Mobile Exhaust Measurement Systems Reveal How

Interview: Bombardier European president of world’s biggest RicardoFeature heading Quarterly Review Q3 2014 train maker answers our questions Reliable offshore wind turbines Sophisticated analytics optimize turbine life and boost the business case for offshore wind power Low carbon vehicles Ricardo’s innovative projects feature in industry-leading LCV2014 show

A focus on the latest in technology, innovation and sustainability

Routecause Mobile exhaust measurement systems reveal how route topology, traffic flow and vehicle technology affect the real-time emissions of Brighton’s bus fleets A NAME YOU CAN’T FORGET. PRODUCTS YOU CAN’T IGNORE.

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Contents Ricardo Quarterly Review • Q3 2014

News Features 08 Industry news...... 04 Real-time bus Jaguar’s all-aluminium XE; Audi first with 48 volts; innovative Renault maps emissions...... 10 As cities across Europe struggle to meet small-car future; EVs expand in France urban air quality limits, research in Brighton & Hove has highlighted how vehicle RQ viewpoint: technology, route topology and traffic flow can influence the real-time emissions of off-highway culture...... 07 public transport fleets.Anthony Smith Cautious attitudes hold back the industry’s explains appetite for innovation, says Ricardo’s Simon Mall Offshore reliability...... 18 10 Developing offshore wind energy is far more Ricardo news...... 24 challenging than simply placing land-based Engineering innovation at low-carbon show; turbines at sea. Anthony Smith reveals how Ricardo supports Clean Air Power, helps Ricardo’s innovative designs dramatically Turkey’s climate change adaptation and wins improve reliability to achieve commercially Indy race transmission supply deal attractive energy costs q & a Laurent Troger...... 08 As European president of Bombardier, the world’s largest transportation provider, Laurent Troger is uniquely qualified A NAME YOU CAN’T FORGET. to comment on how rail, air and road modes PRODUCTS YOU CAN’T IGNORE. will evolve. Tony Lewin puts the questions

If you want to do more, there are two simple syllables you need to remember. Doosan. Ricardo contacts and locations: The task of RQ is to highlight Client confidentiality is of the utmost importance www.ricardo.com/contacts the latest thinking in global to Ricardo, which means that we can only report Doosan delivers performance, productivity, durability, comfort and easy maintenance RQ subscriptions: engineering and technology in the on a small fraction of the work carried out by the in all of its machines. When you look into our products and our committed dealer and www.ricardo.com/rq transportation and clean energy company. So we are especially grateful to those Sales enquiries: sectors and related industries. Ricardo customers who have kindly agreed to [email protected] support networks, you’ll know that we’re up for your biggest, toughest jobs. And We aim to achieve this by presenting an up-to- co-operate with RQ and allow their programmes Head office: date mix of news, profiles and interviews with top to be highlighted in print: without such help from once you experience for yourself what these machines can do, you’ll never forget it. Ricardo plc, Shoreham-by-Sea, Conceived and produced West Sussex, BN43 5FG, for Ricardo by: business leaders, as well as in-depth features on customers it would not be possible to present such United Kingdom TwoTone Media Ltd programmes – both from within Ricardo and other a fascinating insight into the development of new Tel: +44 (0)1273 455611 Editor: Tony Lewin leading companies. products, technologies and innovations. Contributors: Anthony Smith TwoTone Media Ltd contacts: RQ magazine is printed on paper Anthony Smith: [email protected] certified as being in compliance with the environmental and Tony Lewin: [email protected] social standards of the Forest 1.877.613.7970 Stewardship Council ®. DoosanEquipment.com/CantIgnore Doosan Delivers Doosan and the Doosan logo are registered trademarks of Doosan Corp. in the United States and various other countries around the world. ©2014 Doosan Infracore Construction Equipment America. All rights reserved. | 145H-0

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Industry news The latest in technology, innovation and sustainability across world industries

New launches boost connectivity

The wave of new passenger car models laser object tracking systems and Innovative aluminium- systems is not without its risks: launched at the Paris show this year 3D information displays that operate construction Daimler CEO Dieter Zetsche has warned confirms analysts’ predictions that the irrespective of weather conditions, and Jaguar XE (above) and of the dangers of cyber attacks on company’s virtual electronic content of vehicles is rising GM, long seen as a slow innovator in this windscreen display sophisticated vehicles, and JD Power’s sharply, especially where intelligent field, has said it is preparing to launch the (below) latest APEAL study has highlighted systems enabling partially autonomous world’s first mass-produced cars with owners’ discomfort with the operation driving are concerned. eye- and head-tracking technologies to of navigation, voice control and other The new Jaguar XE, whose lightweight tackle driver distraction and inattention. advanced technology content in the aluminium architecture is unique in the Additionally, GM will package Delphi- newest models. compact premium sedan segment, supplied vehicle-to-vehicle and vehicle- incorporates innovations such as stereo to-infrastructure communications from camera controlled automatic emergency the 2016 model year. braking – as previewed earlier in the year Volkswagen’s 2015 Passat, like many in Jaguar Land Rover’s demonstration new introductions, features automatic of advanced driver-assistance parking and 360-degree sensor displays, technologies. Further developments, while Citroën’s Divine DS concept such as the virtual windscreen (right) previews an overhead touchscreen driver could find their way into the XE and other interface and a holographic instrument group models. display behind the steering wheel. Toyota has demonstrated advanced Yet the rapid advance of connectivity

such as electrically powered superchargers “We are using the full bandwidth of Audi commits and drivetrain electrification that would have electrification in our drive principles not have been feasible with current single- strategy. Running part of the vehicle to 48 volts voltage networks. electrical system at 48 volts plays a central Significantly greater energy recovery role in this,” commented Prof. Dr. Ulrich The much-anticipated industry move rates are possible using 48 volt systems, and Hackenberg, member of the Board of towards dual voltage electrical architectures a technology demonstrator based on the Management for technical development at is now officially underway, with VW subsidiary current A6 model has shown savings of 10 g Audi. “It enables us to make more energy Audi announcing it will upgrade part of its CO2/km due to this property alone. Audi’s plan available. That paves the way for new vehicles’ electrical systems from 12 to 48 is for a scalable platform with an ascending technologies with which we can make our volts. The move will allow the company to ladder of features, culminating in the electric cars more sporty, more efficient and more incorporate efficiency-boosting features supercharger. convenient to use.”

4 RQ • Q3 • 2014 Industry News

News In brief Highlighting the latest thinking in automotive engineering and technology worldwide World test procedures Following European Commission research showing how real-world emissions of passenger cars were significantly higher than the figures derived from lab-based official test cycles, Brussels authorities are believed to be preparing proposals to introduce real-world testing methods. What is unclear is how these methods could be made to co-exist with the unified world standard test procedure (WLTP) currently being developed by the Renault concept and road load enable lighter brakes, motor industry authorities. tyres and powertrain. maps small-car The “ZE Hybrid” powertrain links the Backing for lower speed limits 993 cc three-cylinder gasoline engine There is majority support for the lowering of urban speed future with a 50 kW e-motor and a 400 V, limits to 30 km/h according to the results of surveys For a preview of what a next-generation 6.7 kWh lithium ion battery; Renault carried out in Switzerland and the UK. Some 38 percent low carbon supermini might look like, look claims the three-speed clutchless of the Swiss population already live in 30 km/h zones, and no further than Renault’s EOLAB concept, transmission is particularly innovative: their introduction in several UK cities has seen accidents unveiled at the Paris Show. Giving the first and second operate in conjunction fall by up to 54 percent. Separately, the Norwegian Clio-sized hatchback greater credibility with the e-motor and can reach Institute for Transport Economics (TØI) has concluded than many fancy showcars is Renault’s 120 km/h, after which the combustion that intelligent speed assistance is the most effective of claim that the design incorporates engine and third gear engage. eight different driver support technologies in saving lives. almost 100 technical innovations that are A so-called ‘weekday’ driving mode Selective use for high-risk groups such as young drivers destined for production models, some of favours the use of electric power and could be especially beneficial, says TØI. them set to appear before 2020. enables a zero-emission range of 60 Foremost is an impressive weight km; the ‘weekend’ mode combines New cars “cheaper to run” than old models reduction of 400 kg, achieved through both power sources to allow longer New cars cost some 25 percent less to run than their the use of aluminium, composites and distance travel. The outcome is a equivalents from just five years ago according to an even magnesium sheet; aero drag is headline consumption figure of 1 litre of analysis of the latest models carried out by a UK consumer reduced by a third thanks to active flaps gasoline per 100 km on the NEDC cycle, financial website. Moneysupermarket.com looked at five

front and rear. The reduction in inertia equating to CO2 emissions of 22 g/km. different models, comparing new, three- and five-year old examples, and calculated that the lower consumption, insurance, maintenance and taxation of the new cars Modular manufacturing made them a better economic proposition. Keeping valets in check gains ground It is not a problem faced by many, but owners of powerful sports cars must invariably be anxious when they hand their keys to the valet driver at a hotel or restaurant. Now Chevrolet has the answer with its latest Corvette: the potent sports car’s Valet Mode not only locks all the interior stowage areas but also records video, audio and vehicle dynamic data when the car is driven. Speed, engine rpm, gear position and g-force are all captured using the Corvette’s Performance Data Recorder system, developed initially for track-day use by Cosworth.

Daimler and Volvo are among the latest Daimler has a vastly more intricate Steel pistons for Mercedes diesel automakers to reveal production model range spanning two dozen distinct The long-running debate over the merits of steel strategies that rely on modular shapes. Two new Smart models have just for pistons is likely to resurface once more with the vehicle platforms and systematized been released, too, based on rear-engined expectation that Mahle is to supply a production Mercedes manufacturing systems. Renault architecture. Daimler’s own diesel model with this innovation. Steel pistons can be Volvo’s newly-launched XC90 luxury front-drive MFA is well known; now, says made lighter and more compact than their aluminium SUV is the first of the Swedish company’s Daimler’s manufacturing director Markus counterparts and the higher strength of steel allows the models to be built entirely from modules Schäfer (pictured), the company’s global crown to be closer to the gudgeon pin and the rings set in its Scalable Product Architecture production network will also be organized closer together. Important, too, is steel’s lower thermal catalogue and its new standardized four- around the MRA rear-drive architecture conductivity, boosting warm-up efficiency and improving cylinder engines. This architecture will (C, E and S-Class), MHA for SUVs and 4x4s fuel consumption by some 3 percent. eventually encompass all future Volvos. and MSA for sports cars.

RQ • Q3 • 2014 5 Industry News

Low carbon and growth are compatible, say experts

Two recent high-level studies have asserted that reducing carbon emissions need not be incompatible with economic growth: in fact, say the reports, the major structural shift already underway, with people migrating to ever-larger cities, provides an important opportunity to put climate- friendly energy and transport policies into place as those infrastructures would have to change in any case.

Atmospheric CO2 levels passed the 400 ppm mark in May this year and grew by a record amount between 2012 and 2013, and coal-fired plants account for 73 percent of power source of sustainable energy: researchers at Delaware University sector emissions. Yet the cost of solar panels has fallen by 80 estimate that winds blowing from the surface to 3000 metres percent since 2008, solar power has met half of Germany’s could yield as much as 7.5 terawatts – triple the current global energy demand this summer and July saw the connection of a 1 energy demand. megawatt solar storage facility, also in Germany. In Japan, which Presiding over the New Climate Energy Report, former Mexican like Germany is retreating from nuclear power, floating solar president Felipé Calderon said that the world’s finance ministers islands are becoming more important in the energy mix. no longer need to choose between boosting economic growth or Even high level winds are being investigated as a potential fighting climate change because for the first time both are possible.

Baltic innovation Few stretches of water are as environmentally sensitive as the freshwater Baltic between Finland and Sweden. Finnish shipbuilder Wärtsilä has been selected to design a new vessel to operate the Vaasa route to Umeå in Sweden. Wärtsilä has expertise in gas-fuelled propulsion and the vessel needs to be flexible, to carry passengers in the summer schedule and a greater proportion of freight – as well as sea ice – in winter. Design is set to be completed in mid 2015. Urban EVs gain traction in France

Two recent announcements provide evidence that major Renault will take over assembly of the BlueCar at its Dieppe Toyota i-Road: industrial groups are beginning to take EVs and urban car-sharing plant and will investigate the feasibility of a smaller three-seater electric two-seaters schemes more seriously – at least in France. version aimed at car-sharing schemes as well as private sale. on trial in Grenoble Toyota is providing the eastern city of Grenoble with electric Completing the picture for what the companies hope will be a vehicles for its new Cité lib by Ha:Mo car sharing scheme: 35 of convenient turnkey solution for other cities, Renault’s two-seater the innovative three-wheeler i-Road and a similar number of the Twizy will be added to the menu and will join the Bordeaux and more conventional COMS four-wheeler will be available for the Lyon fleets this year. three year pilot programme. Renault has joined with Bolloré, which has provided the vehicles and the infrastructure for several already successful schemes, including Lyon, Bordeaux and Paris where well over 2000 cars are in operation under the Auto Lib banner. While Bolloré has expertise in batteries and charging networks and was the driving force behind the Pininfarina design of the BlueCar now circulating in French cities, Renault has much greater experience in production.

6 RQ • Q3 • 2014 Industry News

Rail: more users, Viewpoint Is off-highway industry culture more innovation constraining innovation? Simon Mall – senior manager, business strategy group, Ricardo

In the early part of 2014 we set motorsport, and as component costs out to investigate the technology decrease and durability increases, strategy of a wide range of players our own expectation at Ricardo is within the international off-highway one of increasing hybridization and sector. Our purpose in this study electrification in the off-highway was to understand the machine and sector in parallel with the ongoing powertrain technologies that will development of traditional engine have the biggest impact in the next technologies to create ever-cleaner five to 10 years. Armed with this and more fuel efficient machines. Against the background of a report showing a rise in world information, our aim was both to passenger and freight use and high-speed trains now validate our own Ricardo technology Organizational culture may be a accounting for one in eight passenger rail journeys, rolling roadmap for the off-highway sector potential brake on innovation stock producers and rail operators are gearing up for further as well as providing, in a manner that While the direct technological insights expansion and advances in efficiency. In rail freight alone, says would avoid revealing company- from the study were extremely the Worldwatch Institute’s Vital Signs Online report, the amount specific information, feedback to valuable and have already led directly of energy required to haul one tonne for one kilometre has more those that had participated. to requests for bespoke studies on than halved since 1970. Our first big surprise in this themes of strategic interest from Among new passenger train launches presented at InnoTrans investigation was just how a number of OEMs, the influence of 2014 in Berlin were Hitachi’s AT200 modular suburban train enthusiastic the international off- organizational culture on innovative system, using friction stir-welded lightweight aluminium highway sector was to engage in capacity was an unexpected finding extrusion construction and with LED lighting, wifi and USB ports the study: twenty-two respondents of the research. In short, it appears at every seat, and Bombardier’s Innovia 300 monorail, set for – ranging from senior engineers to that a conservative engineering use in Riyadh under driverless automatic train control. executive VPs – from seventeen culture, perhaps encouraged by the Besides revealing statistics such as the fact that Asia companies participated in the survey very nature of applications where the and Oceania account for three quarters of all rail passenger from across the globe, most from consequential cost of failures can far kilometres travelled, as well as 37 percent of rail ton-km, the Original Equipment Manufacturers exceed that associated with equipment Worldwatch Institute also highlights some of the negative (OEMs) and suppliers. repair or replacement, can act as a impacts of rail expansion. The report warns of rail’s role in The main factors that shaped significant constraint upon the market maintaining a resource-intensive global economy, and cites a the technology plans in the surveyed implementation of further innovation. big increase in oil spills from rail shipments in the US since 2008. companies included: meeting There are of course some very Worldwide, says the Institute, 28 percent of rail lines are legislative demands and in particular notable exceptions to this, but the electrified. In the UK all main lines are set to be electrified by ensuring emissions requirements research team felt that a distinction 2024, with Network Rail and Bombardier now engaged on tests were achieved; maximizing machine should be drawn between the with locomotives with battery back-up to avoid having to retain efficiency and minimizing the minimization of risk through rigorous diesel units to cover the few remaining stretches of non- machines’ total cost of ownership engineering processes, and achieving electrified track. which included the initial capital the same end through constraining the cost of the equipment as well as the new technology content of products. costs associated with operation and Suggestions for improvement Non-road machinery maintenance throughout its useful included the removal of any internal life. barriers and departmental silos within emissions for Europe organizations, and that OEMs and Hybridization seen the supply chain work more closely The European Commission is set to reveal proposals for as important together in a design innovation regulations to cover the emissions from diesel engines in Despite the distinct lack of hybrid process that delivers the standards non-road mobile machinery (NRMM). The draft rules, which machines in the market at present, of robustness required of this very were leaked following a stakeholder consultation in 2013, this was seen as an important demanding market sector. could cover applications as diverse as generator sets, future technology area by almost In summary, this study showed stationary engines, inland waterway motors, refrigeration all respondents. The rationale that cost reduction, combined units on trucks, and agricultural equipment, railway for the under representation was with improvements in productivity, locomotives and even chainsaws. generally explained in terms of efficiency and fuel economy, currently Many of these sectors are already guided in global high development costs, currently offer the highest focus for technology markets by US legislation, which in many instances is unproven reliability, and a lack investment. Aligning this with a culture stricter than the narrow Euro IV norms that only cover the of market acceptance. As hybrid of innovation and openness to change 19 to 560 kW output range. technologies mature and gain will provide a strong platform for wider acceptance in other sectors companies to succeed in this varied such as passenger cars and and exciting industry.

RQ • Q3 • 2014 7 Interview

INterview Masters in Transportation As president for Western Europe, the Middle East and Africa of Bombardier, the world’s largest transportation provider, Laurent Troger has a unique overview of the interplay between rail, air and road transport. Tony Lewin asks him how transportation is likely to evolve in the future

Do major infrastructure projects such as London’s the train must be designed alongside its infrastructure for Crossrail present an opportunity to promote innovative rail complete compatibility, safety and quality of service. technology, or are cost pressures too great? Major infrastructure projects always present a good opportunity As a supplier of both rail and aircraft systems, do you see high not only to promote our innovative rail technology, but also speed rail taking business from air or creating its own market? demonstrate our commitment to our customers. In the case Both transport solutions have their own advantages, but high- of the London’s Crossrail project, Bombardier will supply an speed rail is mainly attractive for distances between 200 and 600 AVENTRA train for the first time, which is the successor of the km, which would mean approximately up to a two and a half hours Electrostar train. Bombardier committed a substantial up-front train ride compared to an hour flight plus commuting to and from investment into the development of this product platform. It is the airport; after this threshold the appeal of using a high-speed an Electrical Multiple Unit (EMU) that has been designed to be rail decreases and leans towards air travel. lighter, more efficient, have increased reliability, and can carry up to 1500 passengers per train. Cost pressures are clearly What is the outlook for rail freight? present throughout the rail industry, but this should not hinder European operators have experienced recent growth in freight innovation. In our case, Bombardier has taken the cost pressure transport by rail – the only method of freight transport which as a challenge and trigger to continue to evolve as a more is growing at the moment – recovering after a steep decline efficient rail solutions provider without sacrificing innovation. in 2008. Rail freight is a stable market and has a promising outlook, especially in Asia Pacific and North America, but Where do you see the major future expansion in global rail also in Africa with freight networks in development such as networks: in high speed rail or lighter city and commuter the Gauteng-Durban corridor in South Africa. One of the key systems? success factors for rail freight is ensuring that infrastructure Both segments will continue to be important. However, the and rail control solutions are compatible with the rolling stock lighter city and commuter systems are forecast to grow more and are up-to-date; we have seen rail freight accidents in strongly, mainly due to increasing urbanization. We foresee the news in the last couple years, and this is a clear “red flag” the commuter train segment to be the biggest of all rolling for operators to invest in order to continuously improve their stock solutions in the next five years, with metros and light tracks and rail control systems. rail also playing an important role in the urbanization trend. Nevertheless, we also expect further investments in the high- speed segment (for example, in Turkey).

Turning to high-speed rail, how important will it be in the strategic transport networks of the future? High-speed rail projects pose many benefits both for the environment and for the economy. High-speed rail is the most eco-friendly and efficient way to travel long distances and will become a “must-have” for growing economies in the Bombardier near future due to the pollution that other transport means commuter trains impose. In order for this solution to be implemented, the such as this MOVIA Metro in London, political and economic environment needs to be adequate, and incorporate that also means support from local governments to involve innovative technology local communities at an early stage of the project. Significant despite cost pressures in the investment is required in order to implement high-speed rail market projects including associated infrastructure, mainly because

8 RQ • Q3 • 2014 Interview

“High-speed rail is the most eco-friendly and efficient way to travel long distances and will become a “must-have” for In terms of potential savings of CO2, is high-speed rail more important than regional and local light passenger rail systems? growing economies in the near future” These two segments are not really comparable as they have completely different purposes and technicalities, but the reality is that both offer a much greener alternative than For non-electrified routes, is there further potential in diesel and travelling by car or airplane. This is especially true when other types of traction, or will everything become electrified? comparing trains with cars, where a metro for example can There is still some demand for Diesel Multiple Units (DMUs) transport up to 50,000 passengers per hour in an urban and diesel Locomotives, but the clear trend is that eventually environment, while cars can only carry 2,100 passengers. rail traffic should become electrified.

What are the main barriers to high-speed rail in North America? Can the lessons currently being learned with autonomous Huge investments to upgrade infrastructure to bring it driving cars and trucks be applied to urban metro systems? to high-speed level would be necessary. Without these Might driverless trams be feasible? necessary investments, we can only develop incremental high Yes, we actually already supply automated urban systems such speed. Local culture of ownership and property, and travelling as automated metros and monorail trains. As for the driverless on public transportation are not as established as in other trams, as long as they have their own line we might see this countries, and there is limited centralized support for the rail in the future, but when the tracks are shared with streets it industry but strong support for automotive and oil industry becomes much more challenging with cars also being a factor.

What are the advantages and drawbacks of dedicated high- What will be the most important single technical advance in speed routes in terms of safety, cost and emissions? rail in the next 20 years? The main advantages are safety: high-speed rail is safer than Bombardier’s PRIMOVE inductive energy solution is a game driving a car, the reduction of emissions, relieving highway changer in the industry in terms of energy efficiency and congestion, reductions in commuting time, and the creation of environmentally friendly technology. It’s hard to point out additional jobs. Against this must be set the disadvantages of high one single technical advance in the context of our future initial capital costs, and the costs of operation and maintenance. developments, but in Bombardier we are convinced that there is high potential for technological innovation in the rail industry What other technical developments in rolling stock and and we aim to have a head start by following foreseeable trackside equipment offer opportunities for CO2 and cost trends such as e-mobility, predictive maintenance, savings? (e.g. energy storage and release, flywheels etc.). augmented reality, new materials, 3D printing, and of course Which types of route would offer the greatest benefits? higher energy and operational efficiency, all of which are key The on board energy storage is one of the main future technologies drivers in urbanization, which I have alluded to earlier as an to increase competitiveness of public transport systems by making important growing trend. them more economic and environmentally friendly. In contrast to high-maintenance, flywheel-based mechanical energy storage Laurent Troger – President, Division Western Europe, systems, Bombardier has developed the MITRAC Energy Saver, Middle East and Africa, Bombardier Transportation which operates on a purely electrical basis and catenary-free. This ••Troger joined Bombardier in 2004 as vice president, services, on-board solution sets new standards in CO2 and cost savings, as for the European region, becoming services president in 2008. measurements during acceleration up to 50 km/h show a reduction In 2013, his role was expanded to include the rolling stock of the peak power demand by up to 50 percent. It works by storing businesses in the United Kingdom, France and Benelux. the energy released when braking and uses this energy during the ••Prior to joining Bombardier, he worked for 15 years at Alstom next acceleration of the vehicle. This additional energy lowers current Transport. demands from the network, yet the traction effort stays the same.

RQ • Q3 • 2014 9 Emissions and air quality

Routecause As cities across Europe struggle to stay within limit values for urban air quality, research in Brighton & Hove has highlighted how vehicle technology, route characteristics and traffic flow can each have a critical influence on the real-time emissions of public transport fleets.Anthony Smith explains

10 RQ • Q3 • 2014 Emissions and air quality

xxxxxxx

Located on the English Channel’s journeys per head of population outside Brighton & Hove has locations within its Sussex coast, the city of Brighton London, displacing many journeys that central area that regularly experience & Hove might be expected to be the might otherwise be made less efficiently breaches of the limit values for oxides type of conurbation that would enjoy by private cars. of nitrogen. It is generally accepted comparatively clean air by virtue of The largest bus fleet operator, that road traffic is the main source the bracing sea breezes that so often with a dominant market share within of this pollutant, giving rise to public prevail. It is also a highly successful city the city, is Brighton & Hove Bus and health concerns in these urban areas. In in terms of its active encouragement Coach Company, part of the Go-Ahead particular, many measurement studies of public transport. According to UK Group plc, which operates a fleet of indicate that for NOx, diesel traffic is the Department for Transport statistics, the approximately 280 modern buses. most polluting element of the vehicle city boasts the country’s highest – and However, despite its coastal location fleet. For this reason, Ricardo was keen consistently growing – number of bus and its focus on public transport, to work with the bus company to gain a

RQ • Q3 • 2014 11 Emissions and air quality

Ricardo PEMS engineer Simon de Vries operates the test equipment installed on the rear seats adjacent to the engine on each bus tested – in all cases the exhaust system was adapted in the depot prior to tests being carried out on the vehicle (below) so that the exterior profile of the vehicle remained unchanged.

“…it is essential that large urban fleet operators and city authorities consider not only the technologies fitted to vehicles but also look to optimize the deployment duty- cycles of those vehicles in order to maximize their positive environmental impacts” Jon Andersson, Ricardo

better understanding of the real-world emissions in order to understand how heavy goods vehicles and a significant emissions of the fleet, and how these emissions might be reduced not just proportion of the remainder are likely to emissions correlate with the known through the deployment of technology, be of diesel taxis and other light vehicles. pollution hot-spots. but also through possible operational Due to traffic restrictions already in place, “It is well documented that many management measures.” private cars would represent a very small cities across Europe are challenged with proportion of these. Street-level air quality high street-level values for oxides of The North Street measurements tend to show the highest nitrogen and specifically, of NO2,” explains pollution hot spot levels of NO2 close to road junctions, Ricardo manager of aftertreatment North Street is the sole central east- at congested locations and along road and chemical analyses Jon Andersson. west traffic corridor for public transport inclines: the monitoring station on “We know that this is a widespread movements across Brighton & Hove, Brighton’s North Street combines all three problem but to date there have been few and it is a street where bus traffic of these characteristics. if any research studies to assess local predominates. According to City Council “To understand the possible root causes emissions at source and in real time, figures for 2012, buses and coaches of some of the high emissions levels in from the vehicles that predominate in the form approximately 38 percent of this vicinity,” continues Andersson, “we pollution hot-spots. Our aim in this work vehicle movements in the area. A further approached Brighton & Hove Bus and was therefore to measure real-world 6 percent of vehicle movements are Coach Company to suggest a research

12 RQ • Q3 • 2014 Emissions and air quality

Bus preparation for PEMS testing PEMS measurements were performed to a strict daily methodology, including calibration checks of all equipment: •• GPS enabling determination of road speed, latitude, longitude and altitude •• Exhaust flow (allowing calculation of emissions masses from concentrations) measured with pitot tube •• Horiba OBS 2200 PEMS used to measure gases from

raw exhaust (CO, CO2, NOx, THC) •• PC linked to the engine management system records operational data to laptop •• All equipment installed in the rear lower deck seating area, with exhaust sensors installed within the envelope of the bus body

collaboration whereby we measure the Real-world versus be consistent with regulatory drive real-world emissions of a cross-section regulated emissions cycle values. It is arguable therefore of the company’s fleet. Brighton’s North Emissions from vehicles are regulated that it is essential that large urban Street is representative of the challenges by a several European Directives. While fleet operators and city authorities faced by so many towns and cities which the regulatory compliance level at which consider not only the technologies fitted struggle with poor air quality. If we could an individual vehicle is homologated to vehicles but also look to optimize understand how vehicles are behaving in – Euro 1 to 6 (or I to VI for commercial the deployment duty-cycles of those this location and identify potential avenues vehicles) – provides some indication vehicles in order to maximize their to tackle pollution at source, we might of emissions performance, it must be positive environmental impacts.” be able to offer a similar research-led remembered that this is as measured approach to many other conurbations over the regulatory drive cycle and not PM: a problem largely solved across the UK and Europe.” the duty cycle under which the vehicle is Recent changes in emissions To carry out the work, Ricardo operated in day-to-day usage. regulations levels have had extremely also partnered with test equipment “Actual emissions,” explains positive impacts on the reduction of specialist HORIBA, which provided Andersson, “will vary dependent on Particulate Matter (PM). Both light some of its latest Portable Emissions real world driving conditions, much like and heavy duty vehicle emissions Monitoring System (PEMS) technology. fuel economy figures, so they may not regulations now mandate the use of

RQ • Q3 • 2014 13 Emissions and air quality

North Street real-time NOx mass, outbound/downhill journey North Street real-time NOx mass, inbound/uphill journey

Euro IV Run#3 Driver#3 NOx [g/s] Euro V Run#2 NOx [g/s] Euro V hybrid Run#3 NOx [g/s] Euro IV Run#3 Driver#3 NOx [g/s] Euro V Run#2 NOx [g/s] Euro V hybrid Run#3 NOx [g/s]

0.45 16 0.45 16 EGR bus emissions 0.4 0.4 14 (Eu IV) more spiky than Euro IV from SCR buses 0.35 0.35 Hybrid mode, with no 12 All buses show emissions 12 emissions, transitions throughout, while 0.3 Euro IV & V buses to diesel mode later 0.3 Euro V climbing North Street Euro V hybrid show NOx emissions Euro IV Cumumlative NOx [g] Cumumlative 0.25 from the start station of monitoring Location 0.25 station of monitoring Location 8 8 0.2 0.2 6 6 Transient NOx [g/s] Transient 0.15 NOx [g/s] Transient 0.15

4 4 0.1 0.1 Euro V Cumumlative NOx [g] Cumumlative 0.05 2 0.05 2

0 Euro V hybrid 0 0 0 50 100 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350 400 450 Distance from Top of North Street [m] Distance from Top of North Street [m]

North Street real-time NOx mass, outbound/downhill journey North Street real-time NOx mass, inbound/uphill journey

Euro IV Run#3 Driver#3 NOx [g/s] Euro V Run#2 NOx [g/s] Euro V hybrid Run#3 NOx [g/s] Euro IV Run#3 Driver#3 NOx [g/s] Euro V Run#2 NOx [g/s] Euro V hybrid Run#3 NOx [g/s]

4 4 0.1 0.1 Euro V Cumumlative NOx [g] Cumumlative 0.05 2 0.05 2

0 Euro V hybrid 0 0 0 50 100 150 200 250 300 350 400 450 0 50 100 150 200 250 300 350 400 450 Distance from Top of North Street [m] Distance from Top of North Street [m]

North Street NOx Mass

Average NOx Mass Out Bound Average NOx Mass in Bound It was crucial for the At a detailed level, 16 study to understand however, the PEMS emissions in results showed that Brighton’s North poor traffic flow was 14 Street (above) where perhaps the major buses and coaches contributor to higher 12 represent 38 percent NOx, with erratic of vehicle movements. stopping and multiple For the full route the cycles of acceleration 10 three vehicle types and braking correlating followed the expected with the peaks in 8 trend of CO2 and NOx emissions even for the reducing from Euro IV hybrid vehicle. A clear to V and from Euro V conclusion was that 6 to Euro V hybrid. CO2 initiatives aimed at and NOx emissions smoothing traffic flow Cumulative NOx Mass [g] Cumulative events were seen to be and allowing buses 4 broadly aligned so that to operate without in general, measures frequent stop-start 2 taken to improve fuel cycles, could have a economy are likely to large positive impact also have a benefit on on both NOx emissions 0 NOx emissions. and fuel economy. Euro IV - EGR Euro V - SCR Euro V - hybrid

14 RQ • Q3 • 2014 Emissions and air quality

Diesel Particulate Filters (DPFs) which NO2 remains problematic to quantify the benefits on local air have proven highly effective in reducing However, the current issue of concern quality of the overall age of fleets diesel PM to levels indistinguishable for air quality is roadside ‘primary’ (and consequently their Euro level from those of the cleanest forms of NO2 – nitrogen dioxide directly emitted of certification). Moreover, Ricardo internal combustion engine. from vehicles’ tailpipes - much of which experience is that different combustion “Tackling PM has been something is likely to be derived from oxidative systems and catalysts have different of an unsung achievement for the catalysis that assists the very DPFs engine-out NO2 and oxidative ‘abilities’. automotive and heavy vehicle industry,” that have been successfully deployed to As such it is not necessarily true that the contends Andersson. “The full benefits control PM. highest NOx emitting engine has highest of DPF technology will be felt as the As Andersson explains, the problem NO2, or vice versa; the key to informed vehicle parc renews, and it is widely of NO2 emissions is compounded by the understanding is to obtain real-world accepted that the reduction of vehicle fact that as a pollutant, NO2 is not yet data on vehicle emissions performance.” PM emissions over time is being specifically regulated: “Vehicle-level reflected in street-level air quality regulation of emissions of nitrogen Route and vehicle selection measurements. In the UK, there is full oxides is framed in terms of NOx (the Bus route No. 7 was selected for the compliance with the European Limit combination of NO and NO2) rather research work as it traverses the city Value for PM10, another standard set for than individual species. This further through North Street and covers a the protection of human health.” complicates the situation in attempting total of 18 km (9 km in each direction)

RQ • Q3 • 2014 15 Emissions and air quality with significant gradients throughout. The HORIBA OBS 2200 PEMS of the effects of route topology was As such, route 7 is typical of many of equipment was installed on the rear possible.” the buses using this important public seats of the bus adjacent to the engine. transport artery in that buses have In each case the exhaust system was Overall emissions followed been operating for a considerable adapted in the depot prior to tests expected trend length of time before entering the being carried out on the vehicle. This While there has been much debate known pollution hot spot from either enabled the research team to ensure about the extent to which regulatory direction. that all sensors were incorporated into vehicle emissions standards reflect In order to provide a cross-section the system inside the vehicle rather real-world emissions, the three vehicle of the Brighton & Hove bus fleet, than – as is often the case in PEMS types followed the expected trend on the tests were carried out on a Euro work – outside the envelope of the the overall No.7 route, with the CO2 and

IV vehicle fitted with exhaust gas vehicle. Sampling of CO, CO2, NOX and NOx reducing from Euro IV to V and recirculation (EGR) aftertreatment total hydrocarbons was carried out from Euro V to Euro V hybrid. However technology, a Euro V vehicle fitted with directly from the exhaust stream, while it was also found that certification level selective catalytic reduction (SCR) operating data was extracted from the is not necessarily a reliable predictor aftertreatment, and a further Euro V vehicle’s CAN bus to correlate both with of the lowest comparative emissions SCR-equipped diesel-electric hybrid the real-time emissions measurements performance at a particular location or vehicle. Each bus was instrumented and GPS signals for positioning. The instant in time. with HORIBA’s advanced PEMS PEMS measurements were performed No obvious influence of driver or equipment and artificially loaded with according to a strict methodology driving style was observed on either CO2 ballast representing a 70 percent including calibration checks of the or NOx emissions in this study (based passenger load. For reasons of health equipment before each run. on testing of the Euro IV bus). But it and safety, passengers were not “The installation was complex but was found that CO2 and NOx emissions carried and the test runs were not it was important that measurements events were seen to be broadly aligned part of the regular timetable. The of each vehicle’s emissions of CO2 so that in general, measures taken to vehicles were tested on multiple trips and NOx were scientifically recorded, improve fuel economy are likely to also and in normal traffic during business/ robustly and in real time,” explains have a benefit on NOx emissions. shopping hours, pausing at regular Andersson. “By detailed consideration bus stops in a similar manner to the of the type of emissions technologies Traffic flow and route normal passenger service. A number of installed on the vehicle, we could also topology key to emissions different drivers and driving styles were make estimates of the proportion of “Looking at the results in detail across used in testing one of the three vehicles NOx emitted as NO2. By correlating the the whole of the route tested, it was so that the effects of these variables real-time emissions data with the GPS clear that poor traffic flow on the could also be assessed. measurements an accurate analysis westbound journey is perhaps the major

16 RQ • Q3 • 2014 Emissions and air quality

HORIBA PEMS measurement technology

The measurement system used for the Ricardo project with The latest version of this system, the OBS-ONE, offers a particularly Brighton & Hove Bus and Coach Company was HORIBA’s on-board compact and flexible design with 50 percent reduced system power measurement system OBS-2200. The system comprises two state- consumption. The modular system features a removable flame of-the-art technologies: a wet based measurement and an exhaust ionization detector (FID) for THC, a gas analyser unit for CO, CO2, NO, flow meter. The patented NDIR wet based measurement requires NOx and NO2. As with all newly developed HORIBA systems, the new no correction for dry to wet measurement. Additionally, there is no OBS technology uses the HORIBA ONE need for a chiller to extract water content. In this way OBS-2200 PLATFORM and also includes avoids complicated correction calculations and reduces power optional interfaces consumption of the system. The second highlight – an exhaust flow to ECU/OBD data meter – contains high speed response transducers that are also connections with patented by HORIBA. Eight optional attachments cover exhaust test data logging flows ranging from 0-1 m3 to 0-65 m3 depending on the diameter of functions. the exhaust tailpipe. The technology’s proven reliability, robustness and stability allows At the time of writing, Jon Andersson’s team exact measurements at ambient temperatures between 0°C and has placed an order for 40°C, at humidity less than 80 % and at altitudes up to 1500 m. Due an OBS-ONE system and will be using it for to purpose built vibration absorbing base plate, the system is stable future studies of the type even on rough road conditions. reported in this article.

contributor to higher NOx emissions position to make informed judgments purely on the certification level in North Street,” explains Andersson. on the emissions – and by extension, of vehicles, the Brighton & Hove “The erratic stop-start operation that the air quality improvement potential research has shown that this can be is typical on this uphill stretch of the – of possible traffic improvement something of a blunt and potentially route, along with demanding multiple schemes. ineffective policy instrument. Direct cycles of acceleration and braking – “Brighton & Hove, like many cities, emissions measurements on vehicles the combination would be expected to suffers severe air quality problems in that predominate in the location of challenge the performance of EGR and our densely populated and intensely interest can be far more effective SCR emissions aftertreatment control used urban centres,” said Ian Davey, in understanding and reducing air systems, and rapidly depletes the Brighton & Hove City Council Deputy pollution at source. batteries of hybrids.” Leader and Lead Member on Transport. “The recent availability of PEMS This strongly correlated with the “We know that the main contributor is equipment allows us to take real-time real-time vehicle emissions data, which vehicle emissions, yet there is no easy measurements of operating vehicles demonstrated significantly higher levels solution. It is vital that any action taken following their normal duty cycle,” at this location when operating in the to address the problem is based on concludes Andersson. “This approach, westbound and uphill direction. Even evidence and we are grateful for the as demonstrated in this project, allows in the downhill direction, accelerations work that Ricardo is doing with Brighton us to understand at a detailed level were clearly the dominant source of & Hove buses to help us all better exactly where and how emissions are NOx emissions. A clear conclusion of understand the cause of the problems being created. Armed with information the work was that initiatives aimed at and to help focus our efforts on the of this resolution and quality, transport smoothing traffic flow at this location most effective solutions.” fleet operators and local authorities will and allowing buses to operate without Martin Harris, MD of Brighton & Hove be far better placed to make informed unnecessarily frequent stop-start Bus and Coach Company, was equally judgments as to the vehicle technology cycles, could have a large positive enthusiastic at the results of the study: and traffic management improvements impact on both NOx emissions and fuel “The excellent technical research that will be most effective in reducing economy. undertaken by Ricardo has confirmed vehicle emissions at source.” that we are travelling in the right Use of the latest PEMS technology Possible traffic direction with investment in our fleet naturally requires expert handling improvements and in working with partners to reduce and a thorough understanding of The results of the research were delays and stop-start traffic flows for vehicle aftertreatment technologies, presented to Brighton & Hove City buses that adversely impact on the but applied intelligently it can yield Council in early July, and appear to be environmental performance of our extremely valuable insights into the well aligned with proposals already fleet. The research has also informed true emissions of common vehicle under discussion to improve bus flow us of a number of opportunities to types and can help validate potential in the vicinity of the known air quality further improve our environmental improvement initiatives. By considering hot spot. Informed by tangible research performance in the future.” vehicle technology deployment, findings demonstrating how the effects operational management and local of frequent stopping and acceleration Mechanisms of traffic and transport policy in this cycles can significantly affect real-world emissions holistic yet focused and cost-effective emissions of the bus fleet, the Council, must be understood manner, efforts to improve local air the bus company and other local While many initiatives aimed at quality should be both better informed stakeholders are now in a much better improving air quality have focused and more effective.

RQ • Q3 • 2014 17 Offshore wind Offshore reliability Developing offshore wind energy resources is far more challenging than simply placing proven land-based technologies at sea. Anthony Smith reports on a Ricardo strategy to achieve a commercially attractive cost of energy through innovative designs that dramatically improve reliability

If the news output of the mainstream – offshore wind is significantly more newspapers and television channels attractive for rather more practical and is much of a guide, public perceptions hard-headed commercial reasons. of offshore wind are influenced more by a wish to avoid the perceived ‘visual More wind, larger turbines pollution’ of land-based wind farm A typical offshore wind farm location development, rather than in terms of provides a potential wind resource of in a new and more attractive renewable the region of approximately 4000 full energy resource. To the renewable load hours annually, or around double power industry however – from the that which might be expected for a land- major power companies and wind farm based farm. The challenging nature developers to turbine manufacturers of both construction in the offshore

18 RQ • Q3 • 2014 Offshore wind

environment and the commercial costs present a significant, design and operation for robustness imperative to achieve economies of unpredictable and highly variable burden and reliability. “Individual offshore scale also means that the commercial on the total cost of energy generated. turbines are now pushing well above 5 case for larger turbines is compelling. Of the factors affecting the reliability MW capacity, so it is crucial to design In addition to being commercially of individual turbines that give rise and build in the highest standards of attractive, larger turbines are also very to costly unplanned maintenance reliability from the outset,” continues much more practical offshore than they requirements, whether on land or Jordan. “We need to avoid the risk are on land. Freed from the weight and offshore, the turbine’s drivetrain is of high costs of failure and remedial size constraints of transporting nacelles, generally accepted as being one of the replacement of major components such tower components and turbine blades to most significant. as gearboxes, so that drivetrain systems the wind farm location via road and rail, are – as far as is possible with proactive offshore turbine sub-assemblies can Ensuring drivetrain reliability maintenance and advanced monitoring be fabricated at locations close to the Ricardo has been in the business of – fit for the life of the turbine.” dockside, and shipped directly to their assisting wind farm developers and turbine intended installation site. As a result, manufacturers to improve the reliability of Design support for a new rather than the 2-3 MW turbines that are their drivetrains for a number of years, as 7 MW offshore wind turbine typical of the largest land-based wind Paul Jordan, the company’s global head gearbox farm developments, the latest offshore of clean energy and power generation An example of the work of Paul Jordan’s wind projects are adopting much explains: “Reliability is one of the most team in supporting both turbine larger turbine designs of 3-8 MW rated crucial determinants of the commercial builders and gearbox manufacturers capacity. case for wind farm developments. While was reported in Advanced Gearbox and The civil engineering challenge of site selection provides the basic potential Drivetrain Design and Analysis for Lower initial site development – for example in terms of wind resource, the ability to Cost of Energy in the New Samsung accounting for the widely varying seabed convert that potential into revenue for HI 7PM Offshore Wind Turbine which soil conditions, mean depth of water energy sold into the power grid is crucial. If was presented at the prestigious wind and typical marine conditions – can be an operator is suffering excessive turbine industry event, EWEA Offshore, hosted both expensive, and require a range failures, then not only will that operator in Frankfurt in late 2013. The paper of different foundation structures be suffering the burden of unexpected described a recent project to support the than would be found on land. But while maintenance costs, but it will also be losing design of a new compact gearbox for the construction costs are significantly valuable production. The combination of new Samsung Heavy Industries (SHI) 7 higher than on land, they are at least these two factors will serve to increase the MW offshore turbine. DB Wind (formerly reasonably predictable. wind farm operator’s overall cost of energy, known as David Brown Gear Systems) The same cannot be said of operation constraining profits and, in the most was selected by SHI as the turbine’s and maintenance costs, however. With a extreme cases, risking commercial failure.” gearbox supplier in the summer of 2011. requirement for highly skilled personnel, With larger turbines and generally While DB Wind would develop the design specialist equipment and support much more challenging access concept, it contracted Ricardo from the vessels, as well as windows of favourable conditions for maintenance and repair, very early stages of the programme to weather for reliable access to installed however, the offshore environment support this effort in parallel. turbines, operation and maintenance requires extremely high standards of Ricardo’s chief engineer for the project,

RQ • Q3 • 2014 19 Offshore wind

“Reliability is one of the most crucial determinants of the commercial case for wind farm developments… If an operator is suffering excessive turbine failures, then not only will that operator be suffering the burden of unexpected maintenance costs, but it will also be losing valuable production” Paul Jordan - Ricardo

20 RQ • Q3 • 2014 Offshore wind

John Stanton, outlines the company’s bearings are designed to give better involvement: “Our responsibilities were control of and reaction of non-torque Samsung Heavy Industries’ essentially to provide engineering loads from the rotor to the gearbox, support to DB Wind’s design programme reducing the effects of these on the 7MW turbine in order to help ensure that overall cost of drivetrain. energy targets were met. This involved us The location of the gearbox inside ••IEC class 1, 7MW rated power participating in a concept design review the mainshaft saves casing cost and ••25 year design life of the gearbox and drivetrain, followed by weight, and reduces the space required ••171.2m rotor diameter, 110.6m hub height above MSL structural strength and fatigue analysis, in the nacelle. Moreover, the 38:1 gear ••Jacket foundation multi-degree-of-freedom dynamic ratio allows a medium speed permanent ••Internal crane analysis of the drivetrain, validation of magnet generator to be used which is ••Medium speed drivetrain with permanent magnet selected key components, and system smaller and less costly than a larger low ••generator & full IGCT conversion rig test planning and execution, including speed machine. The powersplit torque ••3.28m2/kW vibration measurements and analysis. path and multiple planet gears mounted ••3.5ms-1 cut-in wind speed In addition to these practical aspects on flexpins help achieve better load ••25ms-1 cut-out wind speed of the design process, we also assisted distribution over more gear tooth faces, ••10.6rpm rated rotor speed in aspects of DNV (Det Norske Veritas) enabling higher power density and a ••95ms-1 max rotor tip speed certification of the overall drivetrain lighter, more compact gearbox. ••6.9 MNm torque at rated power design.” ••Gearbox supplier: DB Wind The new SHI 7 MW turbine, one of the Strength and fatigue world’s largest, is aimed at meeting the analysis requirements of far offshore and deeper The team subjected all rotating and drivetrain. “We carried out both modal water wind farms. Supported by jacket stationary components to extensive and forced response analysis of the foundations, it has a rotor diameter of finite element (FE) based strength and drivetrain and gearbox using a complex 171.2 metres and its hub stands a full fatigue analysis. “It was important for us model with both torsional and lateral 110.6 metres above mean sea level. to consider gravitational and assembly degrees of freedom,” explains Stanton. With a maximum rotor tip speed of 95 loads as well as those due to operation,” “The modal analysis was used to m/s, the turbine’s drivetrain is required continues Stanton. “In essence, it is predict mode shapes, frequencies and to handle a truly awesome peak torque important through the analysis work modal energy distributions, such that of 6.9 MNm. This brings significant to accurately represent the effective potential excitation assessments could design challenges, as Stanton explains: combinations of loads that the drivetrain be made. The analysis also included “The cost and weight of a wind turbine could expect to endure during service, flexible blades, to understand the drivetrain typically scale with torque, especially the effects of significant non- While the wind coupled vibrations of the system. From and the intended deployment of these torque loads.” potential of the this we then used forced response offshore environment high-MW machines in far-offshore The analyses included a detailed study is generally much analysis to study system resonances and deep-water locations means that of the effective load share between higher than that on and responses to specific conditions drivetrain design for longevity and the multiple planet gears mounted on land, the cost and of interest; this included a thorough difficulty of access durability is vitally important.” flexpins. During prototype testing this for construction assessment of the housing.” was confirmed using tooth root strain and maintenance of turbines (below) Drivetrain configuration gauges, while further finite element and associated Transient thermal analysis The drivetrain of the SHI 7 MW turbine analysis confirmed the strength and equipment such as The large axial separation between the is a close-coupled, integrated design fatigue life of the flexpin assemblies. transformers (main two bearings, large bearing diameter picture), makes with a modular gearbox located partially extending turbine life and non-uniform distribution of within a hollow mainshaft, supported Drivetrain dynamic analysis and implementing thermal loads within the structure imply on two separate main bearings, inside a In addition to the structural modelling, proactive differential thermal expansion during maintenance crucial shell-type lightweight mainframe. The it was important too to understand in bringing down the warm-up, with the potential to adversely stiff mainshaft and separate taper-roller the dynamic characteristics of the cost of energy. affect the mounting pre-tension applied

RQ • Q3 • 2014 21 Offshore wind

across the bearings. A complex Ricardo technologies transient thermal analysis of the complete mainframe and aimed at optimizing wind gearbox assembly, showed an acceptable control and turbine drivetrain life maintenance of bearing mounting pre-tension during warm up and at steady state conditions. With a very successful design and analysis project completed, the conference paper went on to state that work was progressing with SHI planning to carry out tests of a full prototype nacelle on the new 15MW drivetrain test rig at Narec (the UK National Renewable race is concentrated over a small arc Energy Centre) at Blyth near Newcastle- of some 40 degrees and can lead to upon-Tyne. premature failure, whilst the remainder of the race remains unworn. New technologies “In order to address this commonly improve turbine life found reliability issue with wind turbine While the use of advanced CAE planet bearings, we came up with the MultiLifeTM simulation methods has become an pragmatic solution that involves rotating ••Mechanism to rotate the otherwise fixed inner race of essential tool in optimizing wind turbine the fixed inner race periodically such rolling element bearings drivetrains, Paul Jordan believes that that the wear is distributed around the ••Sensor inputs used to determine incipient damage and achieving further gains in reliability and full circumference,” explains senior optimize indexing strategy for race design optimization – and consequent technologist Jon Wheals. “The MultiLife ••Ensures indexing before damage progresses and reductions in the cost of energy concept offers the potential to extend avoids common causes of secondary damage through generated – will require the application of bearing life by up to five times. It ensures release of damaged material into the bearing new innovations. “There are limits to the that the fatigue damage or wear never ••Shown to deliver life extension of up to 500 percent optimization of drivetrains that can be reaches a critical condition during the achieved through intensive simulation. turbine life – an approach also applicable TorqLifeTM (Torque Only and Torque Truncation) However, there are further step-changes to the outer races of direct drive turbines ••Arrangement of hydraulic cylinders between rotor that can be achieved through the subject to sustained gravity loads.” shaft and gearbox to kinematically isolate non-torque adoption of advanced technologies that Following extremely promising rig loads behaviour and allow torque truncation we have developed from our experiences test results of the Ricardo MultiLife ••Stops off-axis torque into gearbox, even during in other more mature industrial sectors wind turbine bearing management mainframe deformation such as off-highway equipment, system concept in a collaborative ••Full compliance for angular, radial and axial motorsport and road vehicles. For project with the University of Sheffield, misalignment the past few years, Ricardo has been it was announced in late 2013 that the ••Absorbs energy during significant wind events, to actively pursuing the development of a system would be an area of focus for the avoid damaging torque spikes into drivetrain range of technologies that will improve UK government’s Department of Energy the reliability of wind power drivetrain and Climate Change funded OWDIn SensorLifeTM systems as well as optimize the design, (Offshore Wind Drivetrain Innovation) ••Application of advanced acoustic emissions and whilst also allowing proactive operational project. As part of this new initiative, ultrasonic sensors for detection of early-stage faults maintenance through the use of MultiLife systems are being deployed at in bearing and mechanical driveline systems advanced sensor techniques to allow a Scottish Power Renewables wind farm ••Provides advance warning of system health issues enhanced condition monitoring.” location that is known to experience ••Can potentially be used to develop remaining useful aggressive wind conditions. life predictions for key components in the drivetrain MultiLifeTM: Extending bearing life by up to 500 percent TorqLifeTM: Preventing SensorLifeTM is already the subject of a framework Forensic investigation undertaken by overload and non-torque agreement between KONGSBERG and Ricardo. A Ricardo on behalf of wind energy clients loads significant aspect of the collaboration will focus on the has identified a number of bearing failure In addition to its assessment of potential integration of the new Ricardo SensorLifeTM mechanisms commonly found on turbine MultiLife, the OWDIn project is also technology into KONGSBERG’s Wind Farm Management drivetrains. For example, some of these acting as a demonstration of a further System (WFMS). are due to unequal load distribution Ricardo innovation aimed at extending “Ricardo provides an innovative approach to applied to the planet bearings in epicyclic wind turbine drivetrain life: TorqLife. some of the key challenges in condition monitoring,” gears, while others arise due to a range Conventional and hybrid wind turbine explains Kristian Holm, general manager wind for of conditions including, for example, drivetrain architectures are susceptible KONGSBERG. “Combining its expertise and our own running at partial turbine power when to non-torque loads transmitted into advanced methods and algorithms will lift our Wind the rolling elements are prone to skid the gearbox and into the generator Farm Management System to a completely new level, rather than roll and cause scuffing of the for direct-drive architectures where providing energy and cost savings for the client.” precision ground surfaces. Irrespective maintaining the small air gap is critical. of the cause, wear on the inner bearing Moreover, geared systems are also

22 RQ • Q3 • 2014 Offshore wind potentially at risk from torque overload SensorLifeTM schematic under certain operating conditions such as gusts or turbulent wind conditions and fault conditions such as grid loss Acoustic emissions sensors and emergency stop, where high loads can be experienced in the drivetrain before action can be taken to protect the drivetrain by controlling blade pitch. TorqLife is a unique and highly innovative dual-function coupling that avoids drivetrain overloads. It is based on an arrangement of hydraulic cylinders between the rotor shaft and gearbox, or direct-drive generator, which are able to kinematically isolate non-torque loads and enable peak Ultrsound sensor array torque truncation to bring the torque to within acceptable limits. This Ricardo innovation offers the prospect of enabling wind turbine drivetrains to survive in the harshest conditions for their full 25-year operating life without Boundary Mixed Full Film major maintenance intervention. SensorLifeTM: Enabling advanced Condition monitoring While intensive simulation-led design and the adoption of innovations such as MultiLife and TorqLife are aimed at the affected turbine so as to enable the Ricardo MultiLifeTM components in the drivetrain, whether delivering through-life turbine reliability, unit to continue in production until repairs (above/left) can ex- direct-drive or geared.” tend bearing life by up durability and drivetrain optimization, the can be made while also preventing further to 500 percent while ability to identify incipient failures in the consequential damage. SensorLifeTM (above) Cutting the cost of offshore field remains a significant commercial “We are working on next-generation enables advanced wind energy condition monitoring priority for wind farm operators. sensors to enhanced condition and TorqLifeTM (below) With much talk of the incentives for wind Particularly in the offshore environment, monitoring technology, known as prevents overload energy, in the UK at least, being directed maintenance and repair operations need SensorLife, in collaboration with the and non-torque loads towards the offshore environment for from damaging the to be planned around the availability of University of Sheffield,” explains Wheals. turbine driveline. both practical reasons of energy potential highly specialist equipment including “Our focus is on proving the practical as well as for political expediency, turbine support vessels, and also require application of acoustic emission and reliability and cost reduction are now favourable weather conditions. As such, ultrasonic sensors with advanced signal more than ever touchstone issues for the knowledge of the condition at any given processing techniques for detection renewable power industry. moment of key drivetrain systems can of early-stage faults for bearing “The wind energy team at Ricardo be extremely valuable in the scheduling and mechanical driveline condition is seeing a significant demand for its of repairs in advance rather than reacting monitoring. With these techniques, the services both from offshore wind farm after the event. sensor data not only gives advanced developers and the manufacturers of In addition, for both on-land and warnings of system health issues, the latest large-scale multi-megawatt offshore farms, advance knowledge of beyond current state-of-art, but can turbines,” concludes Paul Jordan. “With an impending failure can allow the farm also potentially be used to develop the need to push further in reducing the operator to manage the drivetrain load on remaining useful life predictions for key cost of energy generated by ensuring that the major components of the drivetrain system are sufficiently reliable as to be fit for life, we are also seeing serious interest in our next-generation game-changing reliability technologies, MultiLife, TorqLife and SensorLife, which are being demonstrated on the OWDIn project. Most of all, though – and this is what makes our job really rewarding – is that our endeavours will help ensure that a much greater proportion of renewable power is delivered to the grid, and at a much lower cost, than would otherwise be the case.”

RQ • Q3 • 2014 23 Ricardo News

Ricardo news Latest developments from around the global Ricardo organization Clean low carbon technology meets performance at LCV2014

Ricardo technology demonstrators performance and less than 70 g/km CO2 capable of high fuel efficiency, clean emissions (equivalent to better than performance, and low carbon emissions 100 miles per imperial gallon of diesel) shared a platform with a gasoline-electric as measured over the European Drive McLaren P1 – designed, engineered and Cycle, but at a projected production cost built to be the best driver’s car in the world significantly lower than a comparable full on road and track – at the Low Carbon hybrid electric vehicle. Vehicle Event (LCV 2014). The project is led by Ricardo and Ricardo’s concept of ‘intelligent includes Ford Motor Company, Controlled electrification’ was exhibited in the Power Technologies (CPT), the European form of the launch of the first functional Advanced Lead Acid Battery Consortium integration prototype of the Advanced (EALABC), Faurecia and the University Diesel Electric Powertrain (ADEPT) of Nottingham. Ricardo’s ADEPT was project, which aims to demonstrate joined by the company’s HyBoost concept a powertrain with uncompromised – which featured earlier this year on

Ricardo’s diesel ‘intelligent Jay Leno’s Garage to much acclaim – a electrification’ concept and (right) McLaren P1 gasoline concept that provides hybrid- with its Ricardo battery like fuel economy at a cost premium of management system less than a diesel. “Intelligent electrification offers extremely promising benefits in terms of the cost-effective reduction of

vehicle CO2 emissions and improved fuel economy with uncompromised performance,” commented Ricardo chief technology and innovation officer Professor Neville Jackson. “Ricardo and its research partners in this area have already demonstrated significant success in applying this concept to a gasoline powertrain in the HyBoost project and it is a real achievement to be able to announce today that the ADEPT project team has completed its first functional integration vehicle in time for Ricardo-AEA wins European CHP project display at LCV 2014.” The Ricardo intelligent electrification Ricardo-AEA has been appointed by the European Commission’s Directorate-General for Energy to review displays were joined by a plug-in hybrid and update the reference values that help to determine the efficiency of Combined Heat and Power (CHP) SUV concept and a Ricardo electric vehicle plants across the EU. The combined generation of heat and power using CHP technologies is more efficient concept based on a popular Volvo SUV. than the separate generation of electricity and heat. Under the Energy Efficiency Directive, CHP plants in Perhaps the star attraction amongst schemes generating one megawatt of electricity or more have to deliver primary energy savings (PES) Ricardo’s vehicle displays, however, which are greater than 10 percent, judged as ‘High Efficiency CHP’, to qualify for financial support. was a development test example of the The harmonized reference efficiency values for the separate generation of heat and electricity enable McLaren P1 gasoline-electric hypercar – PES to be calculated in a standardized way across the EU. The European Commission aims to review and loaned by McLaren for the Ricardo vehicle update these values every four years to account for technological developments and changes in the displays at LCV 2014 – which features an distribution of energy sources. advanced Ricardo Battery Management System.

24 RQ • Q3 • 2014 Ricardo News

Second successive Engine of the Year Award for McLaren McLaren was recognized for the second year running in the 3–4 litre category of the prestigious International Engine of the Year Awards, for its 3.8-litre twin-turbo V8 engine – designed and developed in collaboration with Ricardo, and assembled at the state-of-the-art engine production facility at Ricardo’s Shoreham Technical Centre.

Ricardo supports Clean Air Ricardo to host Power’s first production project international motorcycle

Following the successful conclusion of from the concept phase to the first conference the concept study with a global truck phase of production development on Ricardo has announced a high-level technical summit manufacturer announced in February a MicroPilot diesel-natural gas engine addressing key international motorcycle industry 2014, the collaboration between Clean with the potential to deliver a significant themes in the areas of market drivers, and future Air Power and Ricardo will now move improvement in performance and powertrain and vehicle technologies. The Ricardo on to commence the first phase of a efficiency,” commented Clean Air Power Motorcycle Conference will take place in Milan on production development of a diesel- CEO John Pettitt. Monday November 3rd, the day before the start of the natural gas engine based on Clean Air “Our client is a progressive, global EICMA show, one of the foremost trade exhibition events Power’s MicroPilot technology, targeted truck manufacturer with a bold in the global two-wheeler industry. The venue for the at South East Asian and other markets. ambition for the future application Ricardo event will be Milan’s famous Museo Nazionale This first phase of the programme is of compression-ignited natural gas della Scienza e della Tecnologia Leonardo da Vinci. targeted to commence in September engines. Its commitment to move ahead “We are extremely pleased to be able to host our 2014 and will last six months. If with this next phase demonstrates the inaugural Ricardo Motorcycle Conference in Milan at successful, the programme will then enter quality of our technology and the value the start of the EICMA show,” said Ricardo head of a second phase with the objective to bring that our relationship with Ricardo can motorcycle engineering Paul Etheridge. “The clear a MicroPilot diesel-natural gas engine for bring to OEM partners. Our ambition is focus of this one-day event will be upon development. the South East Asian and other markets to become a global design, development We want to talk about challenges, directions and to the start of production in 2017. Clean and delivery partner of compression- trends for the two-wheeler industry globally. In Air Power will continue to be supported ignited natural gas engines and we are doing so our aim is to share knowledge, perspectives by Ricardo as part of the co-operation excited about the potential of this latest and experiences of the latest innovations aimed at agreement signed in September 2013. success to open the door to other OEMs improving motorcycle performance, safety, fuel “We are delighted to be moving partnerships.” economy and emissions, and improving the value delivered to customers. Many of the most senior figures in the industry will already be planning to travel to Milan for the show, and our conference Ricardo-AEA helps Turkey with will provide an ideal and highly complementary programme of technology and business insights, climate change adaptation as well as providing an exceptional opportunity for The Turkish Ministry of Environment city-level adaptation guide available in informed, topical discussions and networking.” and Urbanization has published a new Turkish. Further details can be found at www.motorcycleconference.com. Cities Adaptation Support Package Ricardo-AEA and its partners that has been prepared by Ricardo- developed the Support Package following AEA. The Support Package is aimed at a pilot capacity building project in Bursa, Turkish municipalities and provides a Turkey, which was funded by the UK guide to climate change adaptation, Foreign and Commonwealth Office’s which seeks to reduce the risks posed Prosperity Fund. As part of the project by climate change, such as flooding Ricardo-AEA and its partner Bluecern and drought. Climate change threatens provided capacity building training to urban infrastructure and critical services Bursa Metropolitan Municipality to help such as electricity, water and emergency develop its climate change adaptation services. Turkey’s new Support Package plan for the city of Bursa. The package provides a step-by-step process for provides a step-by-step process for responding to these risks. It is the only preparing a city-level adaptation plan.

RQ • Q3 • 2014 25 Ricardo News

Ricardo to be sole source of Indy Lights transmissions

Ricardo has secured a multi-year contract extension as the the race car by each of the series’ competing teams. This new Indy Lights series sole source of racing transmissions for the US ‘Indy Lights contract also includes an upgrade to the transmission to allow car equipped with Ricardo designed Presented by Cooper Tires’ race series. The Indy Lights series for semi-automatic paddle-operated gear shifting, helping to and manufactured consists of ten rounds of highly competitive racing around bring an attractive level of technology to the newly designed transmission famous North American circuits as the feeder series for the Dallara chassis. (below/left) world-famous Verizon IndyCar Series championship. “We have been supplying racing transmissions to the Under the terms of the contract announced today, Indy Lights series since 2002 with great success and we are Ricardo will provide an in-house designed, manufactured and delighted to announce our continued support of this prestigious assembled racing transmission from its facility in Leamington, racing series,” commented Ricardo Performance Products UK, directly to Indianapolis where it will be assembled into MD Mark Barge. “Ricardo has a long-standing relationship with the teams and chassis manufacturers and we welcome the introduction of new technology to further enhance the racing spectacle that INDYCAR is so famous for.” Advanced Engine Research (AER) will be the Official Engine Supplier, to which the Ricardo transmission will be linked. The Dallara IL-15 chassis will be powered by a 2.0 litre turbocharged four-cylinder engine producing approximately 450 horsepower, with additional power available via a driver-controlled “push-to- pass” feature. Ricardo designs and manufactures racing transmissions for the world’s foremost racing series, including Formula 1, WRC, INDYCAR, Super Formula, World Series by Renault, World Endurance Championship, 24 Heures du Mans and many others.

Aerospace quality accreditation Ricardo Performance Products – the systems standard applicable to Ricardo supports manufacturing and assembly division of companies that supply to aerospace and Ricardo – has secured the prestigious defence industries. It incorporates all of Tenneco China with clean AS9100C aerospace accreditation for its ISO 9001 with additional industry specific manufacturing site at Leamington Spa, requirements for aerospace. diesel technology UK. AS9100C is the quality management Having supplied the Aerospace Ricardo has been selected by Tenneco (Suzhou) Emission industry with complex manufactured Systems Co. Ltd to provide diesel particulate filter (DPF) components for the last eight years, control software and development support. Under the Ricardo Performance Products decided recently announced contract, the company will supply to underpin its robust operations by clean diesel technology including DPF control algorithm creating and maintaining processes and models, hardware-in-the-loop testing support, control working practices which adhere to the strategy calibration tools and on-site calibration training stringent requirements outlined in the to Tenneco’s Kunshan facility near Shanghai, China. AS9100C standard. The latest revision of “I firmly believe that market demands and legislative the AS9100C standard targets a sense of pressures for the latest low emissions engine and process ownership across all functional exhaust aftertreatment technologies are likely to grow departments, providing a level of substantially over the coming years in China, particularly confidence to the company’s clients that within the medium and heavy-duty diesel sectors,” said the organization operates in a considered, Ricardo Asia president Gary Tan. “As a company, Ricardo measured and controlled environment is committed to developing clean, fuel efficient and low that can deliver complex components and carbon technologies and adapting them to meet the assemblies on time and to specification specific needs of our customers in all parts of the world.” with the minimum possible risk.

26 RQ • Q3 • 2014 RICARDO TRAINING TECHNICAL TRAINING BY ENGINEERING EXPERTS Frequent courses o ered in a wide range of disciplines

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