164 YEARS OF TECHNOLOGY AND INNOVATION

MAY 2020

Powering ahead? Why a new generation of giant battery plants, or gigafactories, are key to the UK’s electric vehicle ambitions

20 24 34 TheEngineerUK theengineeruk The Engineer UK

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4 Editor’s Comment 12 cover feature 24 consumer technology 36 from the archive The future of the UK’s automotive Giant gigafatories for the production of Canadian startup Ora is looking to take How automotive engineers turned their sector hinges on our ability to avoid the lithium-ion batteries will be essential to graphene mainstream with innovative talents to Iron lung design during mistakes of the past the future of the UK car industry loudspeaker technology the 1956 polio pandemic 6 NEWS 16 VIEWPOINT 30 Q&A Feature 38 scifi eye Beyond line of sight UAV trials aim to Ian Risk asks whether Covid-19 could An expert panel discusses trends Forget the Terminator scenario, the stimulate innovation and fast-track catalyse the digital revoluion? and developments in the fast-moving future of AI based warfare could be far commercial applications of drones field of XR weirder than that writes Gareth L Powell 18 mailbox 8 covid-19 NEWS Readers speculate on the long-term 32 software products 40 secret engineer Engineers from industry and academia impact of the current pandemic on UK Leading suppliers showcase the lastest Our anonymous blogger calls for a join forces to fight Coronavirus engineering and manufacuring releases and applications more visionary approach to process 10 NEWS ANALYSIS 20 civil engineering 34 late great engineers improvement How SMEs are the unsung heros of the Why a flood defence scheme for the The life and times of antiquity’s greatest 42 digest engineering Covid-19 fightback city of Hull offers a host of benefits scientist, Archimedes of Syracuse Take part in our monthly crossword

COVER Image: Tesla’s Gigafactory1

Editor Jon Excell Commercial director Justyn Gidley Production Kyri Apostolou News 020 8076 0576 +44 (0)20 7738 5454 +44 (0)20 7738 5454 +44 (0)20 807 6779 Display 020 8076 0582 [email protected] [email protected] [email protected] Recruitment 020 8076 0581

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3 May 2020 / www.theengineer.co.uk EDITOR’SNOVEMBER COMMENT 2019

JON EXCELL

READ MORE ONLINE Ba ery manufacturing Engineering a Covid-19 fi ghtback; reshoring scale-up will be vital to UK’s UK manufacturing; and dealing with nuclear waste post pandemic economy www.theengineer.co.uk hilst the UK undoubtedly has a proud history of innovation, an historic failure follow us at to tap into the commercial potential of some of its most striking technological @TheEngineerUK breakthroughs is a cause of considerably less pride. 5 W From the computer to the jet engine, Britain has let some of the most THINGS theengineeruk transformative, world-changing technologies slip though its fi ngers to see other The Engineer UK countries reap the economic benefi ts. WE’VE Fortunately, many of the factors that drove this damaging dynamic are now in The Engineer UK the past. Much of the engineering and scientifi c research base - once distant from the LEARNT coal face of industry - is now arguably more engaged than ever with the commercial THIS realities of the world, and initiatives like the government’s Catapult centres ENGINEER JOBS are helping to create a climate for promising technologies to cross the so-called ISSUE Find your next engineering job commercial valley of death and begin contributing to the economy. online at The EngineerJobs But the impacts of historic inaction sometimes linger on. Automation And a case in point is one of the most ubiquitous engineered components on the 1 helps UK SME planet: the lithium-ion ba ery - power source for our portable electronics devices, lap scale up to 1 million top computers, smart phones, and the electric vehicles that are being produced and protective visors per sold in ever increasing volumes. week As we report in this issue’s cover story, the UK has some serious pedigree in the fi eld: the technology was invented here and, in more recent times, Nissan’s 2 Drone package Sunderland ba ery plant was the largest of its kind in Europe. But as vast ba ery delivery market producing “gigafactories” spring up across the world, Britain is falling down the list of to be worth £21bn by ba ery manufacturing nations. 2030 Given the speed with which the automotive sector is switching to the production Europe of electric vehicles, this is a worrying situation. The fear is that as vehicle producers MISSION 3 projected to switch to producing greater volumes of electric vehicles and wind down internal reach 450GWh of STATEMENT combustion engine production the high cost of importing ba eries (which can annual battery The aim of account for around 40 per cent of the value of an EV) will erode the commercial case production by 2030 The Engineer for making cars here. In our report, we talk to some of those at the frontline of UK ba ery development is to champion Augmented about the need for a new generation of UK-based gigafactories and examine the 4 reality and promote challenges and opportunities created by this scale up. technology is engineering There are, as we report, many reasons to be optimistic that the UK won’t fall enabling remote further behind: a world class research base; a joined-up ecosystem of academic working innovation and researchers and industry partners; and a growing technological edge in some key technology areas. But it is clearly vital - as we look ahead at the industrial priorities of post- Ninety percent development pandemic UK - that we don’t allow this window of opportunity to close permanently. 5 of the key industrial city of across all of Hull is below the high the UK’s key tide line engineering sectors. EDITOR • [email protected] Excell

May 2020 / www.theengineer.co.uk 4 Quick Turn 250MB

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Read more online Follow us at: @TheEngineerUK AEROSPACE theengineeruk • Airbus E-Fan X moves step closer to maiden electric flight The Engineer UK The Engineer UK AUTOMOTIVE www.theengineer.CO.UK • Overnight charging key to NEWS unlocking EV market, says report CIVIL & STRUCTURAL • Widespread calls for non- Skyports joins ‘beyond visual essential construction to end ELECTRONICS & line of sight’ UAV trials COMMUNICATIONS Project aims to validate drones in non-segregated airspace • Entangled photons boost for uncrackable quantum keys JASON FORD reports ENERGY & ENVIRONMENT kyports been accepted • 3D printed coral structures into the UK Civil Aviation could lead to better biofuels Authority’s (CAA) Regulatory Sandbox RAIL & MARINE programme to trial beyond • Late great engineers: Robert Svisual line of sight (BVLOS) UAV Stephenson flights in non-segregated airspace. The CAA’s Regulatory Sandbox SKILLS & CAREERS was established in 2019 to create • Roundtable report: addressing an environment where innovation in aviation can be explored in line industry’s changing skills with its core principles of safety, requirements security and consumer protection. • Comedy and the art of STEM Alex Brown, Head of Remote ID for UAV tracking, “We work with our aircraft communication Operations at Skyports, explained and RSK will apply its skills OEMs to up-spec the aircraft to that BVLOS UAV deliveries are and expertise in environmental a standard where they meet the already happening globally assessment. rigorous regulatory standards through trials and in dedicated “We will be testing the use required to fly Beyond Visual Jobs online corridors that keep UAVs away of the DAA system on our UAV Line of Sight in different types from other airspace users. initially in segregated and then of environments,” he said. “This “To achieve commercial in non-segregated airspace and, includes, for example, enhanced LOOKING FOR A operations at scale, particularly if everything is successful, the triple-redundant communications NEW ROLE? in more congested environments, CAA will have a proven means of systems for the C2 link as well as a Visit delivery UAVs will need to be able providing regulatory approval to parachute system.” jobs.theengineer.co.uk to safely share the skies with UAS operators wishing to fly UAVs Skyport’s fixed-wing UAV to search hundreds of other airspace users in non- into non-segregated airspace, has the greatest range in the segregated airspace, which our which is key to enabling full- company’s fleet with the capability vacancies with leading project in the CAA Regulatory scale, permanent commercial to travel distances of up to 100km employers from across Sandbox is aiming to achieve,” he operations,” said Brown. “We with a maximum ceiling of 3000ft industry said. plan to complete our project by AMSL (above mean sea level), To this end the London-based summer 2020, subject to any depending on the payload weight. cargo drone deliveries specialist future government rules and According to Brown, this makes will work with consortium advice on social distancing in it an ideal platform to connecting partners Iris Automation, RSK response to COVID-19.” hard-to-reach communities in and Thales on putting a long- The drone package delivery more remote environments. range Wingcopter – a fixed wing/ market is projected to be worth “As UAV regulations progress, tilt-rotor aircraft – through the £21bn by 2030. Brown told The we will begin to integrate longer Sandbox project. Engineer that Skyports has distance and heavier payload San-Francisco based Iris is multiple aircraft in its fleet that UAVs, and we have already begun providing its Casia computer- give it the flexibility to overcome discussions with heavier payload vision-based Detect-and-Avoid various logistics and supply chain UAV OEMs about taking this next (DAA) technology, Thales its problems. step.”

May 2020 / www.theengineer.co.uk 6 technology NEWS

Assystem on board with SMRs NEWS IN BRIEF BUSINESS BOOST New fl eet of nuclear reactors to run for 60 years UK businesses will be helped through the coronavirus outbreak JASON FORD reports with a £1.25bn government construction times down by support package. A Future Fund utilising pre-assembled modules, will see £500m in lending made manufactured in purpose-built available to high-growth fi rms, factories and transported to the site. and £750m of targeted support “This will increase product for small and medium sized quality and on-site effi ciency, businesses focusing on research driving the construction and development. The Future Fund schedule down and increasing will provide UK-based companies build certainty. The consortium with between £125,000 and £5m aims to use an iterative design from the government, with private ssystem has joined the UK “The consortium is focusing on process, involving techno- investors at least matching the consortium tasked with developing a concept for a power economic optimisation, with early government commitment. the design and build of the station as a product…and engagement with the regulators and UK’s small modular nuclear following on with the remaining other key stakeholders to deliver HS2 ON TRACK power stations. equipment for power generation” this.” HS2 Ltd has issued a AThe project aims to build up to said Will Machin, Assystem’s Led by Rolls-Royce, the ‘Notice to proceed’ 16 compact, fi rst of a kind power Engineering Manager for SMRs. “We consortium - comprised of Atkins, to the companies stations which are expected to are aiming to build a power plant BAM Nu all, Laing O’Rourke, that will build create 40,000 jobs in the UK, add that in addition to being extremely National Nuclear Laboratory Britain’s second £52bn to the UK economy and have safe is optimised for economic (NNL), Nuclear AMRC, Jacobs and high-speed railway line. “While an export value of around £250bn. power generation. That means that TWI - is match-funding the £18m the government’s top priority Each power station will provide we have to blend the right balance investment from UK Research and is rightly to combat the spread enough electricity - 440MWe - to of power, effi ciency, build time, Innovation (UKRI). The fi rst power of coronavirus…we cannot power a city the size of Leeds. commissioning time and unit cost station is targeted to be built and delay work on our long-term Assystem said it will lead across the nuclear and conventional connected to the national grid by plan to level up the country,” on the Turbine Island, Cooling islands. 2029. said HS2 minister, Andrew Water Island and Balance of Plant Machin, Chief Design Engineer In October 2019 Rolls-Royce Stephenson. “HS2 will be the development of structures and for Turbine Island, Cooling Water estimated the target cost for each spine of the country’s transport systems through Model Based Island and Balance of Plant, added station would be £1.8bn by the time network, boosting capacity Systems Engineering, Generative that a compact and effi cient fi ve have been built. Once online, and connectivity while also design and original Project Delivery site is at the heart of the power each power station will be able to rebalancing opportunity fairly Model Approach. station design, as well as driving operate for 60 years. across our towns and cities.”

HYDROGEN STORE The competition is open to The Engineer Grand Prix award – which New metal-organic framework COLLABORATE TO any project that is truly innovative, is chosen by the editorial team of The materials with ultrahigh porosity INNOVATE 2020 represents a collaboration between two Engineer; and a new trophy, The Future and surface area could help in the or more separate organisations and has Thinking Award, which is sponsored development of next generation AWARDS ARE OPEN had, or is likely to have, a demonstrable by our headline partner Frazer-Nash fuel cell-electric vehicles. We are excited to announce the launch impact in its area of application. Consultancy. Northwestern University in Illinois of the 2020 Collaborate to Innovate For this year’s awards, entries As in previous years, entries will be led the design and synthesis of a Awards (C2I 2020), The Engineer’s are invited from projects addressing judged by leading fi gures from the UK type of a metal-organic framework annual search for the UK’s most fundamental engineering challenges engineering community. that can store more hydrogen innovative, collaborative engineering across eight categories, including This year’s competition is supported and methane than conventional projects. automotive; aerospace, defence by EPSRC and EngineeringUK, and adsorbent materials at safer Now in its fi fth year, C2I – which is and security; information, data sponsored by Frazer-Nash Consultancy, pressures and lower costs. A one- supported by EPSRC and sponsored by and connectivity; healthcare and Babcock, Mazak and HVM Catapult. For gram sample of the Northwestern Frazer-Nash Consultancy – was launched medical; energy and environment; and sponsorship enquiries contact Justyn. material has a surface area that to uncover and celebrate great examples manufacturing technology. [email protected] would cover 1.3 American football of engineering collaboration – a dynamic Other categories include the The closing date for entries is Friday fi elds. considered critical to solving many of coveted ‘young innovator’ award – 10th July. Winners will be announced the challenges and problems faced by which celebrates great examples of at a party in London on Wednesday 4th Read more at www.theengineer.co.uk society. school student engineering projects; November. JE

7 May 2020 / www.theengineer.co.uk COVID-19 NEWS

settings to enable the cabin to be XDBOT SET FOR pressurised whilst on the ground. “Normally the aircraft are COVID-19 CLEANING automatically depressurised on DUTIES IN SINGAPORE the ground to make sure there is no differential pressure that would A semi-autonomous robot that quickly interfere with the doors being disinfects large surfaces is being opened,” he said. “These systems prepared for public trials to support will have to be reconfigured. Singapore’s COVID-19 response. “Different aircraft also use Developed by researchers from different means of pressurisation. Nanyang Technological University, For instance, it would be best to Singapore (NTU Singapore) the use aircraft that have their own eXtreme Disinfection roBOT (XDBOT) compressor rather than running can be wirelessly controlled via a from engine bleed-air. Depending laptop or tablet. on the aircraft used, it might be Comprising a semi-autonomous necessary to provide compressed control unit with motorised wheels, air from an external source.” XDBOT has a 6-axis robotic arm that Patients on a plane He added that pending clinical mimics human movement to access Airliners proposed for Covid-19 therapy trial results, the treatment awkward locations. would probably be performed Instead of a conventional JASON FORD reports in 90-minute cycles, between pressure-spray nozzle, it uses an which times the aircraft would be electrostatic-charged nozzle to rounded aircraft could to prevent patients deteriorating depressurised, enabling people ensure a wider and further spread of be transformed into to the level where they require and equipment to be moved in and disinfectant, behind and over hidden potentially life-saving ventilation. It is standard out as needed. surfaces. hyperbaric oxygen treatment for many diseases “The medical staff would be The nozzle discharges chemicals chambers to treat COVID-19 where hypoxia is a factor, but a well advised to breathe oxygen with a positive electrical charge. Gpatients with airport departure shortage of HBOT chambers has as well during the cycles of These disinfectants will then be lounges used as wards. been perceived as a barrier to compression, to avoid becoming attracted to all negatively-charged This is the vision of Lungfish adoption for COVID-19. saturated with nitrogen over surfaces. Surfaces already covered Dive Systems, life-support Makeshift HBOT chambers time,” Reynolds said. “However, with the disinfectant will then repel system experts in Cambridge can be pressurised to the required in the case of COVID treatment, the spray, making this method very who are working with healthcare levels for potentially effective they would likely be wearing efficient, it is claimed. organisations and aerospace treatment – approximately 1.6 respirators anyway for safety XDBOT navigates semi- companies to explore the times atmospheric pressure. reasons, so this would not be too autonomously using LIDAR and possibility of using commercial Company founder Dr Daniel different from current practice.” high-definition cameras and can be airliners as makeshift Hyperbaric Reynolds told The Engineer that A clinical trial of HBOT under controlled with a laptop or tablet. JF oxygen therapy (HBOT) chambers. the most significant work to an conditions achievable in an HBOT - breathing oxygen aircraft would involve adjustments aircraft is due to start involving Read more at www.theengineer.co.uk under pressure – has the potential to various control systems and patients at a hospital in Canada.

ahead of rapid production and roll-out of In use, the device fits over the EXOVENT IRON LUNG CONCEPT the NPV, which is supported by WMG at patient’s torso and takes over their the University of Warwick, Imperial NHS breathing through gentle and repeating OFFERS ALTERNATIVE TO COVID-19 Trust and The Royal National Throat Nose pressure. It is claimed to increase the and Ear hospital. Two intensive care units heart’s efficiency by up to 25 per cent VENTILATORS will trial the prototype ventilators, which compared to conventional ventilators JASON FORD reports have a small number of moving parts. which squeeze the chest, potentially reducing cardiac function. The iron lung has been reimagined by windpipe intubation. Furthermore, exovent is less likely a multidisciplinary team to potentially “This device is cheap, simple and it to cause a pneumothorax (burst give the NHS an alternative model of will work,” said Sir John Burn, professor lung) as negative pressure ventilation ventilator to treat Covid-19 patients (See of Clinical Genetics at Newcastle produces less micro-trauma to the Archive, page 36). University. “I am convinced it provides a lung, and it does not require medical- Dubbed exovent, the Negative real alternative and is worthy of support.” grade compressed gases, which are at Pressure Ventilator (NPV) is non-invasive, Marshall Aerospace & Defence Group risk of shortage in the NHS due to heavy so patients won’t need to undergo said it is exploring technical aspects levels of demand for oxygen.

May 2020 / www.theengineer.co.uk 8 TECHNOLOGYCOVID-19 NEWS NEWS 3D printer said via email. “Both versions are network open source.” According to the University, PETG can be sterilised and produces PPE reused, unlike many of the current headbands that are being University pools resources to provide vital kit discarded after three hours of use JASON FORD reports by frontline workers. A shipment of 50 visors ngineers at the University of printing headbands from has been delivered to Wolverhampton are utilising home, using University Wolverhampton’s New Cross a network of 3D printers equipment or personal 3D hospital, and 90 more have been to produce headbands and printers. delivered to community nurses. face-shields for frontline When the headbands Almost 400 masks have been Estaff treating patients in the West are printed, a transparent printed so far, with many more due. Midlands. plastic visor, cut to shape With more 3D printers being Using Prusa 3D printing using the School of Engineering’s versions - 3DVerkstan and RC3 – made available to the School of machines from sources including Zund cu ing table, is added to the have been produced, but the team Engineering by their industrial the Telford Innovation Campus, front, creating a protective face will concentrate on RC3 models. contacts and collaborators, the staff from the University’s School shielding barrier. Cura and PrusaSlicer software team are hoping to get as many of Engineering have collaborated Graham Sparey-Taylor from the packages have been used to develop as 30 printers running in a 24 to perfect a fast and stream- University’s School of Engineering and run the print machines and hour production process, with a lined manufacturing process for is leading on the production of the Autodesk Inventor has been used to machine making nine headbands headbands using Polyethylene visors and co-ordinating volunteers. modify designs. per hour, and the potential to make terephthalate glycol modifi ed Paul Bates, Business and “We’re using the RC3 design over 1,500 headbands every 24 (PETG). As a part of the social Technical Resources Manager at at Telford, with any CAD work hours, provided there is enough distancing policy, some staff are the School of Engineering, said two performed on Solidworks,” Bates PETG. CRANFIELD AND ENGINEERING COLLABORATION GEORGIA TECH ROLL- DELIVERS COVID-19 FACE-SHIELDS OUT FLAT PACK BVM VENTILATOR Scottish fi rms united in defence of medics Cranfi eld University and Georgia Tech JASON FORD reports The design brief saw the team have designed and built a low-cost working toward a simple method ventilator to help critically ill COVID-19 rgent PPE equipment is of providing face protection patients. being delivered to a hospital that would be robust, secure, The Bag Valve Mask (BVM) ventilator Uin Scotland following a comfortable and could be rapidly serves two patients simultaneously and collaborative eff ort to design and manufactured in volume. its so-called ‘fl at-pack’ design means it manufacture face-shields. Within a week, the team can be quickly manufactured at scale at In one week, Inverness had sourced materials, refi ned under £75 ($100) per unit. companies 4c Engineering and the design and had its fi rst prototype The ventilator can be linked to an Aseptium designed and manufactured 1,000 face- accepted by Raigmore ICU and Infection Control staff , oxygen generator, positive end expiratory shields destined for the ICU unit at Raigmore Hospital. prompting the production of 1,000 face-shields over the pressure (PEEP) valves and fi lters. The The companies have combined design and rapid course of a weekend. units derive power from standard wall manufacturing capabilities and on March 20, 2020 they “Whilst we are generally happy with the NHS adapters or 12V vehicle batteries. contacted Raigmore with an off er of help during the supply chain, at times of great demand…there can The ventilator device works with Covid-19 pandemic. be interruptions or shortages. We were delighted to ‘positive displacement’, forcing air into Peter MacDonald, Project Manager at 4c be approached by 4c Engineering, who were able to the patient’s lungs, a process that has Engineering, told The Engineer that the off er was source materials locally, and produce much needed to be controlled to ensure the right accepted by Raigmore’s ICU unit within 48 hours, protective visors,” said Dr. Jonathan Whiteside, Clinical amount of air goes in at the right ‘tidal prompting the start of Project Corran, which has Lead, Department of Critical Care at Raigmore. “These volume’. JF since released the face-shield design for open-source have been put to immediate clinical use in our ICU, Read more about ba eries at manufacture. providing staff with the necessary protection.” www.theengineer.co.uk

9 May 2020 / www.theengineer.co.uk NOVEMBERNews analysis 2019

local ICU, an effort that would be ompanies with replicated across the UK. representatives in China “The very spirit of MAN is sensed the Covid-19 storm built on collaboration and this has brewing when cities in been evident in the way we are Hubei province followed coming to terms with the unique Wuhan by implementing challenges presented by Covid-19,” Clockdown in January 2020. Cunningham said. “Some of our Alloy Wire International (AWI) members are extremely busy, has over 40 agents across the whilst others have had to furlough world and a key growth market is staff and introduce temporary the Far East. shutdowns, so the weekly ‘Zoom’ “As the virus spread and media calls can be a real godsend for focus intensified, we knew it was bouncing ideas and concerns off heading for the UK and started Unsung each other.” to take appropriate measures In early March Tecman were in the middle of February,” said warned that there could be a Angus Hogarth, Sales Director heroes significant impact on Automotive at the Brierley Hill-based based OEM output, which would affect company. SME manufacturers across the UK are playing a 60 per cent of the company’s Criticised since for its late vital role in keeping the manufacturing economy business. response, the UK government “We are passionate about imposed an initial three-week ticking over whilst producing key components for onshoring manufacturing lockdown on March 23 that was critical medical equipment and have had constructive extended for a minimum of three conversations with supply chain weeks on April 16. Phase one saw WRITTEN BY JASON FORD partners who support the same ‘furlough’ enter the lexicon as deficit in PPE,” said Kevin Porter, of MAN (Manufacturing Assembly effort,” said Porter. “With the companies scrambled to remain Managing Director of Tecman Network) and CEO of Muller investments that we are making in viable and video conferencing Speciality Materials. “We explored Holdings added that MAN Group automation and the support from services including Zoom were the different options and made companies Grove Design and other UK manufacturing partners, keeping people in touch. the decision that we would be James Lister & Sons developed we have proved that we can It also became clear that most effective in supporting two basic ventilator systems from compete with product pricing that frontline NHS staff were in urgent [efforts] if we fast-tracked the scratch to understand some of the is coming in from Asia. This aligns need of PPE (personal protective development of a face visor that parts and sub-assemblies involved, perfectly with our vision.” equipment) to protect against is designed from the start for high whilst PP Control & Automation Porter estimates a 6-9-month patients’ involuntary reactions volume manufacture. This was is manufacturing over 25,000 period before his company returns to Covid-19, as well as ventilators accomplished within seven days.” harnesses for use in ventilator to pre-Covid levels, but the picture and breathing apparatus to assist Porter said modifications production. Another MAN Group is less pessimistic elsewhere. AWI patients afflicted with the severe to Tecman facilities – including company at the forefront of the retains 200 tonnes of stock and respiratory condition. an investment into automation effort is Brandauer, which is has remained active with orders With manufacturers allowed equipment – is expected to give his producing five million nose clips received from around the world to continue operations, many Leamington Spa-based company for face masks every month. covering numerous sectors. of the UK’s engineering giants the capacity to manufacture over One of the first PPE success “So instead of talking about united under Ventilator Challenge 1,000,000 finished visors a week, stories came from Inverness where recovery, we are hoping that the UK and similar efforts to help with two or three people manning 4C Engineering and Aseptium ‘bounce back’ will build on an meet the demand for breathing the entire the process. pooled their resources to produce already strong performance,” apparatus. Included among them Adam Cunningham, Chairman an initial 1,000 face shields for a said Hogarth. “We have taken the were the SMEs that have rallied to decision to invest over £500,000 produce vital equipment, either into increasing our raw material as a concerted effort or as part of stock, ensuring we are in the best day-to-day operations. WE ARE PASSIONATE ABOUT ONSHORING possible position to meet demand “Initial market research MANUFACTURING AND HAVE HAD CONSTRUCTIVE from customers now and in the quickly revealed an alarming CONVERSATIONS WITH SUPPLY CHAIN PARTNERS future.”

May 2020 / www.theengineer.co.uk 10 HardlockNut_from_Staytite.indd 1 01-Apr-20 3:03:05 PM

IoT calls for fast communication between sensors.

Developing the 5G mobile network may not be the only step to a fully functioning Internet of Things, but it is an important one — and it comes with substantial performance requirements. Simulation ensures optimised designs of 5G-compatible technology, like this phased array antenna. The COMSOL Multiphysics® software is used for simulating designs, devices and processes in all fields of engineering, manufacturing and scientific Visualisation of research. See how you can apply it to 5G and IoT the normalised 3D technology designs. far-field pattern of a slot-coupled comsol.blog/5G microstrip patch antenna array. COVER feature batteries

Powering up a British battery revolution

Artist’s impression of Gigafactory1, Tesla’s giant battery plant in the Nevada desert

Ma 2020 / www.theengineer.co.uk 12 With EV makers increasingly keen to co-locate ba ery and vehicle manufacture, its vital that the UK scales up its ba ery manufacturing capability. Jon Excell reports. battery revolution n the desert just outside of Reno, Nevada, stands a building by the scale of the planned pipeline the political and industrial will to make it that, seen from above, dominates the otherwise featureless elsewhere in Europe. For example, happen? landscape and – in terms of its footprint – dwarfs pre y much Chinese fi rm CATL - one of the world’s Faraday Institution CEO Neil Morris is any other building on the planet. largest providers of EV ba eries - hopes relatively optimistic about the prospect, This is Tesla’s Gigafactory 1, a vast lithium ion ba ery to reach 60GWh at its main German site and told The Engineer that whilst the factory set up to satisfy the fi rm’s sky-rocketing domestic by the middle of the decade. clock is defi nitely ticking, a combination demand for electric vehicle (EV) ba eries and, through In a recent report, the UK’s Faraday of existing expertise and government economies of scale, fulfi l its vision to bring aff ordable electric Institution (a £78m initiative set up support make the UK an a ractive Imotoring to the masses. through the government’s £274m Faraday destination for ba ery investment. When complete the facility is expected to have an annual Challenge fund to drive developments Perhaps the most obvious of these ba ery production capacity of 150GWh per year, enough for 1.5 in ba ery technology) warns that a a ractions is the UK’s current position million cars. Add this impressive boast to the Tesla CEO’s famed failure to scale up could have disastrous as Europe’s fourth largest vehicle knack for generating publicity, and it’s no surprise that the consequences for the UK car industry. manufacturer. And whilst failure to plant has a racted a fair amount of international a ention. But The fear is that as vehicle producers invest in ba ery scale up could see it drop Gigafactory1 is by no means the only show in town. switch to producing greater volumes of down the rankings, Morris believes that Indeed, around the world, in a bid to drive down costs and electric vehicles, and wind down internal the existing base is a ractive to investors simplify supply chains, ba ery manufacturers and car makers combustion engine production, the high keen to tap into ready markets for their are in a fevered race to establish similarly vast facilities to cost of importing ba eries (which can technology. “One of the key criteria produce the cells, modules and packs that will power the EV account for around 40 per cent of the ba ery manufacturers look to when revolution. value of an EV) will erode the commercial placing a ba ery factory is proximity to Whilst Asia remains the stronghold (China alone is projected case for making cars here. car manufacturing,” he said. He added to hit 800GWh of annual manufacturing capacity by 2025) To avert this scenario, and tap into the that the UK’s aforementioned historical Europe is expanding rapidly. Based on current plans - which huge opportunity presented by the UK’s pedigree - though in many senses an all include the construction of facilities in Germany, Sweden, growing EV market, the group claims too familiar tale of missed opportunities – Poland and Hungary - continental Europe will have 450GWh / that the UK will need to build at least is also a positive that has created a legacy year of production by the end of the decade. seven 20GWh gigafactories by 2040. The of skilled workers and facilities that off er But to the growing of concern of many in the UK, there are question is: can it be done, and is there a strong platform to build on. currently no fi rm plans for this country to follow suit: something What’s more, whilst it may not yet of a surprise given its growing EV manufacturing base and have a Gigafactory the UK does have some historic expertise in the fi eld (the lithium ba ery was invented existing and planned manufacturing in Oxford and the ba ery plant alongside Nissan’s Sunderland to meet domestic capability. As well as the Sunderland car factory was once the fi rst of its kind in the Europe). demand the UK will need Envision site, a new ba ery assembly To give a sense of how rapidly things have moved on, whilst to build at least seven centre at Jaguar Land Rover’s Hams that same plant (now owned by Chinese fi rm Envision) remains Hall site, that will produce units for its the UK’s largest facility, its annual 2GWh capacity is dwarfed gigagfactories by 2040 next generation of electric vehicles, is

13 May 2020 / www.theengineer.co.uk COVERCOVER feature feature MARINE batteries TECHNOLOGY

expected to begin operation shortly. to try to understand how to extend the There is also some interesting activity at the lower-volume life of batteries. end of the scale, perhaps most notably through HyperBat a joint There are also a number of projects venture between Unipart and Williams Advanced Engineering looking at different battery technologies. to manufacture batteries for high performance electric cars Researchers at St Andrews University, for including Aston Martin’s Rapid E. instance, are exploring the potential of And it’s not all about automotive. Battery pack assembly Sodium Ion batteries, whilst the Oxford specialist HyperDrive, which is based next door to the Envision led SOLBAT initiative is making major ASEC factory in Sunderland, has enjoyed unprecedented growth strides in solid state battery development by developing battery packs and battery management systems – something of a holy grail for energy for customers including JCB and cherry-picker specialist storage. “They are potentially much Snorkel - a reminder that the opportunity for UK battery higher performance and much safer manufacturers is expanding all of the time. “We’re hanging on because they don’t have a flammable the coat-tails of the huge investment in automotive battery liquid electrolyte,” said Morris. cells and we’ve engineered our product around those,” said A further project, Nextrode, also led Hyperdrive MD and founder Stephen Irish. by Oxford, is looking at how battery UKBIC’s 20,000 square Perhaps surprisingly, the UK also has some of the key performance could be enhanced metre facility in the outskirts elements of the battery supply chain already in place in the by improvements in electrode of Coventry form of some of the largest suppliers of materials for producing manufacturing processes. “If we can electrodes and electrolytes. “We have a chemicals industry in the UK that is potentially well set up to supply into a battery manufacturing industry,” said Electrode manufacturing in Morris. “They’ll need to invest and make slightly progress at WMG different products, but we already export graphite to China so that they can make batteries to sell back to us!” Pointing to a 2019 report commissioned by the Advanced Propulsion Centre and Innovate UK (Automotive Batteries - April 2019) he added that a scale up of UK battery manufacture would provide a major boost for this sector, potentially opening up £4.8bn per year market share. Other less immediately obvious attractions include the UK’s relatively nimble approach to planning and infrastructure development - a key factor for ambitious Asian battery giants not used to too many obstacles ; and also the growing role of renewables in the energy mix. “There’s no point making loads of batteries from dirty coal fired power station in Poland,” he said. “It’s definitely on the mind of the battery manufacturers.” these project are attracting interest from car and battery Perhaps the biggest strength though, from Morris’ manufacturers. That tells me we’re doing perspective, is the strength of the UK research base, and the attracting interest something right, and it has the potential degree to which different academic and industry groups are from car and battery of attracting some of them to invest collaborating with each other. And the Faraday Institution, here. I know there is at least one battery which was established to accelerate the commercial impact of manufacturers. That manufacturer who sees having early this research base, is at the heart of this dynamic. tells me we’re doing access to having some of the technology Since being established in 2017, the body has launched nine something right we might develop as being a potential major research programmes spanning 22 universities and incentive to come here.” involving multiple industry partners, any one of which, said Whilst the Faraday Institution is Morris, could develop into a world leading battery technology improve the microstructure without driving the development of new battery company. changing any of the materials we might technologies, another Faraday Challenge A number of these projects are focused on improving get significantly better performance and funded initiative – the UK Battery the performance of lithium-ion batteries. For instance, The that means having significantly better Industrialisation Centre (UKBIC) - is University of Sheffield led FutureCat project, and the University control over the manufacturing,” he exploring the challenges of taking these of Bath’s CATMAT initiative are both at looking at ways of explained. technologies into production. improving the cathode to get more energy into the battery. All of this activity, said Morris, is From its 20,000 square metre facility Another initiative, led by the University of Cambridge – is helping to build the UK’s profile on close to Coventry airport, the £129m exploring the causes of battery degradation and failure in order the world stage: “These projects are centre, which was grown out of work

May 2020 / www.theengineer.co.uk 14 once you have the first “Once you set up the supply chain and have the first gigafactory – it’s relatively gigafactory it’s relatively easy easy to expand that one or build others,” to expand or build others he said. However, with this snowball effect carried out at the Warwick Manufacturing Group (WMG), already beginning to happen elsewhere is aimed at both proving the manufacturability of emerging in Europe, it’s becoming doubly the battery technologies and helping innovative battery companies critical that the UK moves quickly. take their technologies into production. “There is a sense of urgency here,” said As former general manager of Nissan’s battery plant the Morris, “We are falling further behind. new centre’s MD, Jeff Pratt, knows more than most about the A lot of capacity has been announced HOW TO BUILD A challenges of manufacturing batteries at scale. And whilst in Europe particularly in and around UKBIC is on a much smaller scale than a gigafactory it does Germany and our government was LITHIUM-ION BATTERY contain most of the technologies you would expect to find in probably a bit slower to announce one (see box out). What’s more, it is able to produce batteries at incentives. There is no doubt that the There are four distinct steps in uncertainty around Brexit last year and the lithium-ion battery production the distraction that that caused for the process. government means that we do need to pick up the pace.” Electrode manufacturing Failure to do so, he said, could lead to 1 To form the electrodes precise doses something of a doomsday scenario for of anode and cathode materials are mixed the UK car industry. “If you’re importing into a slurry with water and solvents which is carefully coated onto metallic foils to form the all of the batteries to then export the electrodes (copper for the anode, and aluminium vehicle – which is about 80 per cent of for the cathode). These foils are dried in an oven our car production – just from a supply and formed into a large roll in a “calendaring” A researcher perspective why would you import half process. This roll is then fed into a slitting examines an assembled the value of the vehicle? Why not just machine where it is broken down into smaller rolls cell. Image: WMG make the vehicle closer to where the to make the electrodes required for the cells. market is? If the batteries are all being industrial rates. “The key for UKBIC is demonstrate that you can made somewhere else then maybe over Cell assembly manufacture at a rate that is capable of being marketed” said time car production migrates to where 22 This is where the anode and cathode Pratt. “You can develop a technology in the lab which looks very the battery production is and you lose a materials are assembled into a single unit. promising but if you can’t manufacture at that rate you can’t get lot of jobs.” Although there is a common set of fundamental it to market.” It’s an unsettling thought. But steps, assembly processes vary depending Though NDAs prohibit him from naming them, Pratt Morris is optimistic that there’s an on the type of cell that’s being made. The most confirmed that the centre already has a number of firms signed appetite across government and widely used packaging style is the cylindrical cell – the familiar tubular cylinder - but there is up who want to use the facility to produce cells to test and prove industry to rise to the occasion. “EV a growing demand for pouch cells and prismatic there’s a demand in the market before they invest further. He’s manufacturers would very much like cells which potentially take up less space and also hopeful that some of the larger battery manufacturers will the UK to have battery manufacturing which require different assembly techniques. outsource development work to the site. “As facilities become to support them making more EVs in more utilised worldwide there’s less opportunity for them to the facilities they have here in the UK. develop a new project, take the line down and try something And I think that government wants to Formation and ageing 3 One the cell has been assembled and out.” secure the jobs, and secure a position the electrolyte added it’s time to set the cell It’s clear that the joined-up nature of the UK battery in part of the energy mix of the future chemistry. During this stage the cell is allowed ecosystem has created a fertile climate for innovation, and one and to be a major player in battery to stand for period of time to let the electrolyte which should be appealing to large battery firms. production and battery technology soak around it, before going through a number of But according to Pratt getting them to take the next step and development.” charging and heating processes. invest is likely to require incentives of the kind seen elsewhere Pratt is similarly upbeat about the in Europe. Germany and France recently announced 1billion UK’s prospects: “We definitely have Module and pack assembly and 700 million euros of financial support, whilst Poland the demand here. We’ve got some large 4 Finally, it’s time to bundle up the cells and Hungary have set up special economic zones offering tax OEMs such as Nissan in the north east for the end-customer. In this part of the process relief to EV battery producers. “In September last year the and JLR in the midlands, and that’s multiple cells are connected together to form a government announced a £1bn fund to support getting the first just in automotive. Provided we make module, and modules are connected together Gigafactory on the ground , it now needs to flesh out what this it attractive for companies to invest to form a pack. For context, the 40kWh battery means in practice and what form that support should take,” he in the UK and bring the large-scale used in the latest version of Nissan Leaf uses 24 said. manufacturing here there isn’t any modules, each consisting of 8 cells. Getting the first factory over the line is the tricky bit. But reason why we shouldn’t get our share once that’s in place Pratt believes there will be a snowball effect. of that future investment.”

15 May 2020 / www.theengineer.co.uk NOVEMBERVIEWPOINT 2019

n recent weeks we have and yet limitations on the levels of experienced seismic changes participation in funded within our working and home Ian Risk collaborations are generally lives. Changes which it’s hard to imposed. This creates silos of imagine could have be realised in activity, , in academia, for example, such a short time. The phrase and restricts exchange between I‘necessity is the mother of A Time for those that are moving at pace, invention’ has never been more reducing the impact they can have true – but, to some degree it is not on industry and the eff ectiveness of invention that has occurred, it is Change the whole ecosystem. innovation. To achieve the sought after Innovation in how the Managing and recovering from the coronavirus innovation, you need invention, industrial, technology and crisis could be the catalyst for a long-term digitally education and implementation. engineering communities have driven partnership between academia, industry and Unfortunately these elements are come together to produce much government writes Ian Risk, CTO of the Centre for all managed by diff erent needed ventilators for the NHS. But Modelling & Simulation (CFMS). government departments with also invention with, for example, diff erent budgets that rarely align University College London to achieve a collective goal. In the engineers and clinicians working new world that will emerge from with the Mercedes Formula One The need for safety and makers. It is a cultural shift of epic the current crisis, we need to team to develop a breathing aid to security remains paramount in the proportions, but if we are to realise ensure that joined up thinking and help Covid-19 patients. face of cybercrime. However, if we the potential of the digital era, it action exists within all Digital transformation has are to bring about change and must happen. stakeholders. Without this the been at the heart of this change. realise the potential of Whilst the UK Government has opportunity to rebuild engineering Everyone from the top levels of digitalisation at an industrial scale, been a true advocate of the move to and our economy, runs the risk of government, industry and there is a need to be far more open. digital technology and provided being lost in bureaucracy. education have ‘gone digital’ Building walls of any form, physical funding for initiatives such as Recent events have highlighted overnight, at a scale many thought or virtual, hampers the exchange of Made Smarter to help bring about the fragility of our modern world, would not be possible. The strange data, information and knowledge. that change, the impact is powerful nations being moved to times we fi nd ourselves in are These are the building blocks of the hampered by speed of the brink of recession in the blink demonstrating the maturity of digital world and it is the speed at implementation and imposed of an eye. To build a new, these technologies and, hopefully, which we can convert that operational constraints. sustainable world we will need will pave the way for more knowledge into product that Programmes often take months of science and engineering more than widespread adoption across ma ers. If we are to achieve consultation, evaluation and ever, with a workforce that is fi t for industry. This may be the catalyst change, trust must be established contract preparation before the digital era. As has been said so for change as the old working not only in the data itself collaborations can be initiated, often in dealing with the current paradigms are cast aside through (especially if critical decisions are whilst the digital community itself challenge, we are only going to commercial necessity. based upon it) but also that those does not stand still. The skills achieve this together – just as we In discussions with industry, using the data are doing so for the required to bring about such have seen with the drive to provide there is a real appetite to work right reasons. Scandals such as change are in short supply and we the NHS with more ventilators – in together, to push forward digital Cambridge Analytica have done must empower them. Most exist in a true, agile partnership between technology development and much to reduce our confi dence in academia, research organisations academia, industry and implementation as a collective. But such things. Ultimately, this brings and the start up community who government. all too often this collaborative eff ort about the need for behavioural are far less constrained by large is hampered by rules and change within industry and policy scale infrastructure investment About the author regulations. For many large OEMs Ian Risk is Chief Technology Offi cer there is a real dichotomy in the (CTO) at CFMS, responsible for desire to be more agile and adaptive RECENT EVENTS HAVE HIGHLIGHTED THE evolving the company’s technical whilst they become heavily FRAGILITY OF OUR MODERN WORLD. TO BUILD vision and leading all aspects of constrained by large scale technology development according information technology solutions A NEW, SUSTAINABLE WORLD WE WILL NEED to its strategic direction and in an eff ort to reduce risk. SCIENCE AND ENGINEERING MORE THAN EVER growth objectives.

May 2020 / www.theengineer.co.uk 16 Zero in on efficiency

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17 May 2020 / www.theengineer.co.uk TALKINGMailbox POINT

AFTER THE STORM Readers speculated on the long-term impact of the Covid-19 pandemic on UK engineering and manufacturing

For far too long engineering & manufacturing has been overlooked as a vital part of the UK’s genetic make-up service & financial industries have been prioritised over the backbone of the UK’s real DNA and it’s way overdue that engineering & manufacturing, and all those skilled personnel within the sector are recognised for what they have to offer and how much they contribute. Perhaps the backroom support provided by the manufacturing sector in order to assist the hard working, brave and dedicated NHS staff will now go some way to shine a light on what we have to offer. WWII was won by the factories of the UK, and so will Covid-19 be defeated in a similar way……let’s hope one of the changes evident on the other side of Covid is a new found respect for all those hard working, skilled engineering and manufacturing staff, and the companies they serve The recent collaborative Darren Marson efforts of the engineering industry in developing and Let’s hope things do change, efforts can be fairly termed as This disaster will push the producing much needed but as a cynic I cannot help but ‘charity’, ie. doing something for world economy into a major equipment and material for the think things will return to their nothing albeit for the common recession. We were due one soon present outbreak must be old ways when the dust settles. good. Will this continue after anyway, just different to have the driven home to those who think We have an economic we’re through the worst ? Will trigger something natural rather that an engineer is the bloke environment that is driven by the people realise that a lot of the than artificial. During a recession, who fixes their washing unsustainable belief that profits mess we have been in is because firms tend to stifle innovation machine (however skilled he can keep on increasing, this has of past choices to maximise since it costs money. The public may be in his limited field). just resulted in lack of investment profits over investment? Will outpouring of appreciation of Geoff Wilson and poorer work conditions on UK Industry change and now health workers shows how much the shop floor. invest more, in staff and their more doctors and nurses are During this crisis people have businesses ? Will the government valued compared to engineers. made great sacrifices to help and industry change to ensure

Ian Wilson others and a lot of the brilliant new projects are costed properly phonlamaiphoto.sytock.adobe.com

May 2020 / www.theengineer.co.uk 18 HAVE YOUR SAY share your opinions at www.theengineer.co.uk

The rights and wrongs of “Furloughing”, a word which many of us have only recently used for the first Southampton Uni time, was a topic of much debate amongst readers. researchers collaborate The follies of bare For me work and enquiries minimum stock levels and with industry on respirator have virtually dried up, so the just in time suppliers from government support is welcome – overseas are being exposed! though they’ve dropped a broad for medical staff We need to have the capability hint that it will have to be paid for to produce and supply all by higher taxes in future, so The concept is these things from our own perhaps it should really be almost identical to the resources where possible. The This just shows the considered a loan … ? 3M Racal Respirator I drive to export this base engineering capability of our More generally: furlough - have been using for manufacturing level in order universities, well done on the basically gardening leave (I had to many years for to minimise staff costs is a development. Fingers crossed all the look it up) - seems a reasonable woodturning. There are disaster! Contingency testing goes well. Hopefully the NHS response. The employee gets 80% multiple versions of reserves are also a must! We and all front-line workers can use of full pay, which most should be these positive pressure, need to return to being a this soon. able to get by on and the employer hepa filtered air hoods manufacturing economy not Neil Davidson could pay the balance for especially in use in industry and one based on financial valued workers. It’s all about hobby workshops. Many speculators. retention. Losing good people come with an impact Nick Cole and recruiting and bringing up to resistant helmet and face plate which are heavy and not speed new workers is an expensive necessary for hospital use. and fully ? business The secret is in making it reusable, or cheap enough to I hope I’m wrong because we Trevor be disposable. For Covid19 this means being able to sterilise have a big opportunity to change easily with current procedures and equipment without for the better. The issue with this scheme is causing serious degradation during the sterilisation process Another Steve that employers have to pay the staff or causing overloading of the sterilisation department. first and hope that the government Col It is obvious, from this refunds them the money via a situation we find ourselves in, grant. If a business is already really We really are a nation of innovators. If we could learn putting manufacturing and struggling with cash flow and can’t how to market and produce efficiently we could, once again, Engineering design off-shore has access the funds needed, then they become an industrial world leader. Why does it take a major left this country vulnerable. It is may not even be able to afford to crisis to bring out the best in us. Well done to all of those the same with our utilities, we are furlough someone. taking part. dependent of off-shore owned Josh Ivan Taylor companies. This is not something the UK needs for its future. The situation is unprecedented This is so simple that it beggars the question why has it Alan and the Gov’t have taken not been proposed and manufactured already, but then the unprecedented action. Too easy to obvious is not always obvious. Covid 19 will prove a catalyst. blame them, let’s just wait to see I use a battery filter helmet for my woodworking hobby, the It will accelerate changes already what the effects are. If it works and face is under gentle positive pressure and the visor does happening on a number of fronts: the economy more or less keeps not mist-up, comfortable enough to wear for hours. My bringing manufacturing back to going, there will be a lot of column paramedic son has asked if my helmet could be used but the the UK, increasing online inches to read in the broadsheet filters are suitable for fine dust only. business and shopping, home press! I note that Labour Party This proposed helmet should work provided the filter working, video conferencing and leaders are trying to claim that is pathogen proof and can be disposed of without much more. The catalyst itself is Socialism has come to the rescue. contamination. The prototype design looks cheap enough to horrible, the long-term result Maybe it is merely pragmatism. dispose of every part but keep the motor and fan. probably not so. Dave Childs I look forward to hearing it is in immediate production. Bill Church Edward Lewis

19 May 2020 / www.theengineer.co.uk Civil engineering

Hull and high water An ambitious plan to build a and the damage caused by tidal surges in the Humber estuary, explained that lagoon in the Humber estuary has been a regular feature over the the heart of the proposal - which is decades. Most recently, in December expected to cost around £1.5bn – is a promises to protect the city 2013, a record tidal surge on the east six mile wall in the Humber estuary of Hull from flooding, ease its coast, came within centimetres of that will create a calm water lagoon to breaching the city’s existing flood protect the city from flooding and open chronic traffic problems, and barrier, and devastated the nearby port up a new waterside area. Giant lock gates supercharge the local economy. of Immingham, a key site for UK oil and will be used to impound water and let Jon Excell reports. gas imports. And with similar events shipping and boats in and out, and a new expected in the future, city planners four lane road running along the top of are understandably concerned about the wall will re-route traffic out of the rom the giant and much celebrated suspension the increased impact of such events as city’s notoriously congested centre. The bridge linking the counties of Yorkshire and sea-levels rise. concept also includes the construction Lincolnshire; to the assorted oil refineries, power Officially launched last year (2019) of an outer harbor to support the regions’ stations and wind turbine factories that line Lagoon Hull began life as a direct rapidly growing offshore energy sector. its banks, the Humber estuary is no stranger to response to this continuing threat. It is, said Hatley - who estimates that impressive feats of engineering. But according to the team behind the the scheme could create upto 19000 jobs But a newly proposed flood defence project project - a mix of local business leaders and add as much as £1bn GDA to the for the region - Lagoon Hull - could, it’s proponents claim, and engineers - it quickly became region - much more than a simple flood Fultimately become the most ambitious and impactful apparent that it could deliver a triple defence project. “If you put all of those engineering project of them all. whammy of benefits for the city: not things together what you end up with is Hull is of huge economic importance to the UK. Alongside only alleviating flooding concerns, a new outer harbor to support the port its existing industrial footprint it has, in recent years, become but also addressing chronic traffic and the offshore renewables, you address a key hub for the UKs rapidly growing offshore wind industry congestion problems, and driving tidal flooding, and you address. transport and is regarded as a critical gateway to Europe for the so-called economic growth. connectivity. It’s an infrastructure Northern Powerhouse. Project manager Paul Hatley, a civil project that has multiple outcomes.” But the city - 90 percent of which stands below the high- engineer with over two decades of It’s still early days for the project. tide line - is also unusually vulnerable to coastal flooding, experience of building infrastructure A number of what Hatley terms “pre-

May 2020 / www.theengineer.co.uk 20 In an eff ort to understand these eff ects the team has been so effi cient that everybody naturally working with a number of specialist organisations – including migrates to it. 100 per cent of the marine consultancy ABPmer - to model the impact of the through traffi c goes straight to the new scheme. road because its quicker.” This modelling represented a make or break moment for Whilst the studies performed so the project and Hatley was prepared to be disappointed. “We’re far justify local enthusiasm for the used to the idea that if you to build in the fl ood plain you make project, there is still much to be done it worse, and the immediate assumption from most people before it even gets close to the approval was that if you build a structure out in the Humber estuary stage, and Hatley and the team are now you’re just going to fl ood the other side of the estuary. At best I hoping to a ract government funding was hoping it would be a fairly neutral impact and at worst we to carry out more exhaustive scientifi c were thinking it could be the end of the project.” and modelling work. “Whilst we’ve However, the modelling, which was carried out by two got two sets of model data that show separate independent teams, told a very diff erent story, the same eff ect we’re a long way from suggesting that, thanks to the complex mix of conditions being able to prove defi nitely that there found in the estuary, an obstruction would actually make aren’t other problems,” he said. “We’ve water levels lower rather than higher. done everything you can do sensibly What’s more, an additional simulation study carried out by that tell you that this is worth spending researchers at the University of Hull found that if the lagoon money on, we’re now at the point where had been in place during the 2013 tidal surge, the city would we need to take modelling of the river have had 100 per cent protection with the rest of the estuary system up to a whole new level. ” seeing an 80 per cent reduction in fl ood volume. This group As well as augmenting the work that As well as also found that if the same tidal surge occurred in 2108, when has already been carried out, this next protecting the city sea levels are expected to have risen by one metre, the lagoon phase of studies would looksat a host of from tidal fl ooding, the six mile long structure would continue to provide 100 per cent protection for Hull other factors such as the cyclical longer would also create a with the rest of the estuary seeing a 33 per cent reduction in term changes in the estuary that would new waterside area fl ood volume. need to be properly understood if the lagoon were to be built. The new route could Further modelling would also be remove through-traffi c needed to understand how the lagoon Hull’s quite a unique from Hull city centre could be designed to work in harmony with the sensitive natural habitats in place in that it’s one of the estuary. “If we design things in the the few places in the UK right way we can start doing things like supporting the habitat which that is vulnerable to all the estuary may need to support its four types of flooding conservation status,” said Hatley. “For example. Could we create more areas of intertidal mudfl at to support migrating bird populations?” feasibility” studies have been carried The models have also shown the that lagoon could be used Assuming all of these challenges out – largely funded by local businesses to support eff orts to reduce fl uvial fl ood risks by providing are met, Hatley estimates that if to the tune of around half a million large scale storage for storm water from the River Hull and government were to wade in with the pounds - and the team is now focused Hull frontage storm outfalls during high water periods. “If the support that’s required to take the on drumming up some government river drains into the lagoon where you can control the water project to the next level the project is 10 interest in the project. level, then in storm events you can stop the tide coming in and – 15 years away from fruition. Nevertheless, Hatley reports you can enable the river systems to continue to drain more With Covid-19 currently wreaking signifi cant progress in understanding effi ciently,” explained Hatley. “If you know that rain is coming havoc on the UK economy it’s perhaps how the scheme might fi t into what is into the river and that river’s going to get to your lagoon then fanciful to think that funding will an unusually complex environment. you can run the level down in the lagoon on the preceding tide. be forthcoming any time soon. But “Hull’s quite a unique place in that it’s If you run even a metre off the lagoon, that gives you 5 million as Hatley and his team are keen to one of the few places in the UK that is cubic metres of storage water and at the next tidal cycle you stress, Lagoon Hull is as much about vulnerable to all four types of fl ooding: can empty that. So every 12 hours you can a enuate a fl uvial stimulating economic growth as it pluvial (rainfall), fl uvial, groundwater surge event to the tune of 5 million cubic metres.” is about fl ood protection. And in the and tidal,” he said. “It is at the centre of As well as estuary modelling, the group has also worked aftermath of the current crisis, the all the risk factors, and the project has with the Highways agency to simulate the new road’s impact scheme might provide just the kind had to take into account the knock-on on the city’s traffi c. Once again, said Hatley, the results were of economic stimulus that will be eff ects” extremely promising. “The models show that the route is required.

21 May 2020 / www.theengineer.co.uk Engineering Skills for a Smarter World

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Given the opportunity, one engineer can change their world and ours. consumerENTREPRENEURS technology Sound and Canadian startup Ora is looking to take graphene mainstream with speaker technology that harnesses the material’s incredible properties. vision

Andrew Wade reports

hen Andre Geim and Kostya Novoselov first isolated graphene in 2004, it opened the door for a wave of innovation based on the wonder material’s jaw-dropping properties. Until now, however, it’s fair to say the Nobel-winning discovery has had limited impact for the average consumer. But that could all be about Wto change. Wearable electronics, sports equipment and smartphones have all hitched their wagons to the graphene hype train in recent times, playing on the material’s incredible strength and conductivity. In many cases, its inclusion is probably more beneficial to marketing departments than actual end users, although we’re also finally seeing some products that are genuinely tapping into graphene’s enormous potential. Canadian startup Ora’s GrapheneQ (GQ) headphones

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clever fall squarely into the latter category. GrapheneQ is the cans replacing a loudspeaker’s original membrane with a company’s proprietary composite material, used to make The GQ head- GrapheneQ cone.” the 40mm acoustic drivers that actually deliver sound to phones’ acoustic While battery life is easily quantifiable in the lab, the ear. Consisting of more than 95 per cent graphene, it drivers are made audio fidelity is more subjective. Over the years, speaker retains most of the material’s mechanical properties, while from GrapheneQ, manufacturers have used everything from paper and plastic at the same time being easier to shape and less expensive to a proprietary to wood, ceramics and Kevlar in pursuit of the perfect produce. Rather than recreating graphene’s single layer of composite material diaphragm material. Audiophiles will tell you that each has carbon atoms, GQ consists of flakes of graphene deposited in consisting of more its own unique audio signature, interpreting the bass, mids thousands of layers bonded together with proprietary cross- than 95 per cent and highs of music in various different ways. graphene linking agents. It is lightweight and stiff, with a low density, According to Ora, the frequency response of its GQ drivers making it an ideal material for loudspeaker membranes. is unmatched, delivering tonal balance right across the sound “Without a doubt, the most exciting aspect about the spectrum. Lows gets a restrained two decibel boost, with the technology is the unique mechanical properties it holds,” Ari mids tilted slightly towards the low end to provide warmth Pinkas, Ora’s co-founder and business lead, told The Engineer. and tone. At around the 6 kHz point, the sound signature “It is very uncommon for such a rigid material to be so dips slightly, smoothing out highs for a softer top end, before lightweight. This rare combination of high stiffness and low sweeping up again to provide added clarity and detail in the density allows for some pretty cool things in the audio world. very high frequency range above 10 kHz. To start with, acoustic transducers are already notoriously But what does all this mean for the user? Ora sent me inefficient: less than 10 per cent of the energy that goes into a a review pair of GQ headphones so that I could judge the loudspeaker gets translated to sound, over 90 per cent simply technology for myself, and the sound quality is undeniably turns into unwanted heat.” impressive. Aphex Twin’s Xtal was punchy and clear, with Having an ultra-lightweight speaker membrane results in the bassline benefiting from the subtle low-end boost but a considerable power saving, something that’s particularly the synths and vocal sample sounding crisper than ever. Van desirable for wireless consumer electronics such as Morrison’s Sweet Thing had a richness and depth that I hadn’t smartphones, portable speakers and Bluetooth headphones. experienced with any previous set of headphones. Every “The fact that GrapheneQ is so lightweight means that it instrument – from double bass to flute – was generously takes considerably less energy to move than other materials,” afforded space alongside Morrison’s soaring vocals. said Pinkas. “More concretely, Ora has observed up to a 70 The headphones have touchpad controls on the right per cent extension in the battery life of an audio dedicated earcup that were easy to use, and the lambskin leather pads device when doing physical A/B comparison measurements were comfortable to wear for my hour-long commute. They

27 May 2020 / www.theengineer.co.uk consumerENTREPRENEURS technology

can be listened to wired or wireless and also feature a digital microphone for taking calls. If I had one complaint, it’s that they are a very chunky set of cans and felt a little weighty on the head compared to my over-ear Sennheisers. While product design was of course important, Pinkas explained, Ora’s main focus was always going to be substance over style. “As you can imagine, given Ora’s limited resources as a startup, we had to prioritise certain aspects of our product Material development,” he said. “The vast majority of our efforts went benefits on the development of our material science technology and The low density making sure its implementation generated the levels of and high stiffness sound realism that is expected from graphene’s ‘superman- of the graphene like’ properties. Unfortunately, with under five employees has enabled the directly working on the GQ Headphones, there was no way we development of a light weight and could compete with the resources big brands like Bose and highly efficient Beats may have for flawless product design. And we are OK speaker membrane with that, they can beat us on the design build, we can beat them on what matters to us - sound quality.” Although the company has raised cash through crowdfunding and will be delivering GQ headphones to its backers, Pinkas says the long-term future for Ora is unlikely to be as a consumer brand. Instead, he envisions GQ technology being licensed out to established electronics manufacturers – similar to the Dolby business model – who are looking to incorporate some graphene wizardry into their products. “At one point we thought about pursuing both B2B and B2C strategies, but the pull from big consumer brands was so aggressive - especially those working with micro-speakers - that we are most likely going to focus on getting GrapheneQ ready for integration in other companies’ devices,” said Pinkas. “We are basically a bunch of chemists, materials scientists, audio engineers…there’s not many marketers at Ora. The plan at the moment is to focus our efforts on including our patented graphene materials inside the next generation of consumer devices – we’re already working closely with major brands paying us to develop solutions for their headphones, hi-fi tweeters, TVs, smart speakers, laptops and even smartphones.” The focus on graphene’s technical benefits rather than simply its marketability as a new wonder material is what should ultimately separate Ora from the snake oil and the shysters. As well as endorsements from Grammy-winning classical conductors, GQ has been acknowledged by Kostya Novoselov as “one of the first consumer products to feature a high-content graphene technology.” When he and Andre Geim were collecting their Nobel Prizes over a decade ago, headphones and speakers were probably not at the forefront of their thoughts, but GrapheneQ might just be the first mainstream application that’s worthy of their discovery.

May 2020 / www.theengineer.co.uk 28

Q&A:NOVEMBER XR TECHNOLOGY 2019

PH: Within the last 12 or 18 months, we have seen bigger companies move from a more general level of assessing technologies, such as proof of technology and proof of value, to scaling AR (augmented reality) to suit their requirements. This is also supported by the continued development on the hardware front, such as HoloLens and RealWare technologies – there is a sustained advancement in terms of the hardware and, although there are still some limitations, they’re nothing stopping companies deploying at scale now. RV: In the healthcare space, we are seeing XR implemented in several ways from medical training all the way One growing through to patient care. This includes application area for XR is medical using VR (virtual reality) and AR to training. Image: train and educate medical students as Fundamental VR well as help physicians and surgeons maintain and hone their skills. Our platform Fundamental Surgery is an Q&A: example of this as it lets trainees and surgeons practice their skills through VR and haptics anytime and anywhere. The use of XR allows companies like ours to scale training efforts fast, provide detailed insight into skills Reality Check development and deliver remote, mass multiuser experiences. We are also seeing XR being used in the OR for the An expert panel discusses current and future Richard Vincent development of surgical planning and commercial trends in the rapidly growing field of XR CEO and for patient treatment to help reduce co-founder, stress and execute treatment plans. andrew wade reports FundamentalVR Can you give us an example of an innovative application of XR that you or rom the operating theatre to the What are the key current trends in your a customer has made? factory floor, XR technologies area of XR? PH: We are seeing companies wanting (which include augmented, LM: As businesses focus on planning to push the boundaries of what is virtual and mixed reality systems) for and adapting to the unprecedented possible. That’s particularly the case are increasingly changing the way challenges, we are seeing clear of augmented reality, whereby bespoke Paul Haimes that specialists work and helping trends where MR (mixed reality) can assembly AR experiences, based on a VP European Fto open up new levels of capability. The immediately support, including direct PLM managed configuration context, Technical, PTC Engineer put together a panel of experts and remote servicing of customers allows customers to build experiences to discuss the trends and technologies equipment. In recent months, the that are tuned to the product variant that are shaping this rapidly advancing pandemic has brought to light some that they are making – this is one of field. of the specific Mixed Reality solutions the most exciting areas that we are that can help solve major business developing our technology towards. Meet the experts issues that companies from several A good example of this is PTC’s Richard Vincent - CEO and co-founder, industries are facing. MR is also customer Volvo, who, within its truck FundamentalVR giving businesses the opportunity to Leila Martine engine quality control and assurance Paul Haimes - VP European Technical, rapidly restructure assembly lines UK product process, are exploring the use of PTC’s PTC and corresponding re-training of their marketing director Vuforia Augmented Reality Suite Leila Martine - UK product marketing workforce, while ensuring the health of Mixed Reality, at the inspection end of the engine director of Mixed Reality, Microsoft and safety of staff. Microsoft build line to track any quality issues.

May 2020 / www.theengineer.co.uk 30 Read more indepth reports at www.theengineer.co.uk

and at any time with simulations accredited by the American What exciting developments can we Academy of Orthopaedic Surgeons and the Royal College of expect in the coming years? The pandemic has Surgeons of England. PH: I believe that a Geo Fencing driven shown the need for new AR experience will be a massive part ways of bringing remote Are we going to see more widespread adoption or will it remain of new developments, and evolve a relatively niche technology? at an unprecedented rate, once the individuals together LM: For broader adoption of MR technology to happen, devices can enable it. Through this, Richard Vincent businesses need to establish the ROI and suitable out-of-the- operators will be able to move from box use cases before deploying. There are many immediate one environment to another and solutions available, such as Dynamics 365 Remote Assist, have information streamed onto Building from this context, the prospect which allows technicians to collaborate with colleagues their device, that is specific to their of customer specific experiences from different locations. Businesses preparing for a reduced surroundings and proximity to the configured to consumer products workforce due to pandemic-related safety measures can machines. become possible. use Remote Assist to leverage employee expertise remotely. RV: I believe we are at the exciting LM: A consortium of major businesses Additionally, medical clinicians or technicians maintaining beginning of XR’s full potential, have come together and selected two critical equipment in the field can use Remote Assist while especially in the medical space. I expect existing ventilator designs from UK sharing an in context, real-time view of the work site with we will see developments in the use of firms Penlon and Smiths Group to an expert working from a different location. As businesses full haptics, which will allow for deeper meet high-level specifications for realise the potential of MR, the question is not if we will see immersion and skills development. a Rapidly Manufactured Ventilator more widespread adoption, but when. Additionally, the industry will System, developed by clinicians RV: I believe that XR training in the medical field will become hopefully advance to offer patient and the Medicines and Healthcare mainstream. The Covid-19 pandemic has shown the need specific modelling through XR that will products Regulatory Agency to aid the for new ways of delivering ongoing education and bringing allow for surgeons to personalize their NHS. Leveraging Microsoft HoloLens, remote individuals together quickly. XR is perfect for this. training on each patient. The merging Avanade and PTC are supporting the XR allows people the unique opportunity to step into virtual VentilatorChallengeUK to enable a worlds from anywhere to practice, learn and teach. number of solutions including PTC PH: Last year forward-thinking companies made it a breakout As technologies continue Vuforia Expert, Dynamics 365 Guides year for AR, moving projects along rapidly from pilot to to merge, the rate of and Dynamics 365 Remote Assist to fast production. Now, as the Covid-19 outbreak forces them to track training and knowledge transfer figure out new ways to provide assistance to workers and innovation will increase of hundreds of assembly workers customer in other regions, more and more companies will exponentially across multiple manufacturers and see the true value of AR. Newcomers are already seeing the Leila Martine multiple sites. gains in worker efficiency and quality, whilst reducing the RV: Our platform, Fundamental Surgery, cost of training by more effectively transferring knowledge is a unique and market leading example to new workers via AR. Of course, the issues presented by of mixed and virtual reality hardware of XR in use in the surgical training Covid-19 go way beyond the everyday business concerns of will also allow seamless movement arena. The multimodal platform has productivity or cost. This is about the health and safety of between both. two offerings. workers and thus demands a far more urgent and targeted Finally, developments in improving First, our HapticVRTM product response. AR can provide this, because it is easy and fast to GPU capabilities on smaller devices combines VR with the sense-of-touch set up and requires no specialist equipment to run – we see is expected, which will enhance to allow users to experience the same many companies using tablet and smartphones to consume experiences. sights, sounds and feelings they would AR experiences. LM: From construction sites to in an actual procedure. This allows factory floors, to operating rooms trainees to build muscle memory Microsoft’s and classrooms, mixed reality, AI, the needed to be a surgeon. Hololens intelligent edge and intelligent cloud Our new @HomeVR offering technology is are changing how we work, learn, increasingly compliments our HapticVR platform by communicate and get things done. MR, widely used by bringing our accredited simulations to manufacturers along with smart devices and IoT will standalone VR headsets such as Oculus no doubt transform several areas of our Quest. This combines Cutaneous world, and as technologies continue (tactile vibration) and Kinesthetics to merge, the rate of innovation will (force feedback & position) haptic increase exponentially. Over the technologies in a single platform, coming years we will continue to see which is optimized for various levels of an increase in retail, education and the learning process. healthcare businesses developing MR Overall, our Fundamental Surgery applications and utilising out-of-the- platform lets users train and hone box applications to solve a range of their skills virtually from anywhere business challenges.

31 May 2020 / www.theengineer.co.uk NOVEMBERQ&A SOFTWARE 2019

PTC’s Vuforia Expert Capture AR Technology can be used to assi

rom democratising modelling and greater innovation in the design and simulation to helping engineers Q&A: manufacture of vehicles. Advanced light- produce ventilators for the NHS, weighting approaches via generative software is enabling innovation design will be pivotal to improving at a pace never seen before. The power consumption and the range of Engineer spoke with experts from vehicles. While different materials and FCOMSOL, PTC and Autodesk to ask Quick on compositions will improve the structure about the demands that are driving their of vehicles. solutions. Can you provide one or two examples of Meet the panel how your products are helping customers Bjorn Sjodin, VP of Product Management the draw meet their challenges? at COMSOL BS: Using simulation apps, people who Paul Haimes, VP Europe Technical Sales Experts from COMSOL, PTC are not simulation experts can run at PTC and Autodesk reveal the trends their own tests without needing to Andy Harris, Senior Principal Research that are their driving their comprehend the complexities of the Engineer, Autodesk Research solutions forward underlying simulation. This means an entire organisation can benefit from What trends or customer requirements simulation, which leads to an increased are driving developments in your product JASON FORD reports understanding of how products will area? behave in the real world. Also, apps with BS: One of the biggest trends driving companies making it a breakout year for Augmented Reality highly specialised user interfaces can the development of modelling and (AR). Now, as COVID-19 forces companies to look at new ways of help exceed customer expectations. simulation software right now is the providing assistance to workers and customers in other regions, In addition to providing customers need for democratisation. Modelling more and more companies are seeing the true value of AR. with results in terms of standardised and simulation of physics-based Companies are now seeing the gains in worker efficiency and documents, apps allow customers to problems is an extremely powerful quality, whilst reducing the cost of training by more effectively view the results and even manipulate the predictive tool in product and process transferring knowledge to new workers via AR. The issues inputs by themselves. Simulation apps development. The technology is so presented by Covid-19 go way beyond the everyday business bring real-time answers directly to sales valuable to organisations that many concerns of productivity or cost - this is about the health and meetings, pitch talks and discussions on consider it urgent to make these tools safety of workers and thus demands a far more urgent and the factory floor. available to a wider audience than just targeted response, and AR can provide this. PH: PTC is a partner in the simulation experts. COMSOL provides AH: Globally, companies are using generative design to solve VentilatorChallengeUK consortium, leading technology in this area for app engineering challenges and produce new design solutions that led by High Value Manufacturing building, app compilation and enterprise meet their needs, in less time and with less negative impact on Catapult CEO Dick Elsy and leading UK deployment of apps to serve this need. the environment. One such area is the automotive industry. engineering businesses. The consortium PH: 2019 saw forward-thinking The move to reduce the carbon footprint of the sector has driven has used PTC’s Vuforia Expert Capture

May 2020 / www.theengineer.co.uk 32 Read more about software www.theengineer.co.uk

makes powerful computing resources iot platforms and ar technologies will easily available, whether it is within the domains of an organisation as a eventually impact all parts of our personal and private cloud or publicly available. More professional lives Paul Haimes, PTC computing power means more realistic simulations with more accurately Bjorn Sjodin represented multiphysics models. AR technology and Microsoft’s HoloLens Chalk, leverages augmented reality to VP of Product Vendors are adapting their software to capture the crucial assembly steps enable off site and on-site employees Management at to accommodate more computing and processes involved in building to collaborate in the operation, COMSOL power at the hands of users. Additive Rapidly Manufactured Ventilator maintenance, and repair of all kinds manufacturing changes the way users Systems (RMVS). This will be uploaded of products. It’s like Facetime, with think about the CAD models that are and edited in PTC’s cloud based Vuforia augmented reality superpowers for used as the basis for modelling and Editor technology, to create a virtual industrial se ings, and it’s as easy to set simulation. More fl exible and complex assembly guide and relayed, through up and use. To help during this crisis, geometry analysis is needed with hybrid wearable equipment or smart devices we’re making Chalk available for free. No solutions mixing traditional CAD with such as phone or tablet, to the factories of obligations. mesh-based modelling. In addition, Paul Haimes consortium partners that traditionally do AH: Powered by Autodesk Fusion 360, additive manufacturing frequently VP Europe not make ventilators. Protecting workers generative design uses a combination requires multiphysics analysis in Technical Sales at Smiths Group, Penlon and all of the of artifi cial intelligence and cloud- order to accurately make predictions at PTC consortium partners was essential and at computing to create design possibilities for the wide variety of manufacturing the heart of the project. which take into account performance processes. AH: Autodesk Research recently criteria and real-world manufacturability PH: I feel the combination of IOT collaborated with Briggs Automotive requirements, allowing designers to platforms and AR technologies will Company (BAC) to apply generative explore thousands of designs in less time eventually impact all parts of our design methods to its design and than they could deliver a single concept personal and professional lives. Think manufacturing process for its new using traditional processes. of this combination as converting bits generation BAC Mono. The team focused Andy Harris and bytes into sound and sights which on how generative design could be Looking forward, what products or Senior Principal can be easily consumed by the human. applied to the wheel. We learned about technologies do you see changing your Research Engineer, IOT platforms off er the potential to the aesthetic requirements to build sector? Autodesk Research bring together disparate data sources this understanding into the generative BS: Cloud computing and additive and contextualise it in a form which design setup. This new wheel design manufacturing are changing the CAD Image made using can then can be delivered easily as an was a natural evolution of the original and CAE landscape. Cloud computing COMSOL Multiphys- AR experience. Combine this with rather than a radical break in tradition. ics® software and complimentary capabilities such as Geo The results produced a wheel that provided courtesy Fencing driven AR technology and I can was an impressive 35 per cent lighter, of COMSOL. see this evolving at an unprecedented weighing 2.2kg per wheel, that could be rate – once devices can enable it. manufactured traditionally on a CNC AH: In addition to improving and mill. This was achieved in less time than off ering more generative design BAC had ever designed a wheel before. capabilities within Fusion 360, such as the added layer of unique What’s the key product for you currently aesthetics for the designer using and how is it being applied? it, we are extending this off ering to BS: The key product for COMSOL is the architecture, engineering and COMSOL Compiler. This product construction (AEC) industry. We recently converts simulation applications into announced Generative Design as a standalone, executable applications in feature in Autodesk Revit, allowing users just one click. These applications can to explore, optimise and evaluate data- then be distributed to anyone, anywhere. driven design alternatives based The people you distribute the apps to on project goals, constraints and inputs. can run them without needing to hold With the introduction of Generative a license for COMSOL Multiphysics or Design in Revit, industry professionals COMSOL Server. vendors are adapting their can utilise this algorithmic problem- PH: Augmented reality, in the form of software to accommodate more solving technology to explore design Vuforia Expert Capture, as mentioned alternatives, identify improved outcomes above, and also Vuforia Chalk. PTC’s computing power Bjorn Sjodin, COMSOL and make data-informed decisions faster

Image credit: Solver Technology for Acoustics Acoustics for Technology Solver credit: Image remote assistance product, Vuforia than ever before.

33 May 2020 / www.theengineer.co.uk Late, great engineers ARCHIMEDES OF SYRACUSE Remembered today primarily for inventing a rudimentary screw pump, there is so much more to the Ancient Greek polymath Archimedes of Syracuse, the greatest scientist of antiquity.

Written BY nick smith

ive me a lever and a 12th century Byzantine Greek historian place to stand and I will John Tzetzes is considered reliable move the earth.” These on this point), we can extrapolate that are supposed to be the Archimedes was born in or around the words of the greatest year 287BC. Because he spent most scientist of antiquity, of his life in the Greek city-state of and yet, as with so Syracuse (modern Sicily) where he “Gmuch about Archimedes of Syracuse, was a close acquaintance of King Hiero it is virtually impossible to separate II, it is assumed that this is also his myth from reality. The legendary flash birthplace. Historians think he may of bath-time inspiration – the original have spent his early career in Egypt, ‘eureka’ moment that we were taught but are more definite on the notion that at school – while almost certainly Archimedes published his works in the apocryphal, has passed indelibly into form of correspondence with leading science folklore. It remains popular as mathematicians of the time, including the only incident of public nudity related Conon of Samos and Eratosthenes of to the history of hydrostatics, and yet Cyrene. is unlikely to have been the inspiration As for his death, the ancient Greek for Archimedes’ two-volume treatise biographer Plutarch (writing hundreds of On Floating Bodies. As one biographer, years after the event) says the centurion Eduard Jan Dijksterhuis puts it: “the that put Archimedes to the sword did overflowing of water from the bath does so when the latter refused to leave his not teach anything about the upward Archimedes of Syracuse c.287BC – c.212BC mathematical diagrams to attend a thrust acting on a body immersed meeting with the occupying General in water.” Today, Archimedes’ legacy the son of Pythagoras, and there are claims he was a pupil of Marcus Claudius Marcellus. His last rests on a vague portfolio of ideas: he Plato. Both positions can be dismissed easily, but the fact that words have been handed down to us anticipated calculus, formulated the they routinely make their way into modern discussions about as Noli turbare circulos meos (‘do not eponymous hydrostatic principle, Archimedes seems to amplify the point that biographical facts disturb my circles’), but these are not developed the design of the screw pump about him are scarce. But what we do know about the man mentioned in Plutarch or anywhere else and devised an approach to determining described by the author of A Contextual History of Mathematics reliable. Equally apocryphal, according π (pi) that was to be used for more than a as the “most original and profound mathematician of antiquity”, to Encyclopaedia Britannica, is the story thousand years, while one of the bounds is that there are today nine extant treatises by Archimedes, that Archimedes used a huge array he established for π (22/7) has remained a covering subjects such as On the Sphere and Cylinder, On the of mirrors to burn the Roman ships universal approximation ever since. Equilibrium of Planes, Quadrature of the Parabola, Method besieging Syracuse. Britannica also While there is very little in the way concerning Mechanical Theorems and more besides. questions the historical reliability of his of verifiable historical fact about the There are some biographical facts that have gained two most famous quotations about levers life of Archimedes, there is a wealth of consensus with historians. Because we know that Archimedes and displaced bathwater, while admitting unsubstantiated and fanciful detail. An died during the sack of Syracuse in the Second Punic War that this assortment of unsubstantiated early Arabian biographer claimed that (placing his death at c.212BC), and because we know that he anecdotes creates a picture of “his real

the ancient Greek mathematician was was 75 years old when he was killed by a Roman centurion (the interest in catoptrics (the branch of Library Photo Terry/Science Sheila

May 2020 / www.theengineer.co.uk 34 Read more of our Late, Great Engineers at www.theengineer.co.uk

optics dealing with the refl ection of to design the Syracusia, which at 110m the second of these discoveries, Archimedes left instructions light from mirrors, plane or curved), presses a claim for being the largest for a sphere within a cylinder to be carved on his tomb, a fact mechanics and pure mathematics.” transport ship of antiquity. Capable confi rmed by Roman statesman Cicero who rediscovered the As Johnny Ball says in his book of carrying nearly 2000 people, it was monument a century-and-a-half after Archimedes’ death. In Wonders Beyond Numbers, the most too big to dock at any port in Sicily and his Measurement of the Circle, that exists only as a fragment, famous legend concerning Archimedes so was sailed to Alexandria, where it we see his approach to defi ning π, which consists of inscribing is the one in which he “jumped out of was presented to the king, Ptolemy III and circumscribing regular polygons with large numbers of the bath and ran down the street in the Euergetes. sides. His work on large numbers appears in a treatise called nude” having shouted ‘Eureka!’ (which Although not famous in his lifetime The Sand-Reckoner in which he created a place-value system is traditionally translated as ‘I have it’). as a mathematician, from his treatises of notation with the base 100,000,000, allowing him to express Ball explains that what Archimedes ‘had’ we can deduce what breakthroughs how many grains of sand it would take to fi ll the entire universe. was a scientifi c method of verifying the Archimedes made. In his On the Sphere Apart from the nine extant works, we can infer from later authenticity of the metallic composition and Cylinder he tells us that the surface authors that he wrote other treatises that have not survived, of a crown commissioned by King area of any sphere of radius r is four as well as books of contested provenance on topics such as Hiero II, subsequently produced by times that of its greatest circle (expressed touching circles and geometrical puzzles. two jewellers from a bar of pure gold. today as S = 4πr2), while the volume of a It wasn’t to be until the 8th and 9th centuries, when his According to Ball, when the king saw the sphere is two-thirds that of the cylinder treatises were translated into Arabic, that the true signifi cance crown, “he was thrilled, until someone in which it is inscribed, leading to the of Archimedes as a mathematician was appreciated and his whispered in his ear that the jewellers formula for the volume V = 4/3πr3. For work was developed by medieval Islamic mathematicians. The were not completely honest and may anyone doubting the signifi cance of invention of the printing press meant that his work (in Greek have substituted less valuable silver for this time) gained widespread popularity in Europe, infl uencing some of the gold, which they’d kept for the likes of Johannes Kepler and Galileo Galilei (who praised themselves. The problem was how he Archimedes as ‘superhuman’). His infl uence extended into the could prove it without bashing the crown Give me a lever 17th century via Latin translations that reached René Descartes back into its original gold bar shape? and a place to stand and Pierre de Fermat, and so had a profound infl uence on post- Hiero turned to Archimedes for help, Renaissance mathematics. Today, the Fields Medal awarded by but even he had no idea how to solve the and I will move the International Congress of the International Mathematical conundrum until one day, as he climbed the earth Union – one of the highest honours in mathematics – carries into the bath, water slopped over the a portrait of Archimedes along with the inscription Transire Archimedes of Syracuse sides…” suum pectus mundoque potiri (‘rise above oneself and grasp the The story continues that when the world’). crown was placed into a body of water, it displaced more water by volume than the original volume of the gold The Archimedes screw, also bar, proving that the gold had been known as the screw pump, was adulterated with a lighter metal, silver. originally used to move water from low-lying sources such as rivers Most tellings of the tale rejoice in into irrigation ditches the supposition that the king, armed with the evidence of malfeasance that he required, then executed the two jewellers, despite there being not one shred of evidence for this. However, the ‘incident’ led to Archimedes being able to report in his treatise On Floating Bodies what has now become known as the Archimedes Principle, which is that a solid denser than a fl uid will, when immersed in that fl uid, be lighter by the weight of the fl uid it displaces. His other associated observations were that an object immersed in water will displace its own volume of water, while an object less dense than water will sink until it has displaced its own weight and will then fl oat, eff ectively weightless, on the surface. Which is why ships fl oat. Archimedes used this knowledge

35 May 2020 / www.theengineer.co.uk ARCHIVE FEATURE

December 1956 Improving iron lungs One of Britain’s most prominent automotive engineers turned his a entionheight to alleviating of epidemics the suff during ering the of polio1950s victims at the

written by jon excell

In 1952, Smith-Clarke had taken on the chairmanship of the Coventry and Warwickshire Hospital board of ore than seventy years ago, faced with the management, and as part of this role he’d been asked to prospect of large-scale epidemics of polio, UK look at the engineering of mechanical ventilators. hospitals were a empting to get to grips with a He wasn’t impressed. ‘Some may think, as many challenge that has become frighteningly familiar patients have done, that it had a very uncomfortable to us all in recent months: a shortage of adequate resemblance to a coffi n, and for this reason screens Mbreathing equipment to treat those aff ected by the disease. were sometimes placed around it so that patients 1956 — the year of this article — had been a particularly could not see it when being put in.’ Upset at the bad year, with epidemics in Ireland and the Netherlands distress he’d seen in children being taken out of iron claiming hundreds of lives. The vaccine, which has since lungs, he redesigned the machine used most at the eradicated the disease in the industrialised world and hospital, the Nuffi eld-Both machine, which had come close to wiping it out worldwide, had been developed been in use since 1939. by Jonas Salk only a few years previously and was still in ‘I took over a disused air-raid shelter in the

trials. hospital grounds and with the help of the senior

December 1956 December – Iron lung Iron – In the absence of a vaccine, a key method of treatment physicist and a member of his staff , a Nuffi eld- for the disease was the iron lung, a fore-runner to present Both machine was completely dismantled,’ he day ventilators that was used to help patients breathe recalled in his lecture. ‘It was found impossible whilst the muscles controlling their lungs were paralysed. to obtain working drawings and I had to make Although there were a number of variations on the dimensional free-hand sketches.’ Alvis made the technology, the basic principle relied on enclosing the castings for the larger parts, while Smith-Clarke himself patient’s body in a sealed cylinder and using changes in air machined the smaller parts needed. pressure within the cylinder to help the patient breathe. As well as making the machines more controllable and In a historical echo of the way in which engineers from effi cient at helping patients to breathe, Smith-Clarke also non-medical sectors are pu ing their skills to use in the thought it important to make them more comfortable. current push for NHS ventilators – celebrated automotive He included more ports in the side of the machine, so engineer Captain George Smith-Clarke was determined to the patient could be reached for nursing care without Captain George Smith- aff ecting breathing. He also designed be er head-rests and do something aboutThe it. Engineer In an article for stretcher support system. Clarke, who had been chief engineer at British car Smith-Clarke later helped Alvis employees to set up a manufacturer Alvis from 1922 to 1950 (and had designed company to supply kits to modify breathing cars which won races at Brooklands and Le Mans) detailed machines.” improvements in the designs of iron lungs to help with the polio epidemics.

May 2020 / www.theengineer.co.uk 5636 Breathe easy Captain George Smith-Clarke, former chief engineer at British car manufacturer Alvis re-engineered and signifi cantly improved the design of an existing iron lung system: the Nuffi eld-Both breathing machine

3757 May 2020 / www.theengineer.co.uk NOVEMBERSci-fi eye 2019

to refuse to follow orders or defect wo articles in last month’s to the enemy? issue caught my eye. The Assuming we somehow fi rst was about the Royal manage to avoid insurrection in the Navy’s decision to test ranks, we face another potential extra-large autonomous problem when machines start submarines with a view to gareth L. POWELL upgrading machines on an ad hoc Tincorporating them in its fl eet, and basis. We run the risk that sooner the second concerned the MOD’s or later, they might become too acquisition of fi ve unmanned complex for us to understand. ground vehicles for ba lefi eld Natural selection We’ll lose the ability to repair our resupply missions (Qinetiq’s Titan own creations, as they diverge into UGV is pictured below). on the unmanned a multitude of sub-species, each Now, as I’m a science fi ction with its particular specialisms and author, you might be expecting me evolutionary history. What started to leap straight to the conclusion ba lefi eld out as a tank might come back to that these automated vehicles will us as a swarm of complex drones or somehow rise up against us and Forget the Terminator scenario. The future of AI a slick of nanotechnological goop. destroy the world in a Terminator- based warfare could be far weirder than that At that point, even if they don’t style apocalypse. And while evolve the intelligence to become that may be a fun scenario for a undergoing a rapid Darwinian rough terrain, while being almost disloyal, could we still really claim Hollywood blockbuster, frankly machine evolution dictated by the immune to IEDs and other hazards. to be in control of them? If we can’t any species dumb enough to place circumstances in which they are Earlier, I mentioned how understand how they work, can its entire off ensive capability in operating. unwise it would be to place your we trust them to make the life-or- the charge of a single artifi cial What might such machines entire military capability under death decisions that are necessary intelligence deserves everything look like by the end of a protracted the command of a single artifi cial on a ba lefi eld? If an unmanned it gets. confl ict? If the other side also uses intelligence. However, the ‘smarter’ vehicle decides the success of its No, in this month’s column, I similar technology, would the an unmanned vehicle is, the more mission would be increased by the want to look at some of the stranger evolution be accelerated as each chance it has to survive, so an neutralisation of civilian targets, implications of this technology. side became involved in a race ongoing upgrade of its onboard would we be able to convince it To start with, let me state the to outclass the other? A simple processing power wouldn’t be otherwise? obvious: war produces casualties, unmanned supply truck might unreasonable. But how smart do Some of you may remember and if we’re deploying autonomous evolve into a heavily armoured you want a drone to be? At what the talking bomb in the movie Dark vehicles into active theatres, they stealth vehicle with fat mesh tires point will it assess its situation and Star, which discovers philosophy, are going to get damaged. It’s easy that allow it to traverse any kind of realise its best chance of survival is decides it’s god, and with the words, to imagine automated ambulances “Let there be light,” detonates ferrying human casualties away while still a ached to the ship that from the front line, but what about should have dropped it. That is unmanned tow trucks and drones ANY SPECIES DUMB ENOUGH TO PLACE ITS ENTIRE something we defi nitely want to equipped to repair autonomous OFFENSIVE CAPBILITY IN THE CHARGE OF A SINGLE AI avoid. vehicles? Machines repairing DESERVES EVERYTHING IT GETS We also want to avoid the other machines without human situation described in Philip K. intervention. Dick’s story ‘Second Variety’, where If those machines can be the few remaining human soldiers repaired on the ba lefi eld, perhaps on both sides of a confl ict discover they can also be improved and that their automated weapons have modifi ed in situ to cope with gained sentience and joined forces, unexpected changes in terrain, and are now lying to their former mission requirement, or threat masters about the progress of a war level? Throw in some simple that’s no longer happening. learning algorithms for the tow Leon Trotsky claimed that, trucks, and that sounds like “War is the locomotive of history.” something I could write a story If our unmanned vehicles go on to about: a fl eet of war machines that evolve beyond us, then perhaps war are turned loose and adapt to the will also provide the future of the needs of the ba le as it happens, locomotive.

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BETTER here are a number of “a li le knowledge is a dangerous general techniques that thing.” have been introduced by Moving on from this universal various companies over PRACTICE truth, perhaps we need to consider the past few decades in a how we approach embracing Tbid to remain competitive. Our anonymous blogger calls for a emerging ideologies and All follow a similar method for more nuanced and visionary approach techniques more specifi cally. On implementation: send a group off the whole I have found middle to on a course, the group comes back to embracing new processes and upper management rather averse either evangelical or dismissive methodologies to releasing me so that I can a end and then they apply what they’ve seminars and / or trade shows. I learnt, teaching others along the did initially get a touch paranoid way. Some aspects of company concentrating solely on customer’s from a short while ago when about this but can confi rm that and process management are expectations rather than the a senior member of staff it’s not just me who’s denied such even enshrined within ISO 9001, reasons that may lie behind them. consistently and ruthlessly opportunities. illustrating how crucial this is all The result was, in what struck applied certain aspects of 5S, As professionals we have a seen to be for industry in general. me as being a ma er of u er specifi cally the discarding duty to our employers to keep I always think that none of absurdity, a situation where we of items judged as being of up with the latest ideas but this these techniques, whether overall were going through all of the pain no further use. However, needs a li le more than searching industry practice or job specifi c regarding learning certain project unfortunately it was done without the internet, or even avidly expertise, give a clear advantage management techniques and consultation with those who reading the latest copy of The as such but rather remove a writing the procedure documents, “owned” the items and straight Engineer when it drops through disadvantage when compared but not implementing them to the to the skip rather than into a the le erbox (either virtually or to companies that have already depth where we could gain clear quarantine area for secondary physically). The seminar or trade introduced them. It’s worth benefi ts. A li le consideration on assessment. This resulted in show gives the opportunity to remembering that companies the ma er would have resulted the scrapping of important test see beyond our expectations and do exist without any of these in the understanding that this reference material. A case of paradigm led assumptions. formalised strategies but, equally, was actually an opportunity for wholeheartedly embracing the After all, any research to dismiss them out of hand the company as a whole to be basic concept without considering undertaken by us must have our would be a mistake. Therefore improved. the subtleties. The overriding current level of knowledge as its what’s needed is a judgement The second example comes conclusion that springs to mind is start point, something that cannot call; a review of the benefi ts any be anything other than inherently particular methodology or process self-limiting. can bring to your company and an What’s needed then is a culture understanding of the best way to of promoting visionaries to the implement it. top of the tree. Those who can see Personal experience of two the advantages to be brought from conspicuous failures regarding exposure to environments that this spring to mind, the fi rst being promote the cross fertilisation from a couple of positions back. of ideas rather than just seeing At Company X there existed a the hours that someone may be culture, led from the top, of seeing out of the offi ce a ending a show. the core disciplines around ISO Coupled to that is the need for 9001 (adopted because others had these visionaries to be capable an expectation that we would of grasping the potential of new conform to it) merely as “box ideas as they are brought in, and ticking” exercises. for them to be meticulous enough This is never a healthy a itude to ensure that they are correctly to take about anything. It shows applied. Surely that’s not too much

an approach where the company is to ask? /stock.adobe.com bakhtiarzein

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Across Down 1 Chemical indicator strips (4,6) 1 Move or stir about violently (6) 6 Open way for travel or transportation (4) 2 Consisting of a haphazard assortment of www.theengineer.co.uk/webinar 10 Clean with some chemical process (5) different kinds (6) 11 Putting together broken parts (9) 3 Heavy tool powered by compressed air (9,5) 12 Strong country cider (7) 4 Structure erected on the line between two properties (5,4) 13 Collect discarded or refused material (7) 5 Strong lines (5) 14 Commuters who uses public transportation (12) 7 Combined with a gas in the air (8) 18 Home built by a municipal body (7,5) 8 Remove the oil from (8) EXP 21 Patent medicine whose effi cacy is questionable (7) 9 Service area that sells petrol (7,7) www.theengineer.co.uk/expo 23 Prompting more thought (7) 15 Impressions made by the foot of a horse (4-5) 24 Material with negligible electrical or thermal 16 White trivalent metallic element (8) conductivity (9) 17 Supports oneself (8) 25 Chemically inactive (5) 19 Point on the cutting part of a drill (3-3) 26 Any soft or soggy mass (4) 20 Showing signs of wear and tear (6) 27 Belonging to modern times (7-3) 22 Non-specifi c agent that imparts motion (5) www.theengineer.co.uk/conference

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