHFL¿FDWLRQVIRU,QWHURSHUDELOLW\ Operating Companies and System Suppliers. Our (TSIs) and Common Safety Method (CSM) on Risk range of projects covers Underground, Heavy Rail, Evaluation and Assessment. Light Rail and Metro Systems and all disciplines You will receive a highly competitive salary, with LQFOXGLQJ(OHFWUL¿FDWLRQ7HOHFRPV6LJQDOLQJ5ROOLQJ private medical, employer pension contributions and Stock and Infrastructure. H[FHOOHQWSUR¿WVKDUH,QDGGLWLRQZHVXSSRUWRXU As our portfolio of work includes larger safety people with a competency development programme, projects it allows for those with less experience to which builds on technical skills and industry focus, as shadow and gain support from Senior and Principal well as relationship and project management skills. consultants and conversely gives those with more All consultants are offered the opportunity to join our experience the opportunity to mentor and train MSc programme in risk and safety management. junior engineers. Risktec is an international company and offers For this role, the successful candidate will be opportunities for multi-industry experience and work university educated with a degree in engineering, outside the UK.

In order to be considered for this role, please send an up to date CV with a covering letter detailing your current and desired remuneration to: [email protected]

ASTEC is a Risktec Group Company and manages the recruitment process on behalf of the Group. Risktec and ASTEC operate a strict policy regarding recruitment agents. Neither company will be held liable for fees from any supplier without signed terms of business with us.

56 | theEnGineeR |MAY 2015

TE_0515 56 07/05/2015 12:35 Follow us on : @TheEngineerJobs Connect with us on : The EngineerJobs careers

NOW HIRING ENGINEERS To design bad-ass robots to fight cancer!

ROBOTICS MECHATRONICS ELECTRONICS MECHANICAL ENGINEER ENGINEER ENGINEER ENGINEER

SALARY: £30,000-£40,000 LOCATION: Exmoor National Park, Somerset, UK YOU: Self-starter with a bias for action & delivery

Join us and accelerate science Singer Instruments develop hardware and software for laboratory automation. Our robots propel scientific research in thousands of labs around the world. If you feel a responsibility to science, come and join us! Apply online at singerinstruments.com/jobs

MAY 2015 | theEnGineeR | 57

TE_0515 57 07/05/2015 12:35 Find the latest jobs at www.theengineerjobs.co.uk careers To advertise, contact Mauro Marenghi t:020 7970 4187 e: [email protected]

Due to continued growth, a range of opportunities has arisen across a number of teams: www.mt.com/xray-careers Mechanical Design Engineer Working on both New Product Development projects and custom solutions. The role would be suited to creative designers with experience of conveyor Engineering Vacancies Engineering Vacancies systems and product handling solutions. Other relevant experience also considered (industrial machinery with moving parts, integrated electrical and pneumatic systems). Responsibility to produce 3D designs in AutoDesk Inventor (experience gained in other CAD systems will be considered).

Project Engineer You will be required to review specifications of all new customer orders and co-ordinate teams of engineers in the design of custom products. Suited to Engineers looking for greater responsibility, focused on leading small design teams to deliver rapid projects. Ideally Degree qualified in Mechanical Engineering with experience of designing products containing elements of electrical, electronic and software engineering. Other relevant Engineering backgrounds also considered.

Project Engineer (Sub-Systems) Degree qualified in Electrical/Electronic Engineering with significant understanding and experience of electronic PCB design. Although detailed design is not part of this role - the role focuses on managing the design, test and production release of our key sub-systems. Experience of product development methodology/process desirable. Candidates will be great all-rounders, have an eye for detail yet also possess the ability to effectively deliver projects.

Project Manager Reporting to the Head of Product Engineering you will manage the full lifecycle of specifying, quoting, designing, building, testing and installing specialist x-ray inspection equipment. Candidates are likely to be Degree qualified Engineers who have transitioned into Project Management in product development environments. You will be assertive, have outstanding organisational skills, and be confident with customers.

Software Requirements and Validation Coordinator Establish process to gather requirements for software development, testing, validation, and release. Review existing software platforms to establish baseline specification and testing plan. Candidates must have previous experience of implementing software development practices.

Applications Engineer Providing development support to both current-model engineering and New Product Development, this role focuses on testing the boundaries of our solution capabilities. Working closely with our product development team to understand new customer requirements and identify solutions to new challenges. Candidates likely to have electrical bias with good understanding of electronics, software and mechanical design. Have installation / commissioning / design experience of complex machinery.

Further Vacancies listed on our website Head of Quality Production Engineer Sourcing Engineer Field Service Engineers

For more detailed information on all our vacancies, please visit our website at www.mt.com/xray-careers. To apply, please send CV, salary requirement & a cover letter detailing your relevant experience to [email protected].

Only successful candidates will be contacted for interviews.

Mettler-Toledo Safeline X-ray Ltd Royston Business Park, Royston Hertfordshire, SG8 5HN Tel: +44 (0) 1763 257900

58 | theEnGineeR |MAY 2015

TE_0515 58 07/05/2015 12:35 Follow us on : @TheEngineerJobs Connect with us on : The EngineerJobs careers

BUILD A SUCCESSFUL CAREER WITH CARNIVAL

Carnival Corporation & plc is the world’s biggest cruise ship company with more than 100 ships sailing under 9 brands, comprising of Carnival Cruise Lines, Holland America Line, Princess Cruises, Seabourn, AIDA, Costa, Cunard, P&O Cruises and P&O Australia. We employ over 100,000 people worldwide and serve about 10 million passengers a year.

Our Corporate Shipbuilding team These require degree level and in in Southampton is responsible some cases Masters level knowledge for overseeing all aspects of the in Mechanical, Marine, Electrical, company’s new build projects. Naval Engineering or Naval Managing the process, co-ordinating Architecture as well as significant the specifications and design experience within the cruise industry. approval for every part of each new With support to help you reach your build are key activities and we are potential, attractive company benefits looking for a number of talented and incredible employee offers on individuals in this area to join the discounted cruises we want your 25 strong team. career with us to be a successful and Due to growth we are adding 6 key enjoyable one. This is your chance to new roles in the following areas; join us on our journey. • Commissioning Engineer To find out more and apply, go to • Catering Engineer www.carnivalukcareers.co.uk • Outfitting Engineer • HVAC Engineer • Naval Architect • Project Manager

MAY 2015 | theEnGineeR | 59

TE_0515 59 07/05/2015 12:35 Find the latest jobs at www.theengineerjobs.co.uk careers To advertise, contact Mauro Marenghi t:020 7970 4187 e: [email protected]

NEW CLEAR OPPORTUNITIES

Fircroft is one of the world’s leading technical recruitment agencies. We work globally with top energy, resource and engineering companies and are proud to be supporting major UK nuclear projects.

Powering the nuclear sector We have a range of fantastic opportunities available in the nuclear sector. It’s our mission to connect people to power the world and to achieve this, we are looking for high calibre technical and engineering professionals who are ready to take on a new role.

A trusted technical recruiter It takes a special kind of company to work with the world’s biggest corporations in the Energy and Engineering industries, but we’ve been doing VRIRU\HDUV,QIDFWRXU¿UVWFOLHQWLVVWLOOZLWK us today. We are currently supporting over 8,000 contractors across the world and because we look after them; 95% said they would work for Fircroft again.

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CONNECTING PEOPLE TO POWER THE WORLD.

60 | theEnGineeR |MAY 2015

TE_0515 60 07/05/2015 12:35 Follow us on : @TheEngineerJobs Connect with us on : The EngineerJobs careers

Reach the engineers of tomorrow

The Student Engineer is a new Advertising opportunities available for recruiters. editorial-led careers website from the Find out how you can reach thousands of students from the top UK engineering universities via: publisher of The Engineer - helping you connect with the next • Targeted email and eNewsletter communication

generation of engineering graduates. • Prominent exposure on The Student Engineer and The Engineer website

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For more information please call Mauro Marenghi on 0207 970 4187 or email [email protected]

Follow us on to become part of our growing online community

MAY 2015 | theEnGineeR | 61

TE_0515 61 07/05/2015 12:35 news:digest

may1905 prizecrossword When completed rearrange the highlighted squares to spell out Obituary of Edmund Beckett Denison, designer a structure consisting of a row of evenly spaced columns. The fi rst correct answer received will win a £20 Amazon voucher. Email your answer of the clock of the palace of Westminster to [email protected] As the general election looms and the thoughts of the nation turn, however reluctantly, to Westminster, we can be certain that we are going to see the most distinctive feature of the Houses of Parliament, the clock that we’re not supposed to call Big Ben, ever more regularly on our TV screens and newspapers. The engineer who designed that clock, and the mechanism that produces its evocative chimes, was Edmund Beckett Denison, later raised to the House of Lords as the fi rst Lord Grimthorpe, whose brief obituary appeared in The Engineer. For our predecessors, Grimthorpe was notable for his clock making: he revolutionised the building of large public clocks. He invented a system that more or less eliminated friction in the clock’s escapement – the component of the mechanism that converts the oscillation of the pendulum into the rotation of the escape wheel, the largest of the clock movement’s gears. Previously, large pendulum clocks used a system called a remontoire escapement, which used a secondary source of power to drive the clock’s escape wheel. Every half-minute, the clock’s pendulum mechanism winds ACROSS 18 Establishments for higher up this secondary power source, so the clock’s arms are isolated 1 Happening by chance (10) learning (12) from the movement of the pendulum and vice-versa. 6 Unusually great in size (4) 21 Encloses in a container (7) Grimthorpe took that idea further. He devised a system of 10 Separate into parts (5) 23 Poisonous metallic element (7) suspended weights 11 A diffi cult problem (9) 24 High in price (9) Grimthorpe’s placed on either side of 12 Hole used to collect waste 25 Solder together with high heat (5) the pendulum rod, placed fl uids (4,3) 26 Large holding vessel (4) “system more or less so that one of the weights 13 Terrier with erect tail and ears (7) 27 Community of people smaller was always “elevated 14 Weight that balances another (12) than a town (10) eliminated friction in in advance of the rising the clock’s escapement pendulum”. In falling, it DOWN 15 Being concerned with the social helped the pendulum to 1 Evaluate the quality of (6) and physical environment (9) return to the other side of its arc, ensuring that it always had exactly 2 A tall vertical cylindrical 16 Most tranquil (8) the same driving effect. “The mechanism is exceedingly simple; it supporting structure (6) 17 Rod used to hold a wheel on is very easy to make and need not be very accurate,” The Engineer 3 Series of complex computer an axle (8) said. “Clocks fi tted with it are therefore splendid timekeepers.” operations (4,10) 19 Opening through which fl uid Grimthorpe designed the Westminster clock in 1851; he was 4 Alkaloid poisons that occur in is admitted (6) elected to the Royal Astronomical Society in 1866, and two years tobacco (9) 20 Special importance or later was elected president of the British Horological Institute on 5 Sisters of father or mother (5) signifi cance (6) the condition that he wasn’t asked to attend dinners. We can only 7 Landing area for aircraft (8) 22 Move smoothly along surface (5) speculate whether it was the quality of the food or the company he 8 Made hard or resilient objected to, but he was re-elected every year until his death. SN especially by heat treatment (8) Last issue’s highlighted solution 9 Incapable of being pressed was ELECTRUM. The winner is For more on this story visit www.theengineer.co.uk together (14) Simon Williams.

origineering Anthony Poulton-Smith explores the origins of everyday engineering terms

Look up ‘engine’ in the dictionary and it is defi ned as ‘a device all derived from old French ‘engin’, meaning ‘skill, wit, cleverness’ in that converts energy into mechanical power’. Thus there were some instances and more often as ‘trick, deceit, stratagem’. no engines before the 18th century and the birth of industry. Further back, we fi nd late Latin ‘ingenium’ ‘war machine’ and Yet there are records of it by 1300 and it was used to refer earlier still ‘inborn qualities, talent’. It is the earlier use of ingenium to ‘a mechanical device’ and particularly one used for warfare. that most interests us as this has also resulted in the word ‘ingenuity’. We also fi nd the term used at least a century earlier. These earlier When we hear both words the link is clearer than seeing it in references use it in a variety of senses, including ‘skill’, ‘craft’, ‘innate writing. I know of no engineer who will not be delighted to learn his ability’ and ‘deceitfulness’ or ‘trickery’. These are the original usages, job title is, at least etymologically speaking, akin to that of a genius.

62 | theEnGineeR | MAY 2015

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