Wednesday, October 31, 2007

Research makes diesel engines greener

Ricardo has positioned the advanced diesel alongside gasoline hybrid and fuel cell powered vehicles as future high fuel-economy, environmentally friendly automotive products

Ricardo has achieved Tier II Bin 5 emissions from an automotive diesel engine without the use of NOx aftertreatment. This research continues with the aim of demonstrating clean diesel technology capable of achieving US Super Ultra-Low Emission (SULEV) and Tier II Bin 2 requirements. By achieving this milestone Ricardo has positioned the advanced diesel alongside gasoline hybrid and fuel cell powered vehicles as future high fuel-economy, environmentally friendly automotive products.

This article was originally published on Engineeringtalk on 13 September 2007 at 8.00am (UK)
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Started in late 2005, the early stages of the research project have focussed on developing technologies to deliver engine-out exhaust emissions without NOx aftertreatment that achieve the stringent Tier II Bin 5 US emission requirements, delivering NOx levels approximately one-sixth those of Euro 5.

These technologies include advanced air handling systems, two-stage series-sequential turbocharging, advanced exhaust gas recirculation, and application of closed-loop cylinder pressure-based engine controls.

In parallel an advanced exhaust aftertreatment system has been developed which combines a diesel oxidation catalyst (DOC) and diesel particulate filter (DPF).

When combined with engine optimisation, this has delivered Tier II Bin 5 emission levels without NOX aftertreatment.

Further research has established the feasibility of adding a lean NOX trap (LNT) into the system.
Further reading

US $21.5 offered for fuel efficiency research
Ricardo will be actively involved US Department of Energy fuel efficiency projects, with a combined DOE funding value of US $3.4 million

Engineering support provided to truck manufacturer
An upgrade to Sinotruk's HAEP WD615 engine was carried out in collaboration with Ricardo

GBP 500,000 spent on gear grinding facilities
Ricardo's new Hofler Promat 400kk gear grinding centre will enable the manufacture of more advanced designs at its UK Midlands Technical Centre

Early predictions indicate that the diesel will be capable of meeting the requirements of US SULEV/Tier II Bin 2 emissions standards, thereby achieving NOX levels less than one-tenth of the Euro 5 levels.

The engine has been developed with a competitive power rating of 65kW/litre to meet US emissions regulations for both sea level and altitude compliance.

Having demonstrated these accomplishments on the test bed, the powertrain has now been installed in a test vehicle to enable calibration refinement and validation.

In the coming months Ricardo intends to carry out extensive vehicle testing to validate the achievement of SULEV/Tier II Bin 2.

In doing so, the research team aims to maintain or improve engine responsiveness and customer appeal, while also delivering a significant fuel economy and CO2 improvement over current US equivalent gasoline engines.

Dean Harlow, President of Ricardo, said: 'The achievement of Tier II Bin 5 engine-out emissions without NOx aftertreatment is a major breakthrough and puts us squarely on the path to achieving our ultimate objective of Tier II Bin 2, the world's cleanest emissions standard'.

'By applying a systems engineering approach which combines engine-out optimisation with advanced aftertreatment, we have demonstrated that the diesel can provide a clean, fun to drive, cost-effective, fuel-efficient and environmentally friendly solution for the vehicles of tomorrow'.

'While there clearly remain many challenges in translating this research into high-volume production solutions, this achievement provides significant new confidence in the future viability of the clean diesel in North America'.

Regarding the international applicability of the developed technology Ian Penny, Ricardo's Global Diesel Product Group Director, said: 'The advanced diesel technologies developed and demonstrated through this research project are extremely attractive in the European as well as the North American market'.

'While the future emissions regulations are different for both regions, the technology we have demonstrated as being capable of achieving Tier II Bin 2 US emissions standards is also highly applicable to the challenge of providing cost-optimised CO2 reduction solutions for EU6 and beyond in Europe'.

Carbon fibre recycling slashes disposal costs

All of Brookhouse's waste carbon fibre off-cuts are picked up free-of-charge and taken for recycling

By recycling waste carbon fibre laminations, Brookhouse has eliminated a significant disposal cost, while ensuring that it adheres to its environmental management policy. Brookhouse has recently achieved ISO14001 environmental certification for its Darwen manufacturing site. The company's environmental management programme covers all aspects of its operations and a major activity within the programme is waste minimisation and recycling.

This article was originally published on Engineeringtalk on 13 September 2007 at 8.00am (UK)
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An important production stage in the manufacture of composite components at Brookhouse is the development of multi-ply, pre-preg carbon fibre laminations, which are then cured at high temperature and pressure in autoclaves.

Often this development task must be carried out manually using master models and mould tools.

Naturally, it is a very time-consuming operation and can often produce wastage of expensive pre-preg material.

Brookhouse addressed this problem some time ago by investing in automated ply cutting, where the machine software can plan cutting operations so that individual pre-preg templates can be nested within rolls of material.

This allows complete sets of templates for components to be manufactured and, by better material utilisation, can save up to 10% in material costs.

However, there is still unavoidable material wastage and, formerly, this was transported off-site for incineration at an annual cost of GBP 38,000.

However, investigation revealed that carbon fibre materials were being recycled by a UK company.

Contact was made, an assessment of the waste material was carried out and now all waste carbon fibre off-cuts are picked up from Brookhouse free-of-charge and taken for recycling.

As a result, the company does not have pay the annual disposal charge and a valuable material is able to be re-used.

http://www.engineeringtalk.com/news/rca/rca162.html

Clean Air Power's technology is capable of providing significant CO2 reductions as well as fuel cost savings

Clean Air Power has acknowledged the assistance provided by Ricardo in the development of the company's new natural gas-diesel control system for trucks. Ricardo was contracted by Clean Air Power to modernise the previous product offering in this sector, which enables diesel engines to run on a mixture of natural gas and diesel fuel.

This article was originally published on Engineeringtalk on 25 September 2007 at 8.00am (UK)
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As natural gas contains a lower proportion of carbon than diesel, Clean Air Power's technology is capable of providing significant CO2 reductions as well as fuel cost savings.

The system can also operate on a mixture of biogas and biodiesel, delivering an almost carbon-free powertrain solution.

Ricardo identified an available third-party off the shelf ECU.

It provided a bespoke software solution using an advanced modelling package to translate the legacy system and auto-generate the production code for the new controller.

Using this software technology, Ricardo was also able to provide new functionality to the controller, including knock control and lambda feedback.

This will provide further improvements in emissions and fuel economy, as well as providing new diagnostic capabilities, compatible with new on-board diagnostic (OBD) requirements.

The new control system and its associated Clean Air Power Dual-Fuel hardware can be retro-fitted as an aftermarket device but its benefits are more significant when integrated into an existing diesel powertrain or applied at the design stage of a new engine or vehicle.

Clean Air Power's technology provides an optimal gas/diesel mix in real time, ensuring both smooth and efficient combustion.

Stephen Montgomery, Ricardo Director of Control Systems Software, said: 'The challenge of developing state of the art control systems and software is central to the effective implementation of the next generation of low emissions, fuel-efficient, combustion systems using both conventional as well as alternative fuels'.

'Our work with Clean Air Power is an example of Ricardo's commitment in this area and demonstrates the value of applying the latest software and control systems technology in order both to enable and improve the operation of an advanced low CO2 combustion concept'.

Company expands engineering staff

Walter Dempster brings a wealth of naval platform experience having spent more than ten years working on a major project for Trafalgar Class submarines

Frazer-Nash Consultancy has recruited five new staff to its Glasgow office. 23 year-old Alan Mackay joins the Glasgow team as an engineer, having worked with Ocean Power Delivery during a nine-month placement as part of his studies. As well as gaining a first class degree from the University of Edinburgh, Mackay is a keen sky diver with a bronze medal win at the UK National Skydiving Championships in 2006 and a record of almost 400 jumps to his name.

This article was originally published on Engineeringtalk on 9 October 2007 at 8.00am (UK)
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Walter Dempster joins the team as a Consultant in Electrical Systems.

He brings a wealth of naval platform experience having spent more than ten years working on a major project for Trafalgar Class submarines (with the Ministry of Defence) and most recently as part of the industry team supporting the Astute IPT from within BAE Systems.

Walter will be initially working on equipment replacement programmes for British Energy at nuclear power stations.

Peter Fowler has recently been appointed as a Senior Consultant for the Nuclear Assurance Group.

He was previously employed as a Project Manager of the Nuclear Safety Strategy (NSS) at HMNB Clyde, with particular responsibility for supporting site safety management arrangements.

Peter graduated from the RNEC Manadon with an MSc in Marine Engineering.

Bryan O'Neill and David McKenzie both join Frazer-Nash as engineers.

O'Neill has a BEng (Hons) in Electrical and mechanical engineering University of Strathclyde and will work in Electrical and C and I systems.

McKenzie has a degree in Aerospace Engineering and will join the Structures and Fluids group, as well as the systems design and control group.

Engineering consultants find qualified staff

NDO Consultants is able to locate staff for all kinds of engineering jobs, as well as offering training services

Condition monitoring, instrumentation, product development and engineering equipment are just a few of the sectors that NDO Consultants will be focusing on. Neill Ovenden, NDO Consultants' Managing Director says 'I have my own experience of being unable to find a recruitment agent who understands the knowledge and skills required to fill technical sales vacancies in the fields of vibration and structural analysis'.

This article was originally published on Engineeringtalk on 11 October 2007 at 8.00am (UK)
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'With a background in engineering, commerce, sales and marketing, we can supply an expert recruitment and head hunting service for all levels of staff from admin to executives.' In addition to recruitment, NDO Consultants' business plan is to offer a fully flexible and cost-effective service to small, medium and large companies that will provide a very real method of achieving, improved sales, reduced costs, improved profits, effective management and delivering training services in both commercial and technical areas.

'Training can be tailored to company needs over short or long periods, or we welcome attendees to our programme of seminars starting on 29th November, 2007 with our Commercial Awareness for Engineers seminar in Bedford, Beds'.

Engineering company wins quality accreditation

North View Engineering's new quality accreditation will give it increased access to the petrochemical sector

North View Engineering has been awarded a quality management accreditation, which will allow it to expand its business into previously elusive sectors, including oil and gas/petrochemical. The Darlington-based company, which currently offers engineering services to the construction, steel, process, offshore and manufacturing industries, was awarded the International Standards Organisation's ISO9001:2000 accreditation in recognition of its high procedural standards, adherence to industry regulations and its actions in ensuring customer requirements are adequately met.

This article was originally published on Engineeringtalk on 31 May 2007 at 8.00am (UK)
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In order to achieve the internationally-recognised ISO9001:2000 standard, North View Engineering had to demonstrate its practice of ten core quality management principles to a panel of independent external auditors.

These principles included strong leadership, a good customer focus, the involvement of staff in all aspects of the business, the maintenance of mutually beneficial supplier relationships and continued improvement throughout.

Following the accreditation, the firm, which has been based in the North East since 1953, can now begin working confidently in a new range of sectors including oil and gas/petrochemical, where the ISO9001:2000 is an absolute requirement for all suppliers and contractors.
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Takeover leads to seamless transition
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The Tees Valley Engineering Partnership (TVEP) identified a genuine gap in skills training at first line manager level, which led it to team up with a training consultancy

Jonathan Boggon, Chairman at North View Engineering , said: 'Research shows that companies who achieve the ISO 9001:2000 standard benefit from improved internal working, increased morale and motivation among employees and higher levels of customer satisfaction'.

'Most importantly though, reaching this standard will allow us to operate in areas that were previously closed to us, due to lack of official accreditation'.

'I hope that our customers will appreciate the hard work and dedication we have shown in gaining this type of award and I look forward to branching out into those new sectors'.

Malcolm Potter, Manager of the Tees Valley Engineering Partnership, said: 'North View Engineering has played a significant role in the Tees Valley engineering sector for more than 50 years and it is fantastic now to see them achieving official and international recognition for their high standards of customer management'.

'The level of workmanship we currently have in the region is absolutely outstanding and I would personally like to thank and congratulate North View for the role they have played thus far'.