2015 Design & Project Exhibition the Joseph Black Lecture

2015 Design & Project Exhibition

The Joseph Black Lecture Project to Product The creation of the Moutain Trike All-Terrain Wheelchair Business Tim Morgan Inventor and Managing Director

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design ex booklet 2015 - Final 1.indd 1 28/08/2015 16:02:54 design ex booklet 2015 - Final 1.indd 2 28/08/2015 16:02:54 design ex booklet 2015 - Final 1.indd 1 28/08/2015 16:02:55 1970 1979 Exhibition Design for maintenance in 1986 British Rail The Car of the Year 2000 1971 K Taylor A.C.Rudd BSc (Eng) FSAE Exhibition Chief Mechanical & Electrical Managing Director Engineer Lotus Engineering Ltd 1972 British Railways Board Some thoughts on design 1987 and designers 1980 Design for living Dr T Emerson Effective industrial innovation Sir Montague Finniston GKN Ltd and its contribution to FEng FRS Britain’s economic recovery 1973 V J Osola 1988 The Design Council and Chief Executive Design: The common goal engineering Redman Heenan John Butcher M.P. G E P Constable International Parliamentary Under Head of Engineering Design, Secretary of Department of Design Council 1981 Trade & Industry Investment in new product 1974 development 1989 Design as a team game Viscount Caldecote DSC Industry: design & young E McEwen FEng people Vice-Chairman Chairman Delta Group plc Ivor Owen Engineering Joseph Lucas Director Ltd 1982 The Design Council The context of design Sir Kenneth Corfield 1975 Chairman & Chief Executive 1990 The Ralph Shire Memorial Standard Telephones & Effective management of Lecture: Design problems in Cables Ltd design aircraft gas turbines Peter Hills L Haworth FRS 1983 SERC - Engineering Design Director Higher innovation: the Co-ordinator Rolls-Royce (1971) Ltd management of creative The Design Council disorder 1976 Sir Basil Blackwell FEng 1991 Innovation in engineering Vice-Chairman and Chief Competing with better design Executive Westland plc products in less time Dr A Moulton CBE Keith Nichols Director 1984 UK Marketing Manager Molton Developments Ltd Designing for dependability (CIM) Digital Equipment Ltd in advanced power plant and 1977 associated systems 1992 Ship design Dr W Rizk CBE FEng Concorde and its successor R J Daniels OBE FIMechE Sidney Swadling Director General of Ships Chairman Director of Engineering & Head of Royal Corps of GEC Diesels Ltd and GEC- British Aerospace Airbus Ltd Naval Constructors Ruston Gas Turbines Ltd) 1985 1993 1978 Metrology in the field of The design’s craft Better design for British industry engineering Dr G B R Feilden CBE Sir William Barlow FEng Director General David McMurtry Chairman & Chief Executive Chairman & Chief Executive British Standards Institution of BICC, Chairman of the Design Council Renishaw plc 2

design ex booklet 2015 - Final 1.indd 2 28/08/2015 16:02:56 1994 2001 2008 Tribology in machine design The Farnborough F1 Air Taxi: Design and manufacture: Professor Duncan Dowson, an evolution in air travel dealing with technical CBE, FRS, FEng Richard Noble OBE cultural aspects The University of Leeds Farborough Aircraft Dipl.-Ing. Frank Ludwig BMW Group 1995 2002 Design to thrive Designing the human knee 2009 Prof. Ivan Yates, CBE FEng Professor John O’Connor Design, innovation and Royal Academy of Oxford Orthopaedic competition: establishing the Engineering Engineering Centre balance Visiting Professor, Eng Dept. George W Buckley University of cambridge 2003 3M Council Member, Challenging the design The Design Council process models 2010 Professor Mogens Myrup Health and safety: the cradle 1996 Andreasen to grave approach Innovation-led Technical University of Judith Hackett competitiveness: through Denmark Health and Safety Executive equivalence in product organisation, 2004 2011 technology and culture Information knowledge Designing a spaceship for Professor Gordon Edge management in an everybody: the engineering The Generics Group international design firm challenges of commercial Mike Shears CBE spaceflight 1997 Arup Group Jonathan Firth Engineering and design: Virgin Galactic against the odds 2005 James Dyson Balancing conflicting needs 2012 Dyson Appliances by design Engineering Sustainability: Geoff E Kirk the role of design and 1998 Civil Aerospace, Rolls-Royce engineering in sustainable Technological innovation: a plc innovation managed resource Professor Jeremy Watson Professor Chris Pearce 2006 Arup Group Inbis Group pl Advanced technology for space exploration 2013 1999 Professor Erik K Antonsson Inventing Your Future The creation of the Goss NASA Jet Propulsion Tom Pellereau Challenger Laboratory: 2002-2006 Aventom Ltd Adrian Thompson Paragon Mann Ltd 2007 2014 The engineering challenges Form follows function - Strive 2000 of large scale structures for for perfection and beauty is The birth of a Morgan: wind energy generation the by-product innovation and tradition Dr Ian Chatting Ron Dennis CBE create a new sports car Vestas Technology UK McLaren Group Charles Morgan Morgan Motor Company 3

design ex booklet 2015 - Final 1.indd 3 28/08/2015 16:02:56 Welcome to the 2015 Design and Project Exhibition and to the Joseph Black Lecture given by the Tim Morgan of Mountaintrike

This booklet contains details of the 23 We want to be able to replicate the suc- Group Design and Business projects, cess of our key note speaker, Tim Mor- including Mechanical, Aerospace, Au- gan. Tim was displaying his final year tomotive (Formula Student) projects design project at this Design and Project undertaken by 3rd year students, and Exhibition in 2007. He entered into con- the 192 individual engineering pro- versation with local business man David jects taken by 4th year students. It Rogers, a few connections were made, also contains details of the 38 Inte- conversations, business plans, develop- grated Mechanical and Electrical En- ment and a lot of hard work followed and gineering (IMEE) projects. Details of the rest, as they say, is history all projects are included on the Depart- ments website at https://wiki.bath.ac.uk/ Thus we are delighted to welcome Tim display/MechEngDesignExhibition/Home Morgan, who is both Chief Designer and Managing Director of the MountainTrike The diversity of project activity is again Company, to give his keynote address there for everyone to see, this is across “Project to Product - The creation of both the individual engineering projects the Mountain Trike All-Terrain Wheel- and the Group Design and Business pro- chair Business” jects. It reflects the great strength of the Department.

There have been a couple of important developments in the design area. We now have the Dyson Chair in Design Engineering. This is a 50/50 academic/ practice role at the insistence of the funder. So we are delighted to have our former Royal Academy of Engineering Visiting Professor in Innovation, Gareth Jones in the role. Interestingly, he was Dyson employee number 6.

The “product innovation funding”, has Professor Steve Culley now expanded considerably. We have added to the first two, the Herrington and On behalf of all in the Department who the Embleton bursaries, with three more contribute. from Jon Craton, Mark Farmer and Peter Keevil. This growing portfolio will give us the opportunity to support, and take to the next stage, final year projects of a wide variety of types.

design ex booklet 2015 - Final 1.indd 4 28/08/2015 16:02:56 Tim Morgan Project to Product - The creation of the Mountain Trike All-Terrain Wheelchair Business

The Mountain Trike is a revolutionary all terrain wheelchair designed to give wheelchair users far greater freedom and independence to access and enjoy the countryside. It is the brainchild of British design engineer, Tim Morgan, who was inspired by his love of mountain biking to develop a true manual all terrain wheelchair that would enable wheelchair users to ride off road in the same way he does on his bike. He identified a significant gap in the market for a manual wheelchair that was off road capable, but also combined this performance with everyday practicality in order to fit into the person’s lifestyle. Over a period of four years, the Mountain Trike was developed from Tim Morgan’s final year Masters project at the University of Bath, to a fully certified product launched to the market in August 2011. Since then, the product has been very well received with sales avenues developed worldwide and manufacture facilities setup in the UK. After graduation, Tim accepted a role with his degree sponsor, Bentley Motor Cars, which provided him with the income to live, whilst continuing to work on the Mountain Trike during his spare time. Over a period of three years, development of Proto 2 was carried out in tandem with the other commercial aspects needed to setup the business: market research, product cost and specification of standard components were all additional influences on the design and naturally presented further challenges. A cyclical process of developing prototypes and testing them with wheelchair users was adopted to progress the design. Four cycles of design and test iterations were completed to progress from the initial concept to the final production model. The principles of lever drive, direct steering, independent suspension, disc brakes and three wheeled arrangement formed the core of the Mountain Trike’s design and still feature on the final version. The fourth and final design iteration was the production level, MT4. It included various refinements, final production components and high quality surface finishing. The Mountain Trike is a prime example of how an iterative design and prototype process can be used to develop a university project into a highly successful product. This keynote address outlines the processes used and the challenges faced in this journey from Project to Product

design ex booklet 2015 - Final 1.indd 5 28/08/2015 16:02:58 Our most grateful thanks and acknowledgements are due to the companies identified below and in the following pages for proposing and sponsoring this year’s design projects. The financial support and equipment that they have provided has been crucial to the success of the projects, and the encouragement and insight of their staff has been highly valuable to, and appreciated by, our students.

design ex booklet 2015 - Final 1.indd 6 28/08/2015 16:03:01 The Group Design and Business Project unit is a cornerstone of the 4-year semester-based MEng programme. Students work on nothing else during Semester 2 of Year 3, this unit is worth 20% of the overall degree classification. The project topic areas are split between Aerospace, Automotive, Me- chanical and Manufacturing Engineering sectors. Many projects arrive from industry where real problems have arisen and need to be answered. Some projects will return to industry for further development and implementation after the unit has finished. All projects have a significant element ofbusi- ness subjects (such as marketing, sales, finance, operations, and logistics) incorporated, showing students a more realistic illustration of how engineering businesses integrate professional, technical, and commercial skills into a integrated project activities. This aspect includes the production and delivery of a business investment plan that would support a decision to launch the new product/service.

2015 sees another large class divided into sixteen groups addressing a very wide range of project topics. Some are working against rival groups on the course addressing the same topic; this exposes students to the ‘realities’ of preparing a competitive engineering bid or tender. This helps them to develop skills that will be invaluable in future employment. The unit culminates in the Design and Project Exhibition, held at the end of May every year. This event provides every group with the opportunity to display their proposals in public, and prepare appropriate technical and commercial promotional materials. This year there will be increased emphasis on the use of prototypes and models to demonstrate the key technical features to visitors. This has been supported by a generous donation from the Bath Alumni Fund. 7

design ex booklet 2015 - Final 1.indd 7 28/08/2015 16:03:02 Group 1

FUTURE FORKLIFT

Background Due to the competitive environment of the forklift market, manufacturers are under pressure to develop unique products and establish their position in the industry. Although current trucks have undergone intensive development and testing phases, they offer scope for improvement in areas such as efficiency, ergonomics, safety and visibility.

Design Brief Design Benefits The objective was to create a clean • Lower total cost of ownership sheet design for a forklift that could • 6 to 8% efficiency improvement potentially become the industry standard • Increased operator visibility over the next 5 to 10 years. During the • Lower downtime project, we have received support from • Innovative safety features NMHG to aid in the design development. • Increased operator comfort •

Suspended Cabin Optimised Cabin & Mast Layout

Electric Steering Electro Hydrostatic

Actuators

Regenerative braking Rear Axle Locking

Cylinder PEM Fuel Cell

Design Team Supervisors Chris Bramley (PM) Pedro Santos Jens Roesner, Prof. Andrew Plummer

Gregg Gaffney (BM) Hao Man Vu Sponsored by Christoph Evertz Dominic Noble

design ex booklet 2015 - Final 1.indd 8 28/08/2015 16:03:02 Group 2

Residual Waste Bale Dryer

HANNAH FORBES TOM LEACH ALEX SINCLAIR BERNARD FURLAN MIELKI ● ● ● DAVID CATTERMOLE

Industrial drying of residual waste for financial savings and a competitive advantage.

MJ Church transports 24.5 tonnes of We have a solution to remove this water. residual waste from Chippenham to We are proposing a system that can Germany, 3 times a day, 6 days a week, reduce the moisture content of each at a cost of £100 per tonne. Water lorry load by up to 1.65 tonnes, saving weight accounts for 5.2 tonnes of each over £300,000 per year in transport load, it adds no calorific value and costs alone. accounts for £1,560 of the daily transport costs.

design ex booklet 2015 - Final 1.indd 9 28/08/2015 16:03:03 Group 3 Royal Mail

Systems Development Ltd. Design Brief

The Royal Mail is the UK’s designated Universal Postal Service Provider and in 2014 the Royal Mail handled 1.1 billion packets and parcels. Royal Mail Systems Development is a wholly owned subsidiary company that fills a skills gap in the Royal Mail operations with expertise in Systems engineering. The Royal Mail is looking to improve upon its current manual parcel handling process and move to a semi-automatic process to protect its market position and increase its handling capacity in line with market trends of parcel volume increase. Specifications  Able to cope with all Royal Mail parcel variations,  Fits within current Royal Mail distribution centre’s allocated parcel handling space  Handle parcel volume growth forecasted for the forthcoming 15 years.  Designed for rapid on site implementation over a 32-hour period. As necessitated by the requirement to avoid discontinuity in the current operations.  3 year payback period The Design

A Semi-Automatic Parcel Handling system with a flexible throughput that fits within the allocated parcel handling space at the Royal Mail Swindon Distribution Centre. It is comprised of 5 functional modules: Unloading, Preparation, Inspection, Sorting and Loading.

Group Members: Supervisors: Sponsor: Elisa Buonnani Dr Aydin Nassehi Bardur Hansen Ben McKenzie Mr Rod Valentine Saagar Shah (BM) Nathaniel Taylor Alex von Joest (PM)

10 design ex booklet 2015 - Final 1.indd 10 28/08/2015 16:03:03 Group 4

HOW MUCH IS MY

Roadside incidents last year LIFE WORTH? between the flowing traffic and a stationary recovery vehicle totalled 4 for the RAC and 12 for the UK recovery industry as a whole. A product was needed to: ¥ Prevent ¥ Protect ¥ Detect To keep the patroller and the customer safe. 3 products were designed to minimise the risk at the Height Adjustable Lights roadside: – Improve visibility to ¥ Height Adjustable Lights HGVs and when the ¥ Rapid Deployment recovery vehicle’s boot is Trailer open ¥ Automated Guided Vehicle Rapid Deployment Trailer – Automated wheel strap securer and deployable ramps to remove patroller from danger zones

Team Members: AGV – Provide Mehrnaz Tajmir – PM patroller with early warning of vehicle on a Adam Wilkinson – BM collision course Nick Bourne Michael Douglas Group Supervisors: Luiz Fofano Mudassar Saleem Dr. N Johnston Dr. L Newnes 11

design ex booklet 2015 - Final 1.indd 11 28/08/2015 16:03:04 Group 5

AUTONOMOUS GUTTER CLEANING ROBOT

REDUCE LADDER USE AND PRODUCE A QUICKER, HIGHER QUALITY CLEAN

KEY COMPONENTS - VACUUM BASE STATION - TELESCOPIC POLE WITH HOLDING GARAGE - MAIN ROBOT WITH SHREDDER AND SCRAPER, UMBILICAL SUPPLY TO BASE - DOWNPIPE PROCESSOR ATTACHMENT - ELECTRONICS AND SENSORS FOR SAFETY

FAY JOHNSTON – PM JOSH COLACO – BM QUENTIN BERTUCCHI JOE EDGERLEY KEY SOLUTION SPECIFICATION OLI GILLESPIE - CLEANS 112MM ROUND/SQUARE JAMES NEWTON-SAVAGE GUTTERS MATT SANDS - 5 YEAR LIFESPAN - 0.027MS-1 SUPERVISORS - 6M REACH DR C BANNISTER - 2KG IN GUTTER DR M MCMANUS - MINIMAL MAINTENANCE

design ex booklet 2015 - Final 1.indd 12 28/08/2015 16:03:05 Group 6 Novel system for integrated multi-process finishing of additively manufactured components

Project Background Product Description The additive market is growing Electro Chemical Polishing, at an ever increasing rate Cryogenic milling & Electro (average compound annual discharge machining integrated growth rate of 27% over the last onto one platform to reduce 25 years) with forecasts manual intervention and simplify showing it will be worth in process fixturing. approximately $12.5bn by 2018 Benefits include a reduction of (T. Wholers 2014). However, labour required from 3 operators additively created parts require to just 1, significantly reducing significant post processing running cost. An automatic before assembly or service. process transfer system results in Therefore the post processing a shorter cycle time for extremely market will also need to grow high quality complex geometry. significantly in the coming years.

Project Aim Team The aim of this project is to Kris Henley - Project Manager integrate a set of machining Will Mitchell - Business Manager processes onto a single platform Ben Whiteley – Product so that AM components can be Simeon Howson – Operations finished to the quality required Qiyan Yaw – Sales & Marketing by the medical and aerospace Tomas D.R. Rey – Finance industries Supervisors: Vimal Dhokia Alborz Shokrani 13

design ex booklet 2015 - Final 1.indd 13 28/08/2015 16:03:05 Group 7 Group Design & Business Project RepCycler Project

Design Brief

3D Printing is becoming more democratised; due to the ever increasing availability of smaller kits, cheaper hardware and “affordable” consumables – especially in the FDM market (printing ABS/PLA from Description filament). The RepCycler is a recycler or A popular trend in the 3D extruder that will take the virgin Printing and Maker circles is the plastic granules, mix it with recycling of support material and broken down waste plastic old 3D Printed models back into before extruding and spooling useful plastic filament. the recycled filament. This can The design task is to design a bring reasonable cost savings to “RepCycler” that can break its users due to the massive down these waste plastic and difference in price between reconstitute it back into useable virgin plastic granules and filament. The device is to be a kit plastic filament. Moreover, it form and open-sourced design provides a positive impact to the to align with the RepRap brand. environment as it reduces the RepRap is a reputable brand of increasingly large amount of 3D printers known for their “self- ABS plastic waste that would replicating” and open-source otherwise go to landfills. designs. Project Supervisors Solution Specification Jeffrey Barrie • Desktop sized recycler or Prof. Glen Mullineux extruder • Breaks down average sized Group 7 Team Members models or support material • Extrudes 1.75mm filament Camilla Pollet (PM) • Extrudes ABS/PLA Lee Han Jun (BM) • Extrusion speed: 50mm/s Apostolos Georgiadis • Extruded filament diameter Danyal Naseer tolerance: 0.1mm Jonathan Clark • Able to spool filament Lee Zher Huei 14

design ex booklet 2015 - Final 1.indd 14 28/08/2015 16:03:05 Group 8

Low Cost Electric Powered Wheelchair

Context: According to the World Health Organisation around 1% or 65 million people need a wheelchair. Without the ability to move independently

and interact with society these people remain excluded and condemned to a life in poverty.

Design Brief: The project’s aim is to produce an electric wheelchair with the following features: - $500 manufacturing cost - Solar charging system

- Dexterous user interface - Business opportunity for user

USPs  5 km range  4 mph top speed  Handle rough terrain

 Ergonomic design  Dexterous user interface  Solar Charging . System  Business Opportunity Attachments

Project Team: Sponsor: Supervisors: Thomas Measures (PM) Sam Edwards (BM) Steve Culley Helen Maycroft Gareth Jones Niloy Zaman Jeremy Bigg

design ex booklet 2015 - Final 1.indd 15 28/08/2015 16:03:06 Group 9

SEMI-AUTOMATED PARCEL HANDLING SYSTEM

SAPHS GROUP 9

How to Make £90 Million Profit in 7 Years

The Brief Design a machine capable of automating the UK parcel The Solution handling industry. The innovative design is capable of: Solution Specification  Unloading parcels on to the  Processes 12,000 parcels machine. per hour  Separate them to ensure  Operated by 4 workers per adequate spacing shift (current process  Sort them based on their requires on average 25 postal region workers per shift)  Load them into rolling The Team: containers  Nikul Nathwani (PM)  Transport the rolling  Dan Morey containers to lorries  Chris Abbott  Petros Sakellaropoulos  Syazrul Syafiq  Andrei Culda Project Supervisors: Dr Aydin Nassehi Rod Valentine

design ex booklet 2015 - Final 1.indd 16 28/08/2015 16:03:06 Group 10

Water Conservation Supervisors: Prof Tony Miles for Canal Locks Dr Sabina Gheduzzi

Problem Background Canals that are not fed by many underground piping, an river or water sources can become autonomous control system and unnavigable during dry summer National Grid electrical supply. months. Water loss arises from: evaporation, seepage into the canal bed, and functional lock water usage.

Lock & Quay have created a system for Cotswold Canals Trust to offset functional lock water usage, which causes water to flow downstream. Solution Specification - System Cost £16,500 Requirements - Transports 11ML over 24 hrs - Easily Installable system by - Environmentally friendly volunteers - Modular and easily installable - Low cost, under £30,000 - Low aesthetical impact Lock & Quay Team - Retro-fittable to existing locks Andrew Ma, Project Manager Callum Lyons, Business Manager Lock & Quay’s Solution Duncan Potts The system designed to combat Andrew Marshall this water conservation issue Arthur Goes involves; submersible pump, Matt Udwin Supervisors

Prof. A Miles

Dr S Gheduzzi

design ex booklet 2015 - Final 1.indd 17 28/08/2015 16:03:07 Group 11

The Crofton Beam Engine

Context & Design Brief

The Crofton Pumping Station is a local landmark that combines the efforts of history, engineering and community into one operation. Otherwise, it is known as the home of the oldest working beam engine in the world (Boulton & Watt, 1812) boasting over 200 years of service.

The aim of this project was to develop and To complement the application, 2 produce a design solution focused on interactive fixtures have also been designed increasing the ease of operations of the that give unique perspective of the beam beam engines as well as improving the engines to prospective young visitors by educational and visitor friendly value of the comparing human output with the Crofton Pumping Station. capabilities of the engines.

Key Specifications: Engineering Team: o Utilise non-destructive instrumentation methods. Thomas Coutts (Project Manager), Improve the site’s educational o Damilola A. Adeyemi (Business Manager), prospects. Jonty Usborne, Provide data relating to “how the o Edward Swift, engine actually works”. Amraj Aulak, Solution lifetime greater than 5 years. o Andrew Crutchley. Funding oriented design. o o Implement data display Supervisors: Solution Dr Andy Hillis The final solution is a unified system of 3 Dr Charles Courtney interrelated physical/software solutions working either directly from, or in reference In Partnership With: to one another. These include a data acquisition system that feeds information relevant to the workings of the beam engines to a central hub where an application will be used to generate raw data for operators as well as processed data to be used for educational and functional improvement via features such as virtual tours and intuitive data display.

design ex booklet 2015 - Final 1.indd 18 28/08/2015 16:03:07 Group 12

Low-Cost Powered Wheelchair

Design Brief Description and Benefits The aim of the project was to design a low-cost ($500) wheelchair that could be utilized by users with limited upper body strength and movement, thus the need for it to be powered. The target market of the product are developing countries such as Bangladesh. For this reason, a product suitable for rough terrain and with solar charging capabilities was developed.

Specifications  Solar and mains charging

capabilities The final design consists of a three  Max velocity of 5 km/h up an wheeled arrangement to cope with incline of 15° on rough terrain both paved and rough terrain. The  Able to go up curbs of a max product has two 40W solar panels to height of 50 mm provide ample power for users that th have unreliable electricity supply.  Adjustable to fit from the 5 to th The top solar panel can be folded the 9 percentile of the back (to minimize space indoors) or worldwide population horizontally above the user (to  Dimensions when the top solar maximize solar panel efficiency). The panel is folded back: chair can be operated by users with 1307 x 800 x 970 mm limited strength through the use of the controller gimbal and is fitted with

a foam pressure relief cushion to Team avoid pressure sores. Francesca Poli (PM)

Christopher Davidson (BM) Alex Keating Supervisors Prof. Steve Culley Christopher Degrauwe Prof. Gareth Jones James Acquaye Nortey-Glover

design ex booklet 2015 - Final 1.indd 19 28/08/2015 16:03:07 Group 13

Design Brief GreenDrive is a non-for profit Project Supervisors organisation founded by seven Dr Jos Darling members of Green Bath Racing, Mr Andy Green winning team of the energy efficiency Shell Eco-Marathon Competition GD Vision GreenDrive is set to use its To set the foundations for a more technical expertise to provide resource-aware engineering schools with three complementary workforce to overcome future programmes: workshops, kit environmental challenges.” supply/support and practice events. GD Mission

“To deliver customised and cost- These programs will provide the effective solutions that encourage necessary resources to provide students in the UK to embrace schools with new means of sustainable engineering practices effectively transmitting by facilitating access to Eco- sustainable engineering and Marathon events. environmental practices to their students using the Eco-Marathon vehicle as a teaching focal point.

Team Iñigo Balbin (PM) Manuel Mendez (BM) Cameron Buchan William Hughes Leo Hughes Natasha Collins Lucs Rosillo Group 13

design ex booklet 2015 - Final 1.indd 20 28/08/2015 16:03:08 Group 14

Human-Powered Description Submarine The submarine is fully human powered and can be controlled in Design Brief pitch and yaw. A separate buoyancy system allows vertical A manufacturer of GFRP boats diving (up to a depth of 10m) and wants to use a radical new resurfacing independently of method of increasing global boat forward movement. sales. A team of engineers within the company proposed a promotion campaign, which would involve the racing of human- Team powered submarines at popular Arnaud Doko (PM) global dive locations. Tourist Henry Turner (BM) divers would be able to rent time Zach Bergman in a submarine to race around a Michal Rachowiecki pre-defined racecourse near the Susie Bloodworth-Race beachfront of a local hotel. The Ismail Bello submarine would act as a flashy Marcus Wood display of the boat manufacturer's engineering capabilities and simultaneously promote its brand to new markets.

Specification

¥ Controllable pitch propeller ¥ Fly-by-wire control with electronic safety systems ¥ 1.44m/s at 200W pilot input power

design ex booklet 2015 - Final 1.indd 21 28/08/2015 16:03:08 Group 15

Team Bath AUV

Team Bath AUV have designed an Autonomous Underwater Vehicle capable of carrying several complex inspection and survey tasks to take part in the NATO sponsored SAUC-E competition. The vehicle will compete in the 2016 competition in La Spezia, Italy. The AUV features a Forward Looking Sonar, front and bottom mounted cameras, an inertial navigation system and six external thrusters making it a highly maneuverable, sophisticated and capable vehicle. It utilises Robot Operating System with image processing modules for object detection and visual odometry for navigation.

Team Greg Wintle: Hardware (PM) Ali Bacon: Actuation (BM) Alfie Treloar: Software Phil Blackburn: Structure Abdullah El Agha: Power Dimitrios Dionysopoulos: Sensors

Supervisors Dr Alan Hunter Dr Stuart MacGregor

design ex booklet 2015 - Final 1.indd 22 28/08/2015 16:03:08 Group 16

Design Brief: - To design and race a Motorcycle at the Isle of Man TT Zero - The TT Zero class is an entirely electric class at the prestigious IOM two week event - The IOM race is held on a 37.7 mile road circuit

Power Supply: - Emrax 268 - Max Power 160kW (215hp) The Bike ‘Odin’: - Max Torque 500Nm - Battery pack 18kwh

The Team: - Louis Flanagan - James Lewis Monsma - Robert MacGregor -Lewis Dyke -Theo Rankine - Fourdraine

design ex booklet 2015 - Final 1.indd 23 28/08/2015 16:03:09

We are Team Bath Racing 2016 and our mission is to win Formula Student UK.

This year we are developing our aerodynamic performance with an un-sprung ground-effect-inducing floor and downforce enhancing low rear winglets, pursuing power with a turbocharged single cylinder KTM500EXC, and targeting the most light weight chassis by utilising a full carbon fiber composite monocoque.

TBR16 promises to deliver excellent dynamic performance.

Project Manager: Noel Moorhouse Team Members: Ieuan Guy, Josh Slade, Amelia Lewis, Elsa Reeve, Mark Tranter, Kenta Kawaguchi, Ollie Zabell, Alex Ward, Tom Coombs, Matt Alcock, Rebecca Cooper, Lizzie Atwood, Barney Perenyei, Hieu Dinh, Charlie Ripman, Lenny Paul Georgala, Andy Lightbody, Simon Bell, George Watson, Neil Hoddinott, James Regester, Gus Beltrami, Tom Pine, Tom Rafferty, Jack Liu, Deniz Tosun, Alex Wilding.

design ex booklet 2015 - Final 1.indd 24 28/08/2015 16:03:09

Team Bath Racing don’t just design a car…

To be successful, there are 3 key business considerations that must be addressed:

Finance | Promotion | Logistics

The team is responsible for securing the finance for all of the design and business activities. TBR operate on a total annual budget worth approximately £120,000, made up by financial and service sponsors.

Our current sponsors include...

design ex booklet 2015 - Final 1.indd 25 28/08/2015 16:03:10 Supervisors Academic

Dr R Butler Dr J du Bois Dr MJ Carley Dr D Cleaver Dr F Ciampa Dr JL Cunningham Prof I Gursul Dr P Iravani Dr DN Johnston Prof GD Lock Dr M Meo Prof ST Newman Dr A T Rhead Dr C Sangan Dr M Wilson Dr Z Wang

Industry

Dr J Crocker Mr D Heaton Mr F A Hewitt Sir R Hill Mr M Joynt Prof J Jupp Mr A Langridge Mr C Lynas Mr K MacGregor Mr C Stevens

Sponsors

Airbus UK Rolls-Royce University of Bath Alumni Fund 26

design ex booklet 2015 - Final 1.indd 26 28/08/2015 16:03:11 Bath University Man Powered AirCraft

Design Brief Specification Cruise Speed 7.6 m/s To Design and Build a Human Powered Aircraft (HPA) to fly in Empty Mass 37.5 kg the 2016 Lasham Rally – an Total Mass 112.5 kg (75kg pilot) annual competition for HPA’s. Cruise Power 346 Watts Take Off Speed 8 m/s Wing Area 27 m2

Length 7.6m

30.5m Wing Span

Design Team Supervisors  Nick De Jong  George Lowe (Project Manager)  George Penwarden  Dr M. Carley  Barney McMahon  Lewis Rawlinson  Dr J. Cunningham (Business Manager)  Mateus Dantas  Alex Lougheed

design ex booklet 2015 - Final 1.indd 27 28/08/2015 16:03:12

Design Brief Airbus Specification The Airbus A330 and Boeing 767  2 Class Pax – 200-300 have been in service for over 20  Design Range – 5500nm years; as such there is a gap in  Cruise Speed – 0.82-0.8 the market for a more cost  Time To Climb – 30mins efficient replacement. A  Max Approach Speed – 145kts specification was delivered by  ICAO Airport Code Airbus to design a replacement, Compatibility - Code E capable of carrying 200-300pax  Expected Service Entry - 2025 over a distance of 5500nm.  DOC Reduction (vs 2010 State of the art) – 15%

Team Members Tom Pearce – PM / Cabin and Flight Deck Tim Mok – Business Manager / Fuel Systems Jon Sleeman – Marketing Manager / Landing Gear Jia Juan Lee – Technical Integrator / Project Costing The Blue Sky Azure Martin Dawson – Aerodynamics The Blue Sky Azure Is a / Aftermarket passenger aircraft aimed at Baba Kakkar – Performance / meeting the DOC reduction of Supply Chain 15% with a 2-Class Pax of 276, Mubarak Hassan – Stability and with 373 in a High-Density Control / Direct Operating Cost layout. The Aircraft has a span of Tom Cureton-Fletcher – 58m and total length of 63m. Propulsion / Environment This is within the code E Airport Ka Hin Lau – Wing and Tail Requirement. Structure / Final Assembly Line The Aircraft aimed at Flagship Piotr Lesniak – Fuselage Airliners in the high growth Asia Structure / Regulations Pacific and Middle Eastern Regions.

design ex booklet 2015 - Final 1.indd 28 28/08/2015 16:03:12 Civil Transport The Arrow 600

Background The team Demand for global travel is increasing Robert Templeton (PM) at an unrelenting rate, with civilian Perez Kamagamba (TI) airliners transporting the majority of Matthew Smeeton (BM) passengers. As technology rapidly Alex Hart matures older aircraft become Elan Kumaran obsolete in terms of performance and Hannah Blofield cost. With this in mind a specification Pavan Dhatt was set out by Airbus for the design of Swapnil Patra a new aircraft for medium haul Tingwei Lee operations. William Archer

Key specification data Project supervisors Passenger capacity: 200-300 Dr M. Wilson Design range: 5500nm Dr A. Rhead Optimised range: 3000nm Sir R. Hill DOC: 2010 state of the art minus 15% Prof. J. Jupp Expected entry into service: 2025 Dr F. A. Hewitt Mr D. Heaton The Arrow 600 Retaining the traditional ‘tube and wing’ design the Arrow 600 has optimised this layout to produce a minimum of 4.1% DOC saving against 2010 state of the art aircraft. This was achieved by utilising Hybrid Laminar Flow over the entire tail, extensive use of composite materials, natural laminar flow paint and riblets. The aircraft meets all of the requirements for range and performance set out in the specification. It carries 276 passengers in a two-class layout that sets a new standard for passenger comfort. The aircraft also boasts a high freight capacity of 12tonnes with a full passenger roster. Helping to boost airline revenue on optimised flights.

design ex booklet 2015 - Final 1.indd 29 28/08/2015 16:03:12 Autonomous Aerial Vision Systems

Design Brief Description The demand for Unmanned Aerial The FibreFly is a high wing, Vehicles (UAVs) is growing rapidly conventional aircraft with a for application in sports analysis, pusher propeller which meets the broadcasting, reconnaissance, requirements set by the recreation and more. competition and business applications. We have designed a UAV that will compete in the ‘UAS Challenge’ The UAV can be used in the organised by the Institution of farming industry equipped with an Mechanical Engineers in 2016. The infrared camera for crop quality primary requirement for the UAV is monitoring and fertiliser to fly autonomously and deliver two management. 1kg payloads to a designated target area by navigating a pre- AAV Systems will provide a determined flight path. service to production companies in which the UAV uses a High Specification Definition camera to provide diverse camera angles to - 22m/s cruise speed broadcasting in horse racing. - MTOW: 7kg - Autonomous navigation and Team landing Victoria Sauven (PM) - 73min endurance James Huxtable (BM) - 52nmi range Abdel Darwich Ajjour - 2kg payload capacity Elliot Jane Jakub Kucera Yan Li Project Supervisors Abinesh Mohan Dr. D Cleaver James Walker Dr. J du Bois Dr. P Iravani

FibreFly

design ex booklet 2015 - Final 1.indd 30 28/08/2015 16:03:12 Autonomous Unmanned Aerial Vehicle

Design Brief Description

The Institution of Mechanical The UAV is a semi modular flying Engineers is holding a wing design that will be primarily competition to design a UAV used as a data gathering tool for a capable of carrying 2 kg of variety of market segments that payload to a drop zone and includes agriculture, wildlife navigating waypoints. The conservation and aerial mapping. designed UAV must also perform adequately to be a viable product Specs or service as part of a business. Range: 115 km We have developed a UAV that MTOW: 7 kg Payload: 2 kg is capable of flying in a variety of Cruise Speed: 18.5 m/s wind conditions with a Service Ceiling: 10000 ft replaceable payload in order to carry additional cameras and Team Members sensors to better fulfil the business requirements. Daniel McCullagh (PM) Vicente Laiseca (BM) Project supervisors Lucie Culliford James Barber Dr D Cleaver Barnaby Green Dr P Iravani Priyesh Patel Dr J du Bois Vinicius Bertolini Lik Fong Tiong

design ex booklet 2015 - Final 1.indd 31 28/08/2015 16:03:13 Matt Bennett Rolls Royce Maitham Dib Rolls Royce Supervisor: Dr C Bannister Enterprise architecture Transformational Innovation study The aim of the project is to build an enterprise Working with a cross functional team in Defence model, capturing various views of the organisa- to generate ideas for future products, services tion to identify areas of improvements in efficiency and accuracy of business processes. This and business models that will provide com- project involves modelling business processes, petitive advantage and sector growth. Develop IT architecture and organisational structures selected ideas into tangible concepts showing using industry standards such as TOGAF and technical and business feasibility. UML.

Andrew Coleman EDF Chloe Cunningham The design of a machining head for chal- Advanced Gas Cooled Reactor (AGR) vessel discharge route issues lenging materials

Lorenzo Guercini JMFC George Kalligeros TESLA

Increasing output from fuel cell manufactur- Tesla’s Model X air suspension system ing process The project scope is the mechanical inte- The project aims to establish a new manufactur- gration of the new Tesla Air-Suspension ing route for the assembly of DMFC Membrane System (TAS) in the Model S environment. Electrode Assemblies (MEAs). All processess This involves designing a new layout, used by the Johnson Matthey Fuel Cells manu- bracket and air-line routing for the assem- facturing plant will be critically examined to al- bly, project managing the parts through low an efficient optimization.This will include the manufacturing and assembly and providing creation of various prototypes to prove new con- engineering support during prototype and cepts for material preparation, cutting and wet production phases of the product’s emer- lamination assembly gence process.

Harry Leafe Kushil Lakhani NOV Supervisor: Prof. S Newman MATLAB Rapid Design Tool Calibration artefact design The project objective is to improve the iterative The complete design of a calibration artefact design process currently used by the design for a specialised metrology application. From engineers within the company. The project is an initial project brief, a prototype will be pro- in the form of a MATLAB tool that will be used duced and tested. The design will then be further by the designers to reduce the time taken when refined, and a production standard 3-off batch must then be produced and fully validated and designing a drill bit. The project requires a thor- verified. ough review of the current design process and to determine parts of the process which can be improved with the help of MATLAB

design ex booklet 2015 - Final 1.indd 32 28/08/2015 16:03:13 Chris Saxby Rolls Royce Alex Sherwood FEV

Reduction of inspection burden for Eurofighter Closed loop combustion control The project is aimed to reduce the inspection burden on the EJ200 engine during maintenance, To implement a new injection control strategy for repair and overhaul. The first way of doing this diesel engines, which will improve both fuel econ- is the creation of an intelligent inspection order omy and emissions. The strategy has already which removes unachievable inspection crite- been proven for steady state operation. However, ria whilst also inspecting areas earlier in the this project aims to prove this strategy for tran- process which are more likely to have damage sient operation (necessary for use in passenger thus reducing unnecessary additional inspection. cars). The second is reducing the part burden on the co-ordinate measurement machines by validat- ing alternative measurement techniques using a measurement system analysis technique termed a Gauge Reliability and Reproducibility Stud.

Dan Wright Rolls Royce Surya Sharma Chargepoint

Thermal and fluid systems - tool development Torque Rig for new engine projects The project is to study the impact of operator ap- Aim of the project is the development of thermal plied Torque on the performance and operation of management methods within Thermal & Fluid the ChargePoint Split Butterfly Valve and it’s as- Systems and across Rolls-Royce to achieve a sociated parts. This will involve evaluating Manu- global tool that retains and enhances the com- facturing processes, inspection processes & their pany’s capability in preliminary heat exchanger sizing. This involves coding, testing and validat- repeatability were evaluated by designing and ing various tools to perform sizing calculations for developing a Torque Rig, whilst also examining different types of heat exchanger. the condition of the Split Butterfly Valve and the sub-components.

Matt Waters Chargepoint Katt Whalley Designability

Analysis and redesign of assembly area lay- Dynamic Head Support design for children out for improved efficiency aged 5-9 years with Cerebral Palsy

ChargePoint Technology are looking to move The aim of the EIP (undertaken with Designabil- their stores and assembly operations to a new ity) is to design a head support for children with facility. The aim of the project is to conduct dystonic cerebral palsy. Children with dystonic analysis of their current process and recom- cerebral palsy have poor head control and can mend improvements to improve efficiency. experience whole body extensor spasms. The Recommendations will include changes in work- head rest will allow the child to nod and shake their head and then return the head to a netural ing practice as well as a layout for the new position. facility.

design ex booklet 2015 - Final 1.indd 33 28/08/2015 16:03:13 The External Industrial Project is a design-based project undertaken with industry over a six month period between March and August. Each year, approximately a dozen third year students choose this option instead of a full time group design project. Because of the timing, they do not exhibit their work at the Design and Project Exhibition.

This year’s External Integrated Students are:

Student Organisation Place Bath Supervisor

Adam Mills INPG/Zodiac Seats France Grenoble, France Dr. F. Osman Daniel Gomez Firmat INPG/Zodiac Seats France Grenoble, France Dr. R.F. Ngwompo Mohammad El Agha INPG/Zodiac Seats France Grenoble, France Mr. R.M. Valentine Edward Mulloy INPG/Zodiac Seats France Grenoble, France Prof. S.J. Culley Rory Yonge INPG/Zodiac Seats France Grenoble, France Dr. A. Nassehi

The Department would like to thank all the external input received during the group project activity. In particular, thanks goes to the External Panel Review and Advice team (EPRA), established by Sir Robert Hill in 2011. This is a team of experienced Engineers and Senior Managers from industry, which undertakes a detailed review of each project, with the students.

Andrew Ward David Mattick Malcolm Shirley Bob Hill Frank Mungo Mike & Penny Parkinson Bob Meggs Gan Jenkins Patrick Rotheram Brian Brooksbank Gareth Somerset Paul Maillardet Charles Curnock Jenny Hill Robin & Sarah Kerr Chris Trout John Spencer Tim Cannon Colin Dimbylow Jonathon Reeve

design ex booklet 2015 - Final 1.indd 34 28/08/2015 16:03:13 The Final Year Engineering Project is the major individual research or design part of the MEng degree programmes in the Department of Mechanical Engineering. Students work full time on the project, which counts for 20% of the overall degree classification.

The general aim of the project is to provide the student with the opportunity to show creativity and initiative in planning and executing work on a demanding Master’s level project in a specific topic area which may include experimental, design, analytical, computational and business components. A number of the projects are taken in conjunction with industry, as well as Formula Student and Specialist Design related activities.

design ex booklet 2015 - Final 1.indd 35 28/08/2015 16:03:14 Vipin Ajayakumar Thomas Alderton Supervisor: Prof. I Gursul Supervisor: Dr M McManus Modelling of load reduction for wings near An analysis of the potential of energy stor- stall age in the UK

The aim was to produce a model to predict lift on The UK energy industry faces many challenges an aerofoil with induced flow separation at the today in terms of meeting both the ever increas- leading edge. Joseph Katz designed a model for ing demand for energy and responding to the separated flow at large angles of attack and the environmental challenges to reduce emissions intention was to apply it to low angles of attack of greenhouse gases. In these circumstances and compare with experimental results. The Mat- energy storage has been identified as a possi- lab code matched the theoretical lift slope of 2π ble ‘game changer’. In this study the potential for attached flow but failed to capture separation of energy storage in the UK was investigated by correctly. first analysing the British electricity industry and then examining the storage technologies already available or being researched.

Muhammad Nafi Bin Alidi Ali Alsamawi Supervisor: Dr H Kim Supervisor: Dr S Cayzer Metamaterial Topology Optimisation with The bottom line of community energy Additive Manufacturing and Point Wise Sen- sitivity Analysis Low Carbon Gordano has installed a photovol- taic system near Bristol for £2.2 million. The The University of Bath’s topology optimisation 1.875 MW system consists of more than 7,500 program suffers from an instability in its applica- solar arrays and is expected to power around tion to electromagnetic bandgap problem. This 500 homes. The installed system was analyzed project partially solved this instability problem environmentally, financially, and socially. The while allowing the program to perform faster. The installed system reduces the amount of green- topology optimisation for additive manufacturing house gases by 80% . The installed system was is only discussed in the report. found to be cost effective and having many so- cial benefits to the local economy.

Ross Atherton Matthew Banks Supervisor: Prof. S Culley Supervisor: Dr M Ansell Aircraft damage report analysis Additive layer manufacturing of metal alloys

The project involved the analysis of a large Superalloys are a subset of metal alloys ex- number of aircraft wing repair schemes, de- hibiting excellent mechanical strength and cor- signed by Airbus in response to reported dam- rosion resistance at elevated temperatures, age outside of regular maintenance. Initial which causes them to be extremely difficult to exploratory analysis was used to support an machine with conventional techniques. Alterna- tive processing methods such as additive layer unsupervised learning method. It was found manufacturing have become more mainstream that clusters of airlines and aircraft types in recent years. The project consisted of experi- could be differentiated by damage informa- mental work analysing the quality of additively tion; forming discrete profiles based upon manufactured metal alloy components. The mi- operational variables. A number of interactive crostructure and material properties of Maraging visualisations were developed to provide fur- Steel and Cobalt-Chrome specimens were ther insight into the data set. investigated.

design ex booklet 2015 - Final 1.indd 36 28/08/2015 16:03:14 Amir Beigi Carl Bishop Supervisor: Prof. R Gill Supervisor: Prof. P Keogh Comparing Torsional Stability of X-bolt ver- Modelling of high frequency vibrations in sus Dynamic Hip Screw drill strings

Neck of femur fractures are intertrochanteric High frequency torsional oscillations have been fractures, which can be healed by Dynamic hip recognised as a major source of fatigue damage screws. Dynamic hip screws have been the most in drill strings but the cause of them is unknown. common surgery on these fractures. The new The aim of this project was to improve the under- design of lag screw is the X-Bolt, which is as- standing and prediction of these high frequency sumed to give a better 8.5 the X-bolt is better torsional oscillations using numerical modeling than the Lag screw. and simulation techniques. A particular focus was taken to see if an elastic coupling between the axial and torsional motions was a probable cause for these vibrations.

Mark Bleakley Ross Blyth Supervisor: Dr S Macgregor Supervisor: Dr V Dhokia Optimisation of Propulsion System for Hu- Characterisation of the biomechanical tissue man powered Submarine properties of porcine bowel with the design of a constitutive model to reflect hyperelastic The human-powered submarine has the re- behaviour quirement for maximum propulsive efficiency. The aims of this project were to investigate the In order to achieve this, a project optimising biomechanical properties of porcine large bow- the propulsion system was undertaken. CFD el tissue and to design a constitutive model to and theoretical design methods were used reflect hyperelastic behaviour. This research is to develop a single blade row, two blade pro- destined to assist in the improvement of the de- peller designed to produce the 150N thrust sign process for new colorectal surgical tools and needed to achieve a 6 knot top speed. Fur- in order to reduce leak rates in post-operative re- ther work will include full CFD modelling, scale covery. Through uniaxial tensile testing and Fi- model testing and possibly full scale manu- nite Element Analysis, the study concluded that facturing and use on Salacia in future builds. there was a significant decrease in the maximum strength of the tissue once the surgical staples were inserted. Heather Borsuk Thomas Boyce Supervisor: Dr Z Wang Supervisor: Mr R Valentine Hydrodynamics of fish olfaction and its ap- Tennis Racquet Measurement plication to underwater vehicles In the game of tennis, much of the current This project uses biomimetics to aid in the design research and testing is centered on the tennis of an autonomous underwater vehicle (AUV) that racquet frame, ball and even the court itself. This can track scent. Dye visualisation methods are project aims to demystify the world of tennis rac- used to observe the hydrodynamic behaviour quet strings through a thorough experimental surrounding olfaction in two marine fish; the procedure concentrating on the dynamic guitarfish and garpike. As bulk fluid movement response of the string-bed after a simulated im- through the nasal region is required for olfaction, pact. this project aims to determine if, and how, passive methods are used to harness external flow and ultimately suggest ways of replicating these mechanically.

design ex booklet 2015 - Final 1.indd 37 28/08/2015 16:03:14 Philippa Bradbury James Bridgwater Court Supervisor: Dr S Cayzer Supervisor: Dr A Hillis Energy analysis of printing Novel control strategies for the CCell Wave Energy Converter Emissions and energy demand are a large global concern at the moment, so the need for An adaptation of latching control to pitching understanding energy consumption and emis- wave energy converters is developed and tested sions of everyday devices is vital. This project using empirically derived software models of the investigated changes that have occurred over CCell power take-off and paddle. The efficiency the last eight years in terms of the technology achieved is compared to a simpler controller used within printing devices, the distribution of applying damping based upon direction of mo- these technologies within the market and the tion, finding that the latching controller achieves consumer behaviour, to see what affect this has higher efficiencies. A non-causal version of this had on the environmental impact of the devices controller is also developed using autoregres- and market. sive modelling to achieve real-time short-term forecasting of the shape of the approaching sea.

Charles Brooker Alexander Caldwell Supervisor: Dr M Carley Supervisor: Prof. I Gursul Design of Control Surfaces for a twin fuse- Modelling of lift enhancement with suction lage Human Powered Aircraft Leading edge separation is an unavoidable, Investigation into potential control surface lay- undesirable aerodynamic characteristic of thin outs for a twin fuselage HPA followed by detailed airfoils even at low angles of attack and low design, providing stability and control for com- Reynolds number flow. The lift enhancement of peting in the Lasham Rally. Tailplane and rudder using suction control to reattach separated flow sizing were calculated using volume coefficient was experimentally tested in the University of method and positioned to minimise weight, drag Bath wind tunnel. A computational model in MAT- and stick force. Control surfaces were then test- LAB was built using potential flow theory and ed with different aerofoil sections using Xflr5 at conformal mapping which produced flow visuali- cruise conditions to minimise drag. Final specifi- sation and lift coefficient results that agreed with cation given for integration into the Human Pow- the experimental results. ered Aircraft.

Henry Carr Oktay Cetinel Supervisor: Prof. G Lock Supervisor: Dr I Turner Film cooling of turbine blades Effects of Porosity on Mechanical Properties of a Bone Substitute Material This project involved the use of thermochromic liquid crystals in order to produce flow visualisa- This dissertation was aimed to analyse the tion of two different film cooling holes. The exper- BoneSave® granular material in terms of two dif- iment was undertaken in the small wind tunnel at ferent porosity levels (25% and 50%) to examine the university, with the film cooling holes being the variations in mechanical, mass and mor- machined into a flat plate acting as one of the phological properties over 6 weeks immersion wind tunnel walls. period. These aims were realised via compression testing, measures of mass change and scanning electron microscopy (SEM). Overall, a consistent level of superiority was maintained by the 50% porosity granules in comparison to the 25% porosity in terms of mechanical characteristics and structural features.

design ex booklet 2015 - Final 1.indd 38 28/08/2015 16:03:14 Dhruv Chandel Kieran Chandler Supervisor: Dr P Iravani Supervisor: Mr R Valentine Optical robotic CMM (Coordinate Measuring Developing a Low Cost Transporter for the Machine) Domestic Cricket Market

A Coordinate Measuring Machine was created ‘Drop-in’ technology makes it possible to convert using a consumer level DSLR camera and an traditional grass playing fields into pitches that industrial six-axis KUKA robot. This system took are suitable for professional cricket. The drop- pictures of an object from various angles and in pitches themselves are incredibly heavy and generated a 3D point cloud by utilizing Stereo therefore require a custom machine, or trans- Vision techniques. All this was implemented us- porter, to move them. The project involved the ing custom-written software in C++ using the design of a low cost transporter including stress OpenCV library and MATLAB/Simulink. The sys- testing and the production of a prototype. This tem’s capability to optically measure objects on would be suitable for a wide range of customers, the sub-millimetre level was successfully verified most notably locally at the Recreation Ground, against physical measurements. Bath.

Timothy Chard Jack Chartres Supervisor: Dr J Darling Supervisor: Prof. S Culley Vibrations in passenger vehicles The creation and investigation of a mini hybrid manufacturing machine There are many different types of vibrations that can occur in a passenger vehicle, with sources Additive manufacturing allows geometric com- including the road input influencing the suspen- plexity but falls behind CNC machining in terms sion, and the engine and its internal offset rotat- of part accuracy and surface finish. Combining ing masses. In this project the vibrations in pas- additive and subtractive manufacturing on the senger vehicles were simulated, measured and same platform maximises the advantages of analysed. both processes as well as improving production efficiency and reducing re-clamping errors. A This involved creating computer models in Sim- Fused Filament Fabrication 3D printing extruder ulink, using an accelerometer to measure the vi- was successfully retrofitted to a mini milling ma- brations in vehicles on and off the road and using chine, the hybrid process was compared against MATLAB to analyse the measurements. using the additive process alone and precision applications were investigated.

Chi Cheung Dominic Choi Supervisor: Dr M McManus Supervisor: Dr M Meo Top level assessment of combined heat and Smart materials for impact and acoustic power systems to support the operation of a properties enhancement plastics recycling plant. This study investigates the method of applying In conjunction with the Plastic Economy Ltd, a single layer of shear thickening fluid (STF) this project assessed the suitability of utilizing a between the pre-impregnated carbon fibre rein- combined heat and power system to provide the forced polymers (Prepreg CFRP) as a toughen- necessary electricity and heat to support the oping system to improve the impact properties from erations of a plastics recycling plant in the Philip- a low velocity impact. pines. Result shows that upon impact, the energy is absorbed by the STF applied on the 2nd ply of the laminate from the impact surface, and the delamination were consequently reduced.

design ex booklet 2015 - Final 1.indd 39 28/08/2015 16:03:14 David Clarke Elliott Compton Supervisor: Prof. A Plummer Supervisor: Dr C Courtney Energy-efficient control of a hydraulic robot arm Experimental Demonstration of Acoustic Black Hole An energy-efficient hydraulic system has been designed at the University of Bath. This Astronomical black holes are widely renowned; utilises a real-time controller to achieve the their immense mass traps anything that goes required actuator motion without wasting flow. near it, even light. Acoustic black holes, in- This controller requires accurate information stead of matter and light, absorb incident wave about the loading on the system. To have energy. A two dimensional acoustic black hole more useful applications, the controller needs can be created by varying the local thickness of to cope without initially knowing the load act- the plate. As a plate gets thinner the velocity of ing on the system. This research looked at waves that travel through it reduces. It is, in the- ways to estimate the loads on the system, al- ory, possible to reduce these waves to velocity lowing for an accurate response to a demand zero, damping the vibration. signal.

Laura Cunliffe Konstantinos Deligiannis Barmpalias Supervisors: Prof. S Newman/Dr. A Shokrani Supervisor: Dr M McManus Evaluation of Power Consumption in CNC Whole Systems Analysis of local Anaerobic Machining for Energy Efficient Process Plan- Digestion Plant ning This study set out to assess the environmental This research determined the most sustainable impacts associated with the industrial scale An- machining parameters with key performance in- aerobic Digestion of food waste, in the context dicators power consumption and surface rough- of a facility being built near Keynsham, and pro- ness. Experiments were carried out on alumini- pose improvements to the developers. Life Cycle um due to its prevalent use in the manufacturing Assessment (LCA) methodology and computa- industry. A better surface finish with maximum tional LCA software were employed to determine MRR was found to be achievable with a small those impacts. It was established that it is of out- radial depth of cut and large axial depth of cut. most importance to employ gas-tight digestate Furthermore, increasing MRR reduces energy storage tanks and to minimise fugitive methane consumption for most parameters, but does not emissions from the digestion process. hold for axial depths of cut.

James Douglas Sebastian East Supervisors: Dr M Carley/Dr J Cunningham Supervisor: Dr P Iravani Structural Optimisation and Analysis of a Simulations of a prosthetic foot Twin-Fuselage Human Powered Aircraft Prostheses have historically been developed The low power-to-weight ratio of the human body through trial-and-error clinical trials, from which is what makes achieving human powered flight the results are inherently subjective. Therefore, such a challenge. This project examines the mathematical modelling is being investigated as structural advantages that come with designing a method of analysing prosthetic concepts to an aircraft for two pilots sitting in two separate fu- obtain empirical data. During this project a dis- selages. A static aeroelastic model is presented crete multi-element model of a commercially to determine a structurally optimised wing config- available prosthetic foot was created, and na- uration. Due to the ability to adjust the distance lysed as part of simulations of a human gait. between the two pilots, the twin-fuselage concept Stable walking patterns were found in greement benefits from significantly reduced stresses in the with the literature, through genetic optimisation main wing. of the initial conditions.

design ex booklet 2015 - Final 1.indd 40 28/08/2015 16:03:14 Michael Evans Elis Evans Supervisor: Dr C Bannister Supervisor: Dr A Nassehi Management of elevated operating tem- Self-Programming Lathe peratures in high performance engines This project investigated the issues of creat- Heat rejection, vehicle efficiency, and engine ing a self-programming lathe. This involves us- performance are all areas of modern vehicles ing Artificial Intelligence to generate tool paths influenced by the temperature of the coolant. and make key process planning decisions. The This project, part of a collaboration between subfield of Evolutionary Computing was used Jaguar Land Rover and the University of Bath, to generate tool paths for turning simple parts. examined the impact of a 15°C increase in A program was then written that used Genetic coolant temperature on vehicle performance. Algorithms to create toolpaths with moderate This work looked at the impact of various cool- success. Further development of the program ant system modifications and cooling strate- could integrate more advanced AI techniques gies on mitigating known failures associated and more process planning decisions, like feeds with elevated temperatures. and speeds.

Kieran Evans Jonathan Faulkner Supervisor: Prof. A Plummer Supervisor: Dr C Bannister Flying robot manipulators Evaluating the impact of driving style on vehicle fuel consumption and emissions during The aim of this project was to produce a com- real-world driving puter simulation of a quadcopter with a robot arm attachment. This Simulink model was required to An evaluation of how driver inputs influence include control such that the quadcopter remains the fuel economy and emissions of vehicles. in the same position during robot arm manoeu- The study focuses on the controlled environ- vres. ment of the New European Drive Cycle before extrapolating the learnings to the real world and investigating whether this cycle is representative of real-world driving. Efficiency measures and metrics are created to be able to qualify different drivers based on their efficiency and these are also compared between the two scenarios.

Helle Flom Ross Freeguard Supervisor: Mr M Ould Supervisors: Prof. S Culley/Prof G Jones The Role of Problem-Solving Style Prefer- Design and Observation Laboratory – Set- ences in Design Decision-Making ting up and experiments

This project investigates the impact decision This project set out with two aims. The first was making has on the engineering design process, if to create a set of instructions for the Design and psychometric testing can be used to predict prob- Observation Laboratory at the University of Bath. lem solving styles, and if certain problem solving These instructions would allow the facility to in- styles are better suited for certain parts of the crease its participation in design research. The design process. A design experiment was carried second was to repeat a design study conducted out in five sessions which were all video record- by Edward Elias, which involved introducing in- ed. The videos were analysed, then compared to formation in different formats to five teams and the expected outcome. analysing the impact of this information on the outcomes of the study.

design ex booklet 2015 - Final 1.indd 41 28/08/2015 16:03:14 Oliver Gallop Liam Glen Dr C Copeland Supervisor: Dr A Rhead Simulation of a micro-gas turbine electric Impact Damage Formation in Composite vehicle range extender Laminates

The project aimed to model the performance of An analytical model was developed to pre- a micro-gas turbine for use as an electric vehicle dict delamination initiation and growth within a range extender, through the use of 2D simula- [04/904]s carbon-epoxy laminate, with clamped tion software, GT Power. The primary aim was to circular boundary conditions. The model was explore the system thermal efficiency and power validated through a series of quasi-static in- density of multiple configurations, which include dentations tests, with delamination growth as- a single shaft, twin shaft and mirror gas turbine sessed using both c-scans and CT. Assuming designs. The performance benefits through use mode I fracture, lower delamination area was of heat exchanger technologies, in the form of re- found to be under predicted by 15% up to the cuperators and intercoolers, were also explored. critical propagation load. Upper delamination area was found to be over predicted by the model.

Gavin Grant Enrique Gutierrez Llaser Supervisor: Dr J Darling Supervisor: Dr C Sangan Simulation of a FS car for suspension tuning Autonomous UAV: Optimal Propulsion and optimisation The UoB Stingray UAV taking part in the IMechE A full vehicle simulation software, IPG Formula UAS challenge requires of an optimal propul- Carmaker, was used to create a model of Team sion system. With most of the propulsion system Bath Racing’s 2014 entry to the Formula Stu- components already identified, the process was dent competition, TBR14. Real world testing of focused on the selection of an optimal propeller. TBR14 was carried out at Colerne airfield, the This was achieved through the design of a range model was validated against this collected data of propellers tailored to the UAV performance with an error limited to <4%. This model was requirements, manufactured using a Synthetic then used to investigate the effect of roll centre Laser Sintering method (3D Printed) and experi- height and suspension tuneable variation on mentally validated using the open jet wind tun- the handling characteristic of the vehicle. nel.

Matthew Hale Douglas Hardman Supervisor: Dr A Hillis Supervisor: Dr C Courtney Model-in-the-loop Simulation of a Wave Using ultrasound to create configurable sea Energy Converter floors

Wave energy converters are a relatively under- Ultrasound is an incredibly important piece of developed technology which could make a technology that has a variety of applications. significant zero-carbon contribution to the UK’s Testing it requires real life scenario conditions. energy needs. To assist in future development, Oceans have rippled bases generated by cur- without the expense of wave tank testing, a rents. The aim was to generate the acoustic ra- model-in-the-loop system was created. In this diation force via ultrasound to manipulate parti- system, the waves and hydrodynamics are sim- cles within a tank into various ripple formations. ulated in software, and the motion applied to a Two opposing ultrasound generators (transduc- physical Power Take-Off device. Force measure- ers) were placed within a tank to form a stand- ment is fed back into the hydrodynamic model in ing wave. Particles were manipulated towards real time, creating a closed loop system. the pressure nodes and fell to the base in ripple patterns.

design ex booklet 2015 - Final 1.indd 42 28/08/2015 16:03:14 Tomos Harris Benjamin Harwood Supervisor: Prof. I Gursul Supervisor: Prof. A Miles Modelling the vortex wake of oscillating Biomechanics of the Patellofemoral Joint wings Following Total Knee Arthroplasty

Flapping wings have evolved convergently in The knee rig at Bath currently utilises single axis nature, producing large increases in lift coef- measurement of the patellofemoral joint reac- ficient compared to that of conventional aircraft tion force. The project investigated the accuracy wings. An interesting behaviour for a purely of this technique by comparing the measured plunging wing is that the wake will produce a results against the forces calculated by two mod- steadily deflected jet, either upwards or down- els. The measured patellofemoral joint reaction wards, along with a correspondingly large force differed from both models by a statistically increase in coefficient of lift. This project aims to significant amount, indicating the measurement model this behaviour in MATLAB in order to ex- axis was not aligned with the resultant force axis. plore the parameters governing the onset of this bifurcation.

Way Ping Heng Megan Henson Supervisor: Dr D N Johnston Supervisor: Prof. S Culley Measurement of flow ripple in hydraulic The Optimisation of the Flexible Die Cut- pump ting Process for the Production of Fuel Cell Elements This project aims to compare the current British Standard for measurement of fluid-borne noise This project looked at improving the kiss cutting characteristics of hydraulic pumps, known as process used by JMFC so they become capa- the ‘secondary source’ method, with a method ble of meeting their high volume requirements. known as the ‘two pressures/two systems’ meth- Investigative and experimental work highlighted od in terms of their reliability, repeatability and the need for a reduction in waste. Alterations to accuracy. The paper proposing this method sug- the pack material addressed this issue while the gested that it is much simpler to implement and use of a venturi vacuum unit meant that the waste may have superior accuracy over the secondary removal process was automated and could be source technique. Both methods are tested un- completed simultaneously to another process. der the same test conditions and also simulated The proposed process is 58% more efficient. with Matlab Simulink models to aid the comparison process. Wendel Hortop Lauren Hucker Supervisor: Dr L Newnes Supervisor: Prof. PG Maropoulos Investigate the use of adaptive networks in Design for Verification cost estimating The aim of this project was to provide a frame- Defence equipment is increasingly being pro- work to help meet the verification needs of indus- vided through “Contracting for Availability” try. By reviewing the salient literature and using agreements, leading to the need for a new way case studies, it was possible to classify Design of thinking about the costs of providing such for Verification, develop a framework and eval- equipment. Adaptive networks is a method uate this. The result was a DFV flowchart that of analysing systems with the aim of captur- enabled the designing of turned components. ing the changes which can occur within and There are limitations to this proposed framework could be used to quantify some cost elements but it provides a good starting point for further which are traditionally overlooked. This re- research. search tests this theory through the example of the supply of Eurofighter Typhoon aircraft.

design ex booklet 2015 - Final 1.indd 43 28/08/2015 16:03:14 Natalie James Georgina James Supervisor: Dr C Courtney Supervisor: Dr V Dhokia Characterising the material properties of liv- The Digital Obeya ing cells without touching them A project undertaking work that looks at the Detecting unhealthy cells is of great use to the possbilitiy of creating a Digital Tool based on medical sector. These cells are stiffer than nor- the principles behind the concept of the Obeya. mal cells so manipulating them to find the stiff- The program is intended to be used by small ness would be beneficial. to medium enterprises and aims to benefit decision making, communication and team Acoustic waves were used to deform polysty- management.A foundation for more research rene beads and zebrafish eggs. A test rig was was built from creating a Mock Interface, using built and a driver sent an ultrasonic sinusoidal Macros in Excel and generating Universal Mod- signal to oscillate a transducer with the sample elling Language Diagrams. attached. Some refinement would be needed in future, but there were visible changes in the particles.

Jayna Jogia Matthew Jones Supervisor: Dr S Gheduzzi Supervisor: Dr V Dhokia Investigation of Chip Size and Fluid Phase Design of a termperature controlled RepRap on the Behaviour of Impacted Bone Graft. environment for warping reduction

Identifying vegetable margarine and Sawbones® A temperature-controlled enclosure was de- as experimental substitutes for bone marrow and signed and tested for a low cost RepRap 3D cancellous bone respectively, experimental anal- printer; the aim was to control thermally induced ysis was performed to identify the visco-elastic warping of plastic parts, bridging the gap with and plastic properties of impacted bone graft. vastly more costly commercial FDM machines. Including fluid increases compaction, reduces The enclosure was effective at reducing variation plastic strain and has no effect on elasticity due in warping behaviour. Further work is required in to the prevention of pore collapse and reduced order to reduce the average magnitude of warp- friction. Increasing particle size reduces coming. paction, elastic strain, plastic strain and stiffness due to the preservation of the particle’s internal structure.

Oliver Jones Edward Joyce Supervisor: Prof. S Newman Supervisor: Dr J Roesner An investigation into the optimisation of Improving Efficiency of Forklift Trucks machining environments for the milling of magnesium alloy ZE41 In conjunction with NACCO Materials Handling Group (NMHG), this project has been carried The machining of magnesium alloys can be out to investigate ways to reduce the energy us- troublesome due to flammability and corrosion age of forklift trucks. A baseline model of one of issues. The aim of the project was to test the effect of different machining environments on the NMHG’s vehicles was created in MATLAB Sim- milling performance of aerospace alloy magne- scape, and modifications applied to try to find sium ZE41. The environments tested were: mini- ways to improve efficiency. It was found that a mum quantity lubrication (MQL), dry, air cooled, hydraulic motor in the lift line could be used to and cryogenically cooled. MQL and cryogenic capture the load’s potential energy, with signifi- environments improved the surface finish, and cant reductions in energy consumption. reduced tool wear over dry machining; reducing potential for corrosion, and reducing tooling costs. 44

design ex booklet 2015 - Final 1.indd 44 28/08/2015 16:03:15 Orestis Katsoulas Matthew Kemp Supervisor: Dr S Akehurst Supervisor: Dr T Dodwell An Investigation of Pre and Post Catalytic Modelling crack propagation in composite Exhaust Gas Recirculation on Combustion materials using Peridynamics Performance. Peridynamics is an family of computational An investigation was conducted on the compari- methods useful for modelling crack propa- son between pre and post catalytic exhaust gas gation simply and with relatively few special recirculation (EGR). Focus was set on the added criteria compared to the finite element method. calorific content, added specific heat capacity This project involved the implementation of a and their influence on peak knock pressures. peridynamic solver in MATLAB and verification It was found that non-catalytic EGR generated of the mechanical behaviour of 1D and 2D higher energy values compared to catalysed peridynamic models. Further work included exhaust gases, as well as decreasing the brake the implementation of anisotropic and inho- specific fuel consumption. Values of specific heat capacities did not vary significantly between mogeneous material models and attempts to the two types of EGR configurations. capture the behaviour of composite materials in larger peridynamic simulations. Ian Knowles Andrew La Marche Supervisor: Dr S Cayzer Supervisor: Dr M Ansell To what extent will the government’s housing Development of magnesium alloy body proposal ‘Laying the Foundations’ affect the panels UK’s legally binding climate change targets? A research and development project to under- With the domestic housing sector accounting stand the feasibility of producing magnesium for 23% of the UK’s total greenhouse gas emis- alloy panels for McLaren Automotive. Simulation sions, it is important to understand how the analysis took place in the form of pedestrian head construction of 232,000 new homes per annum impact and dentability testing. Forming simulation will impact the UK’s emission target. Unfortu- was performed on the McLaren 570S Rear Deck nately the outcome is bleak. The domestic panels before full scale parts were manufactured. sector will fail to meet its emission reduction tar- Tensile tests at elevated temperatures were con- gets by 56-63% if existing trends continue and ducted on magnesium and aluminum samples. new homes are built. This outcome is irrespec- The project was a success, resulting in a 30% tive of ‘Laying the Foundations’ ever coming to weight saving compared to aluminum. fruition.

Joshua Lane Alexander Lee Supervisor: Dr M Wilson Supervisor: Prof. R Butler Reintroduction of Supersonic Passenger Air The comparison of failure modes of impact Travel and lightning damage to composite laminates The feasibility of mass passenger supersonic air travel has been plagued in the past by concerns An area of concern for the increased use of surrounding safety, cost and the environment. composites within new aircraft, such as the Air- This project has sought to establish the nature bus A350 and Boeing 787, is the risk of the dra- of the next generation of supersonic airliner. matically reduced load-carrying capability when The main objective has been to conclude if damaged. A unique damage risk to aircraft is fuel economy and ticket price on a supersonic that from a lightning strike. This project looked aircraft could ever compete with that of a sub- to improve our understanding into how lightning sonic aircraft. Extensive numerical modelling in damage effected both the buckling and failure MATLAB was required throughout. modes of carbon/epoxy composites, with impact damage being used as a means of comparison.

design ex booklet 2015 - Final 1.indd 45 28/08/2015 16:03:15 Daniel Yi Rong Lee Joshua Lewis Supervisor: Dr Andrew T Rhead Supervisor: Dr S Akehurst Thin Foam Layers for Improved Performance Modelling Advanced Transmission Concepts of Laminated Aerospace Composites This project involved modelling a wet clutch for Aircraft with composites are prone to low veloc- a Dual Clutch Transmission (DCT) system for an ity impact loading, causing barely visible impact off-road vehicle on Simulink. The final model in- damage. The use of thin foam layers in Carbon cluded factors such as hydrodynamic squeeze Fibre Reinforced Plastics composite laminate forces, different lubrication regimes, cavitation, was investigated to determine their effects on heat generated due to clutch slip, heating of the damage resistance and damage tolerance. transmission oil and resultant changes in fluid Non-destructive testing conducted showed that viscosity, variations in kinetic friction with slip ve- composite laminates with foam layers performed locity and the locking and unlocking of the clutch poorly in damage resistance, exhibiting larger plates. The model can function as a design tool. delamination sizes and diameters. Compression after impact test showed a significant reduction in residual strength of the composite.

Alexander Lewis James Lilburne Supervisor: Rod Valentine Supervisor: Dr C Bannister Drop-In Cricket Pitch Transporter Prototyp- Assessing the impact of novel fuels on the ing performance and emissions of a gas turbine engine Drop-In Pitch’s are an increasing popular method of ensuring a high quality playing surface in Originally by means of experimentation, the aim World Cricket. However, due to high costs there of the project was to assess the impact of novel is currently no Drop-In system suitable for the fuels on the performance and emissions of a British market. This project aims to create a low gas turbine engine. Owing to irreparable dam- cost Drop-In Pitch Transporter by splitting the age sustained by the engine attributed to a loose wicket into four portable sections. The design is sensor, the aim was altered to ‘computationally based on a double A-Frame and was tested, re- predict’ rather than ‘experimentally assess’ the designed and strengthened before the creation performance and emissions. Based purely on of a scaled working prototype. the two aforementioned parameters, it was found that a number of novel fuels had scope for future aviation propulsion applications.

Anna Lockett Peter Mack Supervisor: Prof. S Culley Supervisor: Mr A Green Infographics for Engineering Design infor- Improvement of the Team Green Vehicle mation Engine Performance Using Ricardo WAVE and Experimental Testing Infographics are claimed to rapidly transfer information when compared to plain text. This project Team Green has been competing in Eco- investigated the role of infographics in engineer- Marathon’s as part of the University of Bath ing design information and viability from a busi- since 1996, and has achieved a record fuel con- ness perspective – in collaboration with Airbus. sumption of 6603 MPG. In this project a Ricardo The results of experiments using EN ISO infor- WAVE model was developed and used to ana- mation indicated that infographics could signifi- lyse the vehicles engine. Breathing modifications cantly improve information retention. Qualitative to improve efficiency were identified and imple- feedback from Airbus revealed that, in the future, mented, and experimental testing indicated an infographics would be a viable way to summa- improvement between 2 - 9 % was achieved. rise long documents to improve productivity in Modifications to the vehicle transmission were the engineering industry. also proposed, yielding a further 2 - 3 % improvement.

design ex booklet 2015 - Final 1.indd 46 28/08/2015 16:03:15 Edward Mason Richard Matthews Supervisor: Mr A Green Supervisor: Dr D N Johnston Improvement of Team Green vehicle through Measuring the speed of sound in hydraulic use of cast iron ringless piston fluids

A ringless piston design was considered for the This project involved the comparison of the two University of Bath Team Green Eco Marathon methods for measuring the speed of sound in vehicle, in an effort to improve the fuel efficiency hydraulic fluids detailed in the ISO standard ISO of the engine – via reductions in contact fric- 15086-2:2000. A series of experiments were tion between barrel and piston. An FEA model conducted to establish whether the standards was developed from experimental data, in order provided consistent results, both in repeated ex- to predict thermal expansion of the piston as it periments and in comparison to each other. The accelerates and decelerates during an engine project was extended for one of the methods in burn. Following this, a piston was subsequently order to investigate the effects that entrained air designed, manufactured and tested within the had on the fluid properties of the oil. vehicle.

Alexander Matthews Martin Mciver Supervisor: Mr M Ould Supervisor: Dr A Nassehi Investigation into Teamwork Effectiveness in International Engineering Organisations: Investigating the use of performance man- How Team Dislocation and Cultural Variety agement systems in SMEs Affects Team Working and Decision Making Effectiveness This project was focused on investigating how performance management systems are used in Significant advances in information technologies small-medium sized enterprises, compared to have opened up a global marketplace, mean- larger companies. The project took place in con- ing engineering organisations must go global to junction with Westcut Engineering, a local SME remain competitive. Consequently, engineering which specialises in using modern technology to project teams have become dislocated interna- produce a wide range of components in many tionally, increasing the difficulty of fundamental different materials for all applications. The pro- team processes such as coordination and com- ject found that SMEs can make good use of per- munication, reducing the likelihood of team goals formance management systems, but that they being met. This project aims to develop better face significant challenges implementing and team working and decision making processes using them. applicable to dislocated engineering teams based on current academic recommendations.

Simon McKinney Christopher Meehan Supervisor: Prof. P Keogh Supervisor: Dr C Sangan Laboratory based study into High Frequency An investigation into vapourchromic materi- Torsional Oscillation in Drill Strings als for Gas Turbine Research

The project established an experimental model In gas turbine engines, ingestion is a phe- of a Bottom Hole Assembly (BHA) used in drill- nomenon in which hot mainstream gases ing for Oil and Gas using Froude scaling in order enter the wheel space between the stator and to further understand a recently unknown phe- rotor disks. Current methods exist that attempt nomenon: High Frequency Torsional Oscillation. to quantify the degree of ingress in order to pre- The model was a simple outline of a real BHA dict the required sealing flow. This project in- and showed HFTO occurring at conditions cor- vestigates Vapochromic Crystals, which change roborated by literature, but also went further to colour as a function of humidity, and assesses investigate the effect of damping to decouple their suitability as an alternative technique in gas these oscillations from the rest of the drill string. turbine research, allowing for more accurate pre- dictions related to ingestion.

design ex booklet 2015 - Final 1.indd 47 28/08/2015 16:03:15 Evangelos Menelaou Jonathan Mitton Supervisor: Dr M Ansell Supervisor: Prof. A Miles Mechanical properties of adhesively bonded Stability of press fit acetabular cups in total timber joints hip replacement under dynamic flexion loading Finger joints are end joints that are used to con- nect timber pieces together. This project exam- This project looked at the comparative stability of ines the mechanical properties of adhesively acetabular cups when loaded dynamically with bonded finger joints and examines how different and without a fibrous tissue analogue layer be- factors affect these properties. The factors that tween the prosthesis and the synthetic biome- were examined were the sample orientation, chanical bone model. Comparisons were also bonding pressure and adhesive type. Numer- made to previous static loading studies using tis- ous samples were created and tested in 4-point sue analogues to investigate whether the move- bending, compression and tension. Afterwards, ment experienced by the implant is effected by the microstructure of the samples was examined the introduction of dynamic loading. using an electron microscope.

Mohd Zulazam Mohd Zainul Arifien James Payne Supervisor: Dr M Carley Supervisor: Dr C Copeland Modelling the flow around ammonoids Influence of cylinder deactivation on turbocharger turbine performance This report details the methods and results of modelling the flow around ammonoid using Cylinder Deactivation is a relatively new fuel OpenFOAM, a CFD package. It was carried saving technology that reduces the effective out with the aim to use engineering methods to capacity of an IC engine in order to reduce throt- provide data which might offer insights on evo- tling losses at part-load. This technology changes the lution and diversity of the ammonoids. A geom- exhaust characteristics of an engine greatly, and etry was generated by mathematical functions therefore will impact on any exhaust driven tur- using Gmsh and simulations were carried out bines. The effects on parameters such as Turbine from Reynolds Number of 10 to 3000. Velocity Isentropic Efficiency and Power were identified contours, and drag, lift, and moment coefficients and investigated using 1-Dimensional wave action were investigated. software with models of a 4 cylinder downsized engine.

Hashan Peiris Toby Phillips Supervisor: Prof. P Keogh Supervisor: Prof. C Bowen Controller Design for rotor magnetic bearing Enhancing the secondary pyroelectric effect systems with multi-physics sensing arrays for energy harvesting

Conventional rotor magnetic bearing systems A pyroelectric material generates an electrical rely on feedback of rotor displacement signals to potential through changes in both temperature minimize vibration caused by resonance. How- (primary pyroelectric effect) and strain (second- ever, due to rotor bending, sensors placed out- ary pyroelectric effect). This electrical potential side the bearing stator often log measurements can be harvested to produce power (milli to mi- different to those at the centre of the bearing. crowatt range). This project set out to determine This project investigates the effectiveness of whether the secondary pyroelectric effect could an array of physical senses to improve control be enhanced by bonding a pyroelectric material system performance. A novel piezo actuation to a bistable laminate, a material which exhibits device is used to apply controlled forces without thermally induced strain, using experimental and introducing electromagnetic interference to the theoretical methods. system.

design ex booklet 2015 - Final 1.indd 48 28/08/2015 16:03:15 Sean Phillips Thomas Pierce Supervisor: Dr A Nassehi Supervisors: Dr M Carley / Dr J Cunningham Investigating the use of visual control Propulsion of the Human Powered Aircraft boards to maximise workflow through a machine shop. The project looks into two aspects of the propulsion: the propeller and the drive train. It aims Manufacturing companies constantly strive for to optimize a propeller for the speed and thrust maximum efficiency. One of the key enablers to needed for this type of aircraft using specific soft- achieving this is the reduction and elimination ware. While it also investigates, through experi- of waste. This project works with Westcut En- mentation, the efficiencies of transmitting pedal gineering, a specialist toolmaker. The aim was power to the propeller. The outcome is a total ef- to design a visual control board that not only re- ficiency for a system, which will be used on the duced the time wasted during each job but also final build for the Icarus Cup 2015. ensured that the work of highest priority to the business was completed first, rather than the jobs the operators wanted to do.

Harish Rama Katrina Reynolds Supervisor: Dr M Meo Supervisor: Dr M Ansell Impact damage on an Agusta Westland blade Photocatalytic coatings for improving indoor air quality Helicopter blades are subject to a wide range of impacts, both in flight and on the ground. In order In line with the ECO-SEE collaboration project, to assess the severity of such impacts, a meth- this study aimed to develop a coating to remove odology which accurately determines the impact pollutants from air through the mechanism location is first required. This project proposes of photocatalytic oxidation and subsequently a new methodology which makes it possible to develop a short duration test for photocatalytic accurately locate impacts within the region of an activity. Three commercially available titanium isotropic structure. Experimental and numerical dioxide products were incorporated into polyure- testing was completed, whilst impacts were lo- thane-based coatings which were characterised calised to within 15mm of their actual location. using microscopy techniques and subsequently tested for photocatalytic potential using three experimental methods; methylene blue tests, residual gas analysis and colour analysis of photocatalytic indicator inks.

Luis Rodriguez De La Oliva Hannah Rose Supervisor: Dr M McManus Supervisor: Prof. R Gill House-building: a route to a greener future? Fixing broken hips: nailing vs plating

The anthropogenic effect of Climate Change is There are around 65,000 hip fractures each year undeniable. With stringent energy and Green- in the UK and the cost of treatment is largely de- house Gas emission targets at national, EU and pendent on the correct choice of fracture fixation global levels, it is essential to find ways to reduce device. This project aimed to determine whether the UK’s carbon footprint. The housing industry there are any biomechanical differences in the is responsible for a quarter of the country’s GHG effects of extramedullary and intramedullary emissions, and a third of the total energy con- fixation devices when used in the unstable in- sumption. With an annual target to build 240,000 tertrochanteric fracture type AO/OTA 31.A2. This houses, this project explored ways of reducing study used both computational Finite Element the impact from these new dwellings. Analysis and experimental testing on composite bones to achieve this aim.

design ex booklet 2015 - Final 1.indd 49 28/08/2015 16:03:15 Clayton Rossiter Mohd Hakim Bin Samsudin Supervisor: Dr R Ngwompo Supervisor: Dr D N Johnston Modelling and performance assessment of Investigation of a switched inertance hy- an energy regenerative actuator draulic system

Energy recovery is increasing in demand as it A switched inertance hydraulic system (SIHS) is reduces operating costs, decreases required an alternative method of controlling flow instead power supply, while maintaining performance of the conventional method of using valves to standards. Actuator models were produced and throttle the flow in a hydraulic system. Two con- tested using positional and force input stimuli. figurations of SIHS are flow booster mode which This compared its performance against con- can boost the output flow and pressure booster ventional actuators and sought to maximise the mode which can boost the output pressure. The recovery capacity of the energy regenerative system makes use of the inductive effect of a actuator. To investigate its viability using small diameter line and fast switching between commercially available servovalves, the models the supply and delivery ports. were tested across a range of valve frequencies and the associated energy dissipation was evaluated.

Ben Sanderson Alexander Sanins Supervisor: Dr L Newnes Supervisor: Prof. P Keogh Assessing Perceived Value of Mobile An Investigation into the Static Behaviour of Phones a Drill String Section & the Onset of Dynam- ic Instability It is important for companies to know what factors their potential customers consider to Drill strings are long and thin structures which add the most value to their products, in order are used to drill for oil and gas. The bottom hole to design them to be of high value. This var- assembly (BHA) is used to steer the drill string ies across demographics, allowing for market and cut through the rock. Dynamic instability in segmentation through a number of products. the BHA can be a source of equipment failure, Wealthier people prefer expensive luxury prod- resulting in costly downtime for operators. By ucts, whereas younger people prefer multi- creating a finite element model this project looks functional products, showing the opportunity to into the static behaviour of the BHA and the on- design several products specific to the audience set of dynamic instability. they are targeting, in order to maximise profit.

Meghan Silveira Annarose Schild Supervisor: Prof. GDL Lock Supervisors: Dr J Cunningham/Prof. R Gill Fluid dynamic and thermodynamic measure- Determining the true cause of incomplete ments in wind tunnel ossificationin Springer Spaniels This project aimed to investigate the effect of Incomplete Ossification of the humeral condyle boundary layers and heat transfer in turbu- or IOHC is a condition that affects roughly 14% lent conditions over the surface of a flat plate, of English Springer Spaniels. IOHC is charac- whilst also analysing the efficiency and suitabil- terised by small fissures in the dog’s humerus ity of infrared thermometers to measure surface which leads to fractures but the cause of the temperatures of a substrate. Experiments were condition is unknown. This project looked into conducted in a wind tunnel under controlled tran- creating FEA models of Springer Spaniel humeri sient conditions and the solution of Fourier’s 1D to determine if the cause is biomechanical. This equation was used to calculate the heat transfer was achieved by scanning the bones, convert- coefficient. Results were compared to theoretical ing these scans into models and analysing the correlations to investigate the accuracy and reli- results. ability of the results.

design ex booklet 2015 - Final 1.indd 50 28/08/2015 16:03:15 William Skinner Edvardas Skridaila Supervisor: Dr IG Turner Supervisor: Dr G Owen Ice composites Vehicle Dynamics of a 1954 Indycar: Vehicle Handling Optimization through Simulation In cold regions, ice is used for applications such as roads, runways and sculptures. Its relative The project aim was to transform the handling weakness and brittleness, however, mean that characteristics of a classic IndyCar vehicle to large section thicknesses are often required to suit European road circuits. This was achieved prevent failure. By reinforcing ice with fibrous through the handling analysis of steady state materials, its strength and ductility can be im- models as well as dynamic computational mod- proved but the reinforcing effects of different els. Using the results found, correlation between fibre types is relatively unknown. In this project, known objective theories and subjective driver the mechanical and thermal properties of ten ice feedback was made in order to finalize the solu- composites with different fibre reinforcements tion and to further bridge the gap between objec- were determined experimentally. tive theory and subjective driver feel in vehicle dynamics.

James Sullivan Jonathan Swift Supervisor: Dr CD Bannister Supervisor: Dr Z Wang Evaluating the impact of environmental Unsteady aerodynamics of double-delta conditions on vehicle fuel consumption and wings emissions during real-world driving. An experimental study was performed on a To isolate the impact of environmental conditions 70°/50° double-delta wing in a water tunnel to on vehicle emissions and fuel consumption, investigate the effect of applying a blowing jet from other influential factors such as driver be- over the wing surface on the lift and rolling mo- haviour, regression analysis was performed on ment generated. Blowing was applied at different rolling road vehicle test results. Equations were angles of attack from a range of configurations. developed to predict test emissions and fuel con- Blowing was most effective at 20° and 24° an- sumption based on the ambient pressure, tem- gles of attack, starting at 60% chord, aimed di- perature, and humidity, and were combined with rectly downstream through the strake vortex. weather data from locations around Europe, to demonstrate the expected variation in emissions and fuel consumption due to the varied climates.

Reuben Thomas Andrew Taylor Supervisor: Prof. A Miles Supervisor: Dr D N Johnston Biomechanics of the knee joint Dynamic response of complex passageways in aircraft fuel metering units Total Knee Replacement (TKR) is a highly successful and effective operation for relief of pain The dynamic response of a system such as a and restoration of function to the knee joint, but fuel metering unit is dependent on the inertance until now, investigation of stress patterns in the of the internal geometry. Inertance is difficult tibia has been considerably simplified. This study to calculate theoretically, while CFD modelling investigated the effects of a more complete repli- would normally require a complex turbulence cation of the joint on principal strains at the bone model. A new simpler method was proposed surface, finding considerably different patterns using laminar flow through a porous medium; to those reported for simplified loading regimes this technique has been used to understand the which may hold implications for prosthesis de- effect of typical passageway geometries on in- sign. ertance. By modelling the effect of bend radius and different passageway intersections, correc- tion factors for inertance have been calculated.

design ex booklet 2015 - Final 1.indd 51 28/08/2015 16:03:15 Kristoffer Thuesen Isabel Tiemann Supervisors: Dr S Clift, / Dr J Cunningham Supervisor: Dr M McManus Finite element analysis of a loose total hip LCA of a waste water treatment plant replacement This project uses Life Cycle Assessment to Total hip replacement is the most common or- determine the overall impact of a Wastewater thopaedic operation worldwide. Loosening of the Treatment Plant in Poole, Dorset. Using a whole replacement is the most common long term is- systems approach the environmental impacts sue. Current diagnostic methods are ineffective. over the life cycle of the plant are calculated, as A method known as vibrometry is being explored well as analysis into areas where environmental as an alternative method. The aim of this project improvements could be made in the future. The was the build a finite element model to predict life cycle assessment tool, SimaPro, is used as mode shapes and frequencies of loose and se- part of the analysis. cure implants. The results show that vibrometry is a possible solution with promising results.

Alessandra Verza Luca Volpe Supervisor: Dr J Darling Supervisor: Dr RF Ngwompo Structural Integrity of a Motorhome Body Modelling and Simulation of an Anaesthetic Breathing System The project looked at how introducing a slide out compartment affected the structural integrity of a Anaesthetic breathing systems are used to pro- motorhome body. The body material was tested vide anaesthesia for surgical procedures. The to find its properties; the data was used to model ability to predict a patient’s response to anaes- and analyse the current version of the body and thesia by using a mathematical model can lead to the new design with an FEA software to iden- a better quality of care and recovery. The project tify the main differences. The aim was to identify involved the creation of components in Simulink, weak areas in the new design, suggest design such as a CO2 scrubber, which were validated improvements and the location of additional against experimental data. These components structural reinforcements. were used to create a standard anaesthetic cir- cle system, whose results were compared to that obtained by clinical trial.

Matthew Walsh Wojciech Wasinski Supervisor: Mr J Barrie Supervisor: Dr D Cleaver Biomimetics with application in the Human Autonomous UAV: Experimental structural Powered Submarine study of the AUAV Aircraft

The aim of the project was to increase the per- The object of study - Stingray is an unmanned formance of the Human Powered Submarine, autonomous aircraft concept developed by a through the reduction of drag, by taking biomi- team of engineering students at the University metic inspiration. Research was carried out into of Bath. the drag coefficient of animals, promising forms were replicated into hull and fin designs. The The subject of research is actual structural models were run through simulation software strength, weight and durability of Stingray UAV and results were validated through physical wings. Wings were manufactured from carbon testing. The project found benefits in the replica- fibre reinforced plastic prepreg with use of nega- tion of nature but due to inaccuracies there was tive CNC moulds. Static load destruction tests minimal resistive force reduction. where then performed with Instron test machine and DIC camera set to asses both strength and skin buckling respectively. 52

design ex booklet 2015 - Final 1.indd 52 28/08/2015 16:03:15 Christopher Wheele Robert Wheeler Supervisor: Dr C Sangan Supervisor: Dr D Cleaver Demonstration of a novel infrared flow Jet Flaps for Unsteady Aerodynamic Loads visualisation technique for visualising the Control separation point over a cylinder The unsteady aerodynamic loads caused by ver- The project aim was to quantitatively investigate tical gusts of wind represent the highest loading a novel IR flow visualisation technique for lo- situation for any aircraft. In an effort to reduce the cating the separation point over a cylinder. The loads, and therefore allow for a weaker, lighter entrainment of hot air, supplied by a heat wand structure, a novel jet flap system was studied. positioned at the trailing edge, into the separated By drawing air from the leading edge’s pressure boundary layer allowed the flow separation point surface, and ejecting it through a slot on the suc- to be visualised with an IR camera. The tech- tion surface, reductions in lift of up to 22% were nique was validated quantitatively by comparing observed during wind tunnel tests. the IR images with pressure and drag data collected with an unheated and heated cylinder.

Gregory Whitby Tom White Supervisor: Dr A Nassehi Supervisor: Dr. Michael Carley A system dynamics approach to investigat- Modelling the Stability of Ammonoid Motion ing the deployment of domestic solar photovoltaics under a Feed-in Tariff subsidy This project applies engineering principles mechanism to evolutionary biology to attempt an answer to a long-standing scientific mystery. A great This project was concerned with investigat- deal is known about the evolutionary history ing the dynamic behaviour associated with the of the ammonoid: certain shell forms were deployment of solar photovoltaics under the preferred in multiple independent evolution- Feed-in Tariff, the primary renewable energy incentive scheme for microgeneration technolo- ary events however the cause is currently un- gies in Great Britain. Focussing on the domestic known. It is proposed that this was influenced sector, a system dynamics model was developed by the effect of the shell on the ammonoid’s that allowed a user to customise the conditions swimming. By adapting vehicle stability theo- of the Feed-in Tariff in pursuit of specific policy ry, this hypothesis is tested and compared to objectives relating to installed solar capacity and palaeontological data. total subsidy expenditure.

Henry Wood Althea Yii Supervisor: Dr S Macgregor Supervisor: Dr M Meo Investigating the use of Supercritical Carbon Ultrasound imaging of an Airbus compos- Dioxide thermodynamic cycles to extract en- ite aerospace structure ergy from the exhaust gases of large marine engines This project explored phased array pulse echo ultrasound as an alternate non-destructive test- Marine propulsion and l generation has seen some ing method for detecting barely visible impact impressive efficiency gains in the past 50 years, damage in composite aerospace structures. but mechanical efficiency limit has been reached. The primary aim was to develop an efficient and A computer model to predict the amount of energy reliable phased array system to produce high that can be recovered from the exhaust gases of quality scan images in the least costly and using supercritical Carbon dioxide thermodynamic timely manner. The detection of nonlinear be- cycles was built. It showed that 10% of the me- haviour in damaged composites was also con- chanical engine power can be recovered as useful ducted using waveform generation and signal work and that the system is technically feasible. processing through acoustic emission sensors.

design ex booklet 2015 - Final 1.indd 53 28/08/2015 16:03:15 Jibran Yousafzai Ruojia Yu Supervisor: Dr CM Sangan Supervisor: Dr R Burke Novel infra-red (IR) flow visualisation tech- Control of an advanced, transient turbo- nique applied to an aerofoil charger test stand

The project involved designing an aerofoil and The digital control of a 2.2L 4 cylinders tur- placing it in the wind tunnel, where tests were bocharged diesel engine, which simulated by conducted on the performance characteristics of Ricardo WAVE and controlled by the Simulink. the aerofoil. Then a heat source was introduced The control method include open-loop function, and hot air was blown over the aerofoil. An in- closed-loop function and combined loop func- frared camera was used to picture the variation tion. The control methods are able to control the in heat along the aerofoil, hereby identifying the system in different way, by changing the operat- location of the boundary layer separation point. ing condition and investigating the response of system to different operating condition, which present the real engine test stand response. Moreover, it can carry out the system operating limitation. Huanan Zhao Supervisor: Dr V Dhokia A comparison of tool life and material removal rate in the machining of Cobalt Chrome between MQL and Cryogenic cooling

As heat generation been the major cause of low productivity on difficult-to-machine materials. Conventional flooding method with oil or water based cutting fluid has been used for decades to lubricate the tool-workpiece interfaces and reducing cutting zone temperature. However, with the increasing demand on difficult-to-machine materials, conventional flooding method cannot longer achieve idea cooling & lubricating results with take consideration of environments. This project is aiming to discover new approaches on machining environment.

Peter Alton Robert Ashburner Supervisor: Dr G Owen, Supervisor: Dr K Robinson, The Thermal Evaluation of a Formula Student Intake airflow optimisation for a Formula Stu- Braking System” dent vehicle

This project aimed to assess the progression The aim of this project was to design an effec- and deterioration of the braking performance of tive formula student intake, minimizing losses a Formula Student car over the course of typical and maximising mass flow. Air filters, surface Formula Student circuits. Empirically determined relationships were developed from the running finish and geometry were all looked into. Initial of TBR14, which formed the base of a MATLAB modelling was done using Ricardo Wave before model which gave the ability to predict brake disc using ANSYS CFX was used to conduct CFD. temperatures and therefore brake balance shifts. Prototypes were tested on a flow bench to vali- This determined the optimal setup for best brak- date CFD results. The final design incorporates ing performance and design changes that would Carbon fibre and 3d printed components, en- yield performance gains. suring geometry is met at the minimum possible weight. 54

design ex booklet 2015 - Final 1.indd 54 28/08/2015 16:03:15 William Charles Jocelyn Cheli Supervisor: Dr R Burke Supervisor: Dr J Darling Implementation and Optimisation of Control FS - vehicle dynamics simultion of a FS race Strategies for a Throttle-by-Wire System of a car for chassis design optimisation Formula Student Car In the ever more competitive world of Formula A first for Team Bath Racing, this project ex- Student racing it has become a necessity to plores a Throttle-by-Wire system on one of have an accurate vehicle dynamics simulation Team Bath Racing’s Formula Student cars. of the car that can be used to design the chas- Electronic Throttle Control is used to decou- sis architecture and aerodynamics. This project ple Pedal to Throttle position, with strategies of developed a simulation model of University of Torque-Linearisation, Idle Control and Pedal to Bath car using IPG CarMaker. It was then cor- Throttle mapping, to improve the vehicle per- related against track testing and a method was formance. Future strategies in development in- established for experimenting with chassis clude Auto-Blipping on downshifts and throttle parameters that enables the optimum design to based Traction Control. be found. Dequan Chen Mark Cooper Supervisor: Dr MP Ansell Supervisor: Dr JL Cunningham Natural Fibre Composite Seat for a For- Development and Verification of a Formula mula Student Car Student Car CFD Model for Design of a New Regulation Aerodynamics Package.

Team Bath Racing has been testing flax fibre The project developed a CFD model for the de- composite materials for use in its seat for the sign of new aerodynamics for TBR15. A regu- 2015 race car. Flax fibres are an environmen- lation wing package was manufactured, and tally friendly alternative to carbon fibre Com- measurements collected using track-testing bined with a bio-based epoxy resin system. methods. Predicted drag and pressure showed Our initial test specimens have come out with good correlation with the test data, verifying the an excellent surface finish and early testing accuracy of the model. Additionally, the design suggests comparable mechanical properties of the new aerodynamics package was docu- to the glass fibre and will be a viable alterna- mented. The findings from this project will serve tive to the carbon fibre used in last year’s car. as a guideline for future team members, aiding Team Bath Racing are staying combustion the development of Team Bath Racing’s aero- but going green! dynamic designs.

Toby Davies Oliver Dolbear Supervisor: Prof. C Brace Supervisor: Prof. C Brace Modelling, Testing and Optimisation of a Modelling, Validation & Optimisation of a Formula Student CFRP Monocoque Formula Student Differential A virtual model of the limited slip differential A torsional stiffness test was done on the was created in Matlab, validated through TBR15 Formula Student chassis. This was track testing and used to compare the availa- then simulated on a finite element model, which ble settings. The differential casing was mod- corresponded to within 3% of the physical test ified so that grub screws could be inserted in results. . Composite optimisation software order to adjust the pre load torque. Lap times was used to optimise the laminate design of the carbon fibre monocoque, achieving a 30% around the Formula Student skid pad track increase in torsional stiffness for a 3kg weight were improved by 0.335s, enough to improve gain. Full car simulation software was then Bath’s position from 9th to 1st at Silverstone used to assess the performance gain for the in 2014. optimised chassis.

design ex booklet 2015 - Final 1.indd 55 28/08/2015 16:03:15 Joshua Gillman Michael Graham Supervisor: Dr K Robinson Supervisor: Dr G Owen Development of Carbon Wishbones for a Tyre Selection and Formula Student Vehi- Formula Student Car cle Setup from Experimental Data

This project focussed on developing a new set This project used vehicle testing to iden- of suspension linkages for Team Bath Racing’s tify the performance differential between two 2015 car. The new solution looked to maximise Hoosier tyres, and to identify the influence stiffness and minimise the weight of these com- of damper changes on vehicle handling and ponents to improve performance. To achieve performance. On-board telemetry was used this, a concept involving carbon tubes with bonded aluminium inserts was chosen. The to record vehicle data for analysis, and it was solution was then designed and validated using identified that the wider tyre had a lateral grip FEA, on car testing and sample testing. The advantage, but this did not benefit sprint track final design gave a weight saving of more than performance. Damper changes were found 40%. to affect understeer by up to 13%, and re- sponsiveness by up to 19%.

Benjamin Hansen] Kevin Johnson Supervisor: Dr G Owen Supervisor: Mr A Green Next generation upright design for FS Next generation composite impact attenua- car tor for a FS racing car

The aim of this project was to utilise Direct Metal The design competition Formula Student re- Laser Sintering of high strength Maraging steel quires every car to be equipped with an Impact to generate a 30% weight saving over the previ- Attenuator (IA), which ensures the drivers safe- ous generation upright design through a com- ty in case of an accident. The aim of this project pletely hollow structure. A prototype design was was to produce the lightest IA in the history of manufactured and tested; finding the design to Team Bath Racing. The result, a 24% weight be comparable in stiffness to the previous gener- saving compared to the previous 2014 design. ation whilst also proving sufficiently strong. The This was achieved through utilising high per- final design has a finished weight of just 457g; formance carbon fiber and nomex honeycomb a 27% saving over the previous generation core, arranged in a sandwich construction.

Thomas Peirson-Smith Jake Reid Supervisor: Dr S Akehurst Supervisor: Dr C Copeland Fuel mixing and combustion optimisation and understanding for Formula Student Turbocharger development and optimisa- vehicle tion

This work looks into understanding the dif- The aim of this project was to turbocharge a ference between running E85 (Ethanol) and single cylinder KTM 500 motocross engine Gasoline fuel in a Formula Student Vehicle. for use within the University of Bath’s For- The effect of fuel properties on engine per- mula Student car. This project required the formance for both a naturally aspirated and design, manufacture and optimisation of all turbocharged powertrain are analysed on a sub-systems required for the use of a turbo- dynamometer with combustion analysis. A charger on a naturally aspirated engine. The detailed look at abnormal combustion and main sub-systems were the Intake, Exhaust, mixture preparation through split injection Oil and Coolant systems. Alongside this an was also carried out. The conclusion was that E85 gave a performance benefit due to engine simulation was created and validated higher latent heat of vaporisation and octane. using data from engine dynamometer testing. 56

design ex booklet 2015 - Final 1.indd 56 28/08/2015 16:03:15 Tom Stevens Supervisor: Dr S Akehurst Modelling and validation of a full FS racing car powertrain

Team Bath Racing’s powertrain system is developed using 1-D engine simulation modelling. This project aims to identify which engine parameters have the greatest impact on the accuracy of a Ricardo Wave engine simulation model, through experimental methods and comparisons to the in-house dynamometer. Aspects of the real world engine such as friction, valve flow coefficients and valve lift profiles were experimentally measured, before their affects on the performance curves of the simulation model were determined.

Bruno Ainsworth Nicholas Avery Supervisor: Dr T Adlam Supervisor: Dr N Johnston Load Distribution System For Military Assault Novel variable displacement gerotor hy- Vests draulic pump

The use of personal body armour in conjunction This project explores the feasibility of devel- with heavy equipment carriage is a fundamental oping a variable displacement gear pump part of active military service. Acute and long-term through the use of prototyping and testing. injury has resulted from prolonged loading of the Gear pumps, although favourable due to their shoulders and upper body, through the use of as- ruggedness, low cost and low complexity, are not currently commercially available in vari- sault vests. The task was to design a system that able form. Therefore, the concepts presented prevents the harmful upper body effects observed. may open new market avenues for them, with Key design drivers were, robustness, mobility, user possible application areas including engine size variation, weight and compatibility with other lubrication, steering, and simple motion con- pieces of equipment. trol systems such as for small earth-moving machinery.

Steven Brace Oliver Byrne Supervisors: Dr S Gheduzzi & Prof. R Gill Supervisor: Prof. S Culley Surgical tool for removal of femoral bone ce- A Novel Fall Arrest Device ment This aim of this project was to design a novel fall The design for a bone-cement removal tool arrest device for a company called Latchways. which utilises a chipping mechanism to break After extensive research and concept genera- up the cement within the femoral cavity, was tion, a device that could be used absorb energy successfully taken from conception through to and protect fall arrest systems from high peak a working prototype. The device permits the loading was conceptualised. Main specification removal of cement without risking damage to points included maintaining performance levels surrounding bone by bracing itself on the cement of current ‘sacrificial’ devices, whilst also being mantle. Unlike traditional tools the device does not require a through hole drilled in the cement reusable and configurable. The design solution mantle tooperate. Consequently, risk of cortical is a compact, modular, hydraulics based device. bone perforation during drilling is reduced.

design ex booklet 2015 - Final 1.indd 57 28/08/2015 16:03:15 Jack Carroll David Clare Supervisor: Dr E Dekoninck Supervisor: Dr S McGregor Meal Management for People with Dementia An Efficient Highly Portable Cooking Solution The aim of the project was to increase the nu- tritional intake for people with dementia, helping In trekking and mountaineering the weight them to live at home, independently, for longer. of equipment is of critical importance. An The chosen concept consisted of two reminder experiment showed that recent advances devices and an eating detection mechanism. in portable stove efficiency have come at Development involved designing a reminder sys- the cost of heavier equipment, leading to no tem, carer interface and eating detection algorithm. The final product solution was tested in two net weight saving. This project developed a homes for week-long periods of time and was met radical alternative to the traditional camping with varying success. stove, with the goal of meeting the high end stoves on efficiency while being comparable with low end stoves on mass.

Josh Evans Sachindra Gamage Supervisor: Dr A Hunter Supervisor: Dr L Newnes Action Camera Motion Control Device Life raft inflation system for marine applications This device allows users to create visually interesting footage by moving the camera along The objective of this project was to design a life a user-defined motion path in a smooth and raft inflation device with greater reliability and controlled fashion at a fractional cost of professional lower manufacturing and in-service costs over systems. The product has been designed to func- current products. It incorporates innovative tion in a wide range of environments (often remote) fully-autonomous optimal pressure mainte- and is capable of operating on both taut ropes and nance - a feature unlike any currently avail- rigid rails. Further developments include reducing able - the principles of which were proven to camera vibration, the addition of wheels for mo- work through prototype testing. The design is tion along smooth surfaces and weatherproofing. technically superior to its competitors. The design makes use of OTS components to lower costs and is more reliable due to mini- mised wear.

Steven Goguelin Harry Leeming Supervisor: Prof. T Miles Supervisor: Prof. G Jones Instrument for the Assembly of Modular Hip Headlight for Alta Motors Stems Alta Motors is an engineering company that Instrument for the Assembly of Modular Hip designs electric motorbikes. In order to con- Stems Synopsis:Fretting corrosion is a major is- vert their current off-road model for sale in sue associated with improper assembly of mod- the road going market, the company required ular hip stems. To solve this problem, a device a bespoke street legal headlight design. An which can impart variable impact forces between optical design was pursued which included 2kN-8kN was designed. Development consisted LEDs and mini reflectors; this was validated of a series of prototype iterations which incorpo- with a prototype. A full working prototype with rated a number of mechanical design changes, a thermal and electrical design was also pro- including integrating ergonomics into the device. duced that met the stringent US regulations A final working prototype was shown to produce consistent impact forces and generate sufficient and Alta’s design specification. taper connections between the femoral head and neck.

design ex booklet 2015 - Final 1.indd 58 28/08/2015 16:03:16 Matthew-Ben Mccurrach Thomas Parsons Supervisor: Dr E Dekoninck Supervisor: Prof.G Jones Height Adjustable Desk for Educational In- Man Overboard Recovery Device stitutions The Man Overboard project aimed to produce a Obesity among adolescents is a growing con- solution to quickly locate, capture and recover a cern in many countries. Such health styles are person out of water into a yacht or small commer- widely associated with increased risks of heart cial vessel. Although rare man overboard situa- disease, musculoskeletal disorders etc. One so- tions can often be fatal especially in rough condi- lution to aid in the battle against obesity is height tions and as such it is vital to retrieve the casualty adjustable desks. Being able to stand whilst you from the water as quickly as possible. A novel so- work, gets people moving and progressing on lution has been designed and prototyped and has the path to a healthier lifestyle. the potential to save many lives at sea.

Oliver Pringle Katerina Prokopiou Supervisors: Mr J Muelaner Supervisor: Prof. R Gill Variable Ride Geometry Headset TopiPen

“Enduro” mountain bike racing is the ultimate The Topipen project focused around the design test of a bike’s all round capabilities. The and development of a novel, dose-controlled ap- rapid growth of the enduro racing scene has plicator for corticosteroid creams. The design aims brought with it various technological advance- to improve the ease of treatment of dermatitis and ments in order to allow a more efficient com- reduce commonly observed non-adherence. The promise between downhill and cross country development process included research, require- requirements. Bikes now feature hydraulically ment setting and conceptualisation as well as de- adjustable seat-posts and suspension set- sign embodiment. The proposed solution employs tings can be changed via remote. The aim of a positive displacement delivery system and a this project was to design a means of altering bead-and-track dose-control mechanism that also mountain bike trail and wheelbase whilst riding. provides haptic feedback to the user.

Tim Quigg Oliver Skittery Supervisor: Prof.G Jones Supervisors: Dr D Cleaver/Dr A Rhead Enhancing Knee Rehabilitation Leidenfrost Pump

With an initial aim to enhance rehabilita- The Leidenfrost effect occurs when a liquid droplet tion following severe knee trauma or total in close proximity to a heated surface much hotter knee replacement, project work focused on than the liquids boiling point causes it to levitate. the development of a new device to moni- Furthermore, if the heated surface has an asym- tor patient recovery. The developed product metric ratchet profile droplets can be propelled in utilises remote sensors and a low-energy a controlled direction and even up inclines. The Bluetooth connection to transmit captured aim of this project was to use this ratchet effect to range of motion data to a bespoke Android design, manufacture and test a Leidenfrost pump application. Quantified movement statistics that is powered only by heat and contains no mov- facilitate evidence-based recovery; inform- ing parts. ing both the patient and clinical team of progress throughout the rehabilitation process.

design ex booklet 2015 - Final 1.indd 59 28/08/2015 16:03:16 Peter Smith Prem-Sagar Tank Supervisors: Mr J Barrie/Dr A Lewis Supervisor: Mr J Roesner Training device for the Welsh Rugby Team Decking Treatment Applicator

The project, set by the Welsh Rugby Union, Outdoor decking is a form of garden landscaping, was to design a high resistance and vastly ad- which requires annual treatment with oils or stain. justable Upper Body Ergometer, which is an This process, however, can be laborious and exercise bike used with the arms. The specifi- cause some back pain. This project aims to re- cation was to tailor it for use by elite athletes, duce the strenuousness of decking treatment, with whilst remaining within a £1000 budget. A a semi-autonomous product that synchronises a flywheel positioned near a series of perma- scrubbing effect, drive motion and feed of treat- nent magnets, whose exact location could be ment, such that an even coat can be achieved. controlled, provided the variable resistance. The final prototype embodies an oscillation mech- Prototyping and numerical analysis proved the anism for the scrubbing effect. design met the specification.

Andrew Watt James Wright Supervisor: Dr T Adlam Supervisor: Dr J Darling Ankle Brace for IED injuries The Alcohol Automated Bartender

The aim of this project was to design an ankle This project looks at solving the growing problem brace to help treat severe heel fractures caused of bar queues in night clubs by design of a self- by below vehicle IED explosions in war zones. service bartender machine. The machine allows The brace needed to transfer the load normal- customers to order, pay for, and receive a cup ly experienced by the foot to somewhere else and drink. During this project an initial prototype on the body, allowing the patient to walk with was developed of the main processes of this as normal a gait as possible without the aid of machine which can produce and distribute basic crutches. This was achieved by using a spring drinks to customers. suspended, custom-made cuff, to transfer the load to the knee of the injured leg.

Paul Wrigley Supervisor: Mr R Valentine Automated Tennis Ball Collection

This project involved solving the problem of col- lecting the large amount of tennis balls that can be left on a tennis court after a coaching lesson or service practice. A prototype was produced to test the concept and involved a rotating paddle to scoop the tennis balls into a basket. The device also employed two wheel differential drive for movement and a series of sensors for navigation.

design ex booklet 2015 - Final 1.indd 60 28/08/2015 16:03:16 Elliott Campbell Jake Egbers Supervisor: Steve Cayzer Supervisor: Dr D A S Rees Motif Detection in Domestic Energy Calculating fibre misalignments in composite components: A novel method for curved sections The project consists of taking the smart meter readings of 15,000 houses provided by the A high proportion of composite components Centre of Sustainable energy and applying the currently manufactured exhibit complex ge- Mueen-Keogh motif detection algorithm. This ometries. Currently no method exists allowing is done to establish whether this method could characterisation of fibre misalignments for out- be used to provide energy suppliers with useful of-plane, non-linear sections. Moreover, mis- information about energy consumption patterns. alignments lead to a lack of confidence in a com- Highlighting similar motifs provides information posite component’s true compressive strength, resulting in component rejection which can be that wouldn’t otherwise be obvious, that can be costly financially. Identifying relationships which used to provide further insight into domestic en- quantify this effect would be of interest. In this ergy consumption behavior . paper a novel method for the characterisation of fibre misalignment in curved composite sections is presented.

Naomi Gillgren Rebecca Hillier Supervisor: Dr Alan Hunter Supervisor: Dr R Burke Underwater Acoustic Monitoring of Marine New legislative test for assessing fuel econ- Mammals omy

This project was aimed to design and build This project looks at how old and new legislative a MATLAB programme which implements drive cycle tests compare in terms of fuel con- beamforming to improve the detection and the sumption with real-world data, whilst analysing estimation of direction of arrival of vocalising how drivers, themselves, can improve the fuel marine mammals using a towed passive SONAR economy of their vehicles. Through the design array. The programme is configurable to any of a vehicle model to parameterise driving styles towed SONAR array and can be set to give and the quantification of drive cycle categories, the desired angular resolution. It also includes comparisons were drawn between real-world signal conditioning to optimise for the detection data and the claims made by manufacturers, of certain groups of noise; clicks, whistles and based on NEDC drive cycles. man-made noise (i.e. boats).

Lakshey Jain Dan Hothersall Supervisor: Prof. R Butler Supervisor: Dr Chris Brace Compression After Impact Testing of Com- Engine Testing and ECU Calibration posite-Titanium Joints with Penetrative Re- inforcement For use in range-extended electric vehicles, a TATA Motors 2 cylinder petrol engine has been Composites on an aircraft can experience an calibrated with a new ECU, allowing the control impact load, for example an accidental tool drop strategy to be tuned for increased power output during maintenance, flying debris on a runway and improved fuel consumption. or hailstorm impact in bad weather. This has a significant effect on the strength of thema- The engine has been baselined to generate terial and a sudden failure in service can be data for the look-up tables, and has been cali- catastrophic. This project, sponsored by Airbus brated and optimised specifically to power a Group Innovations was undertaken to study the generator. Modifications have been made to the effect of impact magnitude and location on the engine including an electronic throttle and new strength and failure modes of CFRP panels. intake and exhaust manifolds.

design ex booklet 2015 - Final 1.indd 61 28/08/2015 16:03:16 Shing For Kwok Tym Pakulski Supervisor: Dr A Nassehi Supervisor: Dr R F Ngwompo Fully immersive artificial reality Experimental Assessment of an Optimass 6400 Mass Flow Meter for Determining CO2 Virtual reality has a lot of untapped potential Vapour Quality in all forms of industries worldwide. However much of the technological advances has gone Vapour quality, the mass fraction of a liquid to improving visual and audio experiences that has evaporated, is a crucial parameter in rather than haptic feedback and balance. This the design and commissioning of CO2 cooling project highlights the practical difficulties asso- systems for the particle trackers at CERN. This ciated with a tactile device for the human body, study assessed the practicality of determining and aims to design a feasible concept of such vapour quality using aggregate density meas- device in order for a more engaging and realis- ured by a new coriolis flow meter. A comparison tic simulation. between laboratory measurements and an analytical model characterised performance in various conditions, and identified a range of accept- able accuracy and trends for further research.

Bjarte Ravndal Molly Reid Supervisor: Dr G Owen Supervisor: Charles Courtney Invetigation of 4-wheel steering on an FS car Rotating Microscopic Objects with Sound Vortices A rig allowing for rear-wheel steering is designed, built and retrofitted to a Formula Stu- This project aimed to discover whether we could dent car, in this case TBR14. The rig utilises a cause, and also control, the rotation of micro- pneumatic actuation system, and is controlled scopic objects using ultrasound in a fluid. First, by the driver. Using this rig, a preliminary in- a device capable of trapping 100µm diameter vestigation was conducted into the benefits of polystyrene beads was designed and construct- 4-wheel steering. It was found to significantly ed. Second, rotation of the beads was attempt- increase performance in simple manoeuvres, ed. Once rotation was shown to be possible like hairpin corners. On the other hand, complex analysis was done to investigate if we could manoeuvres, like slalom, would require sophis- control the speed of rotation. ticated control systems.

William Rosier Zhanye Yang Supervisor: Dr K Bray Supervisor: Dr. P Iravani The dependence of place kicking range on Agile robot locomotion ball-release parameters in Rugby Union Active ankle prostheses can help amputees with This project investigated the relationship be- walking. This project is to investigate how the tween the range of a place kick in Rugby Union gait of an amputee with an active ankle prosthe- and the following ball-release parameters: ball- sis differs from the gait of normal people and to placement angle on the tee; projection angle; investigate how the timing of active power from release velocity; and the rate of spin of the ball. the pump influences the gait of the amputee. The aim was to quantify any relationships so that a coach could optimise a kicker’s technique to meet the optimum release parameters and therefore achieve maximum range.

design ex booklet 2015 - Final 1.indd 62 28/08/2015 16:03:16 Benjamin Bell

Bath Assessors: Dr. R F Ngwompo / Mr. J Roesner Host Supervisor: Dr R Moreau, INSA Lyon, France

Neurosurgical simulator coupling haptic feedback and virtual reality

Accurately simulating the forces and tactile sensations experienced in neurosurgery are challenging issues. A realistic reproduction of the forces incurred during an endona- sal endoscopic surgery has been produced using the Omni Phantom robot arm. The research into this field also led to the development of a Simulink toolkit providing aflex- ible environment that simplifies the control and creation of simulations using the Omni Phantom.

Lucas Dann

Assessors: Mr J Roesner / Dr F Osman Supervisor: Elisabeth Schrey, RWTH Aachen, Germany

The technical representation of data for a modularised component in Teamcenter

The Laboratory for Machine Tools and Production Engineering from the University of Aachen has established a Product Lifecycle Management (PLM) research project which aims to identify, how a PLM Software application can support medium sized enterprises. Real product and process data from an electric powered vehicle called the MAXeKART were used to establish a PLM Laboratory. This mock-up environment provided a framework for the analysis of the limitations and benefits of modern PLM Systems like Teamcenter ®..

Stuart Jaeckel

Bath Assessors: Mr J Roesner /Dr. R F Ngwompo Host Supervisor: Rüdiger Ohs, Enzyme Process Technology, RWTH Aachen, Germany

Modelling the Reaction Kinetics of Organocatalysed Acyloin Synthesis

The project aim was to create a kinetic model of the organocatalysed synthesis of Acyloin. Acyloin is produced from the reaction between the two substrates of Benzaldehyde and Phenylacetaldehyde, while unwanted side reactions can also occur. An analytic approach was taken to derive model equations using a method proven to work for enzyme reactions. A sensitivity analysis was conducted on the resulting equations, while methods by which the model parameters could be improved were investigated.

design ex booklet 2015 - Final 1.indd 63 28/08/2015 16:03:16 Matthew Ashworth SImon Cooper Supervisor: Dr P Iravani Supervisor: Dr B Forte Metal filament making for RepRap Automotive Communication using Arduino Microcontrollers and Formula Student Ap- plications The aim of this project was to create a me- tallic filament for use with a RepRap 3D This project covers the implemention of CAN printer. The filament was required to have communication on low-cost Arduino microcon- a low enough melting temperature to be troller boards. CAN is the current industry stand- used with a standard RepRap extruder, low ard method of communication used in most auto- enough surface tension when melted to be motive vehicles. A software library implementing printed successfully, and have a fine enough CAN protocol has been developed alongside a microstructure that the nozzle doesn’t block suitable Arduino shield that adds the relevant and the properties are uniform across it. To hardware for CAN support. The whole system achieve this, a small scale continuous cast- has been tested as part of a multi-node commu- ing machine was created. nication network and as a diagnostic tool for a car. Theofanis Demetriou Megan Doyle Supervisor: Dr M Soleimani Supervisor: Prof. N Mitchell Hardware Development for Electrical Imped- The Influence of Ancient Roman Warship Dock- ance Tomography (EIT) yards on the 21st Century and How They Could Benefit From a Mechatronics Engineering Ap- proach EIT is a non-invasive method for monitoring various body functions (lung motion or brain Does the solution to improving naval dockyard waves) without exposing the patient to harmful efficiency lie in the past? This project comprises chemicals or ionizing radiation. A low AC current of a historical study into Portus, a prominent is all is needed to extract the required informa- Ancient Roman dockyard near Rome; allowing tion. The novelty of this design lays in the CPU a comparison with a typical 21st Century dock- of the system an; Arduino Uno, which is com- yard through a case study on Devonport Royal Dockyard. A focus has been on dockyard layout, mercially available developer kit. The modular facilities and available technology. The analysis design of the project allows individual modules results have determined critical factors of an effi- to be altered to suit different applications. cient dockyard, supporting the progression of an improved dockyard design.

Benjamin Draper Thomas Freethy Supervisor: Dr W Yuan Supervisor: Dr C. T. Clarke Persistent Current Loops Catching Criminals with FPGAs

The aim of this project is to take steps towards Criminal activity often utilises shared illegal files, creating a closed loop of second-generation su- forcing the police to search seized machines for perconducting wire (2G HTS) capable of con- any known illegal files. These files are stored as ducting current persistently. The project identi- a database of hash digests, and the police have fies the most significant step in this process as a system to compare seized files against the da- the formation of a stable, high quality and mini- tabase. Utilising FPGAs, this system can be pipe- mally resistant joint between two strips of the lined and parallelised to achieve a much higher 2G HTS, allowing a single piece of wire to be throughput of files than a conventional CPU, for folded back on itself and formed into a Mobius a much lower power cost. strip shaped loop.

design ex booklet 2015 - Final 1.indd 64 28/08/2015 16:03:16 Luke George Stuart Gordon Supervisor: Dr Robert Watson Supervisor: Dr J du Bois Pole Climbing Robot for Rapid Sensor De- Semi-Active Suspension for Mountain Bikes ployment Active and semi active suspension systems have This project focuses on the design, analysis and existed in cars for several decades improving testing of a four bar link mechanism gripper for a handling and comfort characteristics. The appli- pole climbing robot, capable of climbing behind cation for a semi active system has potential for obstacles such as road signs. The gripper is re- a significant performance improvement; this pro- quired to support the robot weight and an 8kg ject is to investigate the possibility of this system payload. FEA has been used to analyse the grip- and the ways to implement them. The investiga- per stresses, with an ARDUINO and Processing tion uses a prototype variable front suspension used to create a GUI and current inferred force fork with an electrohydraulic servo valve to find controller from an experimental motor current variables to characterise a mathematical model torque curve. describing the system.

Alexander Gresham-Thompson Saul Harris Supervisor: Dr Paul Leonard Supervisor: Prof. R Gill Improving Control of a Self-Balancing Wheel X-Bolt with Miniplate vs. Three Parallel Screws: Investigating the Torsional Stability Self-balancing wheels are similar to Segways in Fixation Devices of Femoral Neck Fractures and also represent the classic control problem of an inverted pendulum. Hence a refined control This project presents a pilot study into the resist- system needs to be implemented to gain a suita- ance to torsional loading of two types of fixation ble behaviour for a person to ride the self-balanc- devices used to treat stable neck fractures of the ing wheel. This behaviour includes fast response femur. Parallel screws are commonly used in the and settling times along with no oscillation. To treatment of this type of fracture with the X-Bolt achieve this, a model for the self-balancing wheel being a relatively new device and a potential is derived. Then control theory is applied to this superior. The X-Bolt uses expanding flanges to model to gain a desirable performance. compress cancellous bone locking the device into the femoral head. The miniplate restrains the device from rotating.

Tom Haydon Alexander Hickson Supervisor: Dr M Carley Supervisor: Dr R Watson Control System For Novel Two Person Hu- UAV Communications project man Powered Aircraft This project aims to establish long range com- This project primarily looks at the production munications between a UAV (unmanned aerial of an electrical system capable of controlling a vehicle) and a ground control station. With a typi- novel human powered aircraft (HPA). The aircraft cal system using UK legal frequencies and trans- in question is currently in the preliminary design mission powers, maximum range is limited to process. As the design progressed the system roughly half a mile. This project aims to increase was developed to accurately represent and con- that to 10 miles through use of an automated trol the changing system dynamics. A control sys- tracking system and directional antenna. tem of this manner has the scope to improve HPA performance, drastically reducing the pilot’s mental workload while undertaking the highly strenu- ous challenge of powering the vehicle.

design ex booklet 2015 - Final 1.indd 65 28/08/2015 16:03:16 Christopher Hopkins William Irlam Supervisor: Mr J Roesner Supervisor: Dr M McManus Improving the Efficiency of forklift trucks Energy: sotrage and connectivity

To help improve the efficiency of a hydraulic The UK is becoming increasingly reliant on forklift truck, novel motor applications have been the use of renewable energy resources be- considered to power the hydraulic pump allow- cause of legislation driving forwards the con- ing an energy saving of around 10% over the cept of a carbon free economy. The major- lift cycle. Key components of a hydraulic system ity of renewable energy is intermittent and are sources of large losses. To help improve ef- therefore unreliable, one possible solution is ficiency further, a new system design has been utilising energy storage. Within this project, proposed, reducing the reliance on the pump. energy storage options have been identified, This has enabled a saving of around 25% when compared and then analysed using the Life coupled with novel motor technology. Cycle Assessment technique. Furthermore, analysis was undertaken on the integration of these technologies into the grid with the use of a roadmap.

Christopher Kirkman Roberto La Spina Supervisor: Dr M Füllekrug Supervisor: Dr P Leonard Parts Counting Machine Design of a Two-Wheeled Inverted Pendulum, MicroPython Controlled Robot and an Ac- Development of a machine which is capable of curately Matched Computer Model for Control counting a range of parts current prototypes are System Development capable of counting nuts and bolts. The machine was developed for a 3D printing kit manufac- The project’s goals are to develop an inverted pen- turer, RepRapPro, this promoted the use of 3D dulum robot capable of self-balance, as well as an printing for the development and production of accurately matched computer model. The robot the machines. So far one of the machines has will be used for UCAS open days and the model for demonstrated a 100% accuracy and with a price Dr. Leonard’s students to develop control systems of £200 per machine represents an affordable which can be ported directly to the robot. solution for smaller companies.

Laur Läänemets Thomas Magowan Supervisor: Dr P Leonard Supervisor: Dr J du Bois Artificial Intelligence in Finance: Artificial Twin Rotor Cyclocopter Implementation Neural Networks and Genetic Algorithms Ap- plied to Algorithmic Trading A Cyclocopter is a novel vertical take-off and landing aircraft where lift is generated perpen- Our pensions depends on the performance of dicular to the rotation axis of the rotor. Although the investment funds that manage our savings, initially developed in the 1930s, only recent re- hence every effort should be made to maximise search in the past 10 years has yielded flying their returns and minimise their risks. The aim prototypes. During this project a twin rotor pro- of this project was to develop and compare Ar- totype aircraft has been designed, modelled and tificial Neural Network based trading algorithms manufactured concluding in the implementation and train them to perform automated trading de- of an attitude controller that has been tuned and cisions in the market place using Genetic Algo- run on a test rig. rithms. The performance of these networks was evaluated using risk-adjusted return metrics.

design ex booklet 2015 - Final 1.indd 66 28/08/2015 16:03:16 Arron Morrow Kun Qian Supervisor: Dr Philip Shields Supervisor: Dr J du Bois Dynamic Video Mapping Rig development for condition monitoring of blade disc Though commonly used for static installations, video mapping is now more frequently being This project introduced a method for condition used dynamically. By detecting position through monitoring of a blade disc. Two similar blade a Microsoft Kinect, this project applies respon- discs (one with crack, the other without) were sive, real-time projection mapping to a moving tested through this experiment. An accelerom- target from two sources simultaneously. eter has been mounted on the bearing house, it will provide lots of vibration data to the computer through the ADC (analog digital converter). In order to get the differences between these two blade discs, this project use FFT (Fast Fouri- ers Transform) and Bicoherence algorithm to analyze the frequency spectrum. Therefore, the damage on the blade disc can be shown on the frequency spectrum and Bicoherence map.

Hayden Sansum Joshua Shaylor Supervisor: Dr P Iravani Supervisor: Dr P Iravani An Investigation into Radar Technology for Design of an enclosed electric tricyle for the Application of Lightweight Autonomous use by commuters UAVs The aim of this project is to design an enclosed Intelligent UAVs are on the rise, and as autonomy electrically assisted tricycle for use by commut- increases so do sensing requirements. Radar ers. The project will focus on the definition of the systems, more specifically FMCW radar, can act overall architecture of the vehicle, quantifying as a lightweight, efficient method for determining the level of effectiveness of said design through relative distances and velocities; allowing appli- calculation and simulation. cations including altitude, collision avoidance and imaging. Primarily this project is the development of a hardware and software interface to a radar transceiver with the aim of creating a reliable signal processing system and determining the overall effectiveness of the system.

Samuel Short James Stewart Supervisor: Dr A Evans Supervisor: Mr A Green Computer Vision Assisted Navigation of a Integration of driver feedback systems on Multirotor via Target Detection, Tracking and the Teamgreen Eco-Marathon vehicle Geo-Tagging for the Purpose of Aerial Video Stabilisation and Composition Current driver feedback systems on the Eco- Marathon vehicle are unreliable, inaccurate The aim of this project was to design a system and visually difficult to read. Using a Rasp- of computer vision algorithms to perform target berry-Pi 2 as the processor platform, the final identification, tracking, geological tagging and composition. The system uses OpenCV to iden- design augments real-time ECU data and a tify known targets via colour detection; unknown camera signal into one LCD display. The pro- targets via visual attention based methods and ject also looks into the design of a wireless combine the two for informed selection. The re- telemetry system and the development of an sulting targets have distortion corrected in order evolutionary algorithm to optimise the race to perform OCR to identify a character and clas- strategy at events sify the target. Further development allowed for multiple target identification.

design ex booklet 2015 - Final 1.indd 67 28/08/2015 16:03:16 Josh Taylor Jonathan Thompson Supervisor: Dr P Iravani Supervisor: Dr A Rees Feasibility Study on the Application of Sa- Instability of a vertical boundary layer mara-Based Wings in a Guided Payload De- livery System This project analyses the critical parameters for the instability of a boundary layer along a Drone-based package delivery is likely to take vertical surface with uniform suction and heat. off in the near future as courier services strive to The limit of instability is defined by the critical provide the quickest possible deliveries. Demand Rayleigh number found from linear stability the- for a safe, disposable means of guiding packages ory, above which an infinitesimal perturbation from aircraft to ground-based targets is therefore applied to the system may grow exponentially increasing. One solution to this may be in the with time and below which it will decay. This form of evolution’s answers to the decelerator – model is two-dimensional and applied to an the autorotating samara. The aim of this project incompressible, clear fluid with Boussinesq is to determine the feasibility of a samara-based approximations. guided payload for application in package delivery

Christopher Wade Luke Walker Supervisor: Prof. C Bowen Supervisor: Dr C Clarke Mechanical and electrical properties of car- Task Switching for Hardware Accelerated bon nanotube-polymer composites Applications

This project involved analysing the effect of car- The Altera Cyclone V SoC has been recently bon nanotubes within a thermosetting epoxy released; this contains a dual core processor as well as an FPGA on the same chip. resin. Measurements were carried out on six test An application has been created that runs samples, with nanotube weight fractions of 0% - software with a customised FPGA configu- 0.6%. Results were obtained regarding the elec- ration on the SoC; it can save the context trical, mechanical, thermal and physical proper- of the hardware accelerated software in or- ties of the materials, as well as the relationships der to achieve preemptable context switch- between these properties. It is important to know ing on the SoC. Partial Reconfiguration on the exact properties of this material so that it may the SoC has been implemented with an aim be used effectively in anti-static or high-strength to achieve position independent, context applications. switchable, hardware accelerated software.

Peter Walker Dian Wang Supervisor: Dr A Hillis Supervisor: Dr M Soleimani Design of a conditional monitoring system Metal flow imaging using magnetic induc- for the Crofton Beam Engine tion tomography

The Crofton Beam Engines are a pair of of Electromagnetic (EM) imaging skills are steam engines situated in Wiltshire, along the widely used in various ranges of applications. Kennet and Avon canal. They are the oldest There are lots of examples in everyday life in- working steam engines in the world. clude metal detector for security screening to vehicle detectors at traffic lights. The essential The project looks at ways of adding modern aim of this project is to get metal flow imaging sensors to the engines to provide both the op- using MIT. Magnetic induction tomography erators and public visitors with an idea of the (MIT) is a contactless and non- intrusive im- workings of the engines. aging method that is using for remoulding the changes of the sophisticated conductivity dis- This project aims to help generate interest in tribution in metal flow in this project. Crofton and funding for its continued running.

design ex booklet 2015 - Final 1.indd 68 28/08/2015 16:03:16 Daniel Williams Woolsey WIlliams Supervisor: Dr J du Bois Supervisor: Dr J du Bois Use of PM Motors in Formula Student Ap- Position estimation system to improve upon plications global positioning systems and inertial navigation systems using sensor fusion tech- An investigation into the use of PM motors in niques formula student applications. This project runs through the process of designing and testing This project is based around the use of Kalman an electric powertrain with a focus on adher- filters to improve upon the output of a Global ing to the formula student rules. With the end Positioning System (GPS) and an Inertial Navi- goal of integrating the designed powertrain gation System (INS). Three different Kalman into an electric go-kart test vehicle, the main filter input options are investigated: a single focus of the project has been around the per- complementary filter input, GPS and INS inputs, formance of PM motors. and GPS and complementary filter inputs. Once the three inputs have been analysed to find the most suitable, an investigation into the effect of including an aircraft model into the prediction stage of the Kalman filter is investigated.

Thomas Willmott Amy Wilson Hardy Supervisor: Dr P Iravani Supervisor: Dr E Dekoninck Water jet autonomous flying platform Ergonomics and instrumentation of an arm grinder Essentially a water-jet powered quadcopter. This project involves the design, modelling, con- This project initially looks at finding the struction and testing of an autonomous platform demographic of professional male rugby play- whose thrust is provided by four jets of water. ers whose data will aid the design of an arm Currently using a pressure washer as a water grinder that will be used in elite sport. This source, this platform could be expanded and includes the design of a test rig that will meas- connected to a fire hose to allow autonomous ure the maximum force exerted by an athlete. fire fighting, or used within the aviation industry The process of designing the interface for the for the autonomous de-icing of aircraft. arm grinder is then discussed, including how the mechanical outputs of the athlete can be converted to useful information.

design ex booklet 2015 - Final 1.indd 69 28/08/2015 16:03:16 Best Performance in a Group Business and Design Project

Elliot Compton

Accenture Business Prize (2013/14)

Westcode HRX Compressor

Jonathan Blackburn Sachindra Gamage Matthew Hale Katerina Prokopiou Luca Volpe Mohd Zulazam

Autonomous Unmanned Aerial System (UAV2) - Stingray

Josh Taylor Marija Popovic Wojciech Wasinski BenWhitfield Enrique Gutierrez Llaser Alex Hickson Sam Short

design ex booklet 2015 - Final 1.indd 70 28/08/2015 16:03:17 Automotive Group (2013/14)

Formula Student - Powertrain

Thomas Peirson Smith Jake Reid Will Charles Harry Leeming Konstantinos Deligiannis Barmpalias Oliver Dolbear Lizzie Atwood Tom Stevens Rob Ashburner Ryan Marsh

Aerospace Group (2013/14) Human Powered Aircraft - Raven

Tom White Tomos Harris Josh Lane Zhiyun Wang

Mechanical Group (2013/14)

Drill Fettle Robot Megan Henson Charles Brooker Gordon Cheung Jamie Douglas Steven Brace Saul Harris

design ex booklet 2015 - Final 1.indd 71 28/08/2015 16:03:17 Prize Sponsor and Award Prize Winner

Royal Aeronautical Society Best Student Graduating in Aerospace Engineering Richard Jackson

Ford Motor Company Best Student Graduating in Automotive Engineering Laurence Hanes

IET Best Student Graduating in Manufacturing Engineering Ali Bastas

Crown Eurpoe Best Student Graduating in Innovation & Engineering Design Oliver Hebden

Frank Wallace Memorial Best Performance in the Language Option Nicholas Pilcher

IMechE Project Prize (Research Project) Joshua Wesley

IMechE Frederic Barnes Waldron Best Student Prize Jordan Bryan

HMGCC Design Best Specialist Design Project Jonathan Ridley

TheThornton Prize Best Materials & Bioengineering Group Student Performance Kinga Czerbak

Armourers and Brasiers Medal for Outstanding Project Work Robert Hardie

Frazer-Nash Best Student Research Project in Aerospace Bruce Edwards

Department of Mechanical Engineering Top Formula Student Final Year Research Project Adam Phelps

Best Final Year Project Poster 1st Prize Eleanor Gordan 2nd Prize Oliver Hebden 3rd Prize Andres Figar

Bryant Prize for Orthopaedic Biomechanical Research Rebecca Shering

Moog International Women in Engineering Prize Chi Zhang

Bath BP Centurion Award Richard Jackson

David Embleton Bursary Chris Shaw

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