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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.
Motors are at the heart of all electric machines. World-leading software developed at the Scottish Power Electronics and Electric Drives (SPEED) Laboratory at the University of Glasgow has been used to design thousands of new motors, enabling the manufacture of millions of machines across a range of industrial sectors. From compressors in refrigerators to the motors in power tools, SPEED has improved the design of products manufactured by over 60 companies across the world including Bosch, General Motors, Grundfos and Rolls Royce. In 2011, the SPEED Laboratory was purchased by CD-adapco, the world's largest independent provider of computer-aided engineering simulation software.
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%.
Research undertaken at City University London has identified new ways to control vapour pockets, known as cavitation, that occur in diesel fuel injection nozzles. These computational methods have led to the design and manufacture of more durable and efficient fuel injectors that have been taken into serial production and are now used by major engine and component manufacturers such as Toyota, Caterpillar and Delphi. The prevention of erosion by cavitation and the greater efficiency of the fuel spray and combustion have generated economic benefits through a rise in sales of advanced injection systems and an extended life for engine components. Cleaner and more efficient engines in turn bring significant environmental benefits.
Practical Waveform Engineering, developed at Cardiff, is having a major impact on how modern- day microwave power amplifiers are designed, delivering real competitive advantages for global communications companies such as Nokia-Siemens-Networks and M/A-COM.
Economic impact is through reduced time-to-market and lower design costs, leading to high- performance power amplifier products. Examples include $40M revenue and employment of additional staff for M/A-Com, and the successful spin-off company Mesuro Ltd., generating revenue in excess of £2.5M.
Impact on practice is through successful demonstration of new device technologies and amplifier architectures, the introduction of PWE-based CAD models, and most significantly, the introduction of the "Cardiff Model" into mainstream simulation tools.
Environmental Impact is by improving the efficiency of power amplifiers and significantly reducing the carbon contribution of mobile communications systems, translating into savings of approximately £2.5M/year and a 17 kiloton reduction in CO2 emission for a typical EU network.
Driven by concerns over public health and intensifying legislative demands of the food industry in Europe and USA, the reliable and effective removal of unwanted objects from food products at a processing stage is increasingly important. The assurance of food quality and safety throughout the pre- and post-harvest food chain makes this issue even more significant. The effective implementation of relevant technological solutions for food safety and quality can dictate the survival, growth and competitive edge of some major sectors of the economy.
Food sorting machines are essential for eliminating unwanted food items from the production process to ensure that quality is maintained at the highest level for consumers. Key research at City University London has led to the development of a unique solenoid actuator valve (ejector), which opens and closes a high-pressure air jet in such machines to remove defective food items more accurately and efficiently from the production line.
The sorting machines which use it have a fivefold improvement in consumer food quality and safety and are 20% more energy efficient. Sales of these machines have been enhanced by 50% as a consequence of these improvements. The new valve delivers approximately 50% less food waste during the first sorting pass and offers a fourfold reduction in power consumption, contributing positively to global agricultural sustainability. The work undertaken has also assisted the industrial partner in opening up a new market for sorting machines for sorting plastics.
The Leicester Variwave project, in relation to electrostatic dust precipitation, utilises a novel high voltage, high frequency, high power transformer within the power supply, which has enabled cuts in industrial emissions of ~50 per cent and considerable cost savings. Most new-build power stations and many other industrial sites now use technology based on that developed in Leicester. As well as fly ash and dust, the technology has the ability to trap sub-micron particulates thought to be partly responsible for the increase in the number of asthma cases during the past few decades. The MD of [text removed for publication] states `Through publications made by ...Leicester ...we were interested to learn how the team designed their high voltage transformer, and how that transformer operated with the high frequency, high power switched-mode electronics. They achieved that `Holy Grail' combination [of high voltage, frequency, high power] in a 70 kW switched-mode power supply (SMPS) running at 20 KHz and at 50 kV. The publication in the IEEE Transactions on Power Delivery was very helpful, and enabled us to choose the direction when pushing the design boundaries in developing our own high power, high voltage technology for electrostatic precipitators'. Dr Devine, a key member of the Leicester team between 1995 and 2000, was employed by [text removed for publication] in 2001 purely on the basis of his knowledge of Variwave. [text removed for publication] now have 200 units in operation. In 2002 Dr Devine was head-hunted for his knowledge of Variwave and moved to [text removed for publication], who also developed commercial units. The uptake of the technology has been growing steadily since 2001. Exemplar data from one company on the associated reduction in emissions shows 195 switched mode power units installed in boiler plants worldwide by 2004 gave a reduction of around 60%. A 60% reduction in emissions is equivalent to a reduction from 40 mg.m-3 to 16 mg.m-3 of flue gas particulates. Since 2004 to date there are now estimated to be at least 5000 units installed worldwide.
Research carried out at the University of Southampton has enabled major players in the aerospace industry — among them Rolls-Royce, Airbus, and Boeing — to produce more fuel efficient, longer lasting engines and aircraft at reduced cost. The research has provided the aerospace industry with modelling tools and software enabling companies to explore complex new designs quickly whilst managing product risk in a competitive market. The research team has also developed new design processes for unmanned aircraft, which — as a result of strong media interest - improved public understanding of such new technologies through worldwide coverage. A spin-out company has achieved strong technological and economic impacts in its own right.
The Computational Mechanics and Reliability Group at the University of Greenwich has been developing design and materials modelling expertise and tools for electronic manufacturing and reliability since the late 1990s. This case study details economic and environmental impacts and impacts on practitioners. In particular it shows how our expertise has:
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.