Redefining Rail

long-distance freight operations freight long-distance mass transit, high-speed intercityaims andto transform the outlookHow for fresh thinking in rail engineeringrail Redefining Rica r do Qua do r te r ly r eview revolutionise car design car revolutionise mastermind plans to plans mastermind U lrich Kranz lrich and manufacture I nterview: nterview: BMW’s city-car Ricardo technology delivers ‘world’s C lean diesel sensation sensation diesel lean cleanest’ off-highway engines off-highway cleanest’ third-party customers third-party Ricardo’s race-proven Ricardo’s race-proven competition GT transmission is GT transmission now available to pen Open

Q2, 2010 A Product of Hard Work

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(FRPD[$$GLQGG A Product of Hard Work Contents Ricardo Quarterly Review Q2, 2010

10 16

News Features 04 Industry news 10 Redefining rail Electric-car battle lines are drawn up as partnerships Inspired by career rail industry professional Simon Scott, proliferate; Scania tops truck power charts; emerging Ricardo’s sector-focused rail team has an exciting blueprint markets fuel post-crisis sales boom; EV prices revealed for technology-led services providing dramatically enhanced value to train operators, suppliers, regulatory 24 Ricardo news authorities and passengers Ricardo fronts consortium to develop next-generation low carbon power for shipping; revolutionary supercharger 16 Going clean – off highway will inspire downsized engines; wind energy marketing in With off-highway emissions set to tighten dramatically, the US; key orders for Ricardo-developed Ocelot military Jesse Crosse reveals the benefits of the Ricardo Twin patrol vehicle Vortex Combustion System that tackles heavy duty diesel emissions at source Questions and answers 22 Racing advantage 06 Ulrich Kranz The highly successful Ricardo GT transmission used by Toyota, Honda and Nissan Motorsport in the Japanese As head of BMW’s exclusive Project i megacity car team, Super GT race series is now available to outside customers, Ulrich Kranz plans to revolutionise not just the car but as Anthony Smith reports manufacturing, sales and distribution too. Tony Lewin hears how

New generation, NOT re-generation The JCB Ecomax T4 engine meets Tier 4i emissions legislation without the need for a Diesel Particulate Filter. Head office: Conceived and produced $" Ricardo plc, Shoreham-by-Sea, for Ricardo by: "! " # ! ! ! " This innovative, highly efficient design will provide OEMs with improved packaging, significantly lower operating West Sussex, BN43 5FG, TwoTone Media Ltd ### ! % ! !# " United Kingdom Editor: Tony Lewin costs and up to 10% better fuel economy compared with Tier 3. With outputs from 55kW-129kW (74-173hp), peak Tel: +44 (0)1273 455611 Contributors: RQ magazine is printed on paper torque up to 750Nm (553lb/ft) and a team of highly experienced Applications Engineers ready to tailor products to Ricardo contacts and locations: Jesse Crosse certified as being in compliance www.ricardo.com/contacts TwoTone Media Ltd contacts: with the environmental and your requirements, JCB is the clear choice for OEMs and the leader in engine technology for the new generation. RQ subscriptions: www.ricardo.com/rq Anthony Smith: [email protected] social standards of the Forest Stewardship Council. For further information contact: [email protected] www.jcbpowersystems.com Sales enquiries: [email protected] Tony Lewin: [email protected]

(FRPD[$$GLQGG Industry News

Electric alliances prepare for battle n a rapidly evolving series of deals Iand partnerships the world’s leading automakers have been constructing alliances that will secure them competitive positions in the coming April 7th, 2010: decade’s volume markets for electric Renault-Nissan and low-carbon vehicles. and Daimler Daimler and its Mercedes-Benz and bosses sign Smart brands, which last year took a co-operation deal stake in California EV pioneer Tesla (below), in April announced a wide- Chinese market. At the same time partnership in place with SAIC of ranging tie-up with Renault Nissan, press reports began circulating that China, to build and market a minivan covering small cars as well as electric Daimler was to co-operate on fuel cell version of the Chevrolet Volt plug- technology for city vehicles. The EV development with Toyota. in hybrid, dubbed the MPV5. PSA following month Toyota, the world’s More recently still, Indian car and Peugeot Citroën has strengthened largest automaker, surprised the industry truckmaker Mahindra announced it its electric vehicle co-operation with by also acquiring a stake in Tesla, was buying the established Indian Japan’s Mitsubishi and will begin allowing Tesla to buy the shuttered EV producer Reva, supplier of the selling Peugeot and Citroën branded NUMMI facility in California to build its compact G-Wiz sold in London and versions of the i-MiEV in Europe late Model S electric sedan, but with little other cities: in the process, GM, which this year, and Nissan’s Leaf – the first obvious benefit for the Japanese giant. had an electric vehicle development dedicated volume production battery- A week later Daimler raised the deal with Reva, decided to pull out powered car – already has a long stakes with an electric car development of the agreement rather than see its waiting list in the US. deal with China’s BYD and the planned technology shared with a competitor. While analysts differ sharply in launch of a joint EV brand for the GM, for its part, already has a their forecasts of likely future EV sales volumes, Renault Nissan is installing an annual capacity of 500,000 batteries, Volkswagen is aiming for a 3 percent EV share of its 10m total volume planned for 2018. The very generous EV sales incentives of almost $9000 just announced for key Chinese cities are likely to trigger significant volume boost and thus allow the long- awaited economies of scale to kick in.

EDCM Unit EVs: the world’s ‘most efficient’ (Invertor Charger) Gordon Murray Design claims its forthcoming T27 city car will be the most efficient electric vehicle in the world. The 2.5 metre Battery and Battery three-seater weighs 680 kg – including its 12 kWh batteries – and Management will have a range of up to 160 km. Murray estimates its effective 12v • CO2 emissions on the UK’s current energy mix at 48 g/km for the • Battery • • combined cycle. Full-cycle CO2 damage will be 42 percent less • than the average UK car, notes the company. Transmission Final Drive Motor Radiator

Retrofit traction control EV safety training Design takeover Traffic light phase assistant BMW is offering retrofit traction GM’s Chevrolet and OnStar Volkswagen group has Audi is using its home city of control kits for certain models of brands are sponsoring a purchased 90 percent of Ingolstadt to trial a fleet of 15 its motorcycles already equipped programme in the US to Italdesign Giugiaro, the Italian vehicles linked via wireless LAN with Integral ABS. The ASC familiarise first-responder design organisation responsible and UMTS to the traffic light system reduces engine torque emergency services with electric for a host of classic shapes, network. The system tells drivers to improve stability and prevent and plug-in hybrid vehicles such including the first-generation what speed to maintain to

News in brief wheelspin. as the Volt. Golf, Scirocco and Audi 80. ensure the next signal is green.

4 RICARDO QUARTERLY REVIEW • Q2, 2010 more importantly, torque of 3500 Nm Ricardo Scania tops from 1000 to 1350 rev/min. The typical Quarterly working pressure of the injection system Review truck power is 1800 bar, says Scania. The engine meets current Euro 5 The task of RQ is to highlight the latest thinking league norms as well as the tougher standards in global engineering and technology in the for Enhanced Environmentally friendly transportation, clean energy and related new top-line V8 and extra-high Vehicles (EEVs); it is pre-prepared industries. We aim to achieve this by presenting an up-to-date mix of news, profiles and pressure fuel injection have for Euro 6. While the top 730 hp unit A interviews with top business leaders, as well as allowed Scania to outrun fellow will appear in Scania’s new R-series – in-depth features on programmes – both from Swedish truckmaker Volvo to claim Truck of the Year 2010 – other versions within Ricardo and other leading companies. the title of the world’s most powerful will be available as loose engines truck engine. At the same time the to outside customers and for non- It is a formula that has certainly been a worldwide hit: in the nine years since RQ was revised engine family meets the highway applications, where strict launched we have had to increase our print run strictest upcoming environmental Stage IIIB and Tier 4 interim legislation to 14,000 copies to keep pace with the demand requirements in Europe and other comes into force next year. All units to read about Ricardo and its activities. major markets. use selective catalytic reduction to reduce NOx emissions to levels which Client confidentiality is of the utmost The new R730 importance to Ricardo, which means that is part of a anticipate Stage IV and Tier 4 final we can only report on a small fraction of the modular family values entering work carried out by the company. So we are of engines into force in especially grateful to those Ricardo customers with five, six 2014. who have kindly agreed to co-operate with RQ and allow their programmes to be highlighted and eight Mercedes- in print: without such help from customers cylinders. Benz is it would not be possible to present such a Displacing among the fascinating insight into the way vehicles are 16.4 litres and truckmakers conceived and developed. using Scania’s who have own XPI warned that common-rail compliance Heavy duty progress injection system with planned and pressures of up to European 2400 bar, the R730 develops emissions limits 730 hp at 1900 rev/min and, will push up the price of vehicles. The Stuttgart- based world leader has estimated the cost increase could be as much as Mercedes recently tested its latest 10 percent for Euro 6, which comes Actros 1844 and its 1964 equivalent, into force for new vehicle types in 2013 the LP1620, back-to-back over a 1160 and for all registrations the following km trans-Alpine route from Stuttgart to year. Operators may also face a fuel Milan and back. Measurements showed efficiency penalty of as much as 6 the modern truck consumed half as percent as a result of Euro 6’s tightened much fuel per tonne payload (1.27 NOx and PM standards. litres per 100 km) as the veteran model and emitted 98 percent less NOx and Scania R-series truck is the first to benefit particulate matter. from the powerful R730 engine

Favourable industry forecasts However, growth will be patchy, says JD Power, with Global light vehicle production will rise by 13 percent emerging markets fuelling the expansion and mature, in 2010 thanks to rising demand in emerging markets, crisis-hit markets such as Europe still likely to show according to projections by JD Power Automotive further falls. While the US will recover to almost 12 m Forecasting. JD Power puts 2010 production at 67.7 units in 2010 and 13.7 in 2011, it will remain well short of its million units and expects a strong surge to almost 73 m historic highs. On a more structural level, BRICs markets units in 2011, taking the industry back above its 2007 (Brazil, Russia, India, China) will account for a third of total level of just over 70 m units. sales in 2010, compared with just one fifth in 2007.

Electric pricing revealed Michelin Bibendum eco rally prototype ICE class as well as Mitsubishi has pegged its i-MiEV at over Held this year in Rio de Janeiro, overall victory. Audi’s electric €41,000, before government subsidies, Michelin’s Bibendum rally saw e-tron concept car was beaten for while after tax credits Nissan’s a wide spectrum of vehicles a class win in the electric intercity Leaf (right), a slightly larger car, competing for honours. A Honda prototype class by a plug-in hybrid will sell at around $25,000 in Insight took the production Intercity Smart, but scooped the design the US and under €30,000 in ICE class and a lightweight Audi award. Heuliez’s Will took the light most European markets. A5 – weighing just 1310 kg – the urban vehicle category.

Q2, 2010 • RICARDO QUARTERLY REVIEW 5 RQ Interview – Ulrich Kranz

Shaping the future BMW is committed to launching its megacity vehicle, a dedicated electric car, by 2013, and has formed a special ‘i’ team to examine radical solutions right the way along the value chain. Tony Lewin questions Ulrich Kranz, the man whose job it is to put this exciting initiative into practice

You are in charge of BMW’s Is it one vehicle you are working on, or the battery and the electric motor – so megacity project, project i. Is this a platform for several vehicles? these components can be used in just a single vehicle? We are talking about a new approach, other cars as well. As you know, we It’s more than just a vehicle. Project i is a new architecture which should open are also working in parallel on hybrids, looking at all the processes within BMW up new ways to do more than just one high-efficiency combustion engines – that includes production, logistics, vehicle. We have a motorcycle division and, for the longer term, on hydrogen. marketing, distribution, design, within BMW, which means we are not In the megacity environment the pure architecture, everything. just looking at four wheels but also two- electric drive makes sense, but if you wheelers, should there be customer drive longer distances a hybrid would Is this for all BMW vehicles, or just demand. The megacity vehicle is the be better. the megacity vehicle? one vehicle that has been confirmed. We were established at the end of What are your criteria for a 2007 as a kind of think tank. We have Will the megacity vehicle be pure megacity vehicle? a couple of people in the team from electric, or does the programme First of all, it’s zero emissions: we have each specific area of the BMW group include hybrids and other solutions? to respond to the new regulations – one is for marketing and sales, for What I can say is that this is a purpose- instance, and another for architecture designed pure electric vehicle. It’s not and design. We have been asked to a conversion of an existing vehicle question how we do business today designed for a combustion engine. The and, where necessary, we have to idea is to optimize everything. come up with answers – what we can change and why we should do it. The BMW has said it will be objective is to move the whole of BMW marketed under a sub-brand a big step into the future. of BMW. Does Mini count as a sub-brand? So the lessons will be learned on No, Mini is its own the megacity vehicle? brand, as are BMW and If the lessons are positive, then they Rolls-Royce. It could be will affect the whole organisation. something like M – That’s the idea behind it. All this comes the cars from our M under the umbrella of sustainability as division. We’re thinking this is the target we have to achieve. of a little bit more than This will not only encompass a zero M. No decision has yet emission vehicle: it will also include been made: we’re still in high-efficiency production systems, the concept phase and distribution and so on. there’s a team working on how to set up the whole How many people work on Project i? brand and sub-brand. When we started we had a core team of about 24 people, but because we Will Project i expertise spill have the ability to get experts from over into the mainstream all over the BMW network – we take BMW brand? Will there be people out for certain tasks and for a electric BMWs too? certain time – we now have about 180 The megacity vehicle has been people working in all these different confirmed, but we are also working on areas. technologies like electric powertrains as a whole – the power electronics,

6 RICARDO QUARTERLY REVIEW • Q2, 2010 that have come up – such as in London You have been running a field trial had driven only the Mini E for a couple where you have to pay a high fee to with the Mini E since last year. What of weeks this fear was gone. They are enter the city limits. These are the has been the feedback so far? quite OK with the range of the Mini E things our customers are looking for: The feedback is very important to us because they can manage their day- they want us to come up with a solution as we feed every idea into BMW and to-day business driving to work, doing that is a premium car – they’re not also into the megacity vehicle. We’ve the shopping and so on. People are asking us for a tiny car but for a decent got the biggest test fleet out there, and quite OK with the range (100-150 km, car with [at least] a couple of seats that those drivers give us information on depending on the outside temperature) they can drive within the city limits their driving profiles and habits, what and what also surprised us was that without sacrificing anything. range they expect, how often they though people originally wanted lots of charge. These are all the things that are charging stations – almost every mile So will this vehicle be the size of necessary to make the right decisions – they aren’t using these stations. They a Mini, say? for the megacity vehicle. are charging at home. What they have I cannot tell you the size, but what I can recommended is to have additional say is that we are talking about a four Have you had any surprises? charging stations in offices, restaurants, seater – and a car should of course have Actually, yes. Before the customers parking garages – all the places where a decent trunk so that customers can had had the chance to drive the Mini E the car sits for longer than an hour. We take some sports gear with them if they everybody was talking about the range haven’t been asked about fast charging want go away for the weekend a little and having sufficient charging stations or anything like that. [For the customer] bit outside the city limits. all over the city. But after the customers it’s quite a steep learning curve until

BMW ActiveE concept is based on the existing 1 Series coupé but houses the second-generation electric powertrain destined for the production megacity car

“It’s more than just a vehicle. Project i is looking at all the processes within BMW – that includes production, logistics, marketing, distribution, design, architecture, everything”

Q2, 2010 • RICARDO QUARTERLY REVIEW 7 RQ Interview – Ulrich Kranz

BMW CEO Norbert Reithofer samples the “The overall material mix will be quite revolutionary battery-powered Mini E (above); the Concept Active E display’s key information on the for a volume car, like nothing we have ever seen driver’s iPhone and can be pre-warmed or cooled on mains power before setting off, before. Together with SGL we are developing a thus saving maximum battery power for fibre that is perfect for automotive use” driving

they experience it and realise they are but we get better mileage. We have 32 Do you plan to include the ability to driving less than 300 km a week and kWh in the Active E and 35 in the Mini swap batteries en route, as proposed only need to charge their EV twice a E, and the Mini is 350 kg lighter than the by Renault? week, conveniently at home overnight. BMW, which is a much larger vehicle For us the battery is an integral part of – but we’ve got a much more efficient the vehicle architecture. That means What have the Mini E drivers powertrain, power electronics and we don’t always place the battery in complained about? battery cells. the same position, so it would be hard They complain about only having two to get it out and put another one in. We seats, and they would prefer a bigger So is the customer feedback also have to be careful about weight trunk. They manage OK, but they prompting you to install less battery distribution to make sure the vehicle would prefer four seats – that’s why capacity in your vehicles? fits the BMW and Mini DNA. This is we have now introduced the BMW It gives us the opportunity to work within key for us. The other thing is that if you Active E to complete the development a certain range, a certain boundary just have a swapping station you have to of the powertrain, the next step to get an idea. We have put the same have a standard for the battery cells towards the megacity vehicle. With questions to all our customers driving and batteries, meaning there will be the new powertrain we have been the Mini E, and we’re getting more or less no innovation in the future. We are 100 able to package the engine and the the same feedback from the US East and percent convinced that with all the things batteries without having to sacrifice any West coasts and from Berlin. This gives that are going on in battery development passenger or trunk space. us the background for our decision on and chemistry and anode and cathode how much battery [capacity] to put into materials there will be more progress Have you managed to package in the the car. The other point is that batteries in the battery cell: the battery itself is same amount of battery capacity? are expensive, so the lighter the car the something that we have under control – We’ve actually got less battery capacity lower the battery capacity needed. all the architecture and reinforcements

1 Control electronics 2 High voltage cable 3 Transmission 4 Electric motor

8 RICARDO QUARTERLY REVIEW • Q2, 2010 that go along with crash performance be driven in a couple of minutes. This How much energy is embedded in and battery management, that’s our means that all the charge in the battery the carbon fibre compared with other turf. The latest battery management will be used for driving and not for materials? technology will appear on the Active cooling or heating the battery. You I’m not an expert in this, but the E: we have fitted a liquid heating and unplug the car and it’s prepared: the good thing is that all this can be done cooling system as we are convinced this battery is in the best possible operating with electricity and green power. is the way to manage the battery cell in window and the interior has been This is something we wanted to do: a more professional way. This will also cooled – or heated. the temperatures are not as high as give us the chance to decide on power with steel – it’s around the figure for output, reliability and range. If it was minus 10 outside, how long aluminium – so for us it is a very good would it take for the battery to reach material from the environmental With the progress you have made, operating temperature? point of view. If we have clean energy would a four seater electric Mini now With the Mini E, which has air-cooled available at a particular location to be possible? batteries, it would take 8 or 9 km on a produce carbon fibre and aluminium, Not as a conversion. Conversions are cold winter morning. It depends on the it fits in perfectly with our sustainable always hard to do: the Mini is a small current – if you do lots of acceleration environmental message. car and you have to make sure the and recuperation it would be sooner. battery is safe, performing all the crash Dipl.-Ing Ulrich Kranz, tests and maybe even changing the You have a partnership with SGL head of BMW project i architecture. For us, a conversion is a for carbon fibre. Which parts of the Born in Merzig, near Saarbrücken good way of gaining customer feedback megacity vehicle will be carbon? on Germany’s border with France, very quickly and getting experience I can’t tell you at the moment which Kranz began his automotive career with the techniques, but to introduce a parts are carbon fibre, but I can say as an apprentice mechanic at a BMW real electrically powered vehicle it has that we are using a significant amount dealership; later he attended colleges to have its own architecture. of carbon material to make the vehicle and Bingen university, where he as light as possible. It is too early to graduated in engineering, joining BMW Why did you choose the 1 series be specific but I can say we are using AG in its chassis R&D division in 1986. Coupé as the basis for the Active E a different material mix wherever the In 1995 he moved to BMW’s demonstrator? material makes sense. On the 7 series Spartanburg facility in the US as head It’s a sporty car, and as a Coupé it’s we already have a mix of aluminium, of chassis development, becoming the size and weight of vehicle where steel and plastic materials; on the project manager for the X5 in 1998. it makes sense to install an electric megacity vehicle carbon will be a A series of roles in the R&D division powertrain. It also represents BMW large part of the mix, not just to cover followed, and in 2002 he became head driving pleasure DNA in a really good things. The overall material mix will be of the Mini product line. Kranz was way and it is rear wheel drive – the quite revolutionary for a volume car, appointed to launch and lead project i motor is integrated into the rear axle. like nothing we have ever seen before. in November 2007. Together with SGL we are developing a Is a series hybrid with a range-extender fibre that is perfect for automotive use, motor also part of your programme? but of course you have to have a certain We’re thinking about all possibilities. volume in order to bring the cost down. These are the things we are taking into Carbon is very strong and stiff, so it’s consideration – it’s so important to get important what kind of an architecture feedback from real customer use of the you use. vehicle. If you then ask the customer what else they need, that’s just the kind If you are looking at a whole lifecycle of feedback we want to have very early analysis, is it not tricky to recycle in order to make the right decision. carbon? In the case of the Mini there isn’t the It is recyclable: firstly, you can recycle anxiety about range: the feedback production offcuts. That’s already is so clear that we [now] know what happening, and we are working to do. With the Active E and the new with other companies to recycle the developments in battery management hardened material once the resin has we will be able to manage the been applied. If you want to make sure experience of range for the customer in everything is sustainable you have to a different way. Independent of outside look into the recycling process too. SGL temperature we can heat up the battery is very experienced in fibres and we are so the battery chemistry is always in the already doing the manufacturing in a best performing window; if it is warm continuous process with the roof panels outside, we can cool the battery. for the M3 and M6.

What else can your new battery The M3 and M6 are high performance management system do? niche models. How much bigger in While the car is linked to the grid and volume will the megacity vehicle be? being charged we can use a remote We will see, but it certainly won’t be a control to look into the car and tell it niche car. to cool down because it is going to Railway Technology

“We are not talking about minor incremental improvements – we will be looking to make substantial step-change advances for our customers of tens of percent rather than single digits “

Redefining RAIL A career rail industry professional with extensive experience in both main line and metro sectors, Simon Scott joined Ricardo in early 2010 to spearhead the company’s growth in international rail markets. Here he talks to Anthony Smith about his vision for technology-led services providing enhanced value to railway operators, suppliers, regulatory authorities – and passengers

10 RICARDO QUARTERLY REVIEW • Q2, 2010 The economic case for high speed rail has been found to be compelling for those parts of the world that have invested in it. Unsurprisingly there are many projects currently at the planning stage in North America, Asia and in Europe where many countries aim to join the early pioneering adopter France with its extensive TGV network and recent large-scale investor Spain with its AVE services (pictured)

hile railways are often perceived transport groups such as Deutsche (£196.6 billion) and was projected to W as being essentially a national, Bahn, Stagecoach Group and Arriva. grow at an annual rate of 4 percent in regional or – in the case of suburban In many cases these large transport the period to 2014. and mass transit networks – city- operators are responsible for multiple based institutions, there has been an rail networks across different countries Strategic skills input increasing internationalization of the and continents, while some are also In joining Ricardo, Simon Scott has industry in recent years. The formerly multi-modal and include inter-city bus a clear mission to deliver an entirely nationally based train manufacturing networks and air travel in addition new range of strategic skills into the companies have largely been merged to rail. The size of this increasingly international rail industry, including into multi-national groups such as globalized market is substantial, too: technical consulting, engineering, Alstom, Siemens, Bombardier, and according to research reported in the technology and production work. “We Hitachi, who compete on a world stage. International Railway Journal in 2009, are aiming to make a substantial and This process has been mirrored the world railway equipment and positive impact for our rail clients in on the operating side of the industry after-sales services market was then terms of tangible considerations such by the emergence of international estimated as being worth €126.5 billion as energy efficiency, quality, robustness

Q2, 2010 • RICARDO QUARTERLY REVIEW 11 Railway technology

and whole life costs,” he explains. “In rolling stock engineer has already been “In the UK and this respect we are not talking about appointed and will be joined by others minor incremental improvements – we in specialist areas of expertise such as Europe the will be looking to make substantial step- signalling, information management downturn is now change advances for our customers of and communications. “By building this tens of percent rather than single digits.” critical mass of rail industry expertise in full swing and Highly experienced in the rail we are now in a position to leverage the revenues have industry, Scott was engineering resources of the company across a wide technical director at Atkins’ Rail range of programmes,” says Scott. yet to pick up. Business with responsibility for a range “In addition to Ricardo’s well-proven However in the of significant engineering innovation capabilities in engines, we have the programmes prior to joining Ricardo. ability to design, innovate and improve US the situation is Before this he held a number of upon everything below the solebar already showing positions associated with the London of the train; structurally, dynamically, Underground network through electrically, electronically, and utilising signs of improving, Metronet Rail, and had appointments sophisticated modelling of NVH for reflecting that with rail sector companies including example. With our power systems Cubic Transportation, Adtranz, British expertise we also have the ability to country’s earlier Rail, and Siemens. reduce energy costs and improve our positioning in the So why did he decide to join Ricardo? customers’ carbon footprint. With “What attracted me to this challenge the combination of the in-depth rail economic cycle” was that I could immediately see the knowledge of my rail-sector team potential benefits that we could deliver and the multi-industry skills and within the rail industry by adapting the capabilities of Ricardo, you name it suite of skills available at Ricardo, such and we can improve it – and improve it as advanced engineering technologies, substantially.” mechanical, electrical/electronic systems integration experience, Warranty management strategic analysis capabilities and Warranty is an issue for which rail state-of-the-art production skills. These market customers are increasingly have all been developed and honed willing to look outside the industry for in the highly competitive industries the right solutions. In an environment to which the company is constantly where rail fleet vehicle assets are exposed: this gives them a robustness utilized for up to forty years, it can and an applicability that is potentially be difficult for train manufacturers game-changing when applied in a rail and operators to update and re-life environment.” systems without consulting the Scott is already in the process of original equipment manufacturer. This recruiting a top-level team of engineers can act as a considerable constraint from the railway industry who can help on innovation with consequent him in focusing the service offering. opportunity costs. With its automotive An internationally experienced chief and power systems expertise in warranty management, Scott believes In the longer term, high-speed rail Simon Scott aims to serve a broad base Ricardo is ideally placed to assist. remains something of a booming of international rail customers including “We can offer the technical expertise global phenomenon. “The economic mass transit systems, transcontinental to provide an alternative form of case for high-speed rail has been frieght, and high speed commuter and inter-city networks warranty management on behalf of found to be compelling in those train builders, as well as for owners parts of the world that have already sealed carbon-fibre flywheel concept, and operators,” suggests Scott. “In invested in it. However, the processes which was taken from the initial idea some circumstances we can bring our of planning and designing this to a working prototype in less than a engineering skills and competence complexity and size of infrastructure year. This system (described in detail into designing the systems so that are extremely time consuming. For this in RQ/Q4 2009) is ideally suited to high- reliability is assured from the outset reason it is perhaps unsurprising that speed rolling stock in particular, and such that the constraining influence many such rail investments are being Scott is already discussing potential of warranty on engines or other touted across the political spectrum applications with a number of train sub-systems can be ignored. In other here in the UK as well as around the manufacturers. circumstances we can offer to take on world. By the time that those projects In complex systems engineering the process of warranty management that make it through planning reach applications too, Scott feels that on behalf of the customer by bringing the construction phase and spending well-proven development processes new suppliers to the market.” on the vehicles, track and signals such as hardware in the loop reaches its peak, the recovery should modelling and design of experiments Recessionary effects on investment be well in place, so it is ideal timing for methods can be a distinct advantage Scott argues that rail industry governments to put high-speed rail in enabling train manufacturers to investment generally lags behind other plans in place now.” develop new products quickly without more mainstream economic indicators compromising robustness. through a recession as the trickle-down More efficient and effective innovation impact of passengers losing jobs – and One of the key deliverables that Scott On-board power hence not needing to make their daily believes Ricardo can offer the rail A major focus of the Ricardo rail sector commute – leads to reduced operator industry is the ability to innovate rapidly team will be on the engineering of revenues. However, the timing of this and bring technologies to maturity supply for multiple units, particularly as is linked to the local economy and this quickly in the form of products that can the requirements of Stage 3b emissions in turn tends to provide a smoothing be marketed. regulations come into force in Europe effect for the global industry: “In the “Culturally, rail has been a heavily together with Tier 4 Interim and Final UK and Europe the downturn is now in regulated industry throughout the in the US. Scott argues that there are full swing and revenues have yet to pick world, and this has acted to an extent some very sound market-based reasons up. However in the US the situation is as a brake on innovation. Conversely for this focus: already showing signs of improving, the intensely competitive environment “While the rollout of electrification reflecting that country’s earlier of the industries in which Ricardo has programmes has been a particular positioning in the economic cycle.” traditionally operated means that the feature of rail industry development While the current worldwide recession company has high-quality processes worldwide for a number of decades, is clearly the most severe in living in place aimed at pulling forward the business and environmental memory, Scott believes that its worst technology quickly and effectively.” case for this is increasingly coming effects have to an extent been offset by As a particular example he quotes under the spotlight. Unless grid stimulus spending on rail investment. the Kinergy high-speed hermetically power supplies can be guaranteed as

Q2, 2010 • RICARDO QUARTERLY REVIEW 13 Railway technology

TRACK RECORD

Inter-modal low carbon be used through social networking study of locomotive manufacture. travel in Germany technology to introduce people who Parallel work streams were carried out Ricardo is working on a project with otherwise might not know each in both design and sourcing, with full partners in Germany to explore how other but live close together and cost analysis including both production intermodal low carbon transport have opportunities for car sharing. and infrastructure. The result of this opportunities for commuter rail Ricardo’s multiple industry background highly confidential study delivered passengers can be optimized. The in rail, automotive (including with a headline cost saving of 30 percent team is looking, for example, at electric vehicle manufacturers) power reduction in the unit cost of production. how station car park electric vehicle distribution and intelligent transport charging posts could be implemented. systems is particularly valuable to this Based on ticket information revealing project. Indian Railways locomotive the journey plans of each commuter, emissions reduction this infrastructure might be used as Ricardo was selected by the part of a local smart power distribution Integrated cost reduction Government of India’s Engine system providing energy buffering the for a train manufacturer Development Directorate of Research to grid and perhaps, electrical power Ricardo has engaged with one of the Designs and Standard Organisation to the station. This same knowledge of major international train manufacturers (RDSO), Lucknow, to provide passengers’ journey plans might also to lead a comprehensive cost-down consultancy on the reduction of

systems that utilize commercial off the “We want to create value-for-money shelf technology; reducing cost and signalling control and information flow increasing competition. It’s been too long a small supply base, particularly systems that utilise commercial off the shelf here in the UK.” technology; reducing cost and increasing Intelligent opportunity competition. It’s been too long a small supply Intelligent transport system (ITS) base, particularly here in the UK.” innovations can also hold out the prospect of some very attractive coming from clean energy sources currently available interim solutions opportunities if systems integration rather than from conventional coal- such as diesel-electric hybridization, is taken one step further than at burning power stations, the embedded alternative fuels, and energy storage present. “Existing driver assistance carbon of electrification schemes can devices such as high speed flywheels, systems provide information and be surprisingly high. According to ultra-capacitors and advanced battery recommendations, but let the driver work carried out by the University of systems, that can provide significant decide what action to take based on Birmingham, the efficiency of an electric benefits in the medium term. Ricardo these inputs. By taking this one stage locomotive using grid power supplied has comprehensively mapped the further and integrating driver assistance from coal-burning generating stations potential technology paths to deliver systems with engine management, is 23 percent, while a diesel locomotive these solutions and has in-depth we can allow the driver to retain a high is 26 percent. As a consequence, the experience in the hybridization of power level of control but subject to some very use of on-board power in the form of and propulsion systems in multiple minor constraints – and of course strict highly efficient, clean diesel engines industrial sectors.” safeguards – while allowing the system linked to advanced energy storage to intervene and operate the engine concepts is increasingly of interest for Information management and control in such a way as to maximize its fuel new fleet investments on lines that are Scott also feels that Ricardo has much efficiency.” not already electrified.” to offer in the area of signalling where Scott believes that much more However, Scott believes that there is bespoke – and hence expensive – radical improvements in fuel efficiency a strong economic case for a network systems have tended to predominate: are also possible with more wide- supplied by both electrified and on- “We have the potential to bring ranging implementation of ITS board power based trains, depending some significant new innovations to technology. By applying concepts upon the nature of the intended route this market using our knowledge of similar to that developed in the and usage. “Diesel multiple units safety-critical, fault-tolerant systems, Sentience project (described in detail should be regarded simply as multiple including, for example, from our work in RQ/Q2 2009), for example, a control units with on-board power sources. on automotive X-by-wire programmes.” system’s knowledge of upcoming With a vehicle life typically in excess of “We are looking to partner with others gradients, weather and alignments 40 years the immaturity of technologies who share our vision of providing open could be used to encourage fuel such as fuel cell systems that might architecture based technologies that efficient driver behaviours or to ultimately replace the diesel engine as could significantly reduce costs and prevent those that might be inefficient, a primary source of on board power, increase functionality,” he continues. unsafe or potentially damaging to the need not pose an immediate constraint “We want to create value-for-money life of the equipment. on innovation. There are many signalling control and information flow “Current systems just look at

14 RICARDO QUARTERLY REVIEW • Q2, 2010 exhaust emissions from the Indian Railway’s diesel locomotive fleet. The work was based on an Alco 251, 16 cylinder (3600 hp) engine which is currently used in approximately 4000 locomotives of Indian Railways fleet. Ricardo was awarded the contract to carry out the first stage of this study which included a concept feasibility study of the changes required to meet US Tier 2 and international railway UIC 624 emission standards. Based on the analysis, Ricardo prepared detailed recommendations on completion of the programme in mid 2009, aimed at achieving the desired emission targets for this widely-employed locomotive engine of the Indian Railways network.

geographical mapping based on is typically provided via expensive with the use of external expert support, GPS and on charts of track gradients cabling: this is a further example of the more vertically integrated railways – few if any worldwide take account how Ricardo can help in engineering such as Deutsche Bahn in Germany and of the vehicle’s power systems, or local renewable clean energy systems SNCF in France also offer some of the the prevailing weather and network independent from the grid. opportunities for improvement as the congestion. We already have the “Our key differentiator is that we are benefits of life cycle costs and value are proven technology on which such a technology-independent and do not all the better realized,” he observes. system could be developed in the form rely on a single favoured approach “It can be more difficult to break in of Sentience”. such as wind or solar,” says Scott. “By to such vertically integrated providers With such a system the driver would combining these renewable power who are culturally used to providing enter the desired route and through technologies and supplementing their own needs,” concludes Scott. the systems’ knowledge of the route energy storage, we can avoid issues “However, we are not talking about details and real-time information on of intermittency and develop localized providing marginal improvements. congestion and prevailing weather uninterruptable power systems We’re talking about significant conditions, on-board systems would capable of handling safety-critical improvements such as 30 percent be managed accordingly and the hardware such as signalling, while at weight savings or 40 percent energy vehicle driven semi-autonomously the same time significantly reducing cost reductions – these are compelling for maximum efficiency. At an the cabling capital investment benefits for any potential customer.” individual vehicle level this would requirement, and significantly give significant potential benefits reducing possession times.” Simon Scott joined Ricardo in February in energy consumption. A higher- 2010 as global rail market sector director. level implementation on a fleet basis Strategic growth Previously, he had been at Atkins, where might also be used to optimize the Just a few months into his new he was engineering technical director, performance of different vehicles role with Ricardo, Simon Scott is rail, with responsibility for a range of through network management – for enthusiastic about the opportunities for significant engineering innovation example to reduce congestion at pinch development. His growing team of rail programmes. points such as major rail junctions. experts has already attracted significant Before joining Atkins, Scott held a While Ricardo has the core business both within and beyond the number of positions associated with technologies readily available for company’s traditional comfort zone the London Underground network the implementation of such rail ITS of power systems (see ‘Track record’ through appointments with Metronet innovations, Scott says that he will look box). Scott sees his customers ranging Rail, where his final post was as head of to partner with universities and other globally from train builders and railway fleet, signals, power and depots whole specialists to optimize the ergonomics equipment manufacturers, fleet and life asset management. Earlier in his of the human machine interface of network operators, to governments and career he also held positions with Cubic such a system. regulatory authorities. Transportation, Adtranz, British Rail, and “I want Ricardo to become the trusted Siemens. Local clean power generation independent technical partner to the A Chartered Engineer and Fellow of the Track-side cabinets are commonplace world class organizations in the global Institute of Engineering and Technology, on modern railway systems, housing rail industry. While the conventional he has a bachelor’s degree in electrical motors, signalling system components, wisdom might indicate that the more and electronic engineering from the relays and control systems. All of liberalized rail markets such as the UK University of Nottingham and an MBA these require electrical power which might be more culturally comfortable from the Open University.

Q2, 2010 • RICARDO QUARTERLY REVIEW 15 Off-highway emissions

Going clean off-highway

Tough new US Tier 4 and European Stage 4 off-highway emissions regulations pose a major challenge to vehicle manufacturers in terms of cost, technology and practicality. Jesse Crosse reveals the benefits of Ricardo’s Twin Vortex Combustion System, which tackles emissions in heavy duty diesel engines at source ome of the greatest challenges bringing the issue into still sharper focus. exhaust aftertreatment systems such facing powertrain engineers today Seeking ways to meet the huge as high capacity EGR systems for Slie in meeting future emissions reductions needed in NOx (nitrogen NOx reduction coupled with diesel regulations for heavy duty, off-highway oxide) and PM (particulate matter) particulate filters (DPF) to control diesel engines. The years between 2011 emissions from heavy duty diesels PM, or alternatively to move to SCR and 2014 will see US Tier 4 regulations, is high on the agenda of OEMs. Until (selective catalytic reduction) which and similar European regulations, for recently it looked as though the only also deals with NOx. off-highway vehicles come into effect, way forward was to install substantial Yet Ricardo has found another

16 RICARDO QUARTERLY REVIEW • Q2, 2010 Going clean off-highway

solution which, for engines rated up to represent a massive reduction in around 23 kW/litre makes it possible NOx and PM emissions of around to do without expensive, bulky and 90 percent. These changes are so sometimes fuel consuming exhaust stringent they will effectively align aftertreatment equipment altogether -- emissions regulations for off-highway the Twin Vortex Combustion System. vehicles with the European EU6 and Its use can greatly reduce the cost US 2010 truck emissions standards. of meeting the regulations, cut the The changes for Tier 4 will be cost of ownership and also improve introduced in two phases, ‘Interim,’ reliability. which for mid-range, off-highway Moving to a new layer of emissions engines of 56 kW-130 kW begins in regulations may not seem that 2012 and ‘Final’, coming into effect in significant. But although this appears 2014. Similarly, Europe will see a shift to be no more than a single step from the existing Stage 3A regulations change from Tier 3/ Stage 3, when to Stage 3B in 2011 and finally, Stage 4 fully implemented the new regulations in 2014.

Q2, 2010 • RICARDO QUARTERLY REVIEW 17 Off-highway emissions

Further complications – altitude and and the decision as to which option the driver’s vision. temperature to choose is a difficult one. It must be One option for controlling NOx is As well as a dramatic cut in emissions made early enough for any chosen SCR (selective catalyst reduction) there are further caveats making the technology to be production ready already popular in on-road heavy duty task of meeting these regulations even when the time comes, while also trying applications and now the passenger greater. For example, Tier 4 includes to anticipate what will be the cost, car market too. SCR is a highly ‘not to exceed’ levels which hold that practicality and maturity of various effective system requiring the injection emissions may not be allowed to drift technologies closer to implementation. of urea into the exhaust stream. upwards due to the environment in The point at which they are on the It can be a ‘bolt-on’ fix, reducing which an engine is being used, such development curve now and where NOx without the need to redevelop as at high altitude or in extremes of they will be at the point of production, the engine, but it does require an temperature. The situation is further are thus significant factors. additional tank to carry the urea, plus complicated for engine developers in Manufacturers are being forced pipe-work and control equipment. A that certification is engine-based and to choose a path and stick to it in a more fundamental method of tackling not vehicle-based, since in the off-road scenario not dissimilar to the choice NOx and one widely used in all types business, ‘loose’ engines are supplied faced by the passenger car industry of combustion engine today is EGR to a variety of vehicle manufacturers, between unit injector diesel fuel (exhaust gas recirculation). But using a serving a range of industries from injection and common rail some high rate of EGR to meet the new NOx agriculture to construction. 15 years ago. The first offered high regulations brings its own challenges Not only is introduction of the new specific power and reasonable too, with substantially elevated regulations (both US and European) emissions control at the time, whereas engine-out emissions of PM needing staggered in terms of timescale, common rail, while offering the a DPF and radically increased cooling different levels are also set based on potential for far superior emissions requirements. power ratings of engines rather than control, was then immature and lacked To achieve an estimated 20 percent their capacity. One of the highest the pressure needed for higher specific EGR flow rate with an EGR outlet volume bands and a good example output. In the current case the choices temperature of 180°C can require to illustrate the options open to are influenced by other considerations an increase in total cooling power powertrain engineers is that occupying too: an important one for off-road for an engine of as much as 40-50% the 56 kW to 130 kW range mentioned machinery is the need to package (depending on the power rating earlier. There are a number of ways to any equipment in a way that does not of the engine). This would require reduce NOx and PM in diesel engines interfere with the vehicle’s function or significantly larger radiators and fans that could pose a significant ”Ricardo’s new Twin Vortex combustion packaging and cost problem for vehicle manufacturers. And on a still system tackles emissions at more fundamental level, engineering source, reducing reliance on exhaust margins to meet extreme emissions standards must be that much finer, aftertreatment systems” impacting on the production capability Andy Skipton-Carter, project director of the plants involved. Heavy reliance

18 RICARDO QUARTERLY REVIEW • Q2, 2010 JCB’s new Ecomax T4 engine

Ricardo has already worked with JCB on its £80- million project to develop what is claimed to be the cleanest off-highway diesel engine in the world, the 4.4-litre JCB Ecomax T4. The engine is equipped with a Twin Vortex Combustion System and is undergoing field testing ahead of Interim Tier 4 and Stage 3B legislation coming into effect in 2012. Thus equipped, the JCB engine offers major benefits to its users including lower fuel consumption, reduced cost of ownership, increased reliability and, thanks to the elimination of the DPF system, superior packaging with no compromise in machine design compared to other systems. JCB’s director of engine programmes, Alan Tolley, says: “we believe the T4 4.4 is not only the cleanest engine in the off-highway sector, but also a first in the industry. Until now, it was expected that in order to achieve the Interim Tier 4 and Stage 3B legislation, the fitting of a DPF would be essential. But for mid- range construction equipment the disadvantages of doing so are exhaust back-pressure and increased fuel consumption. Also, if load cycles are light, the DPF doesn’t self-regenerate and forced regeneration burns yet more fuel.”

on EGR to reduce NOx generally of this process requires the burning its lip, the fuel spray cone and the increases production of PM in the of excess fuel. Doing away with a DPF swirl generated in incoming inlet air. combustion process and makes the avoids cost and packaging problems Essentially, the design creates two use of a DPF more of a necessity. and can benefit fuel consumption by annular contra-rotating vortices in the But most DPFs require regeneration between two and three percent. piston bowl, one sitting on top of the when the engine management system “Ricardo’s new Twin Vortex other. The vortices resemble smoke senses they are full through increased combustion system tackles emissions rings, vigorously rotating about their exhaust back pressure: the initiation at source, reducing reliance on exhaust circumferential centrelines. At their aftertreatment systems,” explains point of intersection the opposing project director, Andy Skipton-Carter. rotations of these rings produce The system comprises an optimised conditions leading to the highly injector nozzle and combustion efficient air/fuel mixing which is chamber design, the use of a high essential to the reduction of particulate pressure, 2000 bar common rail fuel generation during combustion. The injection system, a variable geometry geometry of the injected spray, in turbocharger and cooled EGR for NOx conjunction with the movement of the reduction. The system is designed to air charge, avoids fuel being deposited work without either a DPF or a diesel on the cylinder wall, something which oxidation catalyst (DOC) on engines chills the fuel and increases soot rated below 23 kW/l and in higher formation and fuel dilution of the oil, rated engines, it can be used with an reducing its lubricating properties and open-wall (not requiring regeneration) life. DPF. On a typical 100 kW tractor, The outer portion of the piston bowl running costs can be significantly is concave and its design increases the reduced and thanks to reduced PM vertical motion of the fuel spray as it generation during combustion, oil approaches the upper section of the change intervals can be extended by piston. The carefully profiled lip differs 30 percent. from the chamfered profile used in conventional designs and which would Key elements normally spoil the shape of the main The secret of the Twin Vortex section of the bowl, disrupting the air Combustion System lies mainly in motion necessary for good fuel/air the design of the piston bowl and mixing and low emissions. The result the injected fuel spray. Key elements is a thoroughly mixed cloud of fuel are the shape of the piston bowl and and air extending vertically upwards

Q2, 2010 • RICARDO QUARTERLY REVIEW 19 Off-highway emissions

Ricardo’s Twin Vortex Combustion System already offers a hugely cost-effective solution with which manufacturers of off-highway machines developing up to 130 kW can meet Tier 4 emissions without the need for any exhaust aftertreatment whatsoever and avoiding both the cylinder walls wings at the supplier in anticipation of and outer areas of the combustion the forthcoming emissions regulations.” chamber. Achieving the desired effect not only involved careful piston Six power bands bowl design but also the shape and There is a wide range of power bands geometry of the injector nozzles and addressed in the new regulations. The their juxtaposition with the bowl. US Tier 4 standards list no less than Ricardo’s VECTIS and WAVE software six different power bands starting suites were used for modelling the in- at 8 kW and rising to 560 kW at the cylinder fuel and air mixing. upper limit. The European Stage 3B Using advanced design techniques, and Tier 4 regulations are similar, also highway emissions standards without Ricardo engineers needed to consider covering a total of six bands ranging becoming encumbered with external only four bowl designs before arriving at from 37 kW to 560 kW. Levels for each emissions-reduction equipment. This the optimum. “It’s the air motion that’s type of regulated emission (NOx, HC, is especially significant when it comes crucial when dealing with particulates,” CO and PM) vary across both engine to the supply of loose engines, where says Skipton-Carter, “the EGR takes care outputs and dates of implementation the task of fitting external emissions of the NOx.” An important aspect of the of the regulations, so there would be a control equipment could become even Twin Vortex Combustion System is the number of potential solutions using the more complex and challenging in use of a variable geometry turbocharger. Twin Vortex Combustion System. terms of packaging. “They haven’t been widely adopted for However, in the higher power heavy duty diesels yet because thus far, Real benefits ratings above 23 kW/l some exhaust the cost has outweighed the benefits,” The real benefit of the Twin Vortex aftertreatment equipment may still he continues. “We started development Combustion System in this context, be necessary. Even so, with its lower with a passenger car unit, but a heavy then, is the potential to allow vehicle engine-out emissions of NOx and duty version was already waiting in the manufacturers to meet future off- PM the Twin Vortex Combustion

20 RICARDO QUARTERLY REVIEW • Q2, 2010 System would still make the equipment will be needed to satisfy off-highway machines developing up best starting point. Skipton-Carter Tier 4 further up the power rating to 130 kW can meet Tier 4 emissions anticipates that even in the Tier 4 scale. “One way is the use of even without the need for any exhaust Final 56 kW-560 kW band the system higher fuel injection pressures, and we aftertreatment whatsoever. The will still eliminate the need for a DPF, are undertaking development work on benefits are significant cost reductions only SCR being required to reduce a 3000 bar fuel injection system using since on-cost using the Twin Vortex NOx emissions. “Depending on the our Proteus single cylinder engine,” Combustion System compared to application,” he explains, “people can says Skipton-Carter. Work is also a current Tier 3 compliant engine is just add the minimum they need to the progressing on a system to eliminate estimated by Ricardo as being only Twin Vortex Combustion System to the need for any aftertreatement for marginal in comparison to using a DOC meet requirements.” low power density engines. or DPF. Fuel consumption savings of That said, advanced engineering At this stage, however, Ricardo’s between two and three percent are development work is still continuing Twin Vortex Combustion System also significant, as is the prospect of at Ricardo, investigating ways to already offers a hugely cost-effective reduced servicing costs for many years extend the point at which additional solution with which manufacturers of into the future.

Q2, 2010 • RICARDO QUARTERLY REVIEW 21 GT transmission

Ricardo launches race-proven GT transmission The highly successful transmission used by Toyota, Honda and Nissan Motorsport in the ultra-competitive 2010 Japanese Super GT race series is now available to third party customers, as Anthony Smith reports

n May this year Ricardo announced Power Nissan team in their victory in the the commercial launch of a state- Tourist Trophy at the UK’s Silverstone Iof-the-art motorsport transmission circuit on Sunday May 2, the first win for product providing an ideal solution for the new Nissan car in the 2010 FIA GT1 GT1 and GT2 applications. This six- World Championship. speed sequential transverse transaxle The story of the development of the is designed for use in a front engined new Ricardo GT transmission starts rear wheel drive GT application and is four years ago when the company was provided in an extremely lightweight approached by Nissan Motorsport magnesium non-structural casing. (NISMO) to develop a gearbox for its Alternatively, it can be provided in the SuperGT car. As Iain Wight, Ricardo’s form of the existing proven internals business development director for high in a customer-bespoke casing and a performance transmission products longitudinal arrangement is also possible explains, the product had some if desired. The racing provenance of this exacting targets from the outset: “We Ricardo product is truly impressive: it has needed to design a very structurally successfully competed with excellent stiff transmission with high reliability changed on quite a regular wear characteristics and 100 percent to reduce gearbox costs. The longer a basis with consequent reliability in the 2009 Spa-Francorchamps part lasts, the less often it needs to be impacts on running costs. 24hr race in the GT1 class, and its changed – and that had to be coupled When NISMO and the internals are identical to those of the with a low weight. So a great deal two other manufacturers 2008 and 2009 Japanese Super GT of analysis went into its design, very in the series – Toyota Championship winning cars. Most closely focusing on a very small gear and Honda – compared their recently it was used by the British Sumo cluster. It was very lightweight but experiences, the GT Association took using our experience and CAE analysis the decision to set the regulations to use The internals of the GT transmission were tools including the Ricardo SABR shaft, the Ricardo GT transmission internals developed using Ricardo software tools gear and bearing concept and design as the common standard for the series. including the SABR gear and bearing concept and design package package, we knew it would be able to “What we have done with this last a Le Mans duty cycle of around transmission now is to further develop 5,000-6,000 km.“ it with NISMO but also make it available The SuperGT series provides – with their very generous permission perhaps one of the most punishing – for sale as a product”, explains Wight. environments for competition gearbox “It will be of interest to anybody with reliability. With cars typically weighing a front engined, rear-wheel drive car up to 1.4 tonnes they generate a great because it does give a significant deal of g-force. To combat this they performance advantage with the weight have sticky tyres and given this and all being at the rear. The internals can the fact that they are driven by highly also be repositioned if necessary so professional drivers, the gearbox that it can run as a longitudinal box and is subjected to some exceptionally while the external casing may not suit extreme loading. Keen to reduce the every customer, the internals will work cost of the series, the Japanese GT fine within a bespoke casing that we Association was acutely aware that can design and manufacture for them if gearbox parts were typically being required.”

22 RICARDO QUARTERLY REVIEW • Q2, 2010 ”The adoption of the Ricardo GT transmission by the Japanese GT GT transmission Association and its successful use by Nissan, Toyota and Honda is testament to its high quality of design and manufacture, extremely light weight, robust durability and extreme reliability” Mark Barge, Director of high performance transmission systems

This is an unusual absolutely on the limit. Now it’s proven approach for Ricardo to take itself and gone through to validation in the high performance we have a product that’s had the transmission and driveline benefit of that development. Having market. The company been adopted by the Japanese GT typically operates on an association we are now in a position individual project basis as its customers to make this highly optimized product are looking for competitive advantage available for sale.” rather than a product that is the same The Ricardo GT transmission has as the rest of the field. Conversely the a capacity of 700 Nm torque and in company also carries out projects excess of 650 bhp. It has a six-speed for the governing bodies of single sequential dog engagement, with input make series where development bevel and spur gear final drive. Its gears Nissan, Toyota and Honda is testament costs are effectively spread amongst are 16 mm in width, straight cut and full to its high quality of design and all competing teams. As such the form ground, and are manufactured manufacture, extremely light weight, Ricardo GT transmission is something from S156 single melt case hardened robust durability and extreme reliability. of a unique case, as Wight points out: steel. With its magnesium casing We are very pleased therefore to be “What’s happened here is that we’ve the fully assembled transmission able to make this transmission available worked with the Japanese OEM on a weighs only 53 kgs (117 lbs), giving it to customers across a wide range of very aggressive target both in terms of a significant performance advantage motorsport applications – whether as weight and operating costs in a manner against its competitors. a complete product, an internal gear which can only be really effectively Commenting on the launch of the package, or in customized form specific achieved when working in partnership new Ricardo GT transmission, Mark to their particular requirements. This with a customer. It’s too risky to do Barge, Ricardo’s director of high is a further example of the Ricardo on a speculative development basis performance transmission systems approach of providing advanced as a commercial product, so we have said: “The adoption of the Ricardo and ultra-competitive motorsports sailed very close to the wind technically GT transmission by the Japanese GT products, in line with our philosophy of and have arrived at a product that is Association and its successful use by ‘winning through technology’.

Q2, 2010 • RICARDO QUARTERLY REVIEW 23 Ricardo News

Consortium aims to develop next- generation low carbon marine energy systems s the requirements of increasingly Astrict maritime emissions regulations begin to bite in regional jurisdictions around the world, and with the recent sharp fluctuations in global energy prices, ship energy management and efficiency is a subject which is coming under intense scrutiny. As a company that has long been associated with the development of marine propulsion engines Ricardo is now aiming to help the marine industry grapple with the challenge of significantly improving its energy efficiency. The company believes strongly that advanced marine propulsion systems based on the careful selection of well-proven propulsion, energy storage, aftertreatment and waste heat recovery solutions, have the potential to bring significant fuel consumption savings while also meeting the requirements of existing and planned international emissions regulations. The company estimates that by implementing next- compared with conventional existing challenge required to deliver them is no generation energy management and marine propulsion configurations. less considerable, and arguably beyond propulsion technologies, operational However if the potential fuel saving the resources available of all but the very fuel consumption reductions of benefits are extremely attractive, the largest players in the maritime industry. between 15 and 25 percent are possible scale of the research and engineering For this reason Ricardo has announced

New supercharger technology Ricardo, Lontra and Ford Motor will enable the Company have been awarded grant development of funding by the UK Technology the supercharger Strategy Board to demonstrate for Ford’s engine Lontra’s Blade Supercharger™. package, and the The team will integrate the unique integration of the technology with a downsized engine to boosted engine into a create a Ford vehicle demonstrator. vehicle demonstrator. Lontra and The Blade Supercharger™ is a Ricardo engineers will work together to novel variable flow compressor implement the project. with the ability to meet the boosting Commenting on the announcement requirements of heavily downsized of the details of this project, Jason engines. The grant support provided King, chief engineer in the Ricardo by the Technology Strategy Board Gasoline Engines Product Group,

24 RICARDO QUARTERLY REVIEW • Q2, 2010 the formation of the Ship Efficiency & capacitors, flywheel based systems, Energy Storage Assessment (SEEsA) thermal and pressure based storage. New organization consortium project in which marine Other novel technologies intended to equipment suppliers and shipbuilders, be included in this investigation are: aims to spur US as well as vessel owners and fleet fuel reforming, liquid nitrogen (LN2) operators can pool their resources injection in IC engines, and super wind development and collectively contribute to research conducting systems. Ricardo Inc has teamed up with aimed at enabling the development of The second phase will focus on a fellow Michigan-based LMS significantly improved energy efficiency. more detailed analysis and investigate International to jointly create a This pre-competitive consortium will the efficiency of the sub-systems new umbrella organization for investigate energy management of the including engine combustion and the marketing of wind energy propulsion and auxiliary power systems air handling methods. Technologies expertise in North America. The two and identify potential technology considered will include advanced air companies announced the formation solutions appropriate for the handling and combustion solutions, with of the new North American Wind requirements of applications including a view to identifying how future ship Energy Innovation and Development cruise liners, ro-ro ferries, tankers, bulk operational practice can be optimized Center at the American Wind Energy carriers, container ships, and offshore as the economic climate changes and Association’s Windpower 2010 facility supply and navy vessels. In legislative frameworks evolve. Conference and Exhibition in Dallas, addition to meeting existing and While the SEEsA consortium is Texas, on May 24. future perceived needs, the flexibility now formally launched, it will remain The new umbrella organization of propulsion configurations in the open to applications from prospective will enable wind energy equipment face of potentially changing operating members throughout the duration of suppliers, government agencies, requirements will also be considered. the work. The formation of the SEEsA utilities and other renewable- The work of the consortium will consortium has already generated energy stakeholders to draw on be arranged in a modular format significant interest and appears to be the deep technical expertise and with partners subscribing to a core extremely timely for the international facilities available at Ricardo’s programme of work which can be maritime industry. It marks a new Detroit Technology Campus in Van adapted and augmented to meet their way of thinking about marine energy Buren Township and LMS North specific needs. The first phase will management and efficiency at exactly America’s engineering offices in focus on assessing the best energy the time the industry is having to come Troy. Services will include individual storage solution combined with to grips with emissions regulation and component and systems-level advanced energy recovery systems for the systems based engineering that it design, development and integration, a complete propulsion system under will require. While emissions control as well as software-based modelling different operating conditions including is largely negative in its impact on and simulation, and physical testing normal operation, slow steaming and the bottom line of operational cost, of both new and legacy systems in up to three additional duty cycles that the extension of this approach into the lab or in the field. the consortium members agree as the realms of energy storage and “The United States has evaluated most relevant to their needs. The prime management could well start to pay what it would take to generate movers covered will include diesel dividends for those with the foresight to 20 percent of its power needs and gas engines, and gas and steam join the research and gain early-adopter from wind energy by 2030, and turbine systems, with auxiliary power advantage. it will require hundreds of new systems also including possible fuel Organizations wishing to register an installations, more efficient and cells and Stirling engine applications. interest in participating in Phase 1 or in reliable turbines, significant cost The range of energy storage solutions any of the future modules, can obtain reductions and upgrades to the will include conventional and state-of- further information from marine@ transmission infrastructure,” said the art battery technologies and ultra ricardo.com. Kent Niederhofer, president of Ricardo, Inc. “Developing more energy from said: “The Blade one of Lontra’s initial three sustainable sources like wind is a Supercharger™ applications for our unique national priority, and Michigan is shows significant energy efficient technology. one of the few places in the world potential in We’re very enthusiastic to with the concentration of design, delivering work with such experienced engineering and manufacturing efficiency whilst partners in the automotive expertise to make it happen,” maintaining sector, and look forward to said Michigan Gov. Jennifer driveability. demonstrating the technology M. Granholm. The incremental Ricardo publicly next year.” investment in wind power generation welcomes The Technology Strategy required to meet that target is $43 the opportunity Board promotes UK innovation, billion, or two percent more than to bring its long and the grant is part of its fast the cost of meeting future energy experience of automotive track funding stream, which has a demand with no new investment in innovation to the project.” streamlined application process for wind power. Currently, 36 states have Simon Hombersley, Business projects of 12 months or less. The utility-scale wind projects, according Development Director, Lontra: team anticipate a vehicle demonstrator to AWEA. “Boosting of automotive engines is completed in 2010.

Q2, 2010 • RICARDO QUARTERLY REVIEW 25 Capiton...

Ricardo News

Ocelot receives orders

eam Ocelot – the unique collaboration is common to all and the vehicle can be this initial order Graeme Rumbol said: Tbetween Force Protection Europe transported in a C-130 or underslung “The MoD has already completed a Ltd and Ricardo plc – received its very from a Chinook. Ocelot is equally number of their own tests on two of our first vehicle orders on the same day that suited to operations in desert, jungle, vehicles so we’re delighted that they are the media was invited to experience this mountainous or urban environments. now investing in these vehicles so that revolutionary new vehicle at the UK’s At the ride and drive event, members they can carry out further trials. Ocelot Millbrook proving ground. of the media (including Stuart Birch of is building upon our existing long- Described in detail in RQ Q4/2009, the Daily Telegraph, shown above right) standing relationship with the UK MoD the Ocelot light protected patrol vehicle were given and in-depth briefing on which has most recently seen Ricardo was originally unveiled at the Defence the development of Ocelot by Ricardo’s carrying out extensive fleet upgrades to Systems & Equipment International global vehicle product group director create the new RWMIK Plus standard of Exhibition, London, in September Graeme Rumbol, and David Hind, WMIK vehicle.” 2009, and has since been undergoing managing director of Force Protection Just four weeks later on May 25, rigorous development testing. Offering Europe. Following this they were given this announcement was followed similar levels of protection to the highly the opportunity to drive one of two with a formal invitation from the praised Mastiff MRAP vehicle, Ocelot prototype Ocelots made available for MoD to tender for the demonstration, comprises a core automotive armoured the day. In addition to providing this production and support phases of this spine or ‘skateboard’ onto which a first public ride and drive experience, important UK military procurement number of alternative, special-to-role the event was also marked by the programme. “We firmly believe that pods are mounted. Each of the pods announcement by the UK Ministry of Ocelot has defined the future for light can be easily changed in the field as the Defence that it was to purchase two protected patrol vehicles,” said David need arises and have been designed Ocelots for further extended testing Hind, “and are delighted to have for roles such as patrol, fire support or as part of the Light Protected Patrol received this invitation to tender from protected logistics. Four wheel steering Vehicle programme. Commenting on the MoD.”

Ricardo employees reach high for charity Two Ricardo employees – Jo Vicat- from Ricardo the pair Brown and Ben Thornton – trekked raised a total of £2,212.00 to Everest Base Camp in Nepal in which was presented aid of Chestnut Tree House, the only to the charity in April. children’s hospice in Sussex caring for Chestnut Tree House children and young adults from 0-19 costs approximately years of age who suffer progressive £2 million per year to life-limiting and life-threatening run, yet families are not illnesses. The trek, led by Sherpas, charged for their care and included numerous peak ascents the hospice receives very reaching altitudes in excess of 5,500m little government funding. (where atmospheric oxygen levels As such it relies almost were 50 percent of those at sea-level), entirely on the generosity, ice-covered pass crossings and help and support of the crevasse-ridden glaciers, providing people of Sussex. For more stunning views of many of the world’s information or to make highest peaks – including Everest itself. a donation visit: www. Together with matching contributions chestnut-tree-house.org.uk.

26 RICARDO QUARTERLY REVIEW • Q2, 2010 Ricardo plc Seminars & Events Related to the automobile and clean energy industries

Advanced technology seminars, workshops and training courses Ricardo is recognised worldwide as a leading authority in the development of the latest power systems for automotive and clean energy applications. While best known for our engineering and consulting programmes, an increasingly popular service is our regular series of seminars and training courses through which aspects of the company’s knowledge and expertise can be shared with customers. These events are typically hosted at Ricardo Technical Centres and are led by some of our most experienced engineers and research scientists. We constantly strive to develop new seminars and courses re ecting the very latest thinking and most topical areas of power systems technology and product development. We also strictly limit delegate numbers in order to create an environment conducive to discussion of aspects of particular interest to participants. Modestly priced, our Ricardo seminars and courses provide exceptional value for money but are consequently in high demand. Our current programme of seminars is listed below. Most of these will be hosted at the Shoreham Technical Centre, further presentations may also be made at other Ricardo facilities or at customer sites subject to demand.

Seminar programme: Crankcase Lubricants: Internal Combustion Engine Automotive Transmission 16 June 2010 Fundamentals: Fundamentals: 6-7 July 2010 15-16 September 2010 A one-day seminar discussing the Two one-day seminars covering A two day seminar covering the features of crankcase lubricants, the fundamentals of gasoline fundamentals of automotive the latest developments and likely and diesel engine combustion transmission technology. The future requirements. Provides an and technology. The seminars are seminar will cover the main types For more information insight into lubricant formulation aimed at engineers who wish to of automotive transmission and is about our current and interaction with design and gain a broad based knowledge of aimed at engineers who wish to seminar programme or to discuss individual materials. Includes discussion of engine technology, and who wish gain a broad understanding company-speci c training how to formulate lubricants to to broaden their understanding of of transmission technology, requirement, please meet industry challenges. engine combustion, emissions and applications and future trends. contact: related issues. [email protected]

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