Professional Documents
Culture Documents
uk AUGUST 2013
Eyes on the road
Head-up display for
in-car infotainment
without the
distraction 32
Lessons learned
Terry Hill, former
Arup chairman,
explains what HS1
can teach us 34
The rail
thing
Our panel of
experts answer
readers questions
on controversial
HS2 project 28
For more news, jobs and products visit www.theengineer.co.uk
A mind
of its own
Autonomous
cars take drivers
out of the loop
24
contents
AUGUST 2013 | theEnGineeR | 3
Your number one website for engineering news,
views, jobs and products www.theengineer.co.uk
07
24
16
News
07 Technology Space technology
could help detect sight loss
08 Technology Low-cost
diagnostic device can return
results in 30min
09 Technology Brainwave
monitoring could aid drivers
Features
24 Cover feature The process of
developing self-driving cars is one
of evolution, not revolution
28 Q&A feature Our panel of
experts answer your questions on
the engineering challenges of
building HS2
32 Feature Innovations to tackle the
problem of driver distraction
Opinion
05 Comment If you cant
concentrate on driving, let your
car drive itself
16 Mailbox Your letters to the
editor and views from
theengineer.co.uk
18 Talking Point Is fracking our
best hope for cheap energy, or a
dangerous fantasy?
10 Design Relieving stress in large
ALM components
12 Business BMWs lease and
range-extending options for
the i3
14 Digest The Engineer crossword
and an early aeroplanist
34 Interview Former chairman of
Arup, Terry Hill, on what we can
learn from the HS1 project
36 Electronics feature Flexible
batteries for the new generation
of gadgets
38 Sensors feature New
techniques and technologies for
continuous monitoring of
medical conditions
20 Iain Gray Making the UK a
centre for automotive innovation
21 David Willetts Why the UK is
changing tack and investing in
space propulsion systems
22 Viewpoint The importance of
protecting intellectual property
in China
comment
AUGUST 2013 | theEnGineeR | 5
The only time Ive crashed my car was down to being
distracted by the infotainment system; I took my eyes
off the road in what I thought was a safe, quiet area to
select a new album from my MP3 player, which was
plugged in and displayed its tracks on a LCD display on
the dashboard. Fortunately, I wasnt hurt and no-one
else was involved, although theres a bollard near my
parents house with some blue paint on it.
I can console myself with the thought that its easily
done. If even Michael Schumacher can fall foul of lapses
of attention while driving off-duty, then us lesser mortals are bound to slip
up. But the problems getting worse and it seems that its mostly down to
drivers demands.
Manufacturers of in-car infotainment systems say that theyre responding
to the perception that people want to be able to access all the functionality
theyve got used to on their mobile phones all the time. They want to make
calls, they want to select music, they want to be able to access trafc and
weather updates, they even want to be able to
check email, Twitter and Facebook. Moreover,
they dont just want to do it, they actually do
it: weve all seen people driving with mobile
phones clamped to their ears, and horror
stories about accidents caused by texting-
while-driving are becoming increasingly
common.
So its hardly surprising that infotainment companies are trying to devise
ways for drivers to access the functionality they crave without taking their
attention away from driving. As we detail in this issue, there are many
techniques and approaches to the problem, from touch-screens to head-up
displays and gesture control of in-car electronics.
Is this a solution? It may be, but possibly more radical answers are
needed. Our cover feature in this issue details the development of
autonomous cars. People dont like relinquishing control, but it might just be
the answer to the problem of distraction. You want to check Twitter? You
want to talk on the phone? Fine. You do that. But if youre going to, let the
car do the driving. It doesnt have a mind to be distracted, and you and,
for that matter, everybody else on the road stand a better chance of still
being able to breathe once youve put the smartphone down.
Ditch the distractions
while at the wheel
If you want to check
Twitter, let the car do
the driving. It cant be
distracted
BY STEPHEN HARRIS
New technology for reading brainwaves while
monitoring eye movement could lead to improved
systems for preventing drivers from falling asleep
at the wheel.
Researchers from Leicester University have
developed signal-processing algorithms to
compensate for the electrical activity created by
the eye muscles as they move, which can interfere
with the brain signals captured through
electroencephalograph (EEG) systems.
This means the subject doesnt need to keep his
or her eyes still for the EEG to work and the brain
signals and eye movement can be tracked at the
same time, opening up the possibility of adding an
extra element to eye-tracking systems to make
them more reliable or improving future brain-
computer interfaces. Eye monitoring on its own
doesnt work for everyone, said project leader Dr
Matias Ison. But if youre driving on a long, boring
road you can be starting at one point but your
mind can be wandering and about to fall asleep.
This could be picked up by an EEG system and not
an eye tracker.
Current EEG systems that require electrodes to
be placed on the scalp would be impractical for
use while driving. But Ison said the new system
would enable the next stage of research into brain
activity that occurs when the eyes are moving. In
particular, researchers will need to conduct
experiments to collect data from the brain about
what happens a subject makes different saccades
(fast eye movements), in order to improve the
system further.
The issue is that we need to have a certain
number of saccades of different types and sizes so
we can teach the algorithm what particular types
of [movement] look like, said Ison. We move our
eyes about four times a second and in such a small
period of time we are acquiring information and
deciding where to move our eyes next. Given the
limited speed at which neurons can transmit
information, this is a challenging task.
If the technology were to improve enough, it
could also be applied to computer interfaces,
allowing gamers to move characters around more
naturally or enabling completely paralysed people
to control a wheelchair by moving their eyes. An
earlier application could be in diagnosing dyslexia
by monitoring subjects in a more realistic way
than the current method of checking their brain
activity as they read a succession of single words.
The project was carried out in collaboration
with the University of Buenos Aires and funded by
the EPSRC.
APC advantage
An extra 1bn of investment
to help the UK build the cars of
the future has been
announced as part of the
governments automotive
strategy. The government and
industry will each invest
500m over the next 10 years
in a new Advanced Propulsion
Centre (APC) to help develop
the technologies and supply
chains needed to manufacture
the next generation of
low-carbon vehicles in the UK.
Small rm wins big
The UKs biggest national
engineering prize has been
awarded to a small Cambridge
company whose software is
now used by the worlds
largest technology companies.
RealVNC, co-founded by
Cambridge computing
luminary Andy Hopper,
received the Royal Academy
of Engineerings top accolade,
the MacRobert Award, for its
software that enables remote
access to any computerised
device with a screen from
anywhere in the world.
Worlds largest wind farm
Plans for an offshore wind
farm twice the size of the
worlds current largest have
received approval. The energy
secretary has granted Triton
Knoll Offshore Wind Farm
permission to construct a
1,200MW facility with up to
288 turbines off the East
Anglian coast. RWE npower
has scheduled 2017 as the
construction start date.
Industry investment
The European Commission,
EU member states and
European industry will invest
22bn over the next seven
years in sectors that create
high-quality jobs. Most of the
investment will go to ve
public-private partnerships in
medicines, aeronautics,
bio-based industries, fuel cells
and hydrogen, and electronics.
These research partnerships
are expected to boost the
competitiveness of EU
industry in sectors that
already provide more than four
million jobs.
AUGUST 2013 | theEnGineeR | 9
inbrief
More news daily at
theengineer.co.uk
Algorithm could be applied in driver monitoring systems
ELECTRONICS
Researchers have a brainwave
Intelligent knife could improve hospital patient survival rates
MEDICAL
iKnife cuts cancer detection time
BY JASON FORD
Scientists at Imperial College
London have designed a
surgical instrument that
detects cancerous tissue in
seconds.
The development, led by
Dr Zoltan Takats, has the
potential to improve patient
survival rates and save money
for health authorities by
reducing the need for
secondary operations.
The intelligent knife, or
iKnife, has been adapted from
a suite of chemical-proling
technologies built by Waters
Corporation and is in use at
St Marys, Hammersmith and
Charring Cross hospitals.
It is based on electrosurgical
knives that are commonly used
in operating theatres.
Originally developed in the
1920s, electrosurgical knives
use an electrical current to heat
tissue, allowing surgeons to
cut through it while minimising
blood loss. The heated tissue
vaporises and gives off an
aerosol that is normally
extracted from the operating
theatre.
Takats has adapted the
electrosurgical knife so that it
extracts the aerosol and feeds
it via a tube to a mass
spectrometer in the operating
theatre, which lets the surgeon
know via a display if the tissue
being operated on contains
cancerous cells.
Surgeons currently remove
tumours with a margin of
healthy tissue but it is often
difcult to tell by sight which
tissue is cancerous. According
to Imperial College, one in ve
breast cancer patients who
have surgery require a second
operation to fully remove the
cancer. In cases of uncertainty,
the removed tissue is sent to a
lab for examination while the
patient remains under general
anaesthetic.
Current EEG systems require electrodes to be placed
on the scalp impractical for use while driving
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news: design
10 | theEnGineeR | AUGUST 2013
Find the latest news, jobs & products at www.theengineer.co.uk
Stress free ghters
Process eliminates stresses in printed parts
New legislation has potential to cause chaos
LEGISLATION
IP law must not
stie designers
ADDITIVE MANUFACTURING
With BAEs new technique,
a layer of material is laid
down, melted into shape
using a laser and left to cool
before being cold worked
using the ultrasonic impact
treatment (UIT). The next
layer is then deposited,
heated and the process
repeats.
Jagjit Sidu, ATCs technical
leader for additive
manufacturing said the
combination of cold working
and heat treatment becomes
part of the deposition
process.
UIT is typically used to
treat welded areas in metallic
structures in the rail and oil
and gas industries to increase
their fatigue life.
An ultrasonic transducer
causes the tool head to
vibrate at a very controllable
rate and impart powerful
compression forces while only
placing a small load on the
tool itself, allowing it to be
handheld or tted to a robot.
The BAE team, which also
included Stephen Morgan,
developed a feedback system
that uses load cells in the
base plate, onto which the
structure is printed, to
measure the strains as they
form and adjust the UIT to
correct them in real time.
The company has
demonstrated the technique
by producing 3D printed
structures up to 1m in length
and has applied for patents on
the UIT process and the
feedback system.
BY STEPHEN HARRIS
Aircraft wings built with 3D
printers could be a step closer
thanks to a technique
developed by BAE Systems.
The company has
developed a process to
prevent large metallic
structures made using
additive manufacturing from
distorting or building up
internal stress during
printing.
The technique involves an
established way of making
metal parts stronger by
rapidly and repeatedly
striking them using an
ultrasonic tool as each layer of
the component is laid down
by the 3D printer.
Aircraft manufacturers are
already using 3D printing to
produce hinges. Scaling up
the process to large and
complex metallic parts could
enable the creation of more
complex shapes such as
hollow, lighter wings and
make production of a small
number of these components
more cost effective.
But increasing the size of
3D printed parts raises the
chance that the internal
stresses that build up as the
material cools will lead to
problems, said Andy Wescott,
a senior research scientist at
BAEs Advanced Technology
Centre (ATC).
agree that current legislation
adequately protects against
infringements and warn that
that the wording of the bill has
the potential to create numerous
infringement claims.
Whitehead said, If the
government is determined to
tighten up the legal
consequencesthen it needs to
be done in a way that does not
clog-up the legal system with
hundreds of cases against
designers and retailers who
have followed fashion trends but
have not deliberately copied
registered designs. Nor must it
stie innovation because of fear
of prosecution for presumed
copying. It is for these reasons
that the language of the
Intellectual Property Bill needs
amending.
The governments Intellectual
Property Ofce says the
proposed law is focused on
wrongful business behaviour
and not inadvertant
infringement of a design.
BY JASON FORD
Experts have warned that the
wording of the proposed
Intellectual Property Bill should
change to prevent unnecessary
litigation and protect the rights
of designers.
The bill passed through the
House of Lords on Tuesday July
30, 2013 with an amendment to
improve defences for defendants
who could face 10 year jail terms
if found guilty of infringing
registered designs.
The proposed amendment
includes a clause allowing those
accused of infringement to
defend their themselves on the
grounds that they reasonably
believed that they had not done
so. Patent attorneys Withers &
Rogers said this will extend
protection to defendants who
believe that their own design is
sufciently different to escape
infringement.
The draft legislation is
expected to be debated in the
House of Commons later this
year. Tony Whitehead, IET
policy director and Roger Burt,
president of the Chartered
Institute of Patent Attorneys
A new method of creating an extremely strong bond between
lightweight aluminium and ultra-high-strength steel could help car
manufacturers optimise vehicle design.
The new method from Brigham Young University (BYU) may help
vehicle manufacturers in achieving the 54.5mpg average the US
Environmental Protection Agency is mandating for US eets by 2025.
The technique - friction bit joining - uses a small, consumable bit
to create a solid-state joint between metals. The method was
invented by Prof Michael Miles and retired BYU professor Kent
Kohkonen, in collaboration with Orem, Utah-based company
MegaStir Technologies and Oak Ridge National Lab.
Its all about making vehicles lighter and our process can help to
combine steels and light metals in the same vehicle frame, which
gives engineers more exibility in designing an optimal structure,
Miles said.
The latest development in the process successfully bonds
lightweight aluminium with cast iron by inserting a thin layer of steel
between the two metals, which facilitates the bonding process. JF
Metal bonding process could lighten cars
AUTOMOTIVE
Joined up thinking
BAE Systems has applied for a patent on its new processes
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3D printed
structures up to 1m
in length have been
fabricated already
news: business
12 | theEnGineeR | AUGUST 2013
All aboard the e-train
Transport secretary Patrick
McLoughlin has conrmed a
1.2bn order for trains that
will operate on the East Coast
Main Line. The 30 nine-car
electric trains will be
manufactured by Hitachi Rail
Europe at its new factory in
Newton Aycliffe, County
Durham, as part of the
governments 5.8bn Intercity
Express Programme. Hitachi
believes the deal will reinforce
UK train manufacturing
export capability.
Bentley jobs boost
Around 1,000 jobs are to be
created in the UK following
Bentleys decision to develop
its rst sports utility vehicle at
its base in Crewe. The luxury
car-maker, which employs
4,000 staff in Cheshire, plans
to invest more than 800m
during the next three years in
its headquarters and in the
development of new models.
Structural study
Frazer-Nash has secured a
contract with Culham Centre
for Fusion Energy to provide a
thermal and structural
analysis package in support of
ITERs planned nuclear fusion
reactor. The consultancy will
undertake a structural
analysis study on ICRH
antenna components, which
are comprised of complex,
internally water-cooled,
stainless steel and titanium
components. The antenna is
part of a large system
delivering RF power to the
plasma within the reactor.
Airline order
Boeing and Turkish Airlines
have announced an order for
ve 777-300ER aircraft valued
at $1.6bn at list prices. The
Turkish ag-carrier has
exercised options on ve
777-300ERs that were rst
announced in December 2012
as part of a previous rm order
for 15 777-300ERs. Turkish
Airlines now has 20 777-
300ERs on order from Boeing.
Turkish Airlines eet
currently includes 12
inbrief
More business
news daily at
theengineer.co.uk/
policy-and-business
ELECTRIC VEHICLES
Lease is more
BMW offers i3 range-extending options and hire arrangements
BY STEPHEN HARRIS
BMW has launched an attempt
to win over drivers worried
about electric vehicles (EV)
limited range with its rst
production-ready battery-
powered car.
The BMW i3 includes several
options also being
tried by competitors
including leasing models and
a range-extending petrol motor
that allow drivers to try out
the cars electric capabilities
without spending tens of
thousands of pounds in order to
rely entirely on battery power.
The move comes as EV
sales remain relatively low
and manufacturers look for
ways to push the cars into the
mainstream, despite the
insistence of companies such
as BMW that a more
environmentally sustainable
business model is vital for the
future of long-term protability.
One of the key barriers to
public acceptance of EVs is
range anxiety, despite research
suggesting 95 per cent of trips
are less than 30 miles, well
within the range of most EVs.
The i3 was designed from
scratch with an electric
powertrain in mind, featuring
a low centre of gravity due to
the low, central placing of the
battery, and a lightweight
carbon-bre-reinforced plastic
(CFRP) body to cancel out the
extra mass this adds.
But the vehicles stated
range of 8199 miles
(130160km) in everyday
conditions is still comparable
with those of other models
already on the market, which
have so far only sold several
thousand units in the UK.
To counter the anxiety issue,
BMW is making the i3 available
with a petrol-driven motor that
doubles the cars range
compared with battery power
alone, and offering three-year
leases and options to borrow
other vehicles for longer
journeys.
Although the company has
not released sales or
production targets for the car,
BMW spokesperson Krystyna
Kozlowska said: We are
envisaging that in the rst
instance the range extender
will be a slightly higher
proportion [of sales] than
electric only. But I think over
time that might change as
people come to understand
how they use their vehicle.
The leasing model is already
being trialled by Nissan with
its all-electric Leaf and was
tested by BMW when it ran an
international study of EV usage
with its Mini E, which has yet
to enter mass production.
Research that weve done
has shown that people tend to
prefer to lease this type of
vehicle, said Kozlowska.
There is some element of the
unknown with it and so leasing
rates have been popular.
UK electric car sales are
increasing and at a rapid pace
(although from relatively low
numbers), according to the
Society of Motor Manufacturers
and Traders (SMMT). In 2011
we saw just over 1,000 cars
registered, said SMMT
spokesperson Jonathan
Visscher. By 2012 that had
more than doubled. This year
were already past the 1,500
mark half-way through the year
85 per cent up on where we
were a year before.
Visscher said several factors
were driving the increase in
sales, including falling prices
the cost of buying a Leaf has
dropped from 25,000
(including the 5,000
government grant for EVs) to
15,000 for a basic model.
A big part of that will be the
development of the model,
renement of the technology
and the new model is being
built in the UK, he said. Were
seeing more vehicles come
onto the market and as a result
more competition, better
prices, and different ways of
owning them.
The BMW i3 electric car has the
option of a petrol motor
Price drops
are helping to drive
the increase in UK
electric car sales
A world of
horseless carriages,
velocipedes and
aeroplanists
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16 | theEnGineeR | AUGUST 2013
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thehottopic
Portrayal of engineering: feeling hard done-by?
Classact?
The need for school design and
technology workshops to be
well-equipped triggered some
comment and reminiscences.
Our school metalwork shop
in the late 1980s was equipped
with a brazing hearth, welding
equipment, milling machines,
lathes and a good stock of
metal. Were we allowed
anywhere near this kit? Hardly.
Our teacher was more
concerned about us designing
on paper than building in 3D!
Anonymous
Unless the schools are
properly equiped and use
qualied engineers to teach
the pupils they will leave with
the wrong impression of
Manufacturing. We need to
ensure its in their blood and
keep them interested
throughout the entire training
process.
Mick Jones
Without teachers who have
recent experience working in
industry it will never work.
Most teachers have very little
understanding of the real
engineering world, those that
do need encouraging and
rewarding as they probably
hold our destiny in their hands.
Im a professional engineer
married to a secondary school
teacher. Many of my wifes
colleagues have no idea how
industry works and see little
reason for it to exist.
Anonynmous
In my school the Careers
Master was the only member
of staff who had absolutely no
experience of anything outside
teaching the classics or being
a novice monk! If you wanted
to study ancient Greek he was
your man; Engineering?
Whats that! I had an
interesting conversation with
my Son a few weeks ago on
more or less this subject. My
theses was that we never had
a proper revolution in this
country, we never rid ourselves
of the pointless useless
aristocracy so that, when so
many of our successful
engineering pioneers handed
the family fortune to their heirs
they chose to ape the useless.
My Sons opinion was that
The Germans produce
Engineers, the French produce
Mathematicians and the
English produce Clergy. The
reason is that, because we
have an Established Church,
so much of our education
system was dominated by the
clergy, in one form or another.
So, I say to the guillotine with
all toffs and priests. (Only
Joking, honest).
Anonynmous
I am now fully retired but a
few years ago I spent 3 years
part time with a local
engineering business making
wearing parts for suger beet
Our editorial and poll about the
Sainburys Management Fellowship
calling for an end to the portrayal of
engineers as wearing hard-hats triggered
a debate on how modern engineering
should best be illustrated.
This is a difcult one. How do you portrait
an engineer accurately? Taking a picture of
engineers sitting in front of their screens in
a big ofce could easily be confused with a
call centre. I am not alone in thinking
(many of my colleagues agree) that the
hard hat image is not the issue at all. The
issue is that the media is hardly if ever
reporting about engineering and what
engineers do. In the absence of this, hard
hats get my approval every time
Alek Wanstrowski
What is the alternative to hard hats? People
love stereotyping and this one ts the bill
every time.
Mark Wayne-Thomas
Clothes do not make the engineer! We are
fed continual streams of jounalistic
hyperbole by journalists that can talk about
engineering, but are also not engineers (in
many but not all cases) and editors who
choose the pictures. Not only do the media
people like to see men in hard hats looking
studiously at large blueprints, but they also
seem to like angle grinders creating
showers of sparks in the background!!
We are a profession of thinkers, problem
solvers and appliers of logic based on
careful analysis and understanding.
To the media I can see the photos being
created of the slightly greying but good
looking early 40s intelligent guy with a
good hair cut and frameless spectacles
(holding a slide rule - no maybe thats a
step too far!!) But as Engineers we arent
really interested - we have more engaging
things to deal with - our jobs and the
current project we need to get results on.
How to make it better cheaper faster etc.
And ..........we are everywhere and impact
on everything. Long live Engineers - normal
people from everyday life with a practical
logical view. Im proud to be one!
Anonymous
You might just as well show them in
oil-stained boiler suits. That gives the same
impression and serves to support and
maintain the public belief that any
mechanic, tter, machine operator, fax
repairer or pretty well anyone that touches
an engineered object, is an engineer.
While hard hats may be an on-site
requirement in civil and marine
engineering situations, they are not
synonymous with engineering as a whole.
Engineers should be seen as thinkers,
rather than doers. That might enhance
their prole.
Peter Bessey
At my work site, the only time anyone
wears a hard hat is when a unit is being
lifted by a small crane to shoulder height in
order to transport it from a test rig to a
trolley and vise versa. I wouldnt class that
bit of skill as Engineering. Normally
everyone wears comfortable clothes or
suits if dealing with customers. To me, a
hard hat signies a building site and
builders.
Anonymous
Pictures of engineers wearing hard hats,
safety glasses, etc, etc, are now the norm
when depicting virtually any level of work
within an industrial environment. A few
years ago we published a photo in a house
journal of foreign engineers working at an
overseas location wearing hard hats but no
safety glassses -- the local H&S
requirerments did not demand glasses. We
immediately received complaints from
UK-based H&S inspectors saying that we
were not portraying engineers working
safely within an industrial environment,
regardless of local requirements.
inyouropinion
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AUGUST 2013 | theEnGineeR | 17
thesecretengineer
harvesters. One of our team
was a young chap in his nal
year of an Engineering degree
course at Leeds. This was his
only access to practical hands
on experience, the College had
closed the workshop for Health
and Safety reasons. It was not
his fault, but he didnt even
know which way round a blade
was normally tted into a
hacksaw, such was the level of
College training that existed.
After qualication he would be
expected to run engineering
projects; his lack of experience
would quickly let him down
and maybe dangerously so.
I was deeply saddened by the
whole attitude that prevailed
then and still does today.
Engineering has always been
the poor relation in the UK, not
so in other countries with
whom we try to compete.
Brian Wood
Sailingships?
A story on the Royal Academy
of Engineerings call for
development of low-carbon
ship propulsion led to a few
suggestions from readers.
Why do we need to make
expensive and complicated
changes to a propulsion
method that is extremely
efcient and uses only a tiny
proportion of the worlds oil? If
we do need a new propulsion
method, nuclear is the obvious
option. There are large
numbers of nuclear
submarines and many nuclear
icebreakers none of which had
caused any serious problems
The big problem is the public
perception that small amounts
of nuclear radiation are
dangerous when, in fact, many
studies have demonstrated
that this is not the case. (e.g.
UNSCEAR)
Bryan Leyland
An installation of computer
controlled large rigid aerofoils
to bulk carriers would greatly
improve fuel efciency
allowing reduced engine
power to be used whenever
the wind is blowing. This was
trialled, I believe very
successfully some years ago,
but seemed to fade away,
possibly because of oil
industry lobbying, who knows.
Perhaps the time is now right
for this option to be
re-investigated.
JohnK
Not wanting to state the
obvious but hasn`t mankind
had a low carbon form of ship
propulsion for thousands of
years, one used by many ships
and boats all over the world.
Now many may say sails
would be a retrograde step but
with modern design and
material even the largest of
ships could save thousands of
gallons of oil by utilising the
power of the wind when
available.
Alex Wilks
75 years on from The Mallard Britain still
produces engineers who can, and do, take on
the world writes our anonymous blogger
I dare say that a large number of you reading this will be fully
aware that we recently marked the 75th anniversary of Mallard
(for those who dont know, she is an A4 steam locomotive built
for the LNER) getting the steam hauled rail speed record. A
record that still stands today.
The National Railway Museum at York have marked this
occasion by assembling all of the preserved A4s together for the
rst time since they were withdrawn from general service. They
also threw what was, I can tell you, a rather nice meal on the
evening of the actual anniversary on July 3rd.
The 20s and 30s were a time when achieving superlatives
was seen as a matter of national pride as well as being benecial
to industry and business. The Germans seemed to have Grand
Prix racing sewn up but we
did pretty well with
aeronautical feats, most
notably in the Schneider
Trophy as well as with
altitude and endurance
records.
These examples had a
large input from government
but we also dominated in the land speed record arena too,
always a more personal endeavour by those involved. It seems
that whether you were running the country, building something
in your shed or at any point between then if you wanted a crack
at making your place in history it could be done. In fact one could
go so far as to say that, if at all possible, it was your patriotic
duty to get out there and keep at it until you had gained a
glorious victory.
The reasons for such high octane proigacy may possibly be
found in international tensions. A number of countries were
jockeying for position on the world stage with little doubt as to
the danger of aggressive acts if someone thought they could get
away with it.
Under such circumstances the advantages of direct
technological advances were surely matched by a clear
message sent out regarding just what we could do if we put our
minds to it?
We need only look to a later age where America and the USSR
sought to match each other in the space race to see the pattern
once more repeated. However a different world along with the
sheer size of the task, and possibly the more focussed target,
meant that the 60s and early 70s saw this as a purely
government led competition.
So what of today? We have our threats and troubles, as with
any age, but they are not from rich and powerful countries. No
longer is there seen to be a need to break records for the sake
of our national standing. However our industry still benets
from the exposure gained by these single-minded dreamers.
Thankfully we still produce those who can and do - take on
the world.
Please join me in not only raising a glass to Mallard and Sir
Nigel Gresley but also to those who are breaking records and
ying the ag for British industry today.
Seventy-ve years on from the
Mallard, Britain still produces
engineers who take on the world
It was your duty
to keep at it until you
had achieved
glorious victory
inouropinion
Stephen Harris Senior Reporter
stephen.harris@centaur.co.uk
AUGUST 2013 | theEnGineeR | 19
theengineerpoll
Last weeks poll: a new study
suggests that there might
be far more shale gas than
originally thought in
subsurface rocks in the north-
west of the UK. Should we be
pursuing this resource?
Our poll respondents gave an
enthusiastic endorsement for shale-
gas exploration last week, with almost
two-thirds saying that it should go
ahead because the UK would need
supplies of gas for many years to
come. A further 14 per cent supported
fracking because of the jobs and
exports it could guarantee. Of the
minority who were opposed to shale
exploration, 16 per cent were most
concerned about the possible direct
environmental damage that fracking
could cause, such as the potential
pollution of the water table; the
smallest group of respondents, seven
per cent, said that the risk of not
meeting the UKs carbon emission
targets was the most worrying.
Whats your opinion on this subject?
Let us know below.
yourcomments
What we do here in the UK will have little
effect on the worlds total CO
2
levels.
Developing countries hold the key to that.
They are in need of our help to develop more
earth-friendly supplies of energy, such as
geo-thermal and solar in the hotter climes.
Effectively, if we use the excess funds
created by using cheap supplies from
fracking for developing systems for use in
the developing countries, then that will
have a greater long-term benet for all
concerned. Although there could be
opponents to the altruistic move.
Jeremy
If there is anything to reassure the general
public, as a rst step and compulsorily
fracking companies should be required to
release information about the chemical
admixes they are using and injecting with
what their advocates cite as sand and
water. Try Google to uncover what is
actually used. Information appears veiled
and secretive; itself a worry. So for the
energy issue, like other fossil fuels, their
value as a feedstock into chemical
processes should outweigh any inclination
simply to burn them. Once gone they are
irreplaceable and we continue to cause
environmental harm in the burning
processes. Day-to-day energy needs should
steadily and increasingly be drawn from
renewable sources.
Anonymous
So you want the UK to pass over what looks
like 100 years of energy independence
because we may put out a bit more CO
2
than
the crazy target set by Tony Blair? Our
current annual output of CO
2
is less than the
Chinese annual increase. Get real. What we
do has no effect in real terms. The sooner we
repeal the disastrous Climate Change Act,
the better. Lets have a proper energy policy
and join the real world instead of this fantasy
world in which useless, highly subsidised
wind turbines are promoted as adding vast
sums to our energy bills.
Roger
I really feel that we, the UK, as one of the most
developed countries in the world, should
make an effort to reduce the amount of
greenhouse gas we release into the
atmosphere (lead by example?). Im not
saying we should all jump into a Prius but
should we not make more attempts to use
ssion and renewables in an energy mix? As a
planet we cannot keep releasing more CO
2
into the atmosphere, fracking is not
renewable and the reserves cannot even be
used for carbon capture and storage. Most
denitely a dangerous mistake.
Adam Sutton
Fracking is necessary because neither this
government nor the previous one built any
new nuclear power stations. Therefore we
will have to rely on gas and if this is the
most accessible domestic reserve we need
to start work now. The Luddites dont
appear to appreciate the urgency.
Electricity rationing in 2016 will affect them
and their computers as it will everyone else.
Robert Freer
Shale gas is too valuable as a home cooking/
heating energy source with nearly 100 per
cent efcient energy use rather than being
used to generate electricity with at best 35
per cent efciency. The UK needs this gas as
an energy resource ASAP and George
Osbornes tax breaks are to encourage
investment now to create jobs and
infrastructure now I wish he didnt have
to do it but we need the gas to reduce the
inexorable growth in energy costs and we
need the economic growth now as well as
providing middle-term energy security until
we have replaced fossil-fuel-based
electricity generation by nuclear power like
France. Nuclear power will mean we will
have long-term price stability and can
become a hydrogen economy for heating,
cooking and use in internal combustion
engines, or replace internal combustion
engines with hydrogen fuel cells with
hydrogen generated on Economy 7
electricity at night.
Robin
We owe it to future generations to explore
and develop all options for the production of
gas and electricity. Fossil fuels will
eventually run out and future supplies will
come from nuclear, solar, wind and water
sources. Shale-gas production by fracking is
the here and now option for today.
John Smith
So, the engineering fraternity is quite happy
to see the north-west environmentally
violated for the third time, after King Coal
and Sellaeld have had their nasty way.
What happened to renewables, which were
supposed to benet future generations
cleanly? Admit it, the fracking is there so
the Yanks can rip off the Limeys as usual.
John Gately
After meeting our targets for carbon
emissions, there will still be a substantial
requirement for fossil fuels. It is better
that this requirement boosts the UK
economy rather than weakening it by
sucking in progressively more expensive
gas imports. Perhaps an all-party
agreement among politicians that a large
proportion of the extra tax revenue
generated be dedicated to addressing our
longer-term power needs would silence
the detractors. Tidal barrages across the
Severn Estuary and Morecambe Bay are
two possible uses for this windfall.
James Hopwood
Click here to join the debate
14%
Yes: it would be a valuable boost for
jobs and exports
No: it would wreck the UKs efforts
to meet decarbonisation targets
No: the risk of damage to the
environment (e.g. water quality and
landscape) is too high
Yes: the UK will continue to need
gas for many years
Click here to join the debate
63%
16%
7%
The Low Carbon Vehicles
show held at Millbrook in
Bedfordshire at the end of the
summer is a great opportunity
to see innovation in action.
Being able to look at prototypes
on the Technology Strategy
Board stand one year and then,
just 12 months later, drive a car
incorporating those advances,
demonstrates the rate at which
the automotive sector is working
towards a sustainable future.
The LCV show captures the very
essence of what we mean by the
journey from concept to
commercialisation.
The automotive sector
remains a vibrant and vital part of the UK economy,
and so the industrial strategy unveiled by
government and industry on 12 July has been a big
talking point. As a member of the Automotive
Council, Ive seen just how much work has gone
into identifying the priorities and the resources
needed to maintain our position among the leading
developers and producers of vehicles in the world.
Included in the strategy is 1 billion earmarked
for the creation of an Advanced Propulsion Centre
(APC). It will focus on scaling up innovative ideas
that are ready to be tested at a commercial scale
prior to market entry. The Centre will help develop
the systems and supply chains needed to
manufacture the next generation of low carbon
vehicles here in the UK.
To support that initiative, the Technology
Strategy Board announced a new 10 million
competition on the same day. The successful
entries will be collaborative R&D proposals that are
ready to take the next step towards
industrialisation.
The competition, Building an Automotive Supply
Chain of the Future, aims to integrate the low
carbon vehicle innovation chain, from the science
base, through collaborative R&D to demonstration.
It is the supply chain that allows everyone, from
the smallest suppliers to the biggest OEMs, to play
a part in our automotive success. The key word
here is integrated it involves not just the
industry but all parts of the innovation process.
Only by bringing research, business and
government together to drive innovation forward
can we get the best result for the UK.
And it is really gratifying to see how businesses
can grow through this kind of support. Just last
week, I was talking with Mark Roberts of
Ashwoods Automotive, a small rm that has
worked to develop technologies for hybrid vehicles.
In just a few years, they have gone from being
purely a components supplier to being the
countrys leading supplier of hybrid commercial
vehicles, supplying businesses as diverse as BT,
Royal Mail and the Environment Agency.
Battery manufacturer Axeon has experienced
success too through its involvement with the
Technology Strategy Board. It was involved in the
development of the Jaguar XJ_e and proved itself
such a vital part of the future supply chain that
Johnson Matthey decided to invest in the business
and integrate it into their own organisation.
Xtrac Ltd designed, developed, manufactured,
tested and rened the transmission system. It
provided an opportunity for Xtrac to develop a
dedicated EV gearbox that is suitable for multiple
vehicle applications with little or no modication.
This kind of growth through innovation is what
the Technology Strategy Board was set up to
encourage and enable. These examples (and there
are many others) show just what is possible when
imagination and opportunity come together.
the Iain Gray column
Bringing technologies from research to demonstration is
helping the UK be a leader in low-carbon vehicle development
Putting innovation on the road
Growth
through
innovation is
what the TSB was
set up to enable
->
feature: autonomous vehicles
26 | theEnGineeR | AUGUST 2013
said Fausten. You have very dense trafc, very high-speed
vehicles, and high speed differences between trafc participants.
But the vehicle is doing quite well we are producing quite
good information on what is happening all around the vehicle.
The road tests have also provided some valuable examples
of the technologys growing ability to cope with the unexpected.
Fausten recalls one particular incident where the car pulled out
to overtake just as another vehicle travelling at speed in the
outside lane began pulling in a potentially hazardous scenario
familiar to anyone whos ever driven on a motorway.
As currently required by law, an engineer was poised to grab
the steering wheel and take control, but the vehicle dealt with
the situation on its own. It was really marvellous, said Fausten.
The vehicle recognised it and immediately re-planned the
trajectory and went back to the lane where it came from. It was
a relief seeing a system that is designed to be intelligent and take
decisions on its own doing what it is expected to do.
Faustens anecdote is a reminder of the chaotic and
unpredictable environment that lies in wait for the rst
autonomous vehicles. And while some researchers envision a
fully autonomous future with relatively easy-to-manage road
networks, it could be decades before anything like this becomes
a reality. Volvos Jonas Ekberg, another engineer with direct
experience of operating driverless cars on the road, believes that
the mixed trafc challenge will always be an issue. I dont really
see that we can have dedicated roads for autonomous vehicles,
he said. It wont happen that way for 20 or 50 years or maybe it
never will, so we will need to be able to mix with manually
driven vehicles.
With this in mind, a team of robotics specialists from Oxford
University is taking a different approach and working on the
development of a low-cost autonomous navigation system that
doesnt rely on existing infrastructure or communication with
other intelligent vehicles.
Led by Prof Paul Newman, the EPSRC-funded RobotCar team
has developed an autonomous Nissan Leaf, which, although not
yet as sophisticated as some of the other autonomous vehicles
around the world, boasts a more affordable approach to
navigation.
Based on low-cost lasers and cameras, Newmans system is
aimed at making the technology more affordable for the masses.
We can localise on the roads with a laser that costs about 7,000,
but what were working on now is how you can do this with just
cheap cameras. If you can do it with cameras you can then think
about doing this with just tens of dollars, he said.
One of the keys to the RobotCar approach is that the vehicle
doesnt need to rely on expensive satellite navigation technology
to know where it is. I dont need to communicate with every car
and the road to be able to drive home safely... so must we ensure
that machines do? explained Newman.
He believes it is an area of research where the UK could have a
major impact and is keen to stress that Google isnt the only
show in town. Its not just happening in California, Newman
told The Engineer. The gene pool we pull from in the UK is the
same as at Google our teams got 30 people and the Google
team is the same size.
Newmans vision is shared by the UK governments
Department for Transport (DfT), which, in its recently published
Action for Roads report, predicts a world where by 2040,
semi-autonomous vehicles are commonplace on our roads. The
report also revealed that the DfT is looking at working with
industry and researchers on a close study of the hurdles the
technology faces and how the UK can best exploit its expertise in
the area.
The fully autonomous car will not appear overnight. Despite
some hugely impressive prototype vehicles, the car industry and
the road regulators are rightly conservative. But a number of
technologies slated to appear soon on production vehicles
including trafc-jam-assist technology that will take control of
the vehicle on congested highways will bring the autonomous
dream a step closer to reality.
Newman believes that trafc-jam assist will be a welcome
rst step for driverless car technology. It seems the most sensible
place for it to start, he said. No one ever advertises a car and
says buy this car and youll be happy in a trafc jam... they
always say buy this car and youll be able to drive down route
one with all the beautiful people at 80mph. Thats not actually
where we want a car to drive us. The thing that drives us crazy
about cars is congestion so shouldnt we be starting there?
Another important trend in the emergence of driverless
technology is the way in which it will evolve alongside other
automotive systems, in particular more efcient powertrains.
We know many strategies that can save energy, said Boschs
Fausten. But we can only suggest to a driver that they operate
Checks: There are a number of key
an autonomous car must be able to
perform before taking control
feature:autonomous vehicles
AUGUST 2013 | theEnGineeR | 27
the vehicle in a very economic way. If you have an automated
vehicle you can tell it how to drive and it will do so.
Volvos Ekberg added that a vehicle able to intelligently plan
its own route and reduce its drag by joining closely-packed-
together, autonomous road-trains a lesson learned from Volvo
and Ricardos recently concluded SARTRE project could make
much better use of battery power, an important issue across the
automotive industry.
The general view seems to be that automated driving will
appear rst on highways, where it has already been tested and
where trafc conditions are more predictable. Moving the
technology into a more complex urban trafc environment will
be an order of magnitude more challenging.
There will surely be a push to bring this technology into urban
environments as well, said Fausten. But the big challenge is
that in comparison to a highway you have a very complex trafc
situation. On the autobahn you have just vehicles driving at
more or less the same speed and in the same direction and the
prediction of what will happen next is fairly easy.
If you have pedestrians, they have a rather difcult motion
pattern for prediction and then you have bicycles and small
motorcycles.
One real challenge for the technology is children they are
completely unpredictable.
Fausten said the key to enabling autonomous vehicles to
operate in these more dynamic environments will be teaching
a vehicles perception system to recognise all the types of
situation it will encounter. There is, he said, already some
progress in this area. Were teaching our cameras to recognise
a pedestrian for our automated emergency braking system, but
this has to be further developed, further improved and then we
have to learn how reliable it is and whether it can predict each
and every situation.
So far, all autonomous vehicle tests have required the presence
of a human in the driving seat, ready to take over in the event
that the vehicle gets into difculties. But how realistic is the
long-term goal of completely removing the driver from the loop?
Boschs Fausten envisions cars equipped with a so-called
highway pilot mode by the middle of the next decade, but said
that such a system will require a big leap forward. If you take
the driver out of the loop, he said, youre not allowed to have
any failure in the system that you cannot handle. The biggest
challenge here is to foresee a system that can cope with almost
every situation. It is not just making another functionality as we
have done in the past this will take a long time.
Ekberg, however, believes that there will always be a role for
the driver. The car will take responsibility but will need to be
able to hand responsibility back. It may come across exceptional
things that it cannot handle for instance, an accident on the
road or some environmental condition such as a snow storm that
it is not designed for.
European car-makers must also work within the framework of
the Vienna Convention, which is potentially a major regulatory
obstacle to the roll-out of fully autonomous vehicles. Last
amended in 1968, the convention states that every driver shall,
at all times, be able to control his vehicle or to guide his animal.
Fausten said that while existing and planned driver assistance
technologies are in line with these regulations, the rules will
need to be revised to allow driverless car operation. If we talk
about taking the driver out of the loop then there needs to be
some regulatory change, he said. But the authorities are aware
of it; the US, EU and Japan are all dedicating attention to this
topic. Were condent it will be resolved.
Others claim that the regulations are open to interpretation.
Its really a matter of words, said Ekberg. The original Vienna
convention was written in 1940 and says that the driver should
always be able to control his vehicle or animals. But what does
be able to control mean? Does it mean control all the time, or
control when its needed? The Swedish authorities interpret it
in such a way that it doesnt prohibit highly automated driving.
There are undoubtedly some tough challenges ahead.
Engineers have only scratched the surface of some of the more
complex technical problems. And regulations, consumer
acceptance issues and cost will undoubtedly slow the
deployment of driverless technology. But despite this, there is a
growing consensus that it will ultimately make a major difference
to the way in which we get from A to B.
Rarely can you perceive a technology thats so obviously going
to happen, said Newman. Computing has changed the world in
terms of healthcare, nance, entertainment and communication.
It is yet to change transport but it will.
For more on this story visit www.theengineer.co.uk
If you take the driver
out of the loop, youre not
allowed to have any failure
in the system that you
cannot handle
Michael Fausten, Bosch
furious
times). Variable speeds on the same railway severely
restrict capacity. It will not be possible to remove the
existing trafc from the WCML to avoid this phenomenon.
Recent experience shows that the upgrading of a running
railway is fraught with signicant performance and
nancial risks that were not experienced with HS1.
Felix Schmid: Adding two further tracks to the WCML
would be very difcult, very expensive and very
disruptive. The WCML was built in the Victorian period,
with the technologies available at the time. Reconstruction
of the railway would take 10 years or more and would
have a huge impact on the environment and the
communities. Enhancing the Chiltern Main Line would be
more straightforward but trafc is increasing rapidly on
this former secondary route and any upgrade would also
be very disruptive.
n Why separate HS2 from HS1, rather than linking the
two by using tunnels to have the lines meet around St
Pancras or Stratford, especially as those areas are closer
to Londons main business centres than Euston?
TS: We recently held a consultation on several proposed
phase one route design renements including proposals
on how we could link HS1 and HS2. The consultation
closed on 11 July. The responses to the consultation will
inform the transport secretarys decisions on the design
for the phase one route. The government aims to reach a
nal decision on the design that will be incorporated into
the hybrid bill in the autumn to allow it to be deposited in
Parliament by the end of the year with the formal
Environmental Statement.
PO: The Institution believes that there would be
enormous potential for the rest of the UK in providing a link
around London, which would link the Midlands and North of
England, Wales and Scotland to the Channel Tunnel. Journey
times from these UK regions to mainland Europe would be
considerably shorter and more convenient, thus encouraging even
greater modal shift from short-haul air to high-speed rail with
attendant emissions savings. Indications are that recent designs
are moving in this direction.
n To what degree are the HS2 plans based on proven technology?
How close are we to developing the necessary new technology
and what work still needs to be done?
TS: The design and development of the scheme does not rely on
technologies that have yet to be invented. The technologies
already exist and there may be further development from which
HS2 will benet. Not all the technologies have been used together,
so one of our big challenges will be their integration to achieve
high levels of performance.
PO: There needs to be an aspect of innovation within this project to
make sure that we design a system that is sustainable and t for
future requirements. 400km/h has still not been done elsewhere,
but the HS product is moving in that direction, there are still some
challenges that remain (eg noise, aerodynamics, energy efciency).
Maximising capacity of the built infrastructure at high speeds is a
challenge for the train control system, and the performance and
reliability of the train braking system, including adhesion at the
wheel/rail interface.
Q&A:High Speed 2
AUGUST 2013 | theEnGineeR | 29
->
Third rail: HS2 proponents say it is preferable to
upgrading the West Coast or Chiltern main lines
Q&A:High Speed 2
30 | theEnGineeR | AUGUST 2013
FS: The current plans for HS2 involve tried and tested technology for
the infrastructure that is, tracks, bridges and tunnels. It is likely
that the trains will be built with more advanced technology than that
common today, eg permanent magnet machines, active suspensions
and pantographs. The railway control system (signalling) will be an
updated form of the European Rail Trafc Management System,
possibly involving ETCS Level 3, ie the moving block version of the
European Train Control System. However, most of the novel
systems are currently being tested extensively on other railway
networks and will be introduced only if they are appropriate.
n How much more energy and power do 250mph (400km/h)
high-speed trains need compared to conventional ones?
TS: Our preliminary calculations, which are
dependent on what assumptions are made
about service patterns, timetables and type
of trains, indicate an annual electricity
consumption gure of around 600 GWH
less than 0.2% of todays total UK
consumption in phase one. For phase two
we estimate that it will be 2TW less than
0.6% of todays total UK consumption. The
peak power demand values when operating
at conventional speed have not been
calculated.
FS: This depends to a limited extent on the quality of the
aerodynamic design but, in simple terms, the energy requirement
increases with the square of the speed while the power drawn by
the train goes up with the cube of the speed. On the assumption that
the cross-sectional area and the length of the trains is similar to that
of the comparator train, doubling the trains speed from 200km/h to
400km/h will increase energy use by 300% and the pantograph(s)
will have to collect 700% more power. Current collection is a major
limiting factor of high-speed railways due to the nature of the
electrical contact interface, the noise generated by the pantograph
and the difculty of maintaining good performance in high winds
and when ice forms on the overhead line.
n One reader argues that running trains at 186mph (300km/h) as
on HS1, rather than the proposed 250mph (400km/h), would be
easier, require less land and save energy. Do you agree and, if so,
what are the advantages of running trains at the higher speed?
TS: HS2 is primarily about providing capacity and also of course
connectivity. By running trains at higher speeds more passengers
can be moved per hour more sustainably than other modes of
transport. Reasonable allowances must be made for the future
capacity and this of course must include speed as a factor. If we did
not design for the higher speeds that are available with modern
technology and designed for routinely on
other high speed railways throughout the
world, this capacity would be denied our
future generations and we would be faced
with upgrades and associated disruption that
has occurred on the UKs railways in the past
as it struggles to keep up with demand.
Whilst the design of HS2 for operation at
300km/h (186mph) would require slightly less
land and use less energy, it wouldnt
necessarily be easier. The civil engineering
assets on HS2 will be designed for a 120 year life. To ensure that
future advances in rolling stock technology can be utilised fully, the
track alignment is designed, where possible, for speeds up to
400km/h (250mph). However, the maximum speed of trains running
on HS2 in the early years of operation will be 360km/h (225mph),
with the majority of trains timetabled to run at 330km/h (206mph).
This provides an operational margin which allows trains to operate
at a higher speed should it be required to recover from minor delays
and keep to the timetable.
PO: The lower carbon credentials of moving people and freight by
railway is also an important factor as we move towards our legally
If we did not design for
higher speeds, capacity
would be denied our future
generations
Tim Smart, HS2 Ltd
interview
AUGUST 2013 | theEnGineeR | 35
transformation arguably began
in the 1990s with a creative
scene fuelled by cheap rents
and eventually followed by a
planned regeneration scheme
that included the Olympics.
Surely this was more important
than the building of a high-
speed line to Paris?
His response is that
infrastructure is what enables
regeneration to happen. Great
cities you think of them
because of their icons, their
culture, their society. But
actually its totally underpinned
by efcient infrastructure,
which we take for granted but
actually makes the difference
between a busy and crowded
place and a world city.
For all his enthusiasm
for what infrastructure can
achieve, however, Hill thinks
theres a problem. The world is
changing dramatically as more
and more people move to the
cities, but the way we deliver
infrastructure has yet to move
with it. And if it doesnt, then
we face a crisis, he argued. In
the provision of infrastructure
for cities, weve not had the
transformation that weve had
in other economic areas. If you
look at the digital revolution,
the quality of product from
the automotive industry, the
efciency that comes with the
research that goes into aviation
technology, I dont think weve
had that in construction and
infrastructure.
This poses a huge challenge.
The amount of people living in
cities is going to double over the
next 40 years. Everything thats
been built and provided and run
and operated and maintained
in cities but has developed
over the last 5,000 years has
got to be done again in the
next 40. If we dont do that
smarter then there is a looming
crisis as to what the cities are.
The cities we know and love
and cherish now are going to
be overwhelmed by this tide
of humanity rushing in.
A big part of the problem
has to do with cost. Arguably,
we do have more capable and
efcient infrastructure that
has beneted from digital
monitoring and control
systems. But as a 2010
report led by Hill highlighted,
infrastructure isnt getting any
cheaper. Everything else that
you know, whether its food,
mobile phones, cars, clothing
or whatever, the trend is for
things to get better, quicker,
cheaper. And yet there doesnt
seem to be any trend that way
[in infrastructure], he said.
Its a particular problem in
the UK: Hills report for the
Treasury found infrastructure
costs in Britain were
signicantly higher than in
Europe, placing the blame on
a range of factors including
unnecessary standards, blurred
decision making in government
and a lack of long-term
certainty. Hill also pointed
to the governments lack of
understanding of the risk of
big projects and the tendency
to throw money at a situation
rather than attempt to reduce
costs, which means that we
dont necessarily get the best
value for money.
People are naturally
conservative and think
goodness me, this is going to
go over budget I better have
a big budget, and the trouble
is when you have a big budget
you tend to spend it. So theres
almost a behavioural nature
that ends up in a spiral of
increasing costs rather than
decreasing costs. Its partly
driven by a perception that was
formed in previous decades by
over-running projects such as
the Jubilee line underground
extension and the Channel
Tunnel itself, he added.
But one could argue that
weve now learnt from our
mistakes and our fear of
overspending has made us
better at meeting, or at least
setting, targets. The Olympics
budget was tripled from its
original estimate but then met
without further overspend.
HS1 was not just done on time
and on budget; it opened on
the day we had predicted six or
seven years before, said Hill.
Weve done the rst order
improvement. We now can
predict the outcomes and we
can deliver against those. I
think the second order is just
making it far more efcient and
that means taking some risks
and seeing if we can do things
quicker or at a lot lower cost
than at the moment.
Its not surprising to
discover Hill is in favour of
the new high-speed rail link
between London and northern
England. He argues that people
always object to big projects
because they disturb the
comfort of a familiar if
unsatisfying status quo, yet
once they are nished the
public tend to accept the
change. But just because
people might accept a project
in the long run doesnt mean
its necessarily the best option.
Thats where I disagree
with you, he said. I dont think
you have to get infrastructure
exactly right, because what
happens is the world forms
around it. Was that bridge
between Denmark and Sweden
put in exactly the right place?
People, jobs, investment start
moving and forming round the
new thing. Yes, weve got to
put the emphasis on getting it
as least intrusive as possible.
But that should not deter us
from getting on and providing
it. Because every year its not
provided there are people who
are not beneting from it and,
when its done, they will.
Once again, he believes
innovation is the key to
overcoming public opposition
to major projects. People would
be less sensitive if we could
deliver infrastructure more
efciently. Imagine if we could
do the equivalent of keyhole
surgery with infrastructure. We
are not doing a bad job with
Crossrail: most of it is hidden
from view while were getting
on with it. Imagine if we
could do that with railways,
with power stations, with
waterworks and so on. The
equivalent of keyhole surgery
for infrastructure would mean
that politicians and nanciers
would take decisions a lot
more readily.
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on this story
When you have a big budget
you tend to spend it. So theres a
behavioural nature that ends up
in a spiral of increasing costs
feature: electronics
W
earable and exible gadgets are poised to become
the next major trend in electronics, according to many
observers. Manufacturers such as Samsung have already
demonstrated prototype smartphones with exible screens for the
next generation of smartphones. Wearable consumer products have
debuted in the form of the Jawbone Up wristband activity monitor
and the Google Glass head-mounted computer. There is intense
speculation that Apples next product launch will be a smart
wristwatch, the iWatch. Taking things a stage further, fashion
house CuteCircuit has demonstrated a dress with a mobile phone
integrated into it, embedded into clothing using conducting thread.
The snag with all these applications is that they need battery
power. Batteries tend to be the opposite of exible: solid and
made in awkward shapes not readily suited to exible devices.
Theres no physical reason
that batteries cant be exible;
its just a practical problem,
said Will Stewart, chair of the
IET communications quality
panel and a visiting professor
at Southampton Universitys
optoelectronics research
centre. Batteries just need
a container for the electrolyte
but this is usually rigid. The
container could be made exible, provided it retained its
integrity, said Stewart. As an engineering challenge, he added, it
should be readily soluble.
Reports suggest Apples iWatch may feature a exible
display that wraps around the users wrist, so speculation
ramped up last month with the publication of a patent
application from Apple for a exible battery. In a
wide-ranging list of potential applications,
alongside calculators, tablet computers
and music players, the patent
application specically mentions
wristwatches.
Apples patent application says:
Electronic devices are ubiquitous in
society Many of these electronic
devices require some type of portable
power source [but] also have unique
form factors. Because of this, the
portable power source of any one
electronic device may not t within any other electronic device.
Furthermore, these unique form factors often require exible
battery arrangements, whereas conventional battery packs are
often too rigid to exibly conform to these form factors.
The application sets out to solve this, but not by changing the
design of the cell itself. Instead it describes how a number of cells,
which could be galvanic or photovoltaic, are encapsulated within
a bottom and top laminate layer. Between any two cells the
laminate layers are glued together to isolate the cells from each
other and to seal them against moisture and other contaminants.
At each of these seal points the laminate can ex, allowing the
battery as a whole to be bent into a curved shape as required.
Meanwhile, a team led by John Rogers at Illinois University has
developed a battery which can be stretched by a factor
Flexible batteries are being developed to fuel the next
generation of gadgets. David Fowler reports
Portable
power
36 | theEnGineeR | AUGUST 2013
On the cards: US company
Flexion is marketing batteries
for the next generation of
intelligent credit cards
The iWatch
may feature a
exible display
that wraps around
the users wrist
feature:electronics
of three in any direction. A company, MC10, is commercialising
the idea, aiming at applications in consumer electronics, remote
monitoring for the health industry and implantable medical
devices.
These applications use a 2D array of ultra-miniature batteries
that are separately fabricated and packaged and then connected
by serpentine connections wires in the form of a repeating
zig-zag or S shape, with the connection as a whole looped into
a larger S shape. The cells and connections are embedded
in a stretchable polymer, and as the polymer is stretched the
connecting wires straighten.
A potentially signicant breakthrough, as far as exibility is
concerned, was developed by
a team at Leeds University, led by Prof Ian Ward, who has now
licensed the technology to US company Polystor
Energy Corporation, which is working on
commercialisation. This was a polymer gel
electrolyte that could replace the liquid
electrolytes currently
used in lithium cells used in a wide range of
portable consumer devices such as laptops,
digital cameras, phones and music players.
Traditional lithium-ion batteries are based
on cells lled with a liquid chemical forming
the electrolyte. Anode and cathode, with a
polymer separator between them, are formed
of thin sheets rolled into a spiral within the
container holding the electrolyte. If the
separator is damaged allowing the positive
and negative electrodes to form a short circuit,
the battery heats up rapidly and can catch re.
The polymer gel overcomes this problem,
creating an electrolyte that is solid but exible
and eliminates the need for a rigid container.
The Leeds team developed an automated
extrusion/lamination manufacturing process
that sandwiches the gel between an anode
and a cathode at a rate of 10m/min to create a
highly conductive strip that is just nanometres
thick. The resultant lm can be cut to any shape.
Prof Stewart said that, to some extent, product designers
have been able to work around the shape limitations of current
batteries because of advances in the efciency of electronics, so
that batteries can at least be small. For example, smartphones
have an enormous amount more performance than old mobiles
without signicantly reduced battery life, because processors
are cleverer. For a handheld computer or smart watch, he said,
a exible display is likely to be more signicant.
Where he believes new developments in small, exible
batteries are likely to be very important, however, is in the
internet of things the use of tiny sensors and communication
devices to identify objects and connect them to a network, from
electronic transport tickets to medical implants.
The Flexion range of batteries developed by Solicore, based
in Florida, is designed for this type of application. The batteries
are based on the companys patented solid polymer electrolyte
technology, which allows manufacture of lithium polymer cells
just 0.45mm thick. The company is marketing the batteries for
applications such as the next generation of intelligent credit
cards and security cards, which will contain memory chips or
microprocessors and require embedded battery power. The
batteries can survive the hot lamination process used to make
cards and are also suitable for radio-frequency identication
tags and sensors, security and information devices and thin-lm
medical drug-delivery products that can be attached to the skin.
Solicore vice-president of worldwide sales David Eagleson said:
The key to our battery is the separator layer that in effect acts as
a sponge-like material, which allows the battery to be bent and
continue operating in an effective manner. However, he added:
We have an extremely good bend radius and [producing] a
wristband would not be an issue.
Blue Spark in Ohio also produces ultra-thin batteries, in this case
conventional zinc-carbon batteries, but in printed form. Printed
electronics uses standard graphics processes to print electronic
circuits and components on media such as paper, plastic and
textiles. The concept has been around for some time, but recent
advances in conductive ink chemistry and exible substrates
promise to make possible a range of new markets and applications.
Blue Spark prints the active components on a PET substrate
and adds electrolyte and separator layers; a top PET layer then
seals the battery. One application is Sealed Air Corporations
Turbo Tag radio-frequency identication time and temperature
monitoring system, which features autonomous data logging. The
tag is used for temperature-sensitive foods and pharmaceutical
products and can track and record cold chain temperatures from
the processing plant, in transit, and up to the point of delivery.
Printed batteries could help extend the internet of things to
include almost any small but important everyday object. Stewart
said: Its possible to
imagine that, in future,
any valuable item will
have a sensor built in
so that you can always
nd it.
Stretching out: a 2D array of
tiny batteries are separately
fabricated and then connected
by serpentine connections
Smartphones
have an enormous
amount more
performance
than old mobile
phones without
signicantly
reduced battery
life, because
processors
are cleverer
Prof Will Stewart, IET
Picture of health:
Skin tone measured
with a webcam can
reveal pulse and
breathing rates
feature:medical sensors
AUGUST 2013 | theEnGineeR | 39
interference caused by ambient, articial light has hampered the
application of the technology. The Oxford invention includes novel
algorithms that remove the effects of ambient light interference,
allowing the technology to be used in everyday settings such as a
patients home. Other algorithms are used to process the image
recorded with the webcam and extract heart rate, respiratory rate
and oxygen saturation from it.
Work is also progressing to monitor chemical markers.
Continuous monitoring, particularly as part of the management of
diabetes, is an important trend, said Professor Tony Cass of the
Department of Chemistry and Institute of
Biomedical Engineering at Imperial College
London. When monitoring a condition such as
this, doctors must currently rely on data from a
small number of measurements taken several
times per day. However, many of the factors to be
measured change on a much smaller timescale so
must be measured continuously in order to get
an accurate picture of what is going on.
Aside from glucose monitoring, continuous
monitoring also has an important role to play in
fertility. The two hormones FSH (follicle-
stimulating hormone) and LH (luteinizing
hormone) produced by the pituitary gland
oscillate in order to make a woman fertile.
However, it has recently been discovered that
FSH may have a 95 minute cycle, and if this is not
occurring, it is likely that the person involved will
be infertile. Other hormones such as cortisol and
melatonin also have a daily rhythm if properly
present. Monitoring is usually carried out in a
research context, and natural levels differ
between individuals. Finding out what might be
unusual for a person, rather than unusual compared to a clinical
average, is very useful when deciding if they need treatment.
So attractive has the issue become that it is even the subject of an
XPRIZE. Consisting of two separate and consecutive competitions
over two years, the Nokia Sensing X Challenge launched in April this
year with a goal of aiding development of a wide array of new
sensors for the mobile health industry. Cheshire-based ABI-med are
involved in the rst competition. They have created advanced
miniature ECG devices and software, tailored to continuously
monitor a patients heart rate and perform tasks such as alerting
doctors of any abnormalities using any Android phone, laptop or
tablet PC via WiFi or USB. The ABI-med model is superior to the
existing ECG devices in the sense that it has excellent recording and
signal quality, which is not easily affected by the movements of the
patient, said Dr Constantinos Anagnostopoulos, head of research
and development. However, our aim now is to further deliver to the
market more and more innovative and miniature products, which will
be able to operate without interruption whilst delivering a diagnostic
grade ECG and thus drastically improving the quality of monitoring.
However, there are still a number of challenges to face before
some types of sensor are widely used. There hasnt been a great
deal of success in implanting sensors for home
use, said Imperials Cass. We have to reconcile
the benets with the problems that people
experience, in that the sensors dont work well
for very long. The body is a hostile environment
and implanting an active device is much more
problematic than implanting something like an
articial knee. The act of molecular exchange
that takes place during monitoring means the
sensors are more likely to be rejected, and this is
a big challenge for the whole eld. However, he
believes this can be overcome. Our approach has
been to develop a minimally invasive device a
few microns below the skin so it doesnt even
reach the capillaries - most of the bodys defence
systems are in the blood, he explained. This
interstitial region also has the benet of not
containing any pain centres, so there is minimal
trauma and risk of infection. The patient can
insert the sensors, then remove them 24 hours
later - its like wearing contact lenses. Once they
are mass produced, the cost will reduce and we
hope they will become the equivalent of the
diabetic nger-stick, in terms of price. Putting a different chemistry
on the sensor will allow other substances to be monitored, too. We
could also look at how therapeutic drugs are metabolised, and tailor
doses to suit the individual. Combining this information with a
persons genetic prole will give a much fuller picture than just
looking at the genome itself, especially when it comes to clinical
trials. The Imperial group have scheduled patient trials to begin by
the end of 2013. Although development of such sensors and sensing
systems faces challenges, new interest and funding opportunities
are producing results. It appears this might be the beginning of the
end for the one-size-ts-all approach to treatment after all.
Continuous
monitoring,
particularly for
diabetes
management, is an
important trend
Prof Tony Cass,
Imperial College