BLOODHOUND Project selects Zircotec
as exclusive supplier of thermal barrier solutions

Thermal management specialist Zircotec is to develop and supply a range of protective thermal barrier solutions for use on 1,000mph land speed record project.

Thermal barrier specialist Zircotec has been selected as an exclusive supplier to the BLOODHOUND Project, a land speed record attempt hoping to achieve 1000mph. Technical Product Sponsor Zircotec will work closely with the team's engineers to protect an array of materials including steel, aluminium, titanium and composites using its plasma sprayed ceramics to shield the driver, structure and sensitive electrical systems from heat.

Refer to the pictures: BLOODHOUND SSC (above), Zircotec process (top left) and Plasma spray process (bottom left).

Key applications cited for coating include protection of the composite body panels surrounding the titanium afterburner nozzle petals, which are normally exposed to airflow on a Typhoon fighter. The catalyst pack, at the end of the casing of the 18" Falcon Rocket that will be generating 27,500 lbs of thrust, is another area that generates significant heat In addition to these, the exhaust manifolds for the 650bhp MCT V12, which will be running at 10,500rpm for 22 seconds during the rocket firing cycle, are set to be coated using Zircotec's plasma sprayed ceramics. "All these major heat sources generate a packaging and heat management challenge to the design team," says Conor La Grue, supply chain manager for the BLOODHOUND Programme. "Zircotec products will be invaluable in the overall packaging solution to allow the management and control of heat within BLOODHOUND SSC."

"BLOODHOUND SSC will allow us to push our technology and develop further derivatives of our ultra high performance offerings that will benefit other engineering sectors," says Zircotec's managing director Terry Graham. "An application where package, weight and thermal protection are critical will help us create exciting new products applicable to more everyday installations in cars, homes and industrial applications lighter, safer and more efficient. It creates an opportunity to fast track developments and to help us achieve success in new niches."

Zircotec is also planning to embrace all aspects of the BLOODHOUND Project wholeheartedly; the firm is as keen as project founder Richard Noble to engage schoolchildren and academics to become passionate about this area of engineering and maybe even find future employees. "We firmly believe in using the project to develop both our technologies and the future growth of Zircotec. I am an engineer myself and appreciate just how far this project is going to push knowledge," says Graham. "I am also involved with two local schools (as a governor), and already have seen the interest this project is generating. Seeing how a ceramic less than a millimetre thick can make a vehicle operate more efficiently or more safely will highlight to students the benefits novel technologies can deliver in whatever field they choose, or possibly attract them to a career with Zircotec."

Zircotec in profile
Zircotec offers a wide selection of coating services to protect components against the effects of heat, wear, abrasion and oxidation. Originally developed for the nuclear energy industry, Zircotec's plasma-spray technology allows engineers to optimise material performance in a range of demanding applications including automotive, motorsport, marine, aerospace and industrial. Its new flexible ceramic coating is the first of its kind, providing lightweight thermal protection with dramatically improved ease of installation. For further information, e-mail: peter.whyman@zircotec.com

Powertrain developments cut fuel consumption and CO2 by 10 per cent

Visitors to the recent ATZ/MTZ Congress in Esslingen, Germany, were treated to a brand new concept vehicle, the CO2ncept-10%, the result of a powertrain friction reduction development project between The Schaeffler Group and Porsche.

The development project involved the use of novel, optimised engine components, which when combined, achieve an overall 10 per cent reduction in fuel consumption and CO2 emissions.
 
CO2ncept-10% is a CO2 demonstration vehicle based on a Porsche Cayenne with a V8 engine. In addition to tried and tested, optimised engine components, the vehicle is also equipped with several new powertrain and chassis components supplied by Schaeffler. These components help to significantly reduce the car's fuel consumption compared to existing production models.

In the joint development project, Schaeffler was responsible for the design and testing of components, while Porsche managed system coordination and validation for the entire vehicle.
 
The reductions in fuel consumption and CO2 emissions were verified theoretically through complex simulation calculations at Schaeffler, and practically via extensive bench testing at Porsche. The calculation standard used was the Standardised New European Driving Cycle (NEDC).
 
The engine accounts for 5.8% of the optimised fuel consumption and associated CO2 emissions. Most of this (4.1%) comes from modification of the VarioCam Plus valve control system, by replacing hydraulic cam timers with electromechanical equivalents, as well as the use of optimised switching tappets on the intake side. An extra 1.7% reduction can be achieved through minimising frictional losses, by cross-system optimisation of valve train, belt drive and chain drive components.
 
Schaeffler's double-row angular contact ball bearings that are installed in the front and rear axle differentials generated a further 1.1% in fuel savings. These TwinTandem bearings, which replaced the existing tapered roller bearings, reduce frictional resistance significantly when compared to conventional transmission systems. This reduction amounts to 35% in the front axle transmission and 42% in the rear axle transmission.
 
Fuel consumption can also be reduced via the chassis. By replacing the hydraulic roll stabiliser with an electromechanically controlled equivalent and using smooth running wheel bearings, a 3.2% reduction in fuel consumption is achieved. "As is the case with cam timers, electrically-operated components make such an important contribution because they only require energy when they are operating," explained Dr. Robert Plank, Manager of Corporate Engineering for the Schaeffler Group. "In hydraulically-controlled systems, the pumps need to maintain pressure at all times, resulting in much higher energy requirements."
 
"This project is a good example of successful cooperation between an automobile manufacturer and supplier. This cooperation reduces development times, avoids extensive redundancies and makes an important contribution to competitive ability," commented Dr. Plank. "To us, the CO2ncept-10% is clear proof of the continuing optimisation potential that is also closely related to volume production. This is not the end of the line though. CO2ncept-10% is the sum of its components, and these components are just a few from Schaeffler's portfolio that enable similar levels of energy efficiency optimisation to be reached for vehicles from other industry sectors."

For further information on Schaeffler's range of automotive engine components, view website: www.schaeffler.co.uk   Refer to page 46

SICK gives Inspector I20 2D vision sensor more force

SICK UK recently launched the advanced Inspector I20 2D vision sensor providing a step up in user flexibility and quality control performance and offering more detail precision at short/wide or long distance inspections.

The Inspector series is as powerful as a camera and as easy-to-use as a standard photoelectric sensor.  Complete with a choice of integral lighting, powerful processing, Ethernet comms and rugged industrial IP67-protected metal housing, its competitive price enables the engineer to make a decision for quality inspection within existing budgets.

"The new Inspector I20 uses the original Inspector I10 model as the basis," comments David Hannaby, SICK Vision Systems product manager. "The I20 now offers a choice of Inspector models to meet application needs, especially where higher precision over a greater inspection range is required. Precision where glossy or reflective surfaces cause problems is available with the unique dome light.

Refer to the picture above: The advanced Inspector I20 2D vision sensor providing a step up in user flexibility and quality control performance and offering more detail precision at short/wide or long distance inspections.

"The Inspector I20 allows the user greater on-site flexibility and precision with new features such as exchangeable lenses to suit different application requirements and add-on I/O functionality to meet control and information requirements from users, facilitating inspection of more and more complex product features.

"At the same time, both the I10 and I20 models are rugged, IP67 protected sensors, and are very easy to install and configure - a unique combination of features for a product at this price point."

The Inspector I20 Flex can be rapidly reconfigured to suit changing application needs.  The user is able to exchange lenses to meet requirements for a wider field of view or for inspecting smaller objects at up to 1000mm, with corresponding variations in field of view between 350mm and 150mm.  An excellent resolution is retained at high speed for accuracy and rapid image processing.

The Inspector I20 now offers users the opportunity to define output logic and extend its quality control performance with greater functionality. This ensures that the I20 will deliver inspection results in a format which is immediately usable, with data that can be incorporated directly into a customer's control and reporting requirements.

In addition, the Inspector I20 offers extended I/O functionality, enabling selection of up to 16 reference objects for comparison with the object being inspected, and delivering up to 19 inspection results at once. It also facilitates switching between different products and part types.

The housing incorporates either a standard ring light, or a unique diffuse dome light for successful inspection of glossy, reflective or metallic surfaces.

Individual items do not require identical positioning for inspection, as the software evaluates edges, contours, contrasts, grey scale values or pixels relative to a defined location feature in the reference image. The I20 can be used with or without a part presence trigger. Image capture and evaluation of multiple references occur as soon as an object enters the field of vision, without a trigger signal and thus reducing non-capture errors.

For further information on the SICK Inspector I20 and I10, contact Ann Attridge, email: ann.attridge@sick.co.uk  Refer to page 112