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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.
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%.
University of Huddersfield research into the optimal design of flow-handling systems has been credited with "transforming" the development strategies and global market sales of an industrial partner. Weir Valves and Control Ltd has enjoyed a 75% saving in design lead time and a 1,800% increase in annual sales - from several thousand before its collaboration to millions in 2013 - through the structured integration of researchers' computational fluid dynamics expertise in its design process. The success of this collaboration, which has been described as an exemplar of a Knowledge Transfer Partnership, has also led to further research contracts.
Impact: Economic gains PHYESTA designed 8% of the area of the computer chip for IBM's most recent BlueGene/Q supercomputer product. Global install base of design exceeds $500M.
Significance: Unique experiment in co-design at the cutting edge of technology. Adopted by both IBM and Fujitsu, who have led in Green500 energy efficiency and top500 supercomputer rankings.
Reach: This supercomputer architecture has been installed in labs in the UK, the US, the EU, and Japan and is accelerating computational science and advanced manufacturing around the globe. In the UK the BlueJoule system installed in the Hartree center at Daresbury is driving HPC uptake in the advanced manufacturing sector.
Beneficiaries: IBM, Fujitsu, computational science and the HPC community worldwide.
Attribution: This work was led by Dr Peter Boyle (School of Physics & Astronomy, University of Edinburgh) in collaboration with Columbia University and IBM.
City University London's patented rack generation mechanism, the `"N" rotor profile', offers substantial improvements on the rotary screw compressors widely used in industry at present. It allows for an increase in compressor capacity and makes compressors more energy efficient. Significantly, it can be easily retrofitted to existing compressors, thereby delivering immediate benefit. The mechanism has already been licensed to 27 major manufacturers around the world, resulting in savings of 0.1% of global electricity consumption and an equivalent reduction in global CO2 emissions. City academic staff have worked with an existing firm (Howden Compressors Ltd) to raise funds and train researchers for the development of this technology. In addition, a new spin- out company (Heliex Power Ltd) has been formed to build on research developed since 2009. Important examples of the impact include:
This research has enabled companies that operate worldwide in air compression, refrigeration, air conditioning, oil, gas and process industries to improve their economic and environmental performance in response to demanding governmental demands.
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.
A number of trimaran ocean-going ships, based on original designs conceived by UCL researchers, are currently in use. RV Triton, the demonstrator trimaran, is presently employed as a patrol vessel to provide Australian Customs and Border Protection with increased capability and lower fuel consumption compared to a monohull. The Independence Class of littoral combat ships currently entering service in the US Navy offers improved military capability and one-third lower fuel consumption, with the ensuing benefit of creating almost 2,000 jobs at the shipbuilder, Austal. Similarly, trimaran ferries with their inherent stability have improved passenger comfort and their reduced fuel consumption has lowered operating costs.
As 288,000 UK construction workers were estimated to have contracted vibration white finger and 170,000 had claimed compensation by 2011 this study relates to the design and development of a hand and arm vibration (HAVmeter) monitor by the ERPE Reactec student start-up company. This company initially focussed on optimisation of sweeping for curlers, contributing to team GB winning the 2002 Winter Olympic Gold medal. The current Reactec (HAVmeter) instrument measures and reports on vibration white finger, which potentially affects 5 million British workers.
The HAVmeter has sales in excess of £9M, over the 2008-2013 period, and is now in use by 45,000 construction workers. Reactec, with 23 employees and a turnover of ~£2.5M p.a., company innovation has been recognised with 4 industrial awards since 2009.
Packaging is vital for sales and for product protection for all process industries, with the most widely used world-wide being board and film. For example, the grocery sector alone represents about 70% of the UK packaging market, with 10 million tonnes of packaging used each year.
Packaging materials are variable, which poses significant challenges in packaging machine design. A further challenge has arisen due to environmental legislation that requires the use of thinner, lighter weight materials. There is a need to meet these challenges since the size of the world market for packaging machinery is around €20bn, of which 2% is associated with the UK. Research at Bath has helped address these challenges in a number of inter-related areas:
Research has been undertaken in collaboration with industrial companies consisting mainly of SMEs, end users and research associations. Impact has been gained by embedding the results within the collaborating companies and by on-going use of the results by research associations.
The automotive and aerospace industries are keen to reduce their environmental impact and so have looked to move to lightweight materials. This creates issues in terms of joining, using and disposing of dissimilar materials. Oxford Brookes has therefore worked with national and multi-national companies in the adhesive, materials, automotive and aerospace industries to try to solve these problems. This has resulted in high quality research publications, innovative test equipment, improved numerical methods, novel designs, design guidelines, manufacturing procedures, British Standards, patents, commercial products and further funding. The impact of the work has global safety, environmental and economic benefits with multi-national aerospace and automotive companies implementing the results in current developments.