Summary of the impact

Research led by Professor Chapman at the Knowledge Based Engineering (KBE) lab has resulted in a thriving partnership with the aerospace division of Rolls-Royce. KBE research captures domain-based knowledge and integrates it into refined computational models with automated tools to enhance design processes for engineering complex systems. This research has contributed to important improvements in the design processes used by Rolls-Royce to achieve substantial benefits in terms of accuracy, efficiency and ease of design and innovation in the development of jet engines. The techniques have also been exploited to enhance decision support processes for sustainable energy.

Summary of the impact

Fundamental research undertaken by the University of Cambridge Department of Engineering (DoEng) on the decision-making process in design led to the creation of a software package called DRed. DRed was initially aimed at capturing design rationale, but subsequently broadened in its capability to become a `problem management' tool. DRed has been formally embedded in the Generic System Design Process at Rolls-Royce (R-R), which applies across the whole company such that all R-R engineering staff, including designers and service engineers, have access to DRed. During the period 2008 to 2013, DRed has played a key role in the understanding and resolution of two major aerospace incident investigations, and in the design and development of the Trent XWB engine for the Airbus A350 commercial aircraft.

Summary of the impact

Research in the University of Cambridge Department of Engineering (DoEng), which made it possible for the first time to design a 3D compressor blade as a single component, underpinned the design of compressors in Rolls-Royce civil aero engines. Blades designed using the research results yielded fuel efficiency improvements of 0.8% when deployed in Rolls-Royce Trent engines. The efficiency improvements in engines in service are estimated to have delivered savings of 460k tonnes in CO₂ emissions and USD 145 million in fuel costs during the assessment period. Rolls- Royce's outstanding order book for engines in which the technology made a significant contribution to efficiency is estimated to be worth GBP 27 billion at list prices as at 31 July 2013; orders received during the assessment period are estimated to be worth GBP 18 billion at list prices.

Summary of the impact

The impact relates to improved productivity, operational efficiency, working practice and knowledge management within the European maritime industry through the use of a Virtual Integration Platform (VIP). The platform is a software package developed within the University of Strathclyde that has been used by eleven European ship design, engineering and project management consultancies, which specialise in the application of advanced computational design, analysis and physical modelling techniques within projects on an international scale. Specific company benefits of using the VIP include: 67% reduction in process time; guaranteed data consistency; additional productivity of 15 hours/day from automated over-night operation; capturing and reuse of expertise; cost effectiveness (lack of data consistency typically costs €100k per project); and ease of operation within complex design processes.

Summary of the impact

Research conducted since July 2008 by the University of East London in collaboration with Control Techniques Dynamics (CTD), a leading manufacturer of Permanent Magnet Synchronous Motors (PMSMs), has led to the development of a software tool called the PMSM analyser. This tool has helped CTD to improve its motor design methodology by incorporating electromagnetic, thermal and cost models, together with genetic algorithms. In turn, the design optimisation allowed CTD to enhance motor performance and reduce manufacturing time by 30-40%, leading to an increase of 20% in company sales between 2008 and 2013. During the same period the company was able to cut materials usage by 15%.

Summary of the impact

Compressors developed at the Department of Engineering Science have formed a key component of the cryocoolers used to cool the infra-red sensors on satellites. Their low mass has trimmed almost $250k from the cost of individual satellite missions. Sixty seven have been sold to date, with sales totalling £2.8M between January 2008 and July 2013; three units are currently in Earth orbit with another nine planned to follow in 2014. A specialised version has been developed to achieve extremely low temperatures, with prototypes already built for the Mid Infra-Red Instrument (MIRI) that will form part of the James Webb Space Telescope.

Summary of the impact

Between 1992 and 2002, Loughborough University invented an award-winning approach to planning complex, highly interdependent development projects. Since 2008 the Analytical Design Planning Technique (ADePT) method has resulted in:

1. A sustainable spin-out business (Adept Management Ltd) employing 10 staff with a £6.2 million turnover, providing ADePT services to the majority of the UK's top construction contractors — the business is run by four ex-researchers who were integral to the development of ADePT at Loughborough University;
2. Formation of an Adept Management Ltd technology arm in 2008 providing a state-of-the-art commercial design planning software package incorporating enhancements to the method;
3. Establishment of a US office in 2009 and growth in the number of international clients in Europe, the US, the Middle East and Africa; and as a result
4. Application on projects valuing £11 billion since 2008, with higher levels of cost and time certainty, fewer delays and less waste due to improved design management.

Summary of the impact

Research from the Sheffield Department of Mechanical Engineering has led to major improvements in engineering analysis and design software for aerospace companies such as Rolls-Royce and Airbus. As a result of introducing new practices based on our research, the organisations have reported significantly reduced time input to design components as well as related economic benefits. For example: Rolls-Royce has reported an order of magnitude improvement in the time needed to mesh components. Similarly, by adopting our highly efficient computational aerodynamics solvers, Defence Science & Technology Laboratory has reduced the time its engineers spent evaluating concepts from many days to a few hours.

Summary of the impact

Cost savings in the order of £130M over the REF period have been achieved by Rolls-Royce through the improvement of engine reliability of civil and military aero-engines, industrial machines used for electricity generation and gas/oil pumping applications through the use of techniques and processes developed by the Vibration University Technology Centre (UTC) at Imperial College London.

Summary of the impact

In 1997 ERPE invented a novel automatic machining feature recognition technology which has been incorporated into the Pathtrace EdgeCAM Solid Machinist Computer Aided Manufacture (CAM) package, now owned by Planit plc. EdgeCAM is considered as one of the leading independent solid machinist CAM package, with 10 - 15% of the world market. Related ERPE feature recognition in shape representation and characterisation has enabled the design of a 3D shape browser for product data management systems. Commercialised in 2005 as ShapeSpace with £0.7M current market value, for application to the parts industry in automotive markets, it has attracted the US Actify Inc., as an equity sharing partner to aid ShapeSpace to access worldwide markets.