March/April 2016 March/April Post-earthquake Nepal: the lessons to be learned Sticking to the task: adhesives in aerospace

GIVING A FRESH SPIN TO DESIGN MANAGEMENT Contacts

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President March/April 2016 March/April Ms Maggie Philbin Post-earthquake Nepal: the lessons to be learned Immediate Past President Sticking to the task: Sir George Cox HonFIED adhesives in aerospace Chair Dr Tania Humphries-Smith BSc PGDip MPhil EdD CTPD CEng MIED FHEA FRSA Immediate Past Chair Engineering Designer needs good articles on matters important to Simon BenHeld CTPD CEng CEnv design. Why not write one? You will receive help from the editorial team, FIED(PCh) should you need it. Vice Chair Eurlng Professor SP Vaitkevicius BEng(Hons) MSc CEng FIED GIVING A FRESH SPIN If you want to try your hand at writing a feature for Engineering Designer, TO DESIGN MANAGEMENT Ordinary Councillors please submit an abstract (around 200 words), explaining what your PKR Bateman EngTech AIED Professor GN Blount BSc MSc Editor feature is about, with intended word count. (Features can be between PhD CEng FIMechE FIED(PCh) Brian Wall 1,000 and 1,800 words.) It will then be forwarded to the IED editorial EurIng Dr L Buck BSc(Hons) MA PhD committee for consideration. CTPD CEng MIED FHEA FRSA Art Director DTH Castle IEng RCADMan FIED Martin Cherry MBCS CITP Contact Brian Wall, Findlay Media Ltd, CMC Dowlen BTech CTPD CEng Advertising Manager Hawley Mill, Hawley Road, Dartford, Kent DA2 7TJ FIMechE REngDes FIED FRSA PFHEA Luke Webster D Farrell BSc(Hons) MTech CEng Telephone: Telephone: 01322 221144 Email: [email protected] CTPD FIED +44 (0)1322 221144 EurIng C Ledsome BEng MEng CEng Email: FIMechE FIED MCMI FBIS MDS [email protected] Dr DJB MafHn PhD BEng CEng MRINA MIED(PCh) MAPM ISSN: 00137898 LJ Meaton DipRSA Ifl MIED N Phelps IEng MIED The Journal of The Institution NC Robinson BEng PGDManuf of Engineering Designers IEng MIED MSEE MIET Hawley Mill, Hawley Road, Dr C J Simcock MEng&Man(Hons) Dartford, Kent DA2 7TJ EngD CTPD CEng FiMechE FIED Email: Dr GAL Tizzard BSc MPhil DIC PhD [email protected] Circulation service is recommended or endorsed by the Institution. MIEEE CEng MIED FHEA Website: Established in 1945, The Institution of Engineering Designers Material may only be reproduced in any form by prior I Treacy BA MSc IEng MIED MIET www.engineeringdesigner.co.uk is the professional body for Engineering Designers, Product arrangement and with due acknowledgement to Engineering Designers and Computer Aided Draughtsmen and Designers. Designer. R Yuen MEng CEng MIED Engineering Designer is the Institution’s bi-monthly journal Note: (PP) – Past President, Contact the Editor sent to all Members, as well as design professionals and Notice to advertisers (PCh) – Past Chairman If you would like to write a feature, opinion formers in industry, schools, colleges and It is a condition of acceptance of advertisement orders that Councillor and Honorary add to the news or send your points universities. the publishers, Findlay Media Ltd, does not guarantee the Treasurer of view, write to: insertion of a particular advertisement on a speciHed date, ATA Keegan CEng FIED(PCh) Brian Wall Annual subscription rates for non-Members or at all, although every effort will be made to meet the UK: £66.68 wishes of advertisers; further, the company does not accept Chief Executive Findlay Media Ltd, Single issue: £13.09 liability for any loss or damage caused by any error or EK Meyrick BSc(Hons) FRSA Hawley Mill, Hawley Road Overseas airmail: £92.87 inaccuracy in the printing or non-appearance of any Managing Editor Dartford, Kent DA2 7TJ Schools and colleges: £53.62 advertisement. Although every advertisement is carefully Libby Meyrick Telephone: checked, occasionally mistakes do occur. We therefore ask Editorial Committee +44 (0)1322 221144 Disclaimer advertisers to assist us by checking their advertisements SJ BenHeld, MK Chowdhree, Email: © Copyright The Institution of Engineering Designers 2016 carefully and advise us by the deadline given, should an Unless otherwise indicated, views expressed are those of the error occur. We regret that we cannot accept responsibility KL Edwards, PC Hills, GJ Jeffery, [email protected] editorial staff, contributors and correspondents. They are for more than ONE INCORRECT insertion and that no KW Kempson, C Ledsome, not necessarily the views of the Institution of Engineering republication or discount will be granted in the case of EK Meyrick, JD Poole, L Rowe, Designers, its ofHcers, or Council. The publication of an typographical or minor changes which do not affect the LJ Meaton advertisement or editorial does not imply that a product or value of the advertisement. Contents Volume 42 Number 2

Regulars Features

View from Nepal earthquakes: time for change 6 Sticking to the task 18 the Chair 4 Ramboll engineers Jeremy Foster and Sean Andrew Marks of 3M looks at the key The future and PEIs Smeltzer recount the destruction that criteria involved when choosing adhesives greeted them and their team when they for interiors applications A fair hearing 5 reached Nepal and the lessons to be learned Colin Ledsome kick Accelerating train design 22 starts our new series Gales batter Victorian pier 11 Tim Fryer reports on how Train Zero is of ‘Asides’ articles Is it too late to save this damaged and speeding up Bombardier’s development of with an unusual angle endangered Grade II-listed pier? the next generation of rolling stock, ahead on the APT of the arrival of Crossrail Light materials hit new heights 12 IED News 26 Solar Impulse’s fuel-free flight around the Battle for the skies! 24 Election of Council world has captured the imagination. But Sixteen student engineering teams are Your path to CTPD! how were the lightweight materials chosen? locked in combat to build the best Unmanned Aircraft System (UAS) – and What’s COVER STORY then go head to head in a ‘fly-off’ Happening 29 Getting beneath the spin 15 Nanoparticles control Colin Ledsome looks inside the worlds of Something to chew on 30 soft robots ‘design’ and ‘management’ to reveal the New high-speed cooling tunnels are helping CAD Toolbox aids interplay and common ground that are one company to boost productivity around design optimisation often lost in a fog of confusion its chewing gum manufacturing process

6 12 18 24 VIEW FROM THE CHAIR

ontinuing my theme of change, a discussion paper [3] has recently been circulated among Professional Engineering Institutions (PEIs) asking some very pertinent questions about the future of PEIs to 2025. The paper highlights that “the millennial generation does not thinkC in the same way as the baby boomers; their values and reward mechanisms are different. Over the last 18 months, there have been a series of papers … as to the value of the PEIs [1]…Coerver and Byers [2] … recommend that institutions overhaul governance and committee operations and speciEcally stop tinkering (my italics), stop the charade, stop the next big thing. They note the need to The future empower the CEO and enhance staff expertise, to rigorously redeEne the member market, to rationalize programs and services, and to build a robust technology framework.” and PEIs As my last column clearly set out, and this is reiterated in the discussion paper, there is no issue about the growing Change is inevitable and necessary, if demand for engineers. Interestingly, Sir Bill Wakeham at the PHEE/PHOMME Conference indicated that the outcomes of his Professional Engineering Institutions are latest report would include the notion that accreditation of to remain relevant and viable to those they engineering courses by PEIs was good practice and produces serve, says IED chair graduates that met the needs of industry. Tania Humphries-Smith So there appears to be an important function for the industry in PEIs undertaking accreditation. The issue, then, is about what those engineers and, for us, designers want from and think about professional representation. What is clear is that change is inevitable, if, as PEIs, we wish to remain relevant to you and, importantly, viable. The future is indeed something that has been exercising the Council and staff of the IED. Our CEO is already empowered by the Council to represent the views and needs of the membership on a number of external bodies, including EngineeringUK, Tomorrow’s Engineers, Society for the Environment and the Professional Engineering Committee. You will have noticed that we have made a few changes recently. We launched a new website that enables members to update their membership proEle, pay their membership and registration fees, submit CPD records, track their membership and/or registration applications, and enabled secure online sharing of papers and applications between committee members to help speed up the application and assessment process. We also launched our journal online and changed the way we manage subscriptions – these might be termed ‘tinkering’, of course. By the time you read this column, Council will have met at an Away Day to consider what should be the future focus of the IED, so expect to hear about more changes soon. 1 Universe of Engineering, Edge Report, Letters to the Times etc. 2 Race for Relevance by Coerver and Byers (ISBN 978-0-99034-335-0). 3 Engineering the Future about the Role of Professional Engineering Institutions (PEIs) in 2025 Get Involved If you would like to contribute to any discussions, write to: Dr Tania Humphries-Smith CTPD CEng MIED FHEA FRSA, Chair, at: The Institution of Engineering Designers, Courtleigh, Westbury Leigh, Westbury, Wiltshire BA13 3TA. Or email: [email protected]

4 www.ied.org.uk ASIDES

Every project has its quirks – when some little problem throws up an odd aside from the main activity that requires investigation. Sometimes it turns out to be a red herring. Occasionally it throws up a challenge that changes the whole design. Colin Ledsome CEng FIED kicks off our new series of ‘Asides’ Photo: Alamy A fAIR hearing worked on the Advanced Passenger tunnel, after a few practice runs. The reversal, which meant it became convex, Train back in the 1970s. One day, drivers certainly enjoyed themselves! rather than the normal slightly concave. someone asked the question, “What At that time, Derby had the last organ All of the ear-drums were pink, showing would be the effects on another bellows maker in the country. A large box, the effects of exercise. Immediately after Itrain of the pressure pulse produced by a big enough for two people to sit side by the test runs, all six had improved hearing 250kph train entering a tunnel?” The APT side, was constructed with Perspex sides on test, probably due to the extra itself had a valve to seal the air system inside a steel reinforced frame. The whole exercise on the small bones in the ear. when in a tunnel, but other trains didn’t. top of the box was a giant organ bellows All were back to normal on the Friday. No-one knew the answer, so a small team driven by a hydraulic piston. Volunteers It was concluded that the pressure was asked to find out. (including me) sat in the box while the pulses caused no permanent impairment Some six miles north of Derby, on the pressure pulses recorded in the tunnel and were possibly marginally beneficial. main line to Sheffield, is a one-mile-long were reproduced, suitably scaled to a Of course, in reality no unsealed train straight tunnel, passing under the range of train speeds up to 250kph. Most would have gone through a long series of southernmost hills of the Pennines. One found it very noticeable, while a few were tunnels at that speed, so the tests were weekend, the line was closed, the three uncomfortable. The next question was, extreme. The exercise had no effect on air shafts were blocked by large air bags “Is the pulse damaging hearing?” the design of the APT, but we had and the fun began. Trains were raced One Monday morning, six of us had answered the question, learned something between Derby and Ambergate, a similar our hearing tested, then again on interesting – and we had some fun! distance north of the tunnel, and Wednesday morning. We then had a pressure readings taken as they passed session in the box where our virtual train If you have some interesting design through the tunnel. Some runs had went through a series of tunnels at full ‘Asides’ to pass on, then please get stationary vehicles on the other line to speed. We had an immediate hearing in touch with the editor at: measure the effect. The final runs used test, followed by another on the Friday. [email protected] two trains timed to pass each other in the One subject had a single ear-drum www.ied.org.uk 5 NEPAL, POST-EARTHQUAKE – a time for change

The earthquakes of 25 April and 12 May last year caused devastation across large parts of Nepal and beyond. Ramboll engineers Jeremy Foster and Sean Smeltzer recount the destruction that greeted them and their team when they arrived there – and the lessons to be learned

ithin seven weeks of the at-risk city in the world, in terms of first earthquake hitting potential deaths due to earthquakes. Nepal, a team of four This is largely on account of building Ramboll engineers – collapse during a potential earthquake, JeremyW Foster, Tom Hough, Davide and insufGcient preparedness and Pedicone and Sean Smeltzer – deployed medical response capacity. to Kathmandu to work with local In Nepal, hospital infrastructure is in engineers, aid agencies and the Nepali extremely poor condition and the majority government to assess the damage to a of hospitals will collapse in the event of a number of hospitals in Kathmandu and major earthquake. Surveys in 2002 and the surrounding area, and prepare an 2003 identiGed that 80% of assessed estimate for the cost of repair work. hospitals in Nepal were in the ‘poor This work built upon an earlier project performance’ category for newly to assess the seismic resistance of a constructed buildings and the remaining number of hospitals across Nepal. This 20% deemed at high risk of life- article describes that deployment and threatening collapse. discusses some related issues that were observed during the visit. TRAIL OF DESTRUCTION The earthquake on 25 April 2015, and SEISMIC BACKGROUND the major aftershock on 12 May, killed Nepal is located in the central part of the more than 9,000 people and injured Himalayas, an area with a very complex more than 23,000. The extremely geotectonic framework, with a high shallow depth of approximately 8.2 km likelihood of strong and potentially meant that the shaking was more catastrophic seismic events. intense, but less widespread, than for Earthquakes with estimated intensity in more usual deep earthquakes, which the range 7 to 9 of the Richter scale occur at depths greater than 50km. have been documented since the 13th Nevertheless, more than 500,000 Century, and recent studies had observed houses were destroyed, huge avalanches a seismic gap in central Nepal. were triggered on Mount Everest and According to the Global Earthquake landslides cut off rural villages. The Survey Initiative, Kathmandu is the most estimated Mercalli Intensity was IX

6 www.ied.org.uk NEPAL AFTERMATH

(Violent). This earthquake is considered detailed investigations had been carried Some three weeks after the second to be the worst natural disaster to strike out. The information gathered, together earthquake, a team of four Ramboll Nepal since the 1934 Nepal–Bihar with our associations with local engineers deployed to Kathmandu, where earthquake. consultants John Sanday and Associates we linked up with JSA, DFID and the local The capital city, Kathmandu, suffered (JSA), as well as humanitarian agencies, Ministry of Health and Population severe damage, despite its distance from put Ramboll in a good position to provide (MoHP). Before we left, we established the epicentre. The effects of the a rapid response to the disaster. terms of reference for the deployment earthquake were ampliGed in Kathmandu, due to its underlying ground conditions. Many residential houses were destroyed, along with many UNESCO World heritage buildings.

DEPLOYMENT Before the earthquakes, Ramboll and professional services company Turner and Townsend had been collaborating on a project to improve the seismic safety of the hospitals in Nepal for the Department for International Development (DFID), which is responsible for the management of Britain’s aid to other countries. The objective of the project was to carry out seismic vulnerability assessments on all major hospitals in Nepal. The hospitals were then ranked in order of structural and clinical priority. A programme of retrofitting works to these hospitals was then to be carried out. At the time of the earthquakes, the From left: Ramboll’s Sean Smeltzer, Davide Pedicone, Jeremy Foster and Tom Hough. preliminary assessments and some www.ied.org.uk 7 Raw sewage running down the walls of the garden to Kanti children’s hospital (left of image). and a list of hospitals to be inspected.We to areas with speciGc mention of damage. also received a one-day crash course Staff residential accommodation was from RedR (www.redr.org.uk) in included in the inspection. humanitarian operations, disaster response and working in Nepal. METHODOLOGY The Grst day was given to preparation, STRATEGY and included planning meetings and a In the immediate aftermath of an group walk round one of the hospitals to earthquake, standard procedure is to look at typical damage, assess different carry out rapid visual assessment of the potential remedial works and agree how damage to all public buildings and place to standardise our reporting. This a ‘sticker’, red, yellow or green, giving provided a benchmark for the rest of clear guidance on which buildings are too the assessments. dangerous to occupy and which are On the following days, each team relatively undamaged. Eleven hospitals visited a number of hospitals, entering partially or completely taken out of action every available room and noting and were selected. All were in Kathmandu or photographing all damage. Only non- neighbouring Bhaktapur, except for one at intrusive visual appraisal was possible. Chautara, several hours’ drive outside Where measured plans were available, the city in a severely affected district. these were used as the basis for the Four teams were formed, each inspections. However, no plans were containing a Ramboll engineer, a local available for many of the buildings. In engineer and a representative from MoHP, some cases, particularly the small to facilitate access. All buildings in the residential buildings, hand sketches were selected hospitals were fully inspected by prepared to accompany the report. the teams. Buildings which had green In a small number of locations, a quick stickers were reviewed in a lesser level of measured survey was carried out to detail, with detailed inspection conGned support the assessment. The surveys

8 www.ied.org.uk NEPAL AFTERMATH

were all completed within eight days and SAFE DEMOLITION GUIDE the team returned to the UK. The results were written up in a detailed report. The When operating in a relief environment, it is became apparent that they did not have any report included an estimate of the cost important to retain flexibility and an ability relevant experience, so the remainder of the of repairs to each building. These were to adapt to changing circumstances. One time was spent looking at a number of fed back to MoHP via DfID in early July. example of this occurred when the team was seriously damaged buildings and discussing By getting this into their budget, visiting Chautara hospital, which is about two key issues relating to demolition, with an international funding is facilitated. hours’ drive east of Kathmandu, quite close emphasis on safety. to the epicentre of the second earthquake. On return to Kathmandu, a brief guide to FINDINGS Most of the buildings are built on the assessment and demolition of earthquake- The overall quality of the construction slope on either side of a ridge of land and damaged structures, including a useful industry in Nepal is generally quite low: many suffered severe damage, particularly checklist as an appendix, was written, and workers are not given appropriate during the second earthquake, which was emailed to the engineers and the municipality. training, the materials that are used on much closer. Back in the UK, the document was site are very poor, and health and safety The team received information that the enhanced slightly and issued to the is not perceived as an issue. Also, in local municipality was requesting assistance. humanitarian organisation RedR general, residential buildings, as well as We were able to spare two hours to discuss (www.redr.org.uk) for wider distribution. many other buildings, have not been safe methods of demolishing damaged Future use and distribution of the document designed in accordance with any seismic buildings with two local engineers. is now being considered. Hopefully, the design regulations. The majority of failed After assessing the level of knowledge document will be of value in the field, sections exhibited pre-quake and experience of the two engineers, it in this and future events. deterioration at the point of failure. Adding to these issues is a lack of on- going maintenance. Culturally, it is very difGcult to attract money to what is seen as ‘make do and mend’. A new hospital wing is much more likely to have a benefactor wanting to offer funding and have their name associated with the building. The irony is that a small outlay on maintenance can have a comparatively massive return. Interestingly, at least to us structural engineers, the seismic resilience of many reinforced concrete framed buildings has been signiGcantly improved by non- structural masonry inGll panels acting as ‘shock absorbers’. Not designed for this purpose, the panel stability itself could become a hazard and discrete retroGt restraint formed part of the repair strategy. Fortunately, most of the hospital buildings that we assessed have proved to be a bit more resilient. Many of these buildings have been properly designed and constructed. However, there are cases of buildings with very poor materials and structural arrangements in general. For example, one block at Bir hospital started out as a single-storey building and had two additional Hoors added at a later date. It is a masonry structure and pretty much all of the external masonry piers have failed. The mortar within the brick layers is very low quality, and many structural and non-structural elements are weakened, due to leaks and lack of

www.ied.org.uk 9 NEPAL AFTERMATH

maintenance in general. The building had conduct these designs is probably getting the hospitals back to where they been given a red sticker in the rapid a function of money; similarly when were, but changing the culture, helping to visual assessment and will need to be it comes to the cutting of corners in break the consequences of building demolished. construction and materials. Corruption under poverty. was reported to us as a signiGcant Truly sustainable development means LOOKING FORWARD inHuence in the quality of construction; making the next crisis less severe & GLOBAL CULTURE and we saw the results of that. through infrastructure and preparedness; It's clear from what we found that many If we are to make signiGcant strides it cannot be reactive. Investment now will factors beyond design combine to create in international disaster relief, then there aid resilience through improved skills, sometimes fatal deGciencies. The design are some home truths that we have to materials, construction and care. understanding and skill is undoubtedly recognise. The hardest hit, more often Should we miss this opportunity, the present in Nepal. That being said, it is not than not, are the poorest. next crisis will draw our focus and the rigorously or consistently applied. The As part of the international efforts, lessons learnt may become consigned to availability and depth of the resource to we need to consider not just about memory, rather than shaping action.

PERSONAL PROFILES THE CONSERVATION DILEMMA

Jeremy Foster More than 700 monuments in Kathmandu and matched materials and traditional techniques. Jeremy Foster CEng MIStructE FRSA its environs were damaged in the ‘quake, However, the decision to retroAt with RC ring Conservation Accredited Engineer has over including the durbar squares of Hanuman beams was vindicated during the 2015 25 years’ experience in the construction Dhoka (Kathmandu), Patan and Bhaktapur. earthquakes when those buildings Atted with industry in the UK and abroad. He has won The cost is counted not only in dollars and the 'inappropriate' resilient RC beams awards both personally and with the loss of tourism, but also in the spiritual withstood the earthquakes much better than structures on which he has worked. heart of the community wedded to their their unreinforced counterparts. The nature of His work covers all aspects of structural precious heritage. the original form of construction of the palace engineering, with specialist expertise in One would think that conservation and alone will never be earthquake-resistant. heritage projects. His recent experience seismic resilience go hand-in-hand. However, Is it better to keep rebuilding in historically includes conservation and restoration, somewhat controversially, during the 1980s accurate materials and techniques every time as well as refurbishment, the design of some of the palace buildings around Patan there is an earthquake or is better to introduce complex remediation to historic military durbar square were retroAtted with reinforced a degree of resilience to what is left and to buildings and advanced 3-D analysis of concrete ring beams. From a purest build in resilience when we rebuild? historic masonry in extreme environments, conservation perspective, this degree of The Venice and Burra Charters give us including seismic retrofit. intrusive protection could be argued as international guidance to use appropriate Whilst being responsible for numerous inappropriate and represents an unacceptable modern interventions. The verdict on projects within the UK and abroad, Foster is loss of heritage value. ‘appropriate’ is in question, but certainly a member of The International Council of Certainly, this argument won over the the heritage assets will be lost, if not Monuments and Sites (ICOMOS) and sits Kathmandu conservation bodies, resulting in protected from both natural disasters and on The International Scientific Committee an embargo on repairs in anything other than inappropriate strengthening. on Energy and Sustainability. He is joint Head of Heritage at Ramboll and leads their work in disaster resilience and recovery.

Sean Smeltzer Originally from Belfast, Sean Smeltzer CEng MICE spent most of his 30-year career based in London, interspersed with several periods living and working abroad, in countries as diverse as India, Hong Kong and the Falkland Islands. After working with the UK government, he moved to the private sector 20 years ago and is experienced in a diverse range of projects, from underground stations to residential and commercial structures. He has previously spent time in Banda Aceh, working on post-tsunami reconstruction with the Red Cross.

10 www.ied.org.uk PEERLESS STRUCTURE

GALES rip VICTORIAN PIER apart

An endangered Victorian pier – the only one in Britain to lead to an island – has partially collapsed into the sea. Can it be saved? Brian Wall reports

s winter saw UK winds that was reduced to 1,040 feet (317 m) long. rides dismantled and removed – before gusted at up to 100mph plus, Due to architectural features, such as being commissioned as HMS Birnbeck, a gales brought devastation to the abutments, at either end of the pier, the secret facility for weapons testing. Serious Birnbeck Victorian pier in pier resembles a bridge more than other damage was caused to the island when Weston-super-MareA – the only one in pleasure piers. a Wellington Bomber, operating out of Britain to lead to an island – which Fifteen groups of piles support nearby RAF Locking, inadvertently partially collapsed into the Bristol a continuous lattice girder, each set released a dummy mine while Bying Channel. The pier is among the 10 most comprising four piles screwed into the overhead. When hostilities were over, endangered buildings on a list compiled river bed at an angle, with an X-brace the pier was handed back to its rightful by the Victorian Society. between each adjacent pair. owners and, although the steamer service The Grade II-listed pier shut in 1994 The Atting of screw blades to iron piles, was resumed, Birnbeck became a more and had since fallen into a state of as opposed to the then accepted wooden sedate place, with just a refreshment disrepair and is now on the Buildings at pile, created a deeper and far more room and no amusements (apart from a Risk Register. Actor Timothy West, who resilient base support. In 1990, the pier weekly visit from the British Legion Band!). recently visited the pier, said it was a was severely damaged in a storm and it The pier then passed through several "beautiful piece of engineering" and closed four years later. owners' hands. Today, the Old Pier is needed to be saved. The history of Birnbeck Island and its deteriorating rapidly. North Somerset The main pier was originally 1,150 feet pier is a long and turbulent one: initial Council has brought together several (351 m) long and is 20 feet (6 m) wide, success, followed by years of decline and interested organisations to form a working with a cantilever construction. However, plenty of bad luck, big ideas and little party, in the hope of putting together the low water jetty was damaged in a money. In 1941, the pier was taken over a viable business plan for some form of storm in 1903, rebuilt in 1909 and Anally by the Admiralty and closed to the public – restoration work. dismantled in 1923, meaning that the pier with the fairground and all amusement Time will tell, if the pier can be saved. www.ied.org.uk 11 Light materials on IMPULSE

ircumnavigating the world in The Solar Impulse team are halfway to do just that. To put the challenge into an aeroplane powered by solar proving it to be the latter, as they have perspective, a jet airliner uses about four energy – a simple enough already flown in eight stages from Abu litres of fuel every second – or about task? Perhaps not, taking the Dhabi to Hawaii, where the aircraft waits 50,000kg of fuel for a transatlantic flight. Ccomparison of the solar-powered car. until the summer of 2016 brings longer Transferring to fuel-less flight has meant Even without the power burden of having days of sunshine. Having reached such losing 50 tonnes in fuel weight, a big step to take off, the cars undertaking the a point, it is clear that the fundamental in the ‘lightweighting’ effort crucial to the 3,000km Darwin-to-Adelaide World Solar technical challenges have been met, but success of the project. Challenge are allowed to start off with it has already been a long journey. We have been following this truly 10% stored energy to help them on their It started in 1999 when Swiss remarkable journey closely, most recently journey that can take up to two days. In adventurer Bertrand Piccard, along with via the May 2015 issue of Eureka fact, of this year’s 29 starters, nine did Englishman Brian Jones, circumnavigated magazine (‘The strange phenomena of not finish. the globe in a hot air balloon. It was the solar flight’), just a few weeks after the The indignity of finishing the journey on first time that anyone had flown around first leg from Abu Dhabi (United Arab a trailer is not an option for Solar Impulse the globe without using any fuel for Emirates) to Muscat (Oman) – a 772km – reliability is paramount. Additionally, forward propulsion. Allegedly, he journey which took 13 hours. each stage of Solar Impulse’s journey proclaimed on successful completion of That article outlined the technology would have to be up to five days’ long, the journey, with only a few drops left in behind the solar flight; the use of over continuously flying through day and night, the hot air burner fuel tank, that the next 17,000 solar cells covering the top far longer than its land-based equivalents. time he did it would be without using any surface of wings and fuselage to trickle So is it ‘mission impossible’ or just ‘traditional energy’. And, in 2003, he charge the batteries, providing power day ‘mission very difficult’? launched the Solar Impulse programme to and night to the four 17.4hp motors.

12 www.ied.org.uk SOLAR IMPULSE

Solar Impulse’s fuel-free Borschberg. Even though the cabin is flight around the world small, it was imperative that weight was has captured the kept to a minimum, with the aeroplane taking the scales at just a little over two imagination. While tonnes. But, alongside the material being the main focus has light, it also had to have excellent thermal properties as, once again, concerned the use of heating inside the cabin was a weight solar power, there have luxury that couldn’t be afforded. The been many other temperature at 8,500m, which is just under the height of Mount Everest, can technological challenges. fall to -50°C and to make it liveable, if One of those, as Tim not exactly comfortable, for the pilot, it must not fall below -20°C. Fryer found out, relates Covestro supplied foam materials for to the materials used the cabin, polycarbonate sheeting for the windows and various glues and coatings, but the company had to prove it offered LIGHT-WEIGHT FLIGHT “To create some pioneering spirit with the best solution in all cases. Providing enough power meant having people.” Dr Ehbing said: “We have other sufficient solar panels, and the more The technology he referred to was not projects where we tested our materials, solar panels you have the more weight necessarily new, just applied in different but they were not chosen simply and the more power you need... classic ways to push the available limits. His because other partners supplied better chicken-and-egg scenario. main concern was to design the cockpit, material mainly, as it always has to be The design settled on an optimum a space of only 3.8m3. This only gives lightweight. The most important factor wing span of 72m, 3.5m more than enough room for one pilot, enough food was ‘Can you supply some material that a Boeing 747-8 or Airbus A380. The (2.4kg a day) for five days, 2.5 litres of contributes most to reduction of the critical factor in making an aircraft with water a day and oxygen, as the daytime weight?’” such a broad wing span was to make it flight peaks at the oxygen-rare altitude of Determining the best shape to house as light as possible. That is where Bayer 8500m. Adding a second pilot would add the pilots required several cycles with MaterialScience, since renamed as too much weight and, for the same both mechanical and heat simulation. Covestro, has played a major role. reason, there is no autopilot, so the Then the physical build was started and Dr Hubert Ehbing, director of pilots are trained to live on 20-minute looped through many design cycles, processing and applications technology sleep segments throughout the day. using a wind tunnel and other tests. “It at Covestro, explained the relevance of This is not sustainable in the long roughly took three years to optimise the the project. “We want to inspire people. term, which is the main factor limiting cabin structure,” said Dr Ehbing. We want to encourage people to think flights to five days. There are two pilots, The final material used to make the about traditional ways of travelling, to both with the same sleep training, fairing (the external structure) was an think about having this technology and Bertrand Piccard sharing piloting duties ultra low density polyurethane rigid foam, using it in a different way,” he enthused. with his fellow co-founder Andre which provided the insulation and www.ied.org.uk 13 SOLAR IMPULSE

mechanical properties required to BUILT TO ‘CONVEY MESSAGES’ protect both pilot and equipment. It was also easy to make, maintain and repair. The plane making this epic journey is in fact Solar Impulse II, which was largely completed in 2013 This was the critical area. The only although design modifications have continued through the testing and trialling period. The first sources of heat in the cockpit were a Solar Impulse was essentially the prototype and work on that was started in 2003 when the little from the electronics equipment, but founders, Piccard and André Borschberg, started the project. At the time Piccard said: “Solar mainly from the pilot himself. The only Impulse was not built to carry passengers, but to convey messages. We do not plan to revolutionise way of keeping this heat in at night was the aviation industry but instead to demonstrate that alternative energy sources and new through the insulation properties of the technologies can achieve what some consider impossible.” foam and the polycarbonate. The foam developed ultimately allowed the target minimum temperature of -20°C to be stiffness and little thermo-conductivity. the total weight of the cockpit area, beaten, as it will not allow the We developed a new micro cell targeted to weigh in at 35kg, in fact temperature to go below -18°C. technology by special modification of the weighs only 24kg. Beyond the structural Higher mechanical strength was foam structure; in doing so, we were able insulating foam, other new materials required for the canopy opening system, to reduce the thermal conductivity of the were developed as well – notably several in case it was needed for a bail-out. The foam by forty per cent. That was what composite materials for mechanical required strength was delivered through was required for the project here.” parts and a special flame-resistant foam a polyurethane carbon-fibre composite that was used to house the batteries. produced using a resin-transfer process. COLD COMFORTS Although the main idea behind Solar The canopy was made of a special However, Dr Ehbing claims this has Impulse is to promote the use of cleaner thermoformed multi-layer (aka double– opened up new application areas. “Think technologies, there have been both glazed) polycarbonate sheet. This about building insulation, for example, or tangible and anecdotal benefits for provided a glass-like appearance, but fridges. If you have a fridge that has an Covestro in getting involved, as Dr with mechanical properties that were installation material, which makes sure Ehbing describes. “We found new better than glass. It also added some that you have less heat loss, up to -40%, materials and new technologies,” he safety functions, such as anti-fogging. you can reduce the thickness of the walls points out. “But we also involved lots of This whole fairing was coated in a of the fridge, put more food inside and, people here, thirty in total. For us, it was specially developed film that improved at the same time, have a higher rating very inspiring, as it allowed us to get mechanical performance and provided of your fridge. We are in discussion with hands-on with new technology, bring weather resistance. fridge manufacturers now.” people together for different functions, Dr Ehbing comments: “We had to This foam has a density of less than share new ideas and push the limits.” develop a special foam here, which had 30kg/m3, which Dr Ehbing describes as www.covestro.com a good combination of mechanical ‘virtually nothing’ and as a consequence www.solarimpulse.com

THE JOURNEY SO FAR

The journey from Abu Dhabi to Hawaii has taken on eight legs with stops at Muscat (Oman), Ahnedabad (India), Varanasi (India), Mandalay (Myanmar), Chongqing (China), Nanjing (China), and Nagoya (Japan). The last flight from Japan to Hawaii was easily the longest taking four days, 21 hours and 52 minutes to cover 7212km at an average speed of 86.34km/hr. Maximum altitude was 8874m. The remaining five flights will first take it to Phoenix and then another US city before travelling on to New York. From there is a choice of a Southern route via North Africa or a Northern route via Western Europe, before a final five day stint back to Abu Dhabi.

14 www.ied.org.uk DESIGN MANAGEMENT GETTING BENEATH THE SPIN

There are many definitions of both ‘design’ and ‘management’. Each is an interplay between physical action in the real world and the mental picture the designer/manager has of that activity, as Colin Ledsome CEng FIED reports

esign and management have outcome. These are, in a nutshell, the long series of individual tasks are carried a lot in common, but, on design management tasks. out in accordance with a set pattern of Daccount of their separate standards. A bureaucracy can be a very history and terminology, that WHAT IS MANAGEMENT? effective way of managing repetitive tasks common ground is lost in a fog of You can't look at management, beyond even-handedly, provided you avoid the conflicting concepts. When you try to a superficial level, without qualifying it as inherent tendency for the system to combine them into a single process, to type and application. Management is a dominate the tasks it administers. the complications increase. range of similar, but separately identifiable, Bureaucracies often lack Aexibility, but are The design task begins with an tasks, linked loosely by a common theme tolerant of small errors, since each case is exploration of the need. Who is the of organisation. We can characterise this dealt with separately. customer? What are the real needs they in three basic ways: This provides a high sense of security want to satisfy? Who will make up the The control of a fixed, or slowly for those staff involved in it. This type of design team? How will the product be evolving, organisation, set up to carry out management can be characterised by made? These questions, and more, a repeated series of definable tasks. This ‘Policy, Procedures and Precedence’. are considerations outside the main typically includes most administrative and Managing a system where parts of the requirement of actually designing the financial management, and often requires organisation may change occasionally, product, yet are essential for a successful a bureaucratic system to ensure that a but most remain fixed for long periods.

www.ied.org.uk 15 The system is expected to have a long- There is usually a high level of checking term future, gradually evolving as its role and analysis to verify decisions. This type changes. This is typified by large-scale of management can be characterised by manufacturing, and most business and ‘Communication, Concept, Choice of sales management, where a number of Options and Cross checking’. lines of work may be proceeding together, Two or all three of these management The options available on the Ford Transit but each will be replaced in time without types may be found within a single mean there are 40 million possible types. fundamentally changing the overall organisation. Administrative tasks, such as organisation. This type of management pay, accounting etc will be type 1 tasks. can accept changes that do not threaten Tasks carried out by marketing, personnel often spoken of as if it were a single the integrity of the system, but cannot etc will be type 2. Organisations with a definable topic. In fact, you can't look at adapt easily to large scale changes and significant forward-planning activity will design, beyond a superficial level, without may slowly become outdated. This can be have type 3. As an organisation matures, qualifying it as to type and application. characterised by ‘System and Scheduling’. the management emphasis tends to move As stated above for Management, Design The organisation of a change, which from the more entrepreneurial type 3, is also a range of similar, but separately has a definable conclusion when the through type 2 as the organisation grows, identifiable, tasks; but, in this case, linked system to carry out the task will cease into the more conservative type 1. As this loosely by a common theme of purposeful to have a role. This is, in broad terms, happens, it becomes less Aexible and creativity. We can characterise this in project management, where there is a struggles to adapt to a changing world, three basic ways: specific objective to be achieved. It being more interested in cutting costs than The routine arrangement of standard includes Design Management and even in investing in new activities. Type 3 parts into a configuration that matches the task of setting up, or changing, the management carries a high risk of failure, the immediate need. Examples include: other two types. A project is often prone to but also has the greatest prospect for the design of a kitchen layout, using cancellation or external interference and opening up new areas of activity. standard modules from a fixed range, thus has lower security for its staff, further to fit the space available; and the compounded as it nears its conclusion. WHAT IS DESIGN? ‘customisation’ of a new car, using the Staff often have a far higher sense of There are many ways to answer that options available from the manufacturer. ownership and achievement to question, but suppose we try a similar Usually, some form of catalogue lists the compensate for this insecurity. breakdown to the one above. Design is options and viable combinations, and a vast range of possibilities can be produced from a relatively limited set of options. (There are 40 million variations of the Ford Transit van.) If an individual combination does not work as well as expected, it does not affect any other

Street Signage: a few basic principles allow conformity across a range of needs.

16 www.ied.org.uk DESIGN MANAGEMENT

completely new solution to a previously actually makes it possible to produce a unresolved or unexplored situation is product not seen before, which opens up required, where a current product type a new market. If it succeeds, it can be cannot be developed further or when regarded as an innovation. a technological change opens up new There are, in effect, two levels of product options. design management: the management When televisions first became more of a specific design project; and the generally available, no-one knew what management of the whole company design they were supposed to look like. The programme, allocating human and physical introduction of carbon fibre reinforced resources between a number of projects. materials has changed the design of Designers are, by nature, independent sports equipment, medical prosthetics, thinkers and project management can aircraft and much more. This type of take on a ‘herding cats’ nature. As is design carries a high risk of failure, but usually the case, the best managers are also has the greatest prospect for opening those with experience in the practice, who up new fields of exploration. It can be know when to stay out of the way and characterised as ‘Novelty and Innovation’. when to concentrate minds on the goal. The size, costs and complexity of the This is a type 3 management activity of product are unrelated to its position on a high order. this spectrum. The costs of the early Managing the design activity of an planning stages are usually only a small organisation is mainly a type 2 activity, proportion of the total and yet most of the requiring foresight and planning to ensure remaining costs of the rest of the project that each project proceeds at an are determined then. appropriate pace, and each team retains Hence, it is a wise investment to make the necessary coherence and continuity the effort to get these early stages right. of purpose. Good design never happens in a FROM STANDARD TO strongly type 1 organisation. INNOVATION A complex product may contain two or SIMILARITIES Carbon fibre reinforced materials have even all three types of design. It is usually I have deliberately adopted the same changed the design of medical prosthetics. convenient, and economic, to include descriptive pattern for both management some standard ‘off-the-shelf’ components and design to bring out their similarities. option. This type of design can be in a design (type A), from fasteners and Even so, it should be clear that the two characterised as ‘Modular, Limited and connectors to larger sub-assemblies. topics are closely related. There is an Derivative’. Even in the most novel products, most opportunity for each to learn from the The adaption of a known theme or of the solution is available from existing other. The management of design is technology to new circumstances. experience (type B). Rarely, a totally new probably the greatest challenge an This can range from the adoption of a concept provides a feature that leads to experienced designer can take on. common, recognisable style for a related a successful conclusion (type C), even range of products (such as street signage) though the rest of the design comes from This article is based on a paper given at the to the performance development of a the other types. Sometimes a new ‘Engineering and Product Design Education 2015’ functional product (for example, the Rolls- concept (a material or mechanism) Conference at Loughborough. Royce Trent series of engines, now considerably more powerful than the The Rolls-Royce Trent series of engines: original design). The majority of design now considerably more powerful activities fall within this area. For most than the original design. design challenges, current known technologies can satisfy the functional needs and there are comparable products to help set the human interfaces. This gives the designer the security of knowing that a solution is likely to succeed. This type of design can be characterised as ‘Adaptation and Development’. The development of a novel form of product where previous design solutions will not suit. This usually happens when a

www.ied.org.uk 17 What are the key product selection criteria for OEM components suppliers in the aerospace sector when Aerospace selecting adhesives for interiors applications? Andrew Marks offers his insights STICKING

trict regulations govern all materials used in aircraft interiors, right down to the type of adhesive used in forming the componentsS and structure of an aircraft cabin. Among others, there are three main drivers which govern all materials used in aircraft interiors: passenger safety, weight management and aesthetics. Similarly to other products, the critical requirements for adhesives are that they ensure the safety and comfort of passengers, deliver durability and performance of individual interior components and ensure compliance with industry regulations. From the interiors manufacturer’s point of view, selecting the correct adhesives can also contribute to production efficiency and greater speed of throughput. Flammability regulations relate to all aspects of aircraft interiors, both visible and invisible. Aircraft interiors – wall, floor Administration (FAA) and the European and ceiling panels, seating structures, Aviation Safety Agency (EASA) are galley structures and so on – are largely responsible for the regulations that cover made from composite panels chosen for fire testing requirements for Eame their light weight and high strength-to- retardancy (FR) and fire, smoke and weight ratio. These are fabricated from toxicity (FST). The US regulations focus face sheets made from phenolic resin and primarily on Eame retardancy, the FAA fibreglass, aluminium or aramid fibre, with regulation applying to compartment a honeycomb core structure of Nomex, interiors being 14CFR 25.853. This sets aluminium or aramid fibre and finished out the increasingly stringent, specific fire with decorative laminates and veneers testing requirements that composite or paint. In the process flow for the structures bonded with adhesives and construction of interior components made void fillers must undergo. from composite panels, adhesives play a While the EASA tends to adopt FAA key role at all levels, from core splicing to wording for FR/FST requirements, there is insert potting, edge filling, panel assembly, a difference in regulatory emphasis veneers’ application, and reinforcement between the US and Europe. In Europe, for fixtures and fittings. there are additional regulations relating to toxicity levels, as well as REACH health SAFETY REQUIREMENTS and safety concerns that have to be taken From the safety aspect, there is a range of into account. REACH is the regulation on regulations that impact on the choice of Registration, Evaluation, Authorisation and materials for aircraft interiors, designed to Restriction of Chemicals, which came into ensure passenger safety and reduce force in 2007. Its main aim is to ensure environmental risk. The Federal Aviation a high level of protection both to human

18 www.ied.org.uk ADHESIVES SELECTION

on OEMs and components manufacturers tasked with selecting products for interiors, but also pushes material suppliers to reinvent their offering to interiors – ensure regulatory compliance. As a forward-looking industry supplier, 3M follows a strategy of developing solutions that meet both current and future regulatory requirements, looking at a 10- to 20-year horizon to take into to the task account chemicalslikely to be phased out or banned. In response to REACH, for example, 3M has already developed halogen and heavy-metal compound free FST systems. Scotch-Weld Structural Adhesive 7246-2 B/A FST by 3M was the first standalone FST compliant, non- halogenated and heavy-metal compound- free paste adhesives designed specifically for interior bonding applications.

THE WEIGHT FACTOR When manufacturing composite panels, the choice of void filler can make a critical difference to the weight of the finished panel. From an operational point of view, aircraft weight is a key factor inEuencing fuel consumption, which impacts both on airline profitability and the environment. Depending on 3M’s lightweight, low-density void the speciDcation of the aircraft, fillers are designed to fill, close the weight of the interior and reinforce honeycomb and components could be higher than sandwich structures. the weight of the airframe, and non- health and the environment from risks structural non load-bearing components posed by chemicals. offer the greatest opportunity to reduce REACH places restrictions on the weight. As one way to drive down weight in manufacture, placement on the market aircraft interiors applications, 3M has and use of specific substances known as developed a line of lightweight, low-density SVHCs (substances of very high concern) void Dllers designed to Dll, close and and the list contains over 1,000 reinforce honeycomb and sandwich substances in more than 59 categories. structures. Some, such as Benzene, heavy metal The weight of the void Dller can be and hexavalent chromium (Cr VI), have reduced by ‘adding air’, in the form of limitations on their use and are being microspheres as an alternative to phased out, while others are completely conventional Dllers. This is achieved, banned. These regulations mean that thanks to the 3M Glass Bubbles some materials available in the US cannot Technology – engineered hollow glass be used in Europe and OEMs need to take microspheres, with a high strength-to- account of the fact that any aircraft Eying density ratio. A combination of epoxy resin into Europe is governed by European and Glass Bubbles Technology can deliver legislation, so substances not permitted a density range from 033 to 0.75g/cmF. under REACH cannot be used, regardless Both one-part and two-part structural and of their acceptability in other territories. semi-structural epoxy Dllers are FR and FST This not only inEicts additional restrictions compliant as standalone products, meeting

www.ied.org.uk 19 ADHESIVES SELECTION

The weight of the void filler can be reduced by of curing time requirements. For instance, effectively ‘adding air’ in the form of microspheres. Scotch-Weld Epoxy Adhesive EC-3531 FR reaches handling strength in 20 to 30 minutes, whereas Scotch-Weld Structural Adhesive EC-7246 FST B/A takes 4 to 5 hours to handling strength. When using two-part systems, choosing Dlling and bonding solutions with the optimum curing cycles can help streamline manufacturing and speed throughput. Alternatively, if manufacturing processes allow, using one-part systems, core Dlling of boards can be achieved during the original panel manufacturing process. FAR/JAR 25.863 regulations and ABD environment, elimination of excess weight One-part void Dllers and adhesives are 0031 Airbus Directive requirements, for operational efDciency, and the overall designed to co-cure at the same available in halogen and antimony trioxide- aesthetics and comfort demanded of temperatures as the resins in the free options. aircraft interiors. composite skin during initial panel Modern aircraft interiors do not just With an increasing demand from manufacture. This means that the cured have to be supremely functional; they also airlines for modern fuel-saving craft, there Dller is already in place when the panel have to look good. As well as other interior is a huge order backlog across the comes downstream for routing or drilling products, adhesives can play a part in industry. Heightened demand puts and insert bonding operations, offering ensuring that suppliers products create pressure on any organisation within the opportunities both to eliminate process an aesthetically pleasing interior. supply chain to accelerate deliveries to steps and to reduce process time. Used as an alternative to mechanical help speed up production. For interiors Choosing the right method of Dxings, adhesives provide a smooth, clear manufacturers, the choice of adhesives application can also make a signiDcant surface without any exposed parts. can impact signiDcantly on manufacturing contribution to production efDciency. Additionally, they offer beneDts in terms of efDciency and speed of production, which, Machine or hand-held dispensing performance. Adhesives are lighter in in turn, can signiDcantly add to proDtability. equipment saves time when dealing with weight than mechanical Dxings and bond There are a number of factors that adhesives or void Dllers in large quantities strength enables the distribution of the affect productivity in bonding/Dlling for high-volume applications and also load over a wider area. From the operations: speed and Eexibility of curing, offers the additional beneDt of reducing manufacturer’s perspective, self-adhesive mix efDciency, Dlling capability and the operator’s exposure to the adhesive. Dnishing materials can be applied quickly materials properties. Carefully selecting When dealing with two-part adhesives, with minimal pressure and, to accelerate solutions with the right performance conventional hand mixing not only takes workEow, components can be pre-taped properties is central to having a positive time, but can be inaccurate, whereas a for speed of application. For instance, 3M impact on manufacturing efDciency. pneumatic cartridge dispenser ensures has developed the VHB Tape 5958 FR, a For example, with two-part void Dllers the correct mix, a cleaner operation and solution that replaces rivets, and thus and adhesives, the speed of curing avoids problems such as air entrapment, offers all of these performance and inEuences the rate at which subsequent shrinkage and slump. Using the right appearance beneDts. steps in the manufacturing process can adhesives and choosing the most One disadvantage of many adhesives be achieved. For high-volume small effective delivery method can substantially is that they are dark in colour, so might bonding operations such as insert potting, simplify many aircraft interior require additional surface coatings to a faster curing adhesive is advantageous, manufacturing tasks. The correct choice conceal, thus increasing the number of whereas larger and more complex panel allows operators to complete assembly manufacturing steps and the overall assemblies require a greater open time to speedily and efDciently, whilst meeting the process costs. To overcome this, 3M has allow for correct positioning or alignment. overriding demand for passenger safety developed a Scotch-Weld Epoxy Adhesive So, despite the emphasis on production and, of course, meeting the airlines’ EC-2815 B/A FR, which is a white interiors speed, using a fast curing adhesive is not desire for aircraft interiors that are adhesive that prevents see-through, always the answer. appealing to their passengers. eliminating the need for extra treatment. The solution is to select an adhesive More on this topic at: To meet the ultimate needs of the that cures at an appropriate rate at which https://www.youtube.com/watch?v= customer, when selecting adhesives for it will achieve handling strength, as M6j4DacDJNw the manufacture of interior components, different applications and volumes will OEMs and parts manufacturers have to require different handling times. Having Andrew Marks is senior application address all of the areas outlined above – understood these needs, 3M has also development engineer, 3M. observance of regulations for the safety of developed a portfolio of interiors 0845 604 6395 passengers and the safeguard of the adhesives that offer solutions for all kind www.3m.co.uk/aerospace

20 www.ied.org.uk

It may not be the fastest vehicle on rails, but Train Zero is speeding up Bombardier’s development of the next generation of rolling stock, as it readies itself for the opening of Crossrail. Tim Fryer climbs aboard

esting aerospace subsystems only at the time when they are assembled in the finished aircraft is neither safe nor cost- effectiveT – no one wants to fly untested equipment or have to go back to the drawing board when it should be the end of the design process. So the aerospace industry came up with the ‘Iron Bird’ Accelerating philosophy – providing simulation of an entire aircraft and allowing various subsystems to be plugged into it to undergo testing at a much earlier stage during design and verification. train design It is a ‘hardware in the loop’ philosophy that has proved invaluable to aerospace companies and now found favour in the rail industry. Train manufacturer were looking at a platform-based approach requirement to carry out such processess Bombardier is the company behind ‘Train where they could develop these core as diagnostic and prognostic testing, and Zero’ – the project that aims to cut costs systems and then tailor things around the requirements on those individual and development times of its next customer needs.” subsystems are getting more complex. generation rolling stock. It has particular Initially, the brief had been to improve “Hardware in the loop testing relevance to the company’s contract to and shorten the test and validation fundamentally is intended to bring those supply the new trains for Crossrail (to be process, but Frazer Nash proposed a bits of equipment together in the manner named the Elizabeth Line when it opens in model-based engineering approach. In this that means they think they’re on the real 2018), but all future train developments methodology, system requirements are train,” explains Freeman. “So you can will also make full use of the facility. modelled early in the design phase and bring in a heating system, you can bring in The consultancy that has designed the those requirements can be veri:ed the door system. You can bring in the system for Bombardier is Frazer Nash, through hardware in the loop tests. propulsion system. You can connect them whose brief was to develop a facility that Freeman adds: “The ultimate aim is to to the real, bona :de train control system could, ‘efficiently develop, integrate and shorten the time that it takes when you that Bombardier has assembled for the validate train electrical and control actually have that :rst train built and you Train Zero lab. The entire software-based systems’. Colin Freeman, senior come to do the sign-off type tests that train control and monitoring system that consultant with Frazer Nash comments: your customer needs; it effectively passes will exist on the Crossrail train is already “The Iron Bird example is always cited :rst time. All of the heartache that you built in the Train Zero lab. The third-party where the aerospace industry builds an might have suffered previously has been bits of hardware that are there – aeroplane before it flies, bringing all the removed by the more targeted, smarter sometimes it’s an internally developed systems together. And they see massive way in the Train Zero facility.” piece of hardware, sometimes it’s a third bene:ts in terms of their testing, their Bombardier works with a number party company they work with – can now time to market, their ability to respond to of third-party suppliers for many of all come together, have simulation models customer change, need, requirements and its subsystems. Traditionally, those written around them.” so on. So there was a desire within subsystems interface to the train control Train Zero, which is housed at Bombardier to take a step change and do and monitoring systems found in the Bombardier’s main manufacturing site in something better and different, and that driver’s cab, but they are now also starting Derby, is purely static, but still has the coincided with them looking at developing to interface with each other. As a result, capability of testing and simulating all that next kind of generation of trains. They there is starting to be a greater moving parts and the environments

22 www.ied.org.uk HARDWARE IN THE LOOP

used gave us that distributed IO, so we could take appropriate test resources and put them where they needed to be on the Train Zero. Every time something changes, it’s relatively simple to make sure that that’s had a negligible impact on the rest of the design.” In terms of the software, it quickly became apparent that the NI VeriStand platform was ideal, in that it created a single environment in which to combine, execute and manage all the tests. That meant software and models he suppliers had already worked on could be bought together, irrespective of whether it was in C or C++, MatLab or LabView; it was no longer a bespoke Bombardier environment. “We could compile them all together and put them behind a nice neat front- end, which looks to all intents and purposes like drive desktop train,”states Freeman, “and not have to throw away things – really great stuff that’s been done in the past by both Bombardier and its suppliers for this new approach. “It’s allowed us to pick up what already existed, add to it, reCne it, take it in a certain direction, but certainly not throw anything away.” The actual hardware platform behind the Train Zero is PXI based, an advantage of that being in its easy deployment, as Freeman observes: “We’ve got a PXI- based hardware platform and VeriStand gives us access to those resources straight out of the box. We can easily conCgure that hardware within the VeriStand environment to either communicate direct to a controller or we can take our models, compile them, place them within that VeriStand environment The Crossrail (Elizabeth Line) trains will be the first to be developed using the Train Zero Lab. and quickly build up the entire train.” Consequently, Train Zero has the potential of playing an important role in (such as getting too hot) that they might the plant – the real world environment that the design process. No longer will experience. All these subsystems do, of goes on around that – and the sensors suppliers – internal or external – have to course, have a wide variety of interfaces, that monitor it. “When we came to the work to a initial speciCcation and then which presented an early challenge. point of how can we realise it, what’s the hope it works in a Cnal solution. Instead, “We had to look at the needs of each best software? What’s the best hardware? suppliers can use Train Zero as an on- individual system and say, okay, what What’s the best approach to use? That’s going part of their own iterative design interfaces does that have with the train? where we brought National Instruments process, thereby encouraging innovation. What interfaces does it have with the to the table,” he adds. Complicating the Trains, effectively, can be designed by outside world? What interface does it picture? There are nine fundamental Bombardier and its partners in tandem have with other systems? How much of designs of train carriage and each has and the Crst product of Train Zero should that is going to be real, how much of that many further variations, ranging from the be ready in 2017, in advance of the 2018 is going to be simulated?” says Freeman. drive systems right down to the lighting in opening of the new Elizabeth Line. Typically, that involved breaking the the drivers cabin. Each conCguration must www.bombardier.com system down into elements of the be tested as a unique solution. www.fnc.co.uk controller, the actuators that it drives, and “The National Instruments kit that we ni.com www.ied.org.uk 23 Battle for supremacy of

Sixteen student teams from around the UK and one Egyptian team will compete to build the best aircraft without a human pilot. And there are more tough design challenges to be faced in 2016

he cream of young engineering awareness of engineering and increasing Ttalent in the UK will take on the the profile of the Institution.” 2016 challenge of designing and building an Unmanned Aircraft System The universities confirmed to be taking (UAS). It is a task that will make high part are as follows: demands on the skills of these engineers, ● University of Surrey as they develop their drones – essentially ● Sheffield Hallam University an aircraft without a human pilot on-board. ● University of Bath These systems are predominantly known ● Loughborough University for their use in military and special ● University of Glasgow operations, such as delivering ● University of Nottingham humanitarian aid. ● Swansea University Once they have completed their UASs, ● University of Manchester the young engineers will then take on other ● University of Southampton teams in a ‘fly-off’, where they will be (four teams) challenged to transport a package as ● University of Liverpool (two teams) accurately and rapidly as possible. “The ● University of the West of England event has been set up to give students ● University of ShefGeld ABOUT THE COMPETITION real-world engineering experience before ● Egypt team – Military Technical College, The Unmanned Aircraft Systems Challenge they leave university,” states John Turton, Kafr El-Sheikh University (UAS Challenge) asks teams of chairman of the UAS Challenge. “The and Tanta University undergraduates to undertake a full design competition also offers recruitment and build cycle of a UAS with speciGc opportunities for employers. The challenge Now in its second year, the UAS mission objectives before competing in a helps students to learn more about Challenge is the fourth student engineering Gnal ‘Hy-off’ and judging in early July 2016. practical aerospace engineering skills, as challenge event run by IMechE, following The challenge bridges the gap between well as develop connections with other like- Formula Student (which challenges student academia and industry in developing minded students from other universities. engineers to design, build and race a applied UAS-related activities; giving the “The competition directly supports single seat racing car in one year), the perfect opportunity to strengthen links with the.... objectives of inspiring young people Railway Challenge and the Design industry and universities throughout the about engineering,” he adds, “while raising Challenge – see panel text, next page. UK and enhance employment opportunities for graduates in aerospace. FORMULA STUDENT In preparation for Formula Student 2016, which takes place from 14-17 July, 170 students recently attended masterclasses and presentations to boost their teams' chances. Seventeen Formula Student teams attended the IMechE’s ‘Learn to Win’ event, while 11 connected via the webinar. The University of Bath, which came fourth overall in Formula Student 2015, the highest-ranked UK university, even brought electric and internal combustion teams along. One of the highlights was the chance to hear from FS ambassador David Brabham, triple Le Mans 24 Hours class winner. He spoke of the dynamics of team, driver and engineer in his ‘Preparing to Win’

24 www.ied.org.uk Student challenge the skies!

Students can compete in multiple challenges: from Formula Student (above) to designing and building unmanned aircraft systems.

presentation and inspired delegates with Dan Jones, chief technical scrutineer, realisation in the Hesh of the ideas his Project Brabham story. "I had the also spoke of how impressed he is by the discussed with the teams.” opportunity to outline the winning year-on-year improvement demonstrated by The competition is pulling in more and mentality needed, which not only helps the teams that attend. “Several more young engineers all the time, as the people prepare better, but also perform to universities have already started on their word spreads and their competitive their best levels at an event,” says 2017 programmes – an interesting engineering design skills are challenged – Brabham. "After my talk, I also spoke to development, which other universities none more so than the University of South some of the students individually. The should consider. Wales and the University of Brighton, who intelligence and enthusiasm that these “I look forward to the 2016 event are taking part in FS for the Grst time in students have is incredible." at Silverstone and getting to see the 2016. CHALLENGING TIMES RAILWAY CHALLENGE The Railway Challenge brings together teams of university students, apprentices, as well as graduates working in industry across the UK, and challenges them to design and make a prototype locomotive. They are required to design and manufacture a miniature (10¼” gauge) railway locomotive in accordance with a set of rules and a technical speciGcation. At the end of each academic year, a competition weekend takes place where the teams compete against each other to test their locomotive designs and determine a winner. What the challenge does so well is to inspire these disparate groups of young people to test their business knowledge, design ability and technical skills in a live environment.This year's event takes place from 1-3 July at Stapleford Miniature Railway.

DESIGN CHALLENGE The Design Challenge competition gives undergraduates a taste of the ‘real world’ of engineering by setting them a challenge to design and create a device to a strict technical speciGcation. The challenge is open to teams of up to Gve students in the Grst year of an engineering course within the UK. The competition aims to give students practical experience to complement their theoretical knowledge and hence an edge in the jobs market. The winner and runner- up from each of the regional competitions go through to the National Final to compete for the David Ball Trophy – named after the founder of the competition.

www.ied.org.uk 25 NEWS FROM AROUND THE UK

NEWS BITES Election of Council IED awards: all welcome! Notice is given of an election to fill vacancies on the and Mr I Treacy. The Chair of Council will be Dr T M B The IED’s annual Institution’s Council, in accordance with By-law 42, Humphries-Smith and the Vice Chairs will be: EurIng awards lunch and AGM are to be held on to take effect from the AGM to be held on Saturday, C Ledsome, Mrs L Meaton and EurIng Professor S P Saturday, 9 July, at 3M 9 July 2016. Vaitkevicius. in Bracknell. All The number of vacancies to be 9lled is eight. Honorary Treasurer will be Mr ATA Keegan. members are welcome, Council nominate the following to 9ll these vacancies: Any three corporate members may nominate any along with families and Mr PKR Bateman, Mr D Farrell and Mr R Yuen. other corporate member for election to Council by guests – meet the IED The non-retiring ordinary members of Council will delivering such nomination in writing to the Secretary, staff, take a look be: Mr S J Ben9eld, Professor GN Blount, EurIng Dr L together with the written consent of such person to around the innovation J Buck, Mr DTH Castle, Mr C M C Dowlen, Dr DJB accept of9ce if elected. Nominations must be centre’s interactive Maf9n, Mr N Phelps, Dr C J Simcock, Dr G A L Tizzard received by Monday, 25 April 2016. activities and have lunch with this year’s award winners. Attendance is free of charge, but attendee YOUR PATH TO CTPD! numbers for the lunch and innovation centre The new status of Chartered Technological Product Designer has captured the are limited. Contact: imaginations – and fervour – of many IED members already. Developed specially [email protected] to for designers working in product design, CTPD has the specific aim of providing reserve your place. professional recognition, support and registration to designers, on a par with Chartership: their colleagues who register as Chartered Engineers, Chartered Scientists or apply now Chartered Environmentalists. Our Chartership for Amongst the first IED CTPD registrants were Dr Ben Watson from Product Designers is 3M; Dr Caroline Simcock from Dyson; and Ian Callum, director of proving to be very design at Jaguar. Now it could be your turn. popular – if you work in If you would like to know more about what is involved in product design, or have taking the same prestigious path, here is your opportunity. colleagues who are Following on from the success of the first information day in product designers who October, the IED is hosting another session for those might be interested in considering applying. It will be held at the IED offices in this fantastic Westbury, Wiltshire, on 20 April 2016, starting at 10.30am, Chartership, please do encourage them to with a mid-afternoon finish. A sandwich lunch will be apply. Full details of provided. this unique professional There will be presentations on the requirements of registration can be CTPD, and how to prepare both your application and the found at: Annotated Design Portfolio that supports the application. http://www.institution- You will also have the opportunity to talk with IED engineering-designers.o assessors and be advised on what information needs to be rg.uk/membership/bec demonstrated in your application. omingamember; or To find out more or to reserve your place, contact Sue at: Ian Callum, director of design at Jaguar, email: [email protected] was amongst the first CTPD registrants. to Mnd out more on [email protected] how to apply. Big Bang beckons UNIVERSITIES NEWLY ACCREDITED BY THE IED The Big Bang annual engineering fair from Nottingham Malaysia Top-up Bachelor of Engineering (HE X11/W11) – up to 2017, then extended 16-19 March at the NEC BEng(Hons) Mechanical Engineering – 2014-2018 – Partial CEng to 2019 is free to attend and MEng(Hons) Mechanical Engineering – 2014-2018 – CEng Cranfield introduces the world of Nottingham China MSc Global Product Development and Management – 2012 -2018 – Further engineering to young people, by way of BEng(Hons) Mechanical Engineering – 2014-2018 – Partial CEng Learning to CEng demonstrations, BEng(Hons) Product Design and Manufacture – 2014-2018 – Partial CEng Liverpool John Moores experiments and hands- Nottingham Trent BSc(Hons) Product Innovation and Development – 2011-2018 – MIED on experiences. MSc Advanced Product Design Engineering – 2015-2019 – Further Learning BSc(Hons) Computer Aided Design – 2011-2018 – MIED This really is a not-to- for CTPD BSc(Hons) Product Design Engineering – 2014-2018 – MIED & IEng be missed, fun-Mlled MSc Smart Design – 2015-2019 – Further Learning for CTPD Glasgow and fantastic day for all BSc(Hons) Product Design – 2016-2020 – MIED BEng(Hons) Mechanical Design Engineering – 2015-2019 – IEng partial CEng those budding Open University MEng(Hons) Mechanical Design Engineering – 2015-2019 – CEng engineers. To secure BEng(Hons) Engineering – up to 2019 – MIED & Partial CEng MEng Product Design Engineering – 2015-2019 – CEng your free ticket now, go to: https://www.the MEng(Hons) Engineering – up to 2019 – MIED & CEng BEng Product Design Engineering – 2015-2019 – IEng Partial CEng big bangfair.co.uk MSc Engineering – up to 2019 – MIED & Further Learning to CEng MSc Product Design Engineering – 2014-2019 – Partial CEng Top-up Bachelor of Engineering (Q78) – up to 2017 until end 2019

26 www.ied.org.uk Institution News

Elections & Registrations

Chartered Technological William Alexander Boughton Stefania-Aristea Karanikolaou Max Skull Danny Jones Product Designers William Brown Christopher Keeble James Guillaume Drujon Smith Owain Jones Simon BenMeld Southsea India Claire Brown Joseph Eric Patrick Keech Belinda Smith Oliver Josty Mark Jones Southampton Megan Butler Abbie Keen David Smith Liam Kelly Sui Man Ko Hong Kong Jack Byrne Lewis Kemp William Benjamin Snowdon Tarek Khsib Folk Year Kwan Hong Kong Joshua Cambridge David Kenward Shane Spence Rory Lehane James Winepress Milton Keynes Daniel Carr Muhammad Ali Khalid Michael Charles Stevenson Callum Lewis Philip Cassidy Christopher Stephen Lane Isabel Taylor Samuel Ley Chartered Engineer Angelo Delgado Chiteculo Matthew Lane Anthony Thomas Kirsten Mark David James Alexander Banchory Tsz Kan Chow George Harry Lawford Bradley Thorne Joshua Maskell David Clucas Christopher Laws Michael John Thundow Verity Moorhouse Election to Member Aaron Charles Cody Stephen Lee Lewis William Tribe William Mortimer David James Alexander Banchory Lewis Conner Joseph Fredrick William Lilburn Matthew Usher Serena Pearce Owain Morgan Cardiff Matthew Coombs Leonildo Gomes Afonso Lima Leonce Bonicci Viossi Edmund Pecherek Orianna Maria Sibada Corio Harry Llewelyn Alexey Volin Natalie Primus Election to Associate Matthew Cox William Long Simon Luke Ward Saiba Quqandi Michael Barrett NorthNeet Jorge Miguel Franco Dantas Alexander Mancini Sam Waters Sanjay Sahota Joseph Dartnell Robert Makomborero Samuel Watkins Dominic Sander Election to Graduate Oliver Daughtrey Manyangadze James Weatherley Jareth Saxton Seraj Anaim Ontario Kiora Dekermanjian James Martin Connor Wells Tomos Smee Rhys Clayhills Manchester Uriah Dick Josue Masasu James Whatley Peter Smith Amy Currie Edinburgh Heather Siobhan Douglas Luke May James Wilmshurst William Smith Daniel Hammond Penzance Guillermo Conde Ecker Rebekka McCauley Joe Wilson Patrick Tang Richard Proctor ShefMeld Luchia Ellis Matthew McMaster Emily Wren Sophia Tarling Bobby Enebi Mitchell Milbourne George Tasker Transfer to Graduate Charlie John Roy Evans Joseph Minister Election to Student from Lewis Thomas Raymond Cameron Lyle Falconer- Jemimah Grace Minnigin Cardiff Metropolitan Megan Thurston John Faiers High Wycombe Cunningham Jasmine Minogue University David Todd Steven Grech Mosta Malta Bree Faucher Jean-Baptiste Modley Ugar Alacayir Bastien Vallat Stephanie Smith Ellesmere Port Samantha Katheri Mijares Igor Moritz Mohammad Bilal Azam Thomas Ward Francesca Alys Fernand Rohit Motivaras Daniel Bartlett Oliver Webb Stephens St Albans Nichola Few Mustafa Muhammad Myles Bates Natalie Williams Stephanie Elisabeth Flanagan Naomie Musau Joseph Beavis Yusef Yarmohamed Election to Student Jonathan Flood Bruno S Neri Joseph Bertera Keran Zhu Nidhin Anilkumar Alexandra Charlotte Forrest Mayowa Oshinyemi Sophie Brown Newcastle Upon Tyne Louise Kimberley Foster Guglielmo Padovan Maximilian Bubenheim Election to Student from Jonathan David Samuel Fry Riya Panchal Owain Cadman Derby University Elmer Altham Bideford George Fudge Jacob Parmenter Thomas Campbell Kamil Ahamat Daniel Bratt Stoke-on-Trent Trevor Anthony Garrens Harry Partridge Bartosz Cechowitz Saif Ahmed Connor Dale Burford Anglesey Maria Alejandra Carreno Garzon Henry Passmore Rhodri Clarke Shahir Altaf Rachel Galea Malta Pantelis Georgiou Guillermo Barcala Pastor Christopher David Sohib Asaam Rowan Miles Bournemouth Sam Giles Stephanie Maria Pereira Stuart Davidson Oliver Beetlestone Tarisai Nigel Rubwe Bristol William Goldsmith Joe Perrott William Davies Thomas Bell Munir Suleman Birmingham George Gray Andrew Petty Deio Davies Jack Booth Andrea Vella Rabat Malta Jake Gregory Joseph Peter Stephen Phillips Samuel Davies Laurence Brady Matthew Michael Groome Burt Ron Pickering Rhydian Dobbin Jonathan Charles Election to Student from Pradip Gurung Simone Polzella Carys Edmunds Samuel Joseph Cross Bournemouth University Elliot Heggie Juan Quiroga Reece Elder Josiah Edun-Olusesi Stephanie Oyindamola Meghan Louise Nancy Hill Jake Reid Thomas Fantom Toluwani Aguda Faleti Olayemi Ade Edward Hoare Matthew Thomas Richardson Patryk Glowacki Joe Stephen Greeves Matthew Richard Alcock Daniel Jordan Neil Hopkins Jamie Rickman Malvin Gonzales Chloe Heath Kiera Jaye Ashman Sebastian Alexander Horodecki Chester Righton Thomas Gray William James Huntley Samuel Ayorinde George Hounsome Sophie Rose Andrew Hallam Jana Jaworska Abubakr Azeez Daniel Howard Aiden Sadler Joshua Hart Oliver Johnson Brandon Badenhorst George Stephen Huish Mart Andrei Salem Georgia Harvey Kara McNab James David Baragwanath Hani Hussein Rhys Sargent Sapphira Hill Rory McPherson Matthew Barker Alexander Hutchins Sam Richard Saunders Mia Hill Jayden Newman Duncan Edward Bezzant Mohammed Tamim Ibrahim Kieran Shams-Abbeckah Annabelle Ho Princess Oboh Charandeep Kaur Bhullar Sean Michael Richard Irving George Sheldrick Tia Howells Conor Pegg Attila Blaskovics Piotr Jacucha Jordan Shilladay Huw Jenkins Mukundi Ndinashe Pemhenayi Philip Bond Louis Jones William Simmons Daniel Jenkins Joshua Alexander Pyatt www.ied.org.uk 27 NEWS FROM AROUND THE UK

Elections & Registrations cont.

Eugenia Sist Kelly Kavanagh Alexander Bowen Amanda-Jayne Gow Henry Moorman Toby Wilson Matthew Liam Smith Mardochee Kiza Rae Bradley Lily Hannah Griggs Dominic Vivian Morris Jessica Emily Woodhead Anthony Spencer Hassan Kordi Isaac Broad James Hadley Caitlin Moyniham Alexander James Paul Edward Sunderland Liga Kurzemniece Zachary Brooks Nancy May Wallace Amy Murdock Worthington Joseph Edward Taylor Jannath Latif Louis BroomMeld Halladay Luke Murgatroyd Alexandra Emily Wright Owajigbana Blessing Katrina Leigh Joseph Brown James Harman Ryan Singh Narang Isabel Wu Uloyok Khyamel Shrees Magar Thomas Andrew Richard Abigail Katherine Hatch Aiziel Nazario Roshan Zavery Ayesha Walker Ananda Manaka Bryant Joseph Adam John Higham Bethan O'Brien Lawrence John Welsh Cristian Amos Maris Hannah Brzezinka George Arthur Hill Sam Odell Election to Student Muhib Miah Daniel Burgess Chun Wing Anthony Ho Jasmine O'Garro from Nottingham Trent Election to Student James Musgrove Emily Bussell Liam David Hopley Chee Kin Pang University from London South Aaron Nanton Elliot Matthew Robert James Alexander Hudson Jack Pearce Henry Betts Bank Kaelin Rose G Newton Butler Harriet Hughes Matthew Peers Elliot Bradley Farhat Saleh Abeid Gary John O'Brien Noranil Butt-Gow Emily May Humfress Nicholas James Phelps Adam Brown Afeefa Wilsom Seniz Oznacar Peter Colin Neill Calvert Susannah Humphrey Alexander Phillips Matthew Brunt Izzatullah Ahmadi Darren Philip Paner James Cameron Eleanor Francesca Hunter- Claudia Picone Lushan Chen Tayaba Ahmed Jefferson Ross Panis Jeremy William Cane Cotton Samuel Price Tingting Cheng Alli Abiodun Yaro-Amodu Carlos Pomar Coinneach Carmichael Kieran Henry Hutchings Craig Price Alex Corley Federico Angiolini Emma Pryce Matthew Carr Kamma Joanne Hvass Matthew Putman Clemens Devarajan Kinga Bednarska Margarita Ragina Katie Carruthers Megan Sarah Jackson Nicholas Lee Pyne Fiaz Faruque Awais Bhatti Alan Rallings AlMe James Alan Chappell Daniel James Jacobs Oliver Ravilious Tom Fothergill Fabian Adam Bogusawski Luke William Robinson Olivia Chevallier Thomas Jacques Hannah Rayner Bin Gui Marco Boi Matilde Rodriguez Chutiwat Chiewhawan Honor May Jennings Jake Daniel Regan Fangzhou Han Rhamayanna Breda Raheim Ryu-Nkztn Sean Tendekai Chimbani William Jephcote Stephen James Reid Dominic Henson Matthew James Bullimore Cristiano Dos Santos Aaron Chohan Milan Johal Mohammed Rob Vedant Jaju Bryn Morgan Burbidge Sampaio Jig Yasa Choudhary Harry Richard Jones Samuel Rogers Jarvis Jeffery Muhammad Qasim Butt Sebastien Pierre Senet- Rachel Chung Carys Wyn Storer Jones William Patrick Rolph William Jones Michael Joseph Byrne Larson Andrew Callum Clow Kudakwashe Kamwaza Samuel Rowbotham Sean Keane Piers Oliver Max Campbell Yahya Sheikh Leyland Clowsley Amy Kelly Joseff Nicholas Ryland Olivia Killeya Lewis Can Alexander Snow Maria Collins Danielle Christina Kettle Elizabeth Cora Samuels Daniel Lemm Jed William Chenery Ryan Swainson Edward Cotterell Emily Kidd Daniel Scarff Kuai Liang Khamrun Naher Choudhury Luke Thompson Patrick Euan Crompton Miles Andrew Kilburn Hugo George Munro Scott Robbie Lightfoot Jemma Rosemary Clarke Harry Oliver Thompson Charles Alexander Crook Thomas William Kirby William Edward Scrimshaw Yu Lynn Ng Connor Corcoran Magaly Trigalet-Dombasi Sophie Carol Joan Curzon Ho Yin Kwok Molly Scutt Peter McMullin Niall Coster Truong Quang Vu Rumyana Rumen Amy Lees Megan Smith Dylan Milne Gherghina Cupicencu Simone Danielle Watson Dancheva Scott James Leslie Henry Adam Smith Joel Morris Jack Curbi Sam WinMeld Samuel Philip Dare Richard Lewis Benjamin Smith Harrison Nutton Hayley Megan Davies Daniel Alexander Wrigley Danae Jane David-Ferlance Roisin Lloyd-Jones Jake Snell William Page Jonathan James Davis Joshua Yeates Clinton Davies Courteney Lockley Annabelle Jennifer Stoate Benrao Pandoo Rodrigo Fernando Pedro de Christopher James William Sophie Louise Lonsdale Jack Strachan Daniel Perez Carval Election to Student Davies James Henry Lord Max Alexander Stretton Riordan Sailes Carlo Baculo Zaraspe Dunn from Loughborough Christopher Leon Dennis Susannah Lowe Emma Sutcliffe Sherin Shibu Fafa Dzide University Toby Dibble Max Thomas Lutkin Toby Swannell Calum Simms Ahmed Ezeldin Thomas Peter Antony Catherine Elizabeth Dodds Samuel Ford Ashley Lander Ka Yi Tam Joseph Stevenson Jake Frost Abbot-Davies James Doggart Lyne Peter Taylor Hannah Swain Adrian Patryk Gadyszewski Oliver James Aldous John Doyle Giyuen Ma Claire Louise Thompson Jack Taylor Achyut Gaire Robert Arrowsmith Samuel Dunsford Bradley Mackelden Adele Yan Ming Tong William Walter Michael Quartei Titus Rose Baines Patrick Ellis James Fraser Macmillan Edwin Philip Carrington Connor Whyley Glover James Balfour Sarah Catherine England Matthew James Malindine Towler Bethany Wignall Lawrence E Goldsmith Alberto Maria Barragan Rosie Ann Evans Douglas Marriott Charlie Turner Thomas Wollatt Jamie Goodson Barnaby Barringer Natasha Fairclough Ben Marshall Claire Marie Varin Liam Wright Adge GrifMn Shameel Batavia Kyle Farhadian Sonia Martinelli Rebecca Vickery Clenod Ramos Hamani William Bayne Samuel Farrar Matthew Mason Zoe Wai Shuting He Grace Catriona Beaumont Hugo Franklin Thomas Massey Samuel Stephen Walker Ricky Hehir Liam Bembridge William James Christopher Aishah Matsunaga-Bailey Alice Wardle Elliot Hewlett Thomas Bennett Fuller Jack McInnes Lauren Webb Myles I Isaacs Max David Richard Jonathan Galbraith Ishbel Lorna McLaren Thomas Wheeldon Mohammed R Islam Benning-Batsto Nikhil Anilkumar Gandhi Tom Michelmore Thomas Weller James Jackson George Bents Daniel Golding Sam Middleton Lucy-Leigh Wheller-Parr Abigail Clarice Jackson Asher Thomas Blythen Madeleine Grace Patricia Nevetha Mohanaraj Jack Christopher Whitefoot Danish Javed Elena Bonino Gordon Elias Ruiz Montserrat Emma Wildish

28 www.ied.org.uk WHAT’S HAPPENING

Nanoparticles control soft robots

easily obtained from permanent magnets and electromagnets. The NC State researchers have found a way of embedding long chains of nanoscale magnetite particles in sheets of elastic polymer to form a magnetic polymer nanocomposite. By applying a magnetic field, the researchers can control the way the nanocomposite bends. Sumeet Mishra, a PhD student at NC State, said: "The nanoparticle esearchers from North Carolina State University have developed a chains give us an enhanced response, and by controlling the strength and Rtechnique for using chains of magnetic nanoparticles to manipulate direction of the magnetic field, you can control the extent and direction of elastic polymers in three dimensions, which could be used to remotely the movements of soft robots." control ‘soft robots’. The researchers believe this technique may be especially attractive for The ability to control the motion of soft robots, coupled with their some biomedical applications. "Electrical control can raise safety issues for ,exibility, gives them potential for use in applications ranging from some medical applications," said Mishra. "And both electrical and light biomedical technologies to manufacturing processes. Researchers are signals pose challenges in terms of communicating those signals to devices interested in using magnetic fields to control the movement of these soft embedded in the body. Magnetic fields, on the other hand, pass through robots, because it can be done remotely and because magnetic fields are easily – and pose fewer safety challenges." Toolbox enables system-level modelling

aplesoft has released the MapleSim CAD The MapleSim CAD Toolbox imports CAD kinetic and kinematic properties as well as the MToolbox, an add-on to MapleSim that allows models directly into MapleSim, recreating the spatial relationships between components. It engineers to understand and improve their model components and preserving their offers feature detection, allowing users to mechanical designs by importing their CAD add new coordinates at points of interest, assemblies into MapleSim. The toolbox such as the centre of a hole or along the allows engineers to learn how their edge of a component, and share designs will behave as part of a larger, coordinate frames between separate multi-domain system, and apply the bodies, ensuring the bodies will be analysis tools of MapleSim to investigate properly aligned when joined. and optimise their designs and final The CAD toolbox handles files from application. virtually any CAD system.

£4m grant for will allow scientists and policymakers to ask deeper questions about the ever-expanding cutting-edge sensor data and self-driving vehicles. The Science of networks of sensors. Sensor Systems Software (S4) project brings The project’s outcomes could lead to more systems research together researchers from the Universities of robust water networks, more responsive air Glasgow, Liverpool, St Andrews and Imperial quality monitoring, reliable autonomous driving ork is beginning on a new research project College London with expertise across computing, and precision manufacturing and more. Wled by four UK universities that aims to engineering, and mathematics, together with The project, which is supported by a grant of deliver smarter, more reliable sensor based private and public sector partners. nearly £4.2 million from the Engineering and systems. These will help to determine the future S4 aims to develop new principles and Physical Sciences Research Council (EPSRC), success of smart cities, the internet of things, big techniques for sensor system software that will run until 2021.

Capacitive mini-sensor unveiled

Pressure Profile Systems has unveiled the SingleTact, a miniature capacitive force sensor that is claimed to deliver superior sensitivity and repeatability compared to resistive force sensors. SingleTact is an ultra-thin, single-element sensor claimed to accurately quantify forces with less than 1% repeatability errors, while having over three times the sensitivity of re- sistive sensors. The device is designed to help engineers to develop innovative products where precise and reliable force measurements are required, using open source software and firmware.

www.ied.org.uk 29 MANUFACTURING PROCESS

Gum manufacturing advances- 42 Technology has partnered with Gabler to develop a new generation of high-speed something to chew on cooling tunnels for Mondeleˉz International that have significantly shortened the time needed for gum cooling and conditioning. The tunnels are also 40% smaller than the A new generation of high-speed cooling tunnels is equipment they replace. helping Mondelez International to boost production throughput in its chewing gum manufacturing process

2 Technology and Gabler, system design, developing a theoretical provider of manufacturing model of the cooling process, advising process equipment, have on the ,nal tunnel design and also pooled their resources and helping with the commissioning of expertise4 to help Mondeleˉz International the new equipment. Gabler then built The new high-speed cooling tunnels have make a dramatic improvement in the and tested the prototype system helped Mondeleˉz International to set a ef,ciency of its chewing gum before manufacturing and installing new e.ciency benchmark for its chewing manufacturing process. the ,nal design. gum manufacturing process. This image The companies have designed and Miles van Niekerk, associate shows a final visual inspection stage on developed new high-speed cooling director, new process development at a production line for Dirol, one of the tunnels that are helping Mondele.z Mondele.z International, comments: company’s chewing gum brands. International to step up production “The new high-speed cooling tunnels, Credit: Sputnik/Alamy throughput, reduce work in progress by which have now been installed in three 60%, and further optimise downstream global locations, highlight the processing and packaging. signi,cant commercial bene,ts of 42 Technology was appointed by bringing together partners with Mondele.z International to work with complementary skills. Gabler, the company’s existing supplier “The new tunnels have signi,cantly of cooling tunnels, to bring a fresh shortened the time needed for gum perspective, drawing on its extensive cooling and conditioning, one of the experience in cooling technologies, most time-consuming steps in the -uid dynamics and process manufacturing process, and are also improvement for the food and drink 40% smaller than the equipment they sector. The aim was to identify new replace,” he adds. ways of using combined conductive In addition to helping design the and convective cooling technologies to new cooling tunnel, 42 Technology has The high-speed gum cooling tunnels are help speed up the cooling of extruded also advised Mondele.z International on now installed in three global locations for gum before it is scored, shaped and opportunities to further optimise Mondele/z International. Shown is one of the final inspection stages on a production moves into the conditioning phase. process ef,ciency through improved line for the Hollywood chewing gum brand. The consultancy’s role included control of temperature, humidity and working with Gabler to develop a new other environmental factors.

30 www.ied.org.uk AEROSPACE MECHANICAL ARCHITECTURE AUTOMOTIVE IT & DESIGN PRODUCT ENGINEERING COMPUTING EDUCATION DESIGN Who are we?

This journal is produced by the IED for our Members and for those who have an interest in engineering and product design, as well as CAD users.

The IED, established in 1945, incorporated by Royal Charter in 2012, is a licensed body of both the Engineering Council and Society for the Environment and we register our suitably quali1ed Members as Chartered Environmentalists (CEnv), Chartered Engineers (CEng), Incorporated Engineers (IEng) or Engineering Technicians (EngTech) and Chartered Technological Product Designers (CTPD). We also offer professional recognition to Product Designers, CAD Technicians and those who teach and lecture in design or CAD. “For any design engineer hoping We represent our Members’ interests at the highest levels and raise awareness of the professional standards of our Members, whilst providing a to pursue a career in industry, resource and information service, and a friendly and approachable route to assessment and registration. membership and registration www.ied.org.uk shows commitment to

Why become a member of the IED? continuing professional Membership of any professional body gives you professional recognition and development and promoting status, and an acknowledged code of conduct to work to. Membership of the IED gives you the added credibility of being acknowledged for the role good practice in those with you play in Design and Innovation, and helps to develop your skills and whom we interact on a daily knowledge in these areas. As well as the various registrations, membership of the IED gives you the basis. The IED provides a opportunity to meet with other designers and discuss issues particular to natural home for those whose your 1eld of expertise or interest. Many of our Members prefer to communicate primarily through the discussion forums on our website, as roles encompass a diverse this lends itself to the busy work schedules – however, we also run range of skills.” seminars, meetings and events where Members can carry out CPD and meet up. BH, Chartered Engineer The IED is the only Institution that represents designers in all Engineering and Product Design 1elds, plus those who teach these skills.

How do you join? We have made the application process as simple as we can. To maintain the high standards of membership, we need all prospective members to: ■ Complete an application form ■ Write a professional review report, detailing what you do in your role in design. All applicants are assessed by a Committee of Members and via an interview. If you are a designer who would like to gain formal professional recognition, or work in an organisation which employs designers, and would like to have your employees gain membership and professional recognition, contact Sue at the IED on 01373 822801 or send an email to: [email protected] to discuss your next step. Engineers Without Borders

Engineers Without Borders-UK is an international development organisation that removes barriers to development through engineering. Our programmes provide opportunities for young people to learn about technology's role in tackling poverty.

We are always on the look out for new volunteers, so to get involved or make a donation please visit out donations page at http://www.ewb-uk.org