Public Funding for Jaguar Land Rover Limited

Project GEMSTONE takes a holistic view of the gear manufacturing supply chain. Analysing and optimising each stage of the process from design through to finished component using AMRC's process monitoring solutions, GEMSTONE will reduce investment costs, energy usage and waste while delivering breakthrough levels of transmission component performance. Mazak's innovative thinking in machine tool, tooling and work holding aims to deliver a finished component from a blank in a single step while AFRC developed breakthrough blank geometries and forging technology will minimise waste and cut machining times significantly. Renishaw will deliver in-tool measurement and system condition health checking solutions to ensure accurate and repeatable parts from a machine that can run 24:7 with maximised efficiency. The flexibility of the manufacturing process will enable JLR to develop next generation lightweight and high performance asymmetric gear tooth profiles. Hosted at the leading edge manufacturing facilities of The Proving Factory, the solutions will utilise the latest Tata Steel materials to lay the foundation of a world class transmission production solution in the UK.

Awaiting Public Summary

"""Sim4SafeCAV"" will combine safety and simulation for SAE level 4 autonomous cars to significantly enhance safety analysis and use simulation to demonstrate achievement of safety targets. The outcomes will enable OEMs to establish which mix of sensors and systems can meet global safety requirements, creating efficiencies within the supply chain to accelerate products to market. The project is novel in combining Safety and Simulation activities to offer an innovative solution to meet the safety and the time-to-market objectives of L4 autonomous vehicles. Autonomous car technology is developing rapidly, UK government outlined its ambition for self-driving vehicles on UK roads by 2021\. To meet these expectations, strong joint commitment between academia and industry is needed to support the progress of simulation strategies for L4 automation (no driver back up). Autonomous vehicles are part of the international drive to 'zero deaths' and most stakeholders agree that autonomous cars will be safer. Based on this goal, OEMs have a great responsibility to design safe autonomous cars and to provide evidence that they operate safely across the full range of situations likely to be encountered. Given the impractical possibility of driving continuously for 12.5 years with a fleet of 100 cars to gain sufficient statistical evidence to argue safety, this project tackles the challenge by systematically evaluating system safety, limitations and constraints. We will use this knowledge to inform and enhance simulation capability required to drive an equivalent of 12.5 years in a virtual environment and gain sufficient evidence towards the argument for a safe Autonomous Vehicle. L4 vehicles are exceptionally complex systems, in fact hazardous events can happen due to unexpected behaviour with or without the presence of faults or due to malicious intent. New guidelines to help ensure the 'Safety Of The Intended Function' (SOTIF) are currently under development. We will aim to inform such activity with our insights. We will innovate through (1) Enhancing the SOTIF approach (STPA, top-down, bottom-up analysis, noise analysis), (2) Sensor modelling at different fidelities, (3) Advanced simulation setup for gathering evidence for SOTIF, (4) Enhancing the OEM safety validation strategy."

Energy capture through re-gen braking reduces the duty on a conventional friction brake system. However the ultimate energy storage capacity, weight & residual drag of the friction brake systems have remained unchanged. This is because emergency duty cycles (e.g. ABS) require independent control of the tyre contact patch. A single electric machine (EM) per axle mechanically couples both wheels and cannot offer the level of control required. Consequently significant friction brake downsizing or integration has not been realised to date. That said, multiple independent EMs (1 per corner) do offer the opportunity for integration with the friction brake. This consortium aims to integrate the brake and propulsion systems together into “Integrated Torque Actuator Modules” (ITAMs). It is anticipated these modules would be smaller, lighter and lower cost, yet realise significant vehicle attribute enhancements. The consortium will design, develop and prototype the ITAMs and establish whether they are capable of; 1. All duty cycles including ABS and dynamic stability control (DSC), 2. Zero residual drag torque, 3. Brake emissions capture and storage. 4. zero servicing.

Green mobility is key for a Net-Zero future. Polymer composites are a critical enabler to deliver lightweight solutions with ultimate performance. However, current manufacturing technologies are costly and inherently slow as well as limited in terms of fibre orientation distribution, given that current deposition and laying-up solutions (automated fibre placement - AFP, automated tape laying - ATL, tailored fibre placement - TFP) force straight/geodesic continuous fibre-paths. These issues result in labour intensive and prolonged manufacturing processes with low-productivity, increased energy consumption, production costs and environmental footprint, hindering wide adoption of composites in automotive. Also, whilst delivering lightweight solution in comparison to metal components, CFRP (Carbon Fibre Reinforced Plastic) have a higher embedded CO2e compared to their metallic counterparts. This is primarily due to the energy intensive process use in the production of the carbon fibre. Considering company and government commitment to a net-zero future it is instrumental to make efficient use of such material to balance components/vehicle structure mass, cost and CO2e targets. The SOCA project aims to bring to market CO2e-optimised/net-zero and lightweight composite technologies and body-structure for automotive electric vehicles (EVs) using the award-winning skeleton/flesh concept, which was successfully demonstrated during previous projects. The skeleton/flesh concept includes the use of low-cost/low-performance ''flesh'' material strategically reinforced with structural unidirectional (UD) carbon fibre tapes acting as a ''skeleton'' for the manufacturing of fibre reinforced parts (FRP). This is possible through iCOMAT's Rapid Tow Shearing (RTS) technology the world first automated composite manufacturing process that can place wide composite tapes along curved paths without generating defects. Effective fibre-steering allows alignment of fibres with the primary load-paths and complex geometries required in automotive application, leading to ultra-lightweight cost-effective components of ultimate performance. The SOCA consortium will develop and validate through structural testing and simulation both virtual and physical demonstrators using an existing body structure concept. The aim is to exploit the technology through low-volume in the short-term before expanding to higher volumes following successful demonstration and adoption in low-volume. The implementation of SOCA technologies is expected to reduce body-structure environmental footprint, mass and can enable further vehicle mass reductions due to additionally induced mass savings in secondary systems such as batteries. Furthermore, enabling the use of low-CO2e FRP from recycled fibre and optimised UD laying, will drastically reduce the environmental footprint of current automotive FRP component, specifically when extensively using carbon fibre.

V2VNY Phase 2 proposes the demonstration of a unique AC-V2G solution, targeted at the non-domestic customer market, which utilizes a three-socket charger design which enables potential of V2G, V2B and V2V applications. It builds on the Phase 1 feasibility study and development project, which has proved the viability with a range of vehicle types, including MG, Kia and Hyundai. Fused with CrowdCharge's patented optimization tools, it unlocks maximum value from V2X services for clients, while GridBeyond's aggregation engine provides access to wider flexibility markets. JLR provide OEM perspective and trial vehicles. The unique design has significant potential for V2V, supporting fleets who need to prioritise energy to specific vehicles, opening new business model opportunities for different user groups. A number of business models and use cases will be trialled within the project to understand the value which can be unlocked from each.

The Electric Vehicle Advanced Inverter Technology (EleVAIT) consortium will investigate key inverter technologies and concepts that will enhance the attributes of future Jaguar Land Rover (JLR) electrified vehicles from 2030\. The EleVAIT project will focus on wide band gap semiconductors, integrated device packaging, modelling and utilisation techniques to enable increased power density, higher efficiency and lower costs. The project will support growth of UK manufacturers of automotive power electronic components and products.

NdFeB magnets play a critical role in the fight against climate change as they are used in clean technologies such as wind turbines generators and motors in electric vehicles. As we transition to an electrically driven society then the demand for these materials will increase almost exponentially. The supply of these materials is geographically concentrated in certain parts of the globe and these materials have been identified as being of greatest supply risk compared to all other energy related materials by the EU. The aim of SCREAM is to provide a UK based supply of these materials by recycling magnets from end of life scrap (EoL). HyProMag, Mkango Rare Earths UK, GKN Hybrid Power, European Metal Recycling (EMR), Jaguar Land Rover (JLR), Bowers and Wilkins and the University of Birmingham (UoB) will work together in the SCREAM project to secure critical permanent magnets for the UK. The SCREAM consortium will demonstrate two innovative paths to introduce scrap material back into the rare earth supply chain. The first is to scale up a process developed at the University of Birmingham, "Hydrogen Processing of Magnetic Scrap" from automotive, robotic, separator, loudspeaker scrap streams. The second is to produce a mixed rare earth carbonate for the rare earth supply chain. HyProMag will scale this process to develop magnets that are different grades for a range of applications. Bowers and Wilkins, GKN and JLR will assess the suitability of the magnets for a range of products, and calculate the environmental footprint for production of these materials. The output of the project will be motors, loudspeakers and holding magnet applications containing recycled magnets.

**TOBEV** or **T**hermally **O**ptimised **B**attery **E**lectric **V**ehicle is a project that brings a range of methodologies together to address the optimisation of the thermal system at several levels: * Overall vehicle thermal and energy management using Optimal Control Theory * Subsystem model predictive controls * Architecture cost optimisation The thermal management systems in battery electric vehicles are known to be significant energy consumers. For example, the cabin climate comfort is known to reduce the electric range of a vehicle by almost 1/3rd in cold and hot ambient conditions. There have been many technologies proposed for reducing the thermal system energy consumption such as heat pumps, radiative heaters and other localised heating/cooling solutions however they often consider each technology in isolation without adapting the rest of the vehicle systems to take advantage of them. This project will stand back from the individual technologies and consider the holistic vehicle thermal energy optimisation, by using models of the full vehicle combined with advanced optimisation approaches based on Optimal Control theory. This approach can automatically establish the best way of integrating new components and thermal system architectures into the overall vehicle operation, allowing robust comparisons of component choices -- since they are fully optimised in the target vehicle. The system level optimisation has the potential to increase the vehicle range significantly. These results will be combined with an attribute optimisation to prioritise and deliver the best cost/benefit architectures, with significant reduction in overall cost. Finally, the project will demonstrate the optimised solution in a demonstrator JLR I-PACE vehicle, a class leading electric vehicle. A model predictive controller will be integrated into the vehicle and used to deliver the increase in electric range whilst also reducing development times.

**Our vision for the project:** SPACE will radically change the way companies will interact with each other and how OEMs will award contract work to their supplier base with a focus on small-scale batches or one-off orders. Our vision is to enable small-scale production orders to be placed instantaneously at a supplier with a committed delivery date and price. SPACE will be developed for all industries and independent of the nature of Supplier-OEM interaction. To facilitate this, SPACE will have support from the Automotive and Railway sector and feature representatives from End-User, OEM and Supplier. **Main areas of focus** SPACE will focus on the interaction of Supplier and OEM and tackles a major source of inefficiency in outsourcing departments. These departments don't have the necessary volume to set up dedicated and streamlined processes and rely on iterative, manual work.

Leather is a critical commodity for the premium and luxury automotive industry. It is a by-product of the meat industry. Hides and skins are usually collected and traded between intermediaries through which traceability is lost. The different steps of leather processing can happen in various countries around the world before reaching the end-product manufacturer. Due to this globally dispersed and complex supply chain, leather can often present environmental, social, and economic risks. Jaguar Land Rover, the British multinational premium automotive company, uses different types of leather in various commodities of their cars (seating, headliners, doors, etc.). Because of the premium quality criterium, JLR is in direct contact with tanneries. However, the need for more visibility remains, for the upstream part of the chain from farms to hide suppliers and abattoirs to tanneries, as well as the downstream sewing and wrapping facilities. Jaguar Land Rover conducted a theoretical study with the University of Nottingham on the potential for the adoption of blockchain technology for traceability in its supply chains. Leather was recommended for a practical feasibility study given its importance to Jaguar Land Rover and the challenges that arise in its supply chain. Jaguar Land Rover has identified Bridge of Weir, a sustainable leather manufacturer and their supplier of semi-aniline leather, as a partner to implement a pilot project for leather traceability. Circulor, a UK traceability technology provider, will develop the traceability framework to prove and guarantee the provenance of the leather. The approach to traceability is based on the actual flow of hides through a supply chain. Via Circulor's platform, a 'digital twin' for the raw material will be created, and its progress through the supply chain will be captured at designated scan points. Verification methods like mass balance are integrated to validate and to guarantee a more transparent process. This feasibility study will focus on how the hides and skins can be physically identified and digitalised, from the animal on the farm and throughout the hide tanning processing. This will ultimately provide the insights necessary to implement traceability to the whole leather supply chain. The proof of provenance will benefit the end consumer, ensuring responsible and sustainable leather sourcing. Jaguar Land Rover will be able to improve supply chain performance, prevent and mitigate supply chain risks and disruptions. Implemented as a pilot with one Scottish leather producer, it could be extended later to other leather producers and industries.

The ASTIR (Advanced Storage Technology Into Reality) consortium will develop a new battery concept that will enhance the attributes of future Jaguar Land Rover electrified vehicles from 2024\. The battery system will be optimised for future platform architectures and will be critical to both Jaguar Land Rover and the associated UK supply chain. The ASTIR project will focus on the non-cell hardware and control system leading to a battery system which delivers future electrified vehicles with improved cost, range, efficiency and charging attributes. The development of a novel battery module construction and manufacturing process will be central to the project. In addition, the team will also deliver enhanced modelling techniques which will accelerate future battery engineering. To deliver this exciting project a consortium of UK based, world-class experts has been assembled: AE Oscroft and Sons Ltd -- This SME brings expertise in battery components and heat treatment techniques and will be responsible for developing a new bus bar design aligned with an advanced welding process. Advanced Insulation Systems Ltd - An expert in materials and process technologies gained from the oil and gas industry, who will apply their knowledge to safety and thermal propagation mitigation in battery systems. AVL UK -- A major provider of global engineering services with extensive experience in battery engineering and vehicle integration. They will lead the realisation of the proof of concept system and vibration modelling of the battery design. Siemens PLC will use their extensive modelling portfolio to explore the battery technical challenges and develop validated models which will accelerate future battery development. The Warwick Manufacturing Group will apply their world-renowned expertise in battery technology to develop and validate advanced models as well as testing of the integrated battery solution. Jaguar Land Rover will provide overall project coordination including battery application engineering and lead integration of the findings into the Jaguar Land Rover vehicle portfolio. Successful execution of the project will enable UK production sourcing, and sustain as well as generate UK jobs growth during the critical transition period from conventional internal combustion engines (ICE) to electrified powertrains. The realisation of the ASTIR battery technology will cement Jaguar Land Rover's position as a leading provider of world-class electric vehicles, building on the global success of the Jaguar I-PACE, the world's first premium all-electric performance SUV.

The electric revolution is gathering pace. As more vehicles become electrified, greater volumes of batteries and battery materials are required. These batteries will eventually reach end of life and must be repurposed or recycled. Currently, the UK lacks the infrastructure to recycle the batteries and recover their materials, so vehicle manufacturers are paying thousands of pounds to ship the battery packs abroad for treatment. Not only is this unsustainable, it exports valuable metals that are vital to the future of transportation. The RECOVAS project will introduce a new circular supply chain for electric vehicle batteries in the UK by developing the infrastructure to collect and recycle electric vehicles and their batteries.

**Public Description** This feasibility study/project considers the application of a planned UK manufactured battery module, of a standardised format, into existing and future battery electric vehicles. This will exploit the emerging economic and technological opportunities available. The battery module is claimed to be highly efficient and sustainable; this will be examined through the study. Managed through project milestones, critical knowledge and capability will be generated within the UK engineering and manufacturing sectors. The project will develop collaboratively through academic research, theoretical analysis and physical manufacturing and testing. The work will establish robust tools, standards and parameters for an existing battery electric vehicle, and it will also deliver a tangible outcome, a running vehicle, for evaluation, knowledge sharing and public demonstration. It is a springboard for accelerated implementation at cell, module and battery pack level, so customers can easily adopt this battery technology which has been developed and produced in the UK.

This project will develop novel range finding and 3D imaging systems which will be used for driver assistance and the autonomous vehicles of the future. The cameras are based on detecting single photons (light particles) in the infra-red region of the electromagnetic spectrum. Depth information is gained by measuring the time of flight of the photons from the illuminating laser, to the object and back to the photon detector in the camera with sub-nanosecond precision. By detecting single photons, the faintest possible light signals, we will realise cameras that can 'see' further than the 3D cameras available today.

Jaguar Land Rover requires the development of cutting-edge electrified propulsion technologies to remain globally competitive. This aligns to the strategy for all new Jaguar Land Rover models to have an electrified option from 2020\. Jaguar Land Rover has created a consortium of world-class academic and industry partners to create a state-of-the-art highly integrated "High Voltage Integrated Battery Electronics System" (Hi-VIBES). The Hi-VIBES unit will be used to control Jaguar Land Rover's future BEV traction batteries, including power and thermal management, 2--way charging (V2G), and interfacing to the vehicle's 12V power supply systems. The Hi-VIBES unit will offer significant cost, weight and package benefits versus current industry solutions through its high level of integration, and will introduce innovative features such as 2-way charging, allowing the traction battery to dissipate power back into the grid during peak demand periods. To deliver this exciting project, Jaguar and Rover has assembled a consortium of UK based world-class experts including: **Industrial partners:** Lyra Electronics -- A UK based SME will lead in key areas of design and analysis, building on significant cutting-edge experience in the field of power electronics. Pektron -- A UK based electronics manufacturer and tier 1 OEM supplier will bring manufacturing expertise to the team, supplying prototypes and ensuring a design that is highly orientated towards efficient and modular mass production in high volume. **Academic partners:** Nottingham University will apply their world-renowned expertise in electronics to support the creation and analysis of the overall design concept. **Jaguar Land Rover** will provide overall coordination including futured target setting, software development, and lead integration of the unit into the Jaguar Land Rover family of vehicles. Successful execution of the project will result in significant opportunities for UK production sourcing to sustain and drive new jobs growth in the UK electronics industry during the critical transition period from conventional ICE to electrified powertrains. Hi-VIBES will also drive significant growth in electronic system design and manufacturing capability within the partnership and will provide the consortium partners with a competitive edge to create UK intellectual property (IP); a strong UK supply chain; and downstream exploitation opportunities in adjacent fields. The creation of the Hi-VIBES unit will cement Jaguar Land Rover's position as a provider of world class electric vehicles, evidenced through the recent Jaguar I-PACE triple award of "2019 World car of the year"; "World car design of the year, and "World car green award".

Jaguar Land Rover requires the development of cutting-edge electrified propulsion technologies to remain globally competitive. This aligns to the strategy for all new Jaguar Land Rover models to have an electrified option from 2020\. Jaguar Land Rover has created a consortium of world-class academic and industry partners to create a hydrogen fuel cell electric vehicle (FCEV) prototype to evaluate Hydrogen Fuel Cell Technology large premium SUVs. The project will deliver a benchmark, zero emissions premium FC SUV concept with Jaguar Land Rover attributes such as long range, quick refill, towing, off-road capabilities, low temperature performance. To deliver this exciting project, Jaguar and Rover has assembled a tightly focussed consortium of UK based world-class experts including: Delta Motorsport -- A UK based SME will lead the development of a class-leading, high performance battery Marelli Automotive Systems - part of a global automotive group with UK base will support the design of the cooling system and the development of high-performance heat exchangers suited to FCEV. The UK Battery Industrialisation Centre is part of the UK government's Faraday Battery Challenge to establish a new national facility for battery manufacturing development. Jaguar Land Rover will provide programme leadership, lead technology integration, and hardware and software development for vehicle power management. Jaguar Land Rover will lead the vehicle physical integration and manufacture demonstration vehicles Successful execution of the project will result in significant opportunities for UK production sourcing to sustain and drive new jobs growth in the UK during the critical transition period from conventional internal combustion engines to electrified powertrains. The project will also drive significant growth in FCEV design and manufacturing capability within the partnership and will provide the consortium partners with a competitive edge to create UK intellectual property (IP); a strong UK supply chain; and downstream exploitation opportunities in adjacent fields.

Jaguar Land Rover demands the development of cutting edge electrified propulsion technologies to remain globally competitive. This aligns to and sustains the strategy for all new Jaguar Land Rover models to have an electrified option from 2020. Jaguar Land Rover have created a consortium of world class academic and industrial partners to create a state of the art electric drive unit (EDU), and the supply chain to deliver it, to power future Jaguar Land Rover electric vehicles. The electric drive unit will stretch the boundaries of the electric motor, inverter and transmission technologies to provide an integrated electric drive unit which will offer class leading efficiency for increased vehicle range, coupled with high power and torque density, all within a lightweight and compact package envelope. The unit will build on Jaguar Land Rover's existing learning and partnership arrangements and will provide Jaguar Land Rover and its expert consortium partners with a competitive edge intended to create UK intellectual property (IP) and supply chain. Jaguar Land Rover will provide overall management of the programme, and lead specifically in the areas of integration and industrial procurement. The expert UK based partner group will lead in the following areas: Industrial partners MDL, Inetic, Lyra will lead on e-machine and inverter design, analysis,integration and support prototype build. Tata Steel and Bradauer will lead on electric steel material supply and stamping development. Fuchs will lead on lubricants/coolants and support design, analysis and manufacturing. Academic partners WMG will support EDU and e-machine integration, manufacturing and metrology,analysis, pilot build and testing. Newcastle University will support transmission design, including prototype build and testing. The proposed industrialisation of the unit at Jaguar Land Rover's Engine Manufacturing Centre (EMC, Wolverhampton, UK) will serve to create and sustain UK job opportunities within Jaguar Land Rover; the project's industrial and academic partners; and critically, it will provide a compelling product landscape to drive additional vehicle sales and promote the establishment of a UK production supply chain. The involvement of UK subcontractors and SMEs will represent a key enabler to the development of a UK production supply chain. The creation of this EDU is intended to cement Jaguar Land Rover's position as a provider of world class electric vehicles, evidenced through the recent Jaguar I-PACE triple award of "2019 World car of the year"; "World car design of the year, and "World car green award".

This proposal is for a Connected Vehicle data Exchange (ConVEx) facility: an open platform for the commercial exchange of data to enhance and accelerate the development of connected and automated vehicles (CAVs). This will help to position the UK as a leader in CAV research and development (R&D) and accelerate anticipated CAV benefits including improved safety, easier access to mobility and more efficient transport. The consortium is led by Bosch, and includes Jaguar Land Rover, Transport for West Midlands, WMG, and three SMEs: Valerann, Synaptiv, and Immense Simulations. InterDigital and Transport Systems Catapult will both support the consortium in their role as subcontractors. The vision for the facility is for a centre that aggregates data relevant to the development and/or operation of CAVs from a diverse range of sources. These data could be already publicly available, available under licence or purchased by the facility. Services will include curation of these datasets within in a single ‘shop window’ for organisations seeking data resources relevant to CAV development and deployment; data cleansing and analyses, drawing together relevant datasets and exploring connections that generate further insights into CAV development, deployment and operation; and enabling organisations to monetise data resources that may have previously been left dormant.

"The Government's Faraday Battery Challenge program is supporting an exciting research project to bring solid-state batteries much closer to market in future electric vehicles. The main advantage of solid state batteries (SSBs) lies in their increased safety, power performance, enhanced cycle life and increased energy density as compared to current Lithium-ion cells. This should translate into electric vehicles which can travel much further between charges, simpler battery pack designs and faster re-charging when it is necessary. This would ease any remaining customer worries about long charging delays or running out of power on long trips and help more people make the switch to electric motoring. However, solid state battery technology is still in its infancy and no one has yet worked out how to deploy the science on an industrial scale and at reasonable cost. Project Granite will explore the cost-effective routes for scaling up the solid-state technology developed by Ilika, a pioneering leader in this technology, with the support of AGM Batteries, which has industrial experience in manufacturing Lithium-ion cells. The project is led by Jaguar Land Rover, which will develop the new battery pack designs to fit within their future electric vehicles. Warwick Manufacturing Group will supply academic excellence in abuse modelling and cell performance evaluation. The consortium's expertise, backed by Government financial support, will allow Britain's best talent to be brought to bear, so that the UK can take the lead in this transformative technology."

"The Government's Faraday programme is supporting an important new research project to improve the safety of batteries for use in electric vehicles and as stationary power sources. Businesses Jaguar Land Rover, Denchi Power, 3M, Potenza, Lifeline and Tri-Wall are pooling resources with academics and experts at the University of Warwick and the Health and Safety Executive to ensure public safety in the age of electric motoring. Electrically-powered vehicles and battery storage installations thankfully have a good safety record in the UK, but engineers and academics involved in battery design are taking no chances. Lithium-Ion battery cells have the potential to catch fire aggressively, and with consumers demanding that batteries give them further range and faster charging, there is an urgent need to develop an understanding of how such ""thermal runaway"" (TR) events may be triggered, suppressed and contained. The use of improved prevention materials, methods and mechanisms and a focus on identifying and detecting all early signs of risks, will ensure that fires can be prevented, or if necessary isolated and suppressed before they spread. Project LIBRIS seeks to improve understanding of the range of potential causes of TR in individual battery cells and through scaling up tests and scientific understanding, develop better computational models for assessing the spread of TR within battery packs. The team will use real vehicle and stationary Lithium-Ion battery designs and applications to model theoretical work and will take forward the most effective innovations into newly designed packs which will be tested to make sure that the inventions actually work. The group will then use this experience to develop standard tests for assessing the effectiveness of any future battery fire prevention mechanisms, thus assisting the next generation of work on this vital issue. The project will lead to better battery pack design and control software, better fire sensing equipment, more use of innovative flame-retardant materials and better packaging for batteries in transport and during storage. It will create business opportunities and investment in the UK, whilst also contributing to public safety. It will also build UK public sector capability to influence future international safety standards and regulations, so that safety remains paramount, but is science-based and not used as an artificial excuse for trade barriers."

"Jaguar Land Rover is leading an exciting research project to investigate and develop strategies and capability to convert internal combustion engine manufacturing facilities to also make electric drive units for hybrid and electric vehicles. The company's engineers will work with industrial partners, Mapal, JW Froehlich, Fives Landis and Horizon and with the Manufacturing Technology Centre, the High-speed Sustainable Manufacturing Institute and Birmingham City University to ensure that its state-of-the-art manufacturing machinery, systems and processes are flexible enough to manufacture both internal combustion engine and electric drive units efficiently along the same production line. This ambitious and highly innovative project will deliver manufacturing flexibility at a time when the exact speed of the changeover to electric motoring remains uncertain. If car buyers want more electric cars than expected, Jaguar Land Rover will be able to ramp up supply quicker than some of its rivals. If demand for diesel and petrol persists for longer, there will be no expensive electric drive factory sitting idle. The project will also ensure that the company builds on its existing manufacturing capability, rather than having electric drives built separately. The project therefore helps protect Jaguar Land Rover facilities and the staff during the switch-over to electric. The Government is supporting the project through its Advanced Propulsion Centre because the technology involved is both innovative and has the potential to benefit a range of UK businesses. The project will help ensure that the UK becomes a major centre for the production of electric drive units, encouraging suppliers of electric car components to invest and develop their businesses in this country."

Currently the automotive industry is launching semi-autonomous driver assist features where the driver has to be aware of their surroundings to regain control where the car can't cope. Moving towards full autonomy, the vehicle will have to operate without a driver as a backup. Vehicles will have to handle complex situations and any road junction. The vehicle relies on its sensors to operate safely and efficiently. These sensors have limitations when there are obstructions in the way or there are rapid lane change and fast moving traffic where a clear view is not possible for example some lane merges or roundabouts. The AutopleX project includes the technical domains of cybersecurity, cooperative autonomous driving, vehicle-to-anything (V2X) communications, Advanced Driver Assistance Systems (ADAS), and Internet of Things (IoT) to demonstrate enhanced autonomy for complex vehicle manoeuvres at junctions, supporting SAE Level 4+ autonomy.

In 2016 many people were predicting fully autonomous cars within 5 years. After initial quick progress, their recent development has slowed significantly. The market is now adjusting to the new, slower rate of development. This has been seen in more measured predictions from manufacturers and experts, with some companies rolling back on autonomy plans and projects. Whilst machine learning and computer vision has enabled vehicles to reach near autonomy in controlled conditions, it is real world driving in all weather conditions that is proving difficult to achieve. Although there have been demonstrations of autonomy using a combination of fully mapped environments and data from large numbers of sensors, the environments in which the demonstration vehicles operate are highly constrained and therefore, do not represent some of the key environmental challenges that will be encountered by these vehicles in real-life driving scenarios. Several challenges have been highlighted in this CCAV call to facilitate full autonomy, however challenges on "autonomous vehicle features that provide real-world benefits to users to work as part of a wider transport system" cannot succeed if the system cannot robustly understand the environment in which the vehicle will drive, i.e. different weather conditions (sunny, dark, raining, foggy or snowing), or different road surfaces across the world. The project addresses the development of key enabling technologies and sensing techniques for autonomous driving in all-road and all-weather driving conditions. Radar systems remain relatively unaffected by adverse environmental conditions (dirt, rain, ice, snow, fog etc…), However, the radar does not have the same level of resolution as a camera. Often is not possible to classify an object based solely on its radar return signature. This is changing as manufacturers add more and more transmit and receive elements to their radar boards. This is improving the accuracy and resolution to create an 'Imaging Radar'. Cortex will use advanced radar processing and beamforming techniques to improve resolution and reduce the known issues e.g. MIMO high side lobes. The objects in the resulting radar images will then be classified and the complete scene will be segmented into different classes. The resulting identification and labeling of objects will not be affected by weather, in the same way a camera would. Autonomous driving based on machine learning, using CNN algorithms from the camera images is common. There is however a new class of 'Transformer' algorithm, previously applied to speech and simple waveform data, that is now being applied to images. This project will explore the Transformer Algorithms and their use in object identification and image segmentation. The project will take real world driving data from on road and off road and compare the classification from radar and camera images.

"Automated valet parking (AVP) is a key feature needed in a level 4/5 automated vehicle. Users of premium vehicles don't want to care about parking and ""taking the vehicle away"" is vital for Mobility as a Service vehicles. The question is ""_where does the vehicle go?_"". Circulating streets is inappropriate, so parking is needed somewhere. Parking could be at bays on street, subject to legislation, payment terms and vehicle restrictions, but a vehicle may need to stay close to the pickup to reduce waiting. It could be parked off street some distance away, in bulk storage. And a traditional car park could transform into a drop off hub, releasing value in parking property for retail and residential. Delivering this requires filling gaps: 1. Knowledge of available spaces of the right size, routes to access and a payment mechanism; and 2. Ways to ensure AVP avoids the disastrous customer experience of receiving a parking ticket even though the customer thinks they have paid. This could mean pre-booking spaces not usually used for parking. Addressing this requires scalability and evidence to prove payment. It also needs a business model that links automotive to parking with suitable investment return, changes to infrastructure to support drop off and a data model understanding customer and road authority expectations. And it needs to be secure and compliant with new privacy laws. Our vision is a customer experience better than ""manual"" valet parking, and to support ""Mobility As A Service"" . The business question is: _How do we make large scale automated valet parking work for demanding customers in the real city, and develop a sustainable business that can be rolled out globally?_ Our feasibility study therefore focuses on innovation in: * Exploring AVP deployment in very different cities (Coventry &Westminster) with real world problems, based on car park operator (NCP) market knowledge * Capturing data for parking, blurring the line between on and off street, looking at how to get data into the vehicle to make parking decisions (Appy) * Building a business model of revenues, data ownership and liability * Demonstrating AVP in a complete data chain model and customer storyboard * Validating this against an OEM's global customer and business requirements (Jaguar Land Rover) From a 12-month study , the outcome would be an innovative business model for how AVP might run and changes needed, proposed standards for AVP data exchange and a global view of UK industry opportunities."

"The VeriCAV project is developing an integrated test framework to allow Automated Driving Systems (ADSs) to be validated in simulation, exposing them to large numbers of complex driving situations such that developers and regulators can have real confidence in their reliability and safety when deployed on the roads. The project will go beyond scenario-based testing to a paradigm where optimal test cases are generated from the space of all possible situations. VeriCAV is also aiming to improve the efficiency of testing by minimising human effort necessary to supervise the huge number of tests expected. As part of this approach, a test analyser (also known as test oracle) will automate the evaluation of an ADS's performance during a test run and also aggregate information on the simulation setup in order to automatically create test coverage statistics. The project will also create realistic smart agents, representing other vehicles and pedestrians that interact with the ADS. Finally, the project will verify that the test framework performs correctly, by testing a real ADS as the system-under-test in the simulation framework, and additionally by performing physical tests with a vehicle running the same ADS to correlate performance with the simulation."

"Autonomous vehicles are being developed with the promise of improving road traffic safety and convenience. This project addresses a gap in the UK automotive supply chain, the algorithms used within the sensors add most of the value and this is an area where the UK can further develop ability and the UK should be able to generate significant revenues by exploiting this technology. Autonomous functions that take control of the driving tasks off the human driver are heavily dependent on the system ability to perceive and understand the vehicle's surroundings through complex sensor systems. Most are actively emitting signals to use their reflections from the environment to understand the scene. The sensor data-processing algorithms produce this understanding of the environment, enabling the autonomous function control system to adapt in response to prevailing conditions. The autonomous functions sensors will be the car's ""all-weather-eyes"" and their performance is fundamental to their reliability and safety, but there are insufficient comprehensive performance-verification methods and tools available. The immediate future challenge comes from the co-existence of many active sensors in diverse traffic environments with high probability of their signals interfering with each other. Autonomy function sensor performance verification is of unprecedented importance for reliable real-world autonomy as many vehicles with these sensors increasingly share the same road space. This project will bring innovation through new sensors characterisation and new modelling methods building upon MoD-funded defence expertise, particularly for radar sensors. These models will enable studying autonomous functions performance through the simulation of challenging scenarios for the sensors in the real-world but challenging to replicate in a controlled real environment for assessment. This consortium holds an unrivalled global-level strength and potential to describe and solve this challenge, by understanding of the complex interactions between environment, sensors and vehicles: \*JLR --know-how of real-world automotive systems and their sensors requirements (the UK automotive manufacturing business with the largest investment in automotive R&D). \*MIRA -developing the most comprehensive independent test services for the UK CAV ecosystem. \*UoB -strong expertise in all aspects of radar systems, including hardware design, radar signature modelling, channel characterization and signal and image processing. \*Igence -bespoke radar simulators for applications including airborne early warning, maritime surveillance, fighter aircraft and air traffic control. The project will directly support best-practice, guidelines, policy and regulation for the development and deployment of autonomous vehicles in the UK, effectively contributing to the transference of these technologies to the UK roads."

"_Where am I?_ This is the main starting point for the operation of many of today's self-driving vehicles. From knowing their position, they can go on to assess what else is out there, and what to do next. To do this effectively is challenging , as autonomous vehicles are incredibly complex real-time systems to design and engineer. As with any such system, it is crucial to be able to _debug_ their development process in order to gain insight and understanding of why varying system configurations perform differently. In engineering terms, obtaining the vehicle position is known as _localization_. A key element of developing technologies in this area, is to be able to define a **ground-truth** reference against which the performance of the autonomous vehicle can be assessed under different experimental test conditions. This might be in response to changing environmental conditions (e.g. weather), different sensors configurations (e.g. LiDAR plus cameras, and where they are looking) , or in relation to external factors (e.g. cyber-attack). This project sets out an innovative framework - consisting of a hardware sensor and analytics software - that can be used to measure the localisation of the vehicle between where it **thinks** it is, compared to where it **actually** is on the road. The result can be used by the development teams to quickly and effectively measure the performance of different vehicle sensor and how they are configured to operate, as well as understanding how the software is making decisions. Crucially this framework requires no additional external infrastructure to operate (unlike enhanced GNSS solutions) and can work under real road driving conditions (i.e. at normal speeds, under varying weather conditions, etc.). Furthermore, it is completely independent of the sensor or software component being evaluated - so can be used to objectively verify and optimise performance by the development team from the very early to late stages of self-driving vehicle development. This will result in an extremely valuable tool for enabling Level 4 autonomy and beyond, as well as independently delivering critical assessment of safety during the development and validation process."

Stiffer, lighter vehicle structures are required to enable mainstream electrification of common vehicle platforms, boosting adoption of electrified vehicles and improving their environmental performance. However, this requires a step-change in cost effective structural performance at a design, material and manufacturing-level which is currently unmet across the industry. In Project Tucana, Jaguar Land Rover leads a consortium of world-leading academic and industry partners spanning the entire supply chain to introduce large composite assemblies and realise world leading lightweight body structures. The consortium will leverage globally cutting edge industrialised materials, design and manufacturing concepts to integrate much higher quantities of affordable lightweight carbon-fibre composites into premium volume automotive applications, while also increasing the knowledge of these global businesses and the UK research base. As an enabler for a zero-emission electrified vehicle platform, Project Tucana has potential to reduce vehicle CO2 emissions and improve range and air quality. The project will deliver inward investment opportunities and strengthen UK capability by integrating existing automotive lightweight technologies and developing knowledge to deliver a new UK supply chain at a globally significant scale for cost competitive carbon-fibre-composites.

"**The Faraday Challenge (FC) Round 2 is designed to support the creation of a viable UK electric vehicle (EV) battery supply chain with an emphasis on safety of Lithium Ion Batteries (LIBs). A major known concern relating to the use, transportation and storage of LIBs is the need to ""eliminate _thermal runaway_ risks for enhanced safety"". PreLIBS (Preliminary feasibility study into Lithium Ion Battery Safety) aims to develop an understanding of key areas linked to this area. The study will act as a precursor for further research.** It is envisaged that the industrial benefits would include: * Manufacturers taking Lithium-Ion battery safety responsibly and benefiting from enhanced solutions to address Thermal Runaway and subsequent Thermal Propagation mitigation strategies * The ability to predictively model fire propagation would allow the optimisation of solutions -- delivering lighter weight and lower cost without reducing safety * Encouragement of an increased uptake of EVs, providing greater efficiencies in use over ICEs * UK LIB safety testing at HSL would give UK manufacturers an early advantage in taking these technologies to market **The PreLIBS team is made up of a consortium with members from Jaguar Land Rover (JLR), Warwick Manufacturing Group (WMG), Health and Executive, Science Division (HSL), Warwick Fire, Potenza Technology, Lifeline Fire and Safety Systems Ltd (Lifeline) and 3M UK PLC (3M); knowledge and expertise would be pooled to navigate the challenge. A review of existing literature would be conducted with a focus on Standards & Regulations. Data from a preliminary body of test and modelling work, which would provide initial guidance for sensing and mitigation solutions, considering a variety of potential materials.****Key deliverables from the PreLIBS study would include:** * **Guidance on navigating and evidence to inform the standards** * **Analysis of sensing and detection methods** * **Evaluation of material effects in thermal runaway** * **Cell and cell group data to inform modelling and material design** **Industry, including battery manufacturers and organisations using batteries in their products, is actively seeking information about how to integrate battery safety into their products, processes, and procedures. These concerns need to be addressed now to ensure that safety issues do not become barriers to the effective and safe deployment of LIB technology for EVs.**"

Jaguar Land Rover is leading an exciting research project to develop future state of the art electric hybrid vehicle systems, in conjunction with universities and businesses across the UK. The project aims to significantly improve the vehicle system efficiency through utilisation of innovative electronic systems and componentry.

This project will reduce vehicle emissions by developing (i) a novel ferrite motor technology for a passenger vehicle application, and (ii) electro-mechanical analysis tools enabling high levels of system integration. Permanent magnet (PM) machines are most common for EV/HEV due to superior efficiency and power density. Rare-earth types are prevalent but suffer from supply chain issues, which can be removed by using ferrite PMs. Initial studies show that significant increase in efficiency and power density is possible, achieving values similar to rare-earth machines. The project will develop analysis tools to optimise system performance - efficiency, NVH, durability, thermal performance, cost, and lightweighting. The structural design of a ferrite motor is challenging, hence this topology will form the basis for the analysis tool development, with results transferable to other topologies. Co-simulation of state of the art electromagnetic, thermal and structural physics will be used to derive novel, faster, yet accurate, reduced order models which capture electro-mechanical interactions as early as possible to improve process efficiency and achieve true system optimisation. Testing of material properties (laminations and magnets) will improve the structural and electromagnetic models. The prototype drivetrain will be tested to demonstrate system interactions and vehicle-level efficiency improvements.

"The projects aims are to develop and demonstrate low cost 12V batteries for electrified vehicles. These batteries are used for lighting, security, control of the traction battery management system and other critical features. Generally, in electrified vehicles, these batteries use lead acid technology on account of their low cost and specialised requirements. The consortium is seeking to replace these batteries with lower weight and lower volume batteries of comparable cost and performance based on sodium-ion chemistry, a technology which uses more sustainable and lower cost materials than lithium-ion technology but is otherwise very comparable. The consortium members include Jaguar Land Rover the automotive supplier, Croda the specialty chemicals company who will be developing electrolyte additives, Talga Technologies who will be focussing on natural carbon anodes, Faradion Ltd the developer of sodium-ion batteries and Warwick University home to the Warwick Manufacturing Group and the centre for battery pilot plant manufacturing in the UK.."

"AMPLiFII 2 is aimed to take the results of the successfully delivered Amplifii project (in the form of a modular, scalable, flexible battery architecture for deployment on low to medium volume vehicle platforms) and accelerate their integration into vehicle products for JLR, JCB, Ariel and ADL. It will take the manufacturing technology developed during Amplifii and adapt it for implementation by the partners. Further, it will develop additional functionality for the AMPLiFII battery system, including 800V high power charging and discharge, location based BMS control, advanced and highly robust cooling, distributed BMS, use of new 21700 cell format, and cost-down measures. The project will result in four fully developed management demonstrator vehicles, a pilot production facility at Delta Motorsport, and a production ready BMS system by Potenza and Trackwise."

Future Transport Systems, Jaguar Land Rover, Warwick University and Videre Global are collaborating on the development of an energy storage system that takes advantage of 2nd life electric vehicle batteries. The 2nd hEVen project will research and develop variations on Future Transport Systems' existing E-STOR energy storage system identifying how it can use a range of 2nd life batteries of different types and states of degradation. The collaboration will also research the economics and business cases associated with the use of 2nd life batteries. A key area of research in the project is the use of 2nd life battery storage systems in developing countries and Videre Global, a specialist in smart grid systems in the developing world will assist in determining and testing market requirements. Warwick University will undertake research into the use of 2nd life battery module based systems. Ultimately the project will help accelerate development of the E-STOR technology for high volume deployment.

This proposal considers testing, evaluating and enhancing the performance of 5G Vehicle to Infrastructure communications in a vehicular environment and in particular in a motorway-speed scenario. 5G mmWave communications will be explored for high data rate delivery and a feasibility study to evaluate the technology for mobility will be performed. Using Road Side Units (RSUs) spaced regularly along the motorway or road, data rates in the order of gigabits per second are anticipated. To overcome the high path loss at mmWave frequencies, adaptive beamforming will be used to focus signals to and from the vehicle. The project will perform real world radio channel measurements leading to data trials using a suitable demonstration system.

The DRAFC project brings together Jaguar Land Rover Limited (JLR) and the University of Glasgow to collaborate on the application of a novel technology for flow control in road vehicles with the aim of reducing aerodynamic drag to deliver improvements in carbon emissions and fuel economy.

Jaguar Land Rover is leading a consortium of UK technology companies and universities to develop world- beating new lightweight vehicle technology. New materials and manufacturing technologies will be designed to reduce pollution with no compromise on premium vehicle performance and Jaguar Land Rover plan to integrate the technology and deploy it on future generations of exciting new cars and SUVs. Each innovation alone does not deliver sufficient improvement to justify the high cost of investment and innovation to such high technical standards but, collectively, with backing from Jaguar Land Rover, project partners and with Government support, there is a package of innovation that can beat the best other countries have to offer. The technology is expected to draw inward investment into the UK, develop new components with a minimum 10-year expected manufacturing life span, embed new skills into the UK's supply chain, and create and protect UK jobs in engineering and manufacturing

The 36 month REALITY project will enable the development and industrial deployment of sensor-based scrap sorting technologies to separate wrought and cast alloys and then to further separate wrought alloys into alloy types for the first time. Full scale recycled scrap based sheet and castings will be produced and evaluated. End-of-life vehicles will be shredded and automatically sorted using state of the art sensing and sorting technologies. The recovered wrought and cast scrap will be alloyed, melt conditioned to remove or tolerate impurities and then supplied for either coil production or for the commercial scale shape casting production by high pressure vacuum diecasting. Materials evaluation and characterisation will be carried out on both the resultant sheet and cast product forms. Cost effective automated separation processes for shredder scrap will enable the closed-loop recycling of end-of-life vehicles back into high performance product forms for new vehicle body manufacture in the UK, providing significant CO2 savings (less or no primary metal) and major cost savings. The UK, the major exporter or the more than 1Mt of aluminium scrap from the EU each year, will be uniquely placed to use rather than export this precious scrap based secondary aluminium alloy resource.

The automotive industry faces major challenges to meet targets for emissions, efficiency, performance and cost; light weighting of parts using composites enables all of these to be addressed, except for cost. A key driver of cost of composites is the limited ability & capacity in the joining technology available. In project Light-Join, JLR, Nissan and their Tier 1 suppliers aim to develop a number of solutions that will enable cost effective integration of high performance composite components into volume car production. Light-Join aims to enable replacement of specific metal vehicle components with composites, specifically focussed on developing rapid joining solutions, raising the manufacturing maturity to produce a small scale demonstrator component (MRL5) and assessing the potential for scale-up to MRL9A. This project will develop a solution leading to 30% weight reduction for all-aluminium construction (for JLR) and 60% compared to an all steel construction (for Nissan). Critically this approach will have industry wide applicability, allowing a lower risk introduction of lightweight composite components to the mass market.

The is a great pressure on the UK vehicle manufacturers to reduce fuel consumption and lower CO2 emissions. Great improvements in these requirements have taken place over recent years mostly by the development of highly fuel efficient engines. This trend of improved engines will not be sufficient to meet impending legislative requirements on carbon emissions. Therefore weight reduction of vehicles is vitally important. This must be done cost competitively, consumers would not pay much more for vehicles so cost effective solutions must be found. This programme seeks to find new ways of producing optimised structures using the approach of applying different materials where they are needed. This novel part of this technology is to develop the modelling techniques that allow the efficient use of these multiple materials. By doing this, both weight optimised and cost optimised structures can be produced.

Breathe is a package of collaborative innovation, predominantly led by suppliers, which will reduce emissions of CO2 by 16.5% for Jaguar Land Rover's (JLR) next-generation petrol engines. Reducing emissions from petrol engines is vital to reducing overall transport emissions: petrol will remain predominant in propulsion systems for many years (allowing time to establish the global infrastructure necessary for electric vehicles, especially in developing countries). JLR provides integration capability and a route to market for all the technologies: partners can pursue interest from other OEMs to exploit further. Each innovation alone does not deliver sufficient improvement to justify the extra investment and risk but, collectively, with backing from JLR and with Government support, they: constitute a package of innovation that can deliver environmental gain without prejudicing performance, draw inward investment into the UK's supply chain, develop technologies with a minimum 10-year expected manufacturing life span, embed new skills into the UK's supply chain, and create and protect 713 direct (3,294 indirect) UK jobs in engineering, manufacturing and production.

Aluminium Matrix Composites (AMCs) offer the strength and stiffness of steel, but with the density of aluminium, making them an exciting candidate for reducing the weight of ground and air vehicles to help improve efficiency and reduce CO2 emissions. Advantages over carbon fibre reinforced plastic composites include higher temperature resistance, better toughness, recyclability and no corrosion in contact with aluminium structures. However the drawbacks are the current high cost of the alumina reinforcements and difficulty in applying existing techniques to high volume manufacture. This project aims to further develop and demonstrate a novel multiplex energy laser consolidation (MELC) process in combination with advanced 3D weaving to produce AMC components in a rapid, low energy, low waste process which is anticipated to enable the tough cost targets of the automotive industry to be met whilst reducing CO2 emissions in both the manufacturing and use phase of the components.

An innovative research project led by Jaguar Land Rover, HyPACE (Hybrid Petrol Advanced Combustion Engine) will investigate new petrol engine technologies. The collaboration will integrate UK expertise from JLR (Combustion and Development), Borg Warner UK (Advanced Boosting Systems), Johnson Matthey UK (Emissions Control Technology), Cambustion (Emissions Development), MAHLE Powertrain UK (Engineering Consulting Services) and the University of Oxford (Advanced Optical Combustion Diagnostics). The collaborative project will target 10% engine fuel economy improvement in combination with emissions reduction and enhanced drivability. The collaborative project is part of JLR's wider strategy for lower emissions and improved engine fuel efficiency. While developing technical innovations, the partners will increase UK automotive competitiveness and skills. The project is aligned with the continued JLR investment in powertrain research as shown by the £1bn investment in the Wolverhampton Engine Manufacturing Centre.

The High Pressure Exhaust Gas Recirculation Generator (HiPERGen) project will develop a novel recovery system that will be integrated into the high pressure exhaust gas recirculation (EGR) loop to utilise the un-used throttling energy for electricity generation using a turbine coupled with a high speed generator and achieving up to 3 % WLTP CO2 reduction. Valeo’s experience in developing and validating a similar technology in a laboratory environment provides the background IP and knowledge consistent with an early TRL4. JLR will provide the operational conditions for the EGR recovery system and, together with Valeo, will specify the performance targets for the different components of the subsystem. An innovative turbine designed by ADT to withstand and perform under challenging operating conditions will be coupled with the novel e-machine designed by Valeo, and these two components will be embedded into the HP EGR loop. The performance of the optimised subsystem will be validated by simulations and experimental results in a gas stand test performed at UCL and in a vehicle demonstration performed by JLR and hence, reaching TRL6.

The TOSCAA project brings together a number of collaborating organisations to integrate a range of innovative, lightweight material and process technologies, enabling the development of a unique TP overmoulded structural automotive component for Automotive vehicle application. The project aims to demonstrate how TOSCAA technology offers the opportunity for this technology deployment in other applications on the vehicle and of interest in other sectors with lightweighting demands such as rail and aero.

The MOVE-UK project will help the UK to become a world leader in the development of automated and driverless cars. The project partners (Bosch, Jaguar Land Rover, TRL, Direct Line Group, The Floow and the Royal Borough of Greenwich) will speed up the entry of automated, driverless car technologies to the motor market. The project will allow these technologies to be developed and tested more rapidly and at lower cost to manufacturers. Driverless systems will be tested in the real world, providing large amounts of data that will be used to develop and improve the technology. These technologies will not control the test vehicles but will generated information which will be fed into a unique data store. This data store will allow us to develop new, faster ways of improving and demonstrating the safety of the automated driving systems. We will also use this information to provide “smart cities” with new ways to improve services for residents and the environment; to help us understand how detailed data from cars can be used in the future to benefit drivers; and, to help the project partners to understand the how driverless technologies will change their businesses in the future.

The UK Connected and Intelligent Transport Environment (UK CITE) creates a real-world-lab for companies to test how connected and autonomous vehicles (CAV) can interact with communications infrastructure (so called V2X). The project will install the relevant infrastructure along sections of the M42, M40, A45, A46 and Coventry city centre. This test environment will be available to other vehicle manufacturers or fleet users who wish to test V2X technologies. It will act as a world class research asset to attract R&D to the UK. CAV test vehicles will examine the impact of V2X on road safety, traffic flow and the ability to provide other services like WiFi. Cyber-security will also be included from the outset. V2X will improve a vehicles journey through the road network. E.g. in case of an accident instead of an expensive gantry on the motorway a connected car could provide warnings and guidance to the driver, or an autonomous vehicle could respond automatically. The impact on the UK road network will be simulated based on these trials - enabling the UK to get the most benefits from CAV for the least infrastructure cost.

The project will develop a new highly innovative lightweight exhaust system for forced induction diesel and petrol automotive vehicles. This project will deliver cost-effective materials and manufacturing technology, including metrology and CAE methods to enable a step change reduction of 50% of the mass of an exhaust system. It will provide innovative solutions to the manufacturing challenges associated with down-gauging exhaust components in terms of jigging, forming, joining and metrology as well as the overall design methodology. Furthermore, the project will focus on the development of new and innovative material processes for the catalytic hot-end of the exhaust system including the associated manufacturing challenges. The ultimate aim is to significantly reduce the overall system mass, thus for instance giving an annual CO2 saving of 325M tonnes, reduced customer fuel bills and a 5% reduction of precious metals being used in catalytic converters. The project brings together 3 industrial and 2 academic organisations in a 2 year project costing £1.59M

An innovative research project led by Jaguar Land Rover, LAtiTuDE investigates new technologies for the Ingenium engine family to improve on its class-leading fuel efficiency whilst maintaining the in-vehicle feel Jaguar and Land Rover customers expect. The collaboration brings together leading expertise from UK engineering organisations Ricardo and GRM, and suppliers Borg Warner and Bosch. The collaborative partnership will research a variable geometry, multi-stage and electronic boosting system integrated with an advanced engine combustion system incorporating leading edge fuel injection equipment and controls. Allied with an optimised engine structure, the research package is targeted to deliver over 10% fuel economy and CO2 improvement compared with current vehicles. The consortium members recognise the importance of collaborative research projects in supporting the UK’s competitiveness and developing skills, innovations and new manufacturing capability throughout the automotive supply chain.

An innovative research project led by Jaguar Land Rover, TRANSCEND - TRANsmission Supply Chain Excellence for Next generation Dual clutch technologies - strives to maximise fuel efficiency whilst maintaining the invehicle feel Jaguar Land Rover customers expect. The collaboration will develop a new transmission based around an ultra-wide ratio dual clutch architecture incorporating Jaguar Land Rover intellectual property. Drive System Design will lead the development of the transmission design and control while Tata Steel, Productiv and HVM Catapult will be responsible for developing both the manufacturing processes required and the supply chain necessary to take the transmission to production. The transmission will also benefit from 48V mild hybrid drive. This innovative transmission will offer improved fuel economy, low weight and seamless range changing performance. The consortium members recognise the importance of collaborative advanced research projects supporting initiatives that will expand the UK’s competitiveness and develop skills, innovations and new technologies in the automotive sector and throughout the supply chain

UK Autodrive - Milton Keynes leading the way in partnership with Coventry and the motor industry is a large programme of work aimed at exploring and demonstrating the potential for autonomous vehicles to become part of our everyday lives. The programme, which involves the demonstration of road-going cars and lightweight self-driving pods designed for pedestrianised spaces, will be delivered on behalf of the UK by the City of Milton Keynes working in association with the City of Coventry. The partners in the programme include JLR, Tata, Ford, RDM, Thales (UK), AXA, Wragge-Lawrence-Graham, Oxford University, Cambridge University, the Open University, and the new Transport Systems Catapult. Consulting group Arup has devised the programme and will provide programme management and technical co-ordination skills.

Awaiting Public Summary

The project will develop a novel energy recovery and boosting system for internal combustion engines, leading to a step change in vehicle energy efficiency, fuel consumption and CO2 emissions. Aeristech’s Full Electric Turbocharger Technology (FETT) is a mechanically decoupled turbochaqrger and comprises of 3 elements; (1) an electric turbine generator recovering exhaust heat energy, powering (2) an electric compressor to boost the engine on demand, through (3) a power management unit. Jaguar Land Rover Limited, Advanced Design Technology Limited, Bath University and Aeristech will match the FETT concept to JLR’s Ingenium engine family, and the FETT development will be supported by an extensive simulation phase at system/engine level, as well as vehicle level for an optimised vehicle energy efficiency. This simulation, led by JLR and Bath University will provide Aeristech and ADT with a detailed FETT target specification. ADT will focus on the design of optimised turbomarchinery, for a decoupled turbine and compressor, whilst Aeristech will concentrate on the design of electric machines and power management device with best-in-class efficiencies.

Air conditioning in vehicles is very energy intensive. In internal combustion engines up to 8% of the fuel is used, but in EVs there is limited waste heat that can be reused. This means that up to 40% of the energy within the battery can be required, which directly impacts the range of the vehicle. One way to address this is to engage the recirculation mode more frequently, but this has limited use, particularly in vehicles with many passengers, as carbon dioxide (CO2) levels build up as a result of the occupants breathing. The CLEVER project (CLimate control solution for EVs with Extended mileage Range) aims to show that the air within the vehicle can be actively managed like a bubble, so that on recirculation mode, CO2 and other contaminants are kept to set levels. This concept has the potential to increase the range of electric vehicles by 25%, whilst simultaneously protecting passengers from external pollutants. It is achieved by using a regenerable CO2 scrubber, that captures CO2 from the cabin, and periodically releases it to the outside.

A novel, sequential, net-shape process will be developed to enable complex, light-weight components to be created with minimum waste capable of supporting a wide range of production volumes. Metal powders are encapsulated in a complex-geometry reusable rubber tool and isostatically pressed. The resulting compacts are fully densified using a novel hot isostatic pressing (HIP) method that enables the densification of multiple green compacts into full density. Key innovations include novel tooling method to produce partially consolidated complex compacts and novel processing route to simultaneously consolidate multiple components to full density.

European regulations stipulate a reduction in carbon dioxide emissions for automotive vehicles, this can only be achieved by lightweighting of the vehicles themselves alongside more efficient engine and drivetrain technologies. Current engine designs require higher operating temperatures alongside higher combusion pressures, these can only be achieved with the use of metal composite components. Metal composites have proven to be a successful engine component material for motorsport applications, however the cost restrictions on commerical automotive vehicles has prohitited the use of these materials for larger volume applications. The POWder to POWertrain (POW2) program will examine the issues to realise the larger volume manufacturing of metal composite automtive drivetrain components, focusing on pistons. The project will conocentrate on low cost routes for metal composite production and the shaping and machining of the final piston components and will aim to achieve a cost reduction of 50% compared to current conventional manfacturing routes for metal composite components.

Lightweight crash management systems are of increasing importance for most forms of ground transport. Automotive OEMs like JLR have advanced aluminium automotive body designs but still depend on steel for bumper beams. For rail applications steel based crash systems predominate. Constellium has developed considerably stronger extrusion alloys based on the AA6xxx alloy system that are fully recycling compatible with the sheet used for automotive structures and body panels. Brunel University has developed alloys and casting technologies that enable extrusions and castings to be combined in novel ways to produce a new generation of compact lightweight crash management systems. The envisaged work programme will include a high strength alloy being combined with casting alloys using overcasting techniques and the use of bonded and riveted joints to demonstrate the potential for both increased crash resistance and weight saving. The project will demonstrate and evaluate optimised designs for crash management systems for both automotive and rail transport.

This project lays the foundations for Jaguar Land Rover and UK suppliers to combine their powertrain expertise and experience in a new, collaborative environment. This project will create an experimental "make-like-production" facility in which Jaguar Land Rover and our supply chain partners will participate in the investigation of manufacturing and assembly methods suitable for possible future use. The facility will include prototype machine tools and assembly systems which will allow us to research and innovate in this highly competitive area. The knowledge and confidence gained from the project will enable Jaguar Land Rover to continue to be market leaders in reducing consumption and emissions.

An innovative research project led by Jaguar Land Rover, ALIVE6, - will apply new technologies to the Ingenium engine family, striving to maximize fuel efficiency whilst maintaining the in-vehicle feel Jaguar Land Rover customers expect. The collaboration with Grainger and Worrall, Automotive Insulations and Nifco will research low friction cylinder bore coatings, thermal engine encapsulation and a composite sump respectively. Bosch (UK) Ltd and Mahle Powertrain bring advanced control technologies while downsizing and NVH technologies are supported by FEV UK Ltd and UEES The innovative powertrain technologies will offer improved fuel economy, low weight and excellent transient performance. The consortium members recognise the importance of collaborative advanced research projects supporting initiatives that will expand the UK’s competitiveness and develop skills, innovations and new technologies in the automotive sector and throughout the supply chain.

This ABACUS project is directly aligned with the research challenge of preserving the value of products at end-of-life and keeping them in productive use for longer. The consortium is led by Jaguar Land Rover and includes G+P Batteries, Potenza Technology and the University of Warwick – WMG. The ABACUS project aims to achieve a waste stream reduction of 50%-70% through new business models and new innovative approaches to battery system design that (a) support the in-service life of the battery and (b) extend its productive life beyond first vehicle installation. The project will define the complete value chain for the battery. It will identify key breakpoints, for example when it is economical to service, test, recover, remanufacture and redeploy the battery. The project will address the strategic need for accurate and easily obtained data for driving commercial decisions that are economically viable and environmentally sustainable. For the first time, strategic circular economy principles such as prevention, modularity, re-purposing and re-manufacture will be embedded with traditional automotive targets for reduced product cost, weight and volume.

This project aims to deliver a revolutionary real-time remote collaboration platform, using a combination of natural gaming interface technologies, such as Microsoft Kinect™, and standard virtual and augmented reality technologies, such as immersive environments. The proposed platform will enable two geographically dispersed teams to remotely collaborate in real-time and solve a shared engineering problem by exchanging not only words, videos and images but also their physical interactions with engineering work pieces that will be captured, digitised and exchanged synchronously over the web. The remote collaboration platform will consist of knowledge capture, knowledge sharing, and knowledge recording and reuse systems. Jaguar Land Rover UK, a partner in this consortium could be the first to adopt the platform to help its product experts collaborate in real-time with their global dealership network to provide remote engineering and training support without the need for the experts to travel. This solution has the potential to impact multiple high-value manufacturing sectors within the UK and the world.

Jaguar Land Rover, in partnership with Ford Motor Company Ltd, European Thermodynamics Ltd and Nottingham University, will launch a 3-year program of research in which conventional concepts of engine management of thermal energy will be re-examined using state-of-the-art simulation tools and a novel test engine which will allow the heat available to be directed to the most import components such as the cylinder liner walls. Some of the heat that will inevitably escape down the exhaust will be converted into electricity using a Thermo Electric Generator. In the longer term, if all the project targets are met, it is believed that a 5% improvement in fuel economy is possible through the conversion and management of heat energy. This research programme, scheduled to start in early 2014, is enabled by a £2 million grant from the UK government’s Technology Strategy Board (TSB), and builds on an earlier programme which was also co-funded by the TSB.

The latest augmented virtual reality (AVR) and immersive environment technologies are being implemented only in select business areas, despite being commonplace in our personal lives. As these technologies become ubiquitous, user acceptance and even expectation for use in the workplace increases. Service environments do not currently utilise such capabilities, yet are faced with the challenge of maintaining in-service products. This is particularly difficult when unexpected product failures occur that demand new processes to be deployed, and skills to be learnt, rapidly. This project will investigate and challenge the effectiveness of traditional training and learning environments and methodologies, creating new configurable - dynamic environments that will transform the way we train and develop staff. By monitoring user behaviour and considering individual learning profiles these environments look to unleash the value of data stored in PLM (product lifecycle management) systems to enrich virtual training environments with existing information about product components and configuration requirements. By focusing on efficacious training for exceptional events, LARTE will prove out the ability to create training environments that support the learning of infrequent tasks which could become commonplace learning environments to accomodate increasing customisation in future widescale manufacture. The project brings together the human factors research skills of University of Nottingham with the visualisation technology expertise of HoloVis International and the extensive data and use case provision within manufactiring and service environments of Jaguar Land Rover.

The CARBIO project will develop automotive structures with reduced weight, cost, environmental impact and improved noise, vibration and harshness (NVH) by the incorporation of novel flax-bioepoxy composites into carbon fibre components. The need to reduce vehicle weight is leading to the adoption of carbon fibre, which is expensive, energy/CO2 intensive, difficult to recycle and can lead to poor NVH. Flax fibres are low cost, renewable, CO2 neutral and have excellent vibration damping properties, whilst bio-based epoxy resins offer enhanced toughness and sustainability over synthetic epoxies. This project will develop and optimise flax/carbon hybrid biocomposite materials and test them according to automotive OEM specifications. A number of case study parts, such as a door, wheel arch panel and seat structure, will be designed and validation parts will be produced and tested.

The PrinTEG project builds on the previous development work of a UK-based consortia of SMEs and RTD partners who have developed cutting edge thermo-electric silicide materials and automotive demonstrators that use these materials to generate electrical power from waste exhaust heat. The PrinTEG project aims to take this intellectual property and develop advanced automated manufacture and in-process sensing technologies to enable the low-cost, mass-manufacture of these thermo-electric generators. In so doing the consortium will maximise the chances that the manufacture of these technologies will be undertaken within the UK, rather than being lost to the Far-East, as has been the case with electronics manufacture over the last few decades. PrinTEG is a business-led consortium, with Jaguar Cars acting as the initial route to market for the technology. The specific developments to be undertaken within the project relate the development of: - Automated powder handling and mechanical forming technoligies for the creation of nano-structured thermo-electric material. - Automated sintering technologies for the creation of net-shape thermo-electrics without the need for wasteful cutting and milling. - Automated Pick + Place technologies for the handling and placement of the thermoelectic legs that are of complex shapes. - Automated brazing and in-process sensing to optimise speed, quality and yield for the fabrication of thermo-electic generators.

The Practical Lithium Air Batteries project brings together a range of academic and industrial partners with complimentary skills to work on improved lithium air battery single cells and assess their feasibility in the wider context of future battery pack and system design, compact air purification approaches and general viability for use in automotive applications. Finding an improved stable electrolyte that survives the operating conditions at the lithium air cathode is a key enabler for this technology. Thus substantial efforts will focus on synthesis and investigation of new liquid electrolytes and gels and the optimisation of electrode structures containing these often viscous media, to achieve maximum cell performance. Academic partners Queens University Belfast and Liverpool University will work on synthesising and characterising the new electrolytes, whilst Johnson Matthey Technology Centre will produce novel cathode and anode materials, optimise electrode structures and perform electrochemical testing. The participation of Jaguar Land Rover as an end user, Air Products a component manufacturer and Axeon (a Johnson Matthey Company) will provide an applications focussed approach. These industrial partners will perform a paper feasibility study on how high performing lithium air single cells would be incorporated into automotive systems in the future, assessing the mechanical and ancillary system integration and low weight/cost/volume options for on board air purification. The final output will assess the feasibility for lithium air battery systems to achieve a 400Wh/kg power density.

The Evoque_e project will design and develop innovative hybrid and electric propulsion systems, integrated structures, power electronics, electric drives and energy optimisation. The project will deliver a technology platform which is scaleable, configurable and compatible. The collaboration of partners is led by Jaguar Land Rover, established large companies and 1st tier suppliers: GKN Driveline (GKN), Zytek Automotive, AVL Powertrain UK Ltd (AVL), TATA Steel and Johnson Matthey (Axeon). Three innovative SMEs: Delta Motorsport, Drive System Design (DSD) and Motor Design Ltd (MDL). Plus three leading Universities: Cranfield University, Bristol University and Newcastle University. For the first time, this unique project develops an integrated approach to system development and optimisation, from design to testing, encompassing three technology vehicle demonstrators: Mild Hybrid Electric Vehicle, Plug-in Hybrid Electric Vehicle and a Battery Electric Vehicle. All vehicles will be based on the Range Rover Evoque platform optimised for high volume production and capable of delivering benchmark performance in terms of cost, weight and sustainable use of materials.

The ULTRAN transmission & driveline research project will develop complimentary lightweight technologies in order to deliver a step-change in transmission and driveline weight. Using the latest developments in sustainable materials, coupled with novel manufacturing processes and pioneering computer aided analysis techniques, an optimised passenger car drivetrain will be developed. In addition to delivering reduced fuel consumption and CO2 emissions the technology will contribute to improved vehicle performance, handling and agility at an equivalent cost to todays technology. The project partnership consists of an automotive manufacturer (JLR), material suppliers ( Tata Steel , Lubrizol), design and analysis consultancies (GRM Consulting Ltd, Ricardo), a tier one component supplier ( American Axle Manufacturing) and the Universities of Southampton, Newcastle and Warwick.

Today’s automotive electric drivetrains use e-machines requiring large quantities of rare earth magnets and copper and operate below 15,000rpm. The Low Cost Electric Drivetrain (LCED) project will dramatically reduce the cost of electric vehicle drivetrains through the introduction of innovative technologies allowing higher operating speeds, a clear focus on design for manufacture and the elimination of expensive materials. It brings together the automotive supply-chain (JLR, Tata Steel, Sevcon & GKN) and the results of academic research (Newcastle University) to undertake an optimisation of the mechanical and electrical drivetrain components. This project is critical as the cost of manufacture of EVs and hybrids remains much higher than that of conventional vehicles; this is a significant barrier to the growth of low carbon vehicle sales. The cost savings in the motor, gearbox and power converter along with improvements in system efficiency will help offset battery costs.

Two SME’s, Composite Metal Technology Ltd and C&J Antich & Sons Ltd, will bring their knowledge and skills in composite castings and technical weaving to a project with Jaguar Land Rover, to develop ground-breaking woven 3D reinforcement systems for automotive components. CO2 emissions can be directly addressed by using lightweight, low inertia materials, such as aluminium matrix composites (AMCs), which can combine the strength and stiffness of steels with the weight of aluminium. This work builds on a previous TSB project, which proved the feasibility of using AMC inserts, incorporating 3D woven fibre preforms, cast inside an aluminium component. The project will develop a suspension upright, along with design proposals for a number of other automotive components. The work will include optimisation studies for insert designs, to reduce cost and maximise functional efficiency, rendering the technology suitable for widespread adoption by the automotive industry.

To develop and embed improved electrochemical energy storage solutions for hybrid and electric vehicles.

REALCAR 2 enables lightweight automotive body structures to be built using aluminium sheet derived from lower cost, energy efficient, recycled post consumer sources. The project makes innovative use of waste collection techniques and material production to produce a new to market high recycled and high impurity content 5xxx series sheet alloy, supporting a low manufacturing CO2 footprint and providing significant value to the supply chain and end user. The project will exploit growing volumes of post consumer aluminium waste from Mechanical Biological Treatment plants, driving the associated recycling infrastructure. The new 5xxx series aluminium alloy chemistry will be produced as full sized production coils; this requires evaluation of the rolling/production phase to produce sheet for full characterisation. REALCAR 2 is intended to deliver key environmental and commercial benefits for the next generation of Jaguar Land Rover vehicles.

The Provoque project is a Research & Development initiative designed to accelerate the introduction of cost effective fuel economy improvement, CO2 reduction and enhanced driving experience on a Range Rover Evoque. It will use grant funding to progress a wide range of technologies to the point where they can be considered for production, supporting growth of UK manufacturing, component sales, and engineering service sales, and the likely resultant products have a strong demand in overseas markets to benefit UK exports. The technologies that will be developed as a result of the project include low friction engine concepts, lightweight engine components, diesel combustion systems, electric boosting systems, active technologies to improve vehicle refinement, vehicle electrical archtecture, and mild hybridisation. The broad range of technologies being developed, combined with the quality of the consortium members make this project excellent value for money.

The VARCITY project delivers new vehicle body architectures for the premium city car of 2020 which will utilise the structural performance and weight advantanges of advanced Carbon Fibre Reinforced Plastic based composites whilst delivering a sustainable and economically viable proposition for volume production. The project targets a series of technology developments and innovations that currently prohibit wide-scale, volume implementation of CFRP based composites for vehicle body construction. A major goal of the project is the establishment of leading UK supply chain comprising the core industry partners. VARCITY drives the technical capability development of this fully integrated supply chain and will deliver major commercial benefits for wider market opportunities. Furthermore, the project also acts as a catalyst to stimulate the science, engineering and technology base to support the C02 and sustainability challenges facing the UK's automotive industry.

Structural aluminium alloy castings are an essential part of future Low Carbon Vehicle (LCV) body structures. They are presently made from primary aluminium using alloy compositions that are not sufficiently ductile or compatible with the closed loop recycling of end of life vehicles. Research at Brunel University has demonstrated that a novel alloy composition can meet the Jaguar Land Rover requirements for structural castings in terms of mechanical properties, joinability using self-piercing rivets, and a recycled content of 75% including both process and post consumer scrap. The 24 month project will enable high pressure diecastings for structural BIW (Body in White) applications of the new alloy to be developed at Brunel University and demonstrated on an industrial scale as a function of recycled scrap level. The goal is both a fully UK-based supply chain and significant CO2 savings in vehicle production and use.

Jaguar Land Rover has brought together and is leading a consortium of technology partners including seat supplier Johnson Controls and a Coventry based innovative SME, CL-7 supported by Coventry University automotive and industrial design specialists to research and develop a novel lightweight seating architecture for the premium automotive sector and with applications to electric vehicles that will reduce CO2 emissions, improve cabin climate comfort and reduce the load on vehicle heating and ventilation systems by the application of new materials, simulation and optimisation processes.

Al-Si casting alloys have a wide range of applications in the automotive sector. These alloys contain high levels of silicon, which causes large grain sizes. Refining the grain size is crucial to achieve the superior performance castings. Grain refiners used for non-cast aluminium alloys are ineffective in cast aluminium due to the silicon levels. Brunel’s new grain refiner (BGR) provides a much needed solution to this problem. The BGR has the potential to transform practices in the Al-Si casting industry by enabling innovative, cheaper, and simpler casting to produce high performance cast structures. Delivering benefits to a wide range of casting techniques, it should enable castings with superior properties, thereby, allowing aluminium to replace some steel components in the automotive sector. The project aims at applying grain refiner to produce high performance Al-Si alloys cast components for automotive applications.

Rapid Design and Development of a Switched Reluctance Traction Motor

The aim of the project is to develop innovative, lightweight, bio-based structural/functional materials with low acoustic transmittance for applications in vehicles. The materials will comprise novel engineering polymers, based on renewably sourced wheat and sugar cane fibre (bagasse) from Tate & Lyle Process Technology (TLPT) and resins. The polymeric composites will be processed by the Wolfson Centre for Materials Processing at Brunel University (WCBU) using moulding techniques. International Automotive Components (IAC) will scale up the production of the mouldings for testing and evaluation by Jaguar Cars Ltd for automotive applications. Axion will investigate the viability of recycling the materials from ELV.

The aim of this project is to take the micro gas turbine range extender as developed under the TSB BN096F “ULRE” project and accelerate its validation for automotive use. To achieve this requires the definition and implementation of new tests to validate a novel component in an application with different requirements to those of large scale gas turbines. The project will define these validation requirements based on automotive test practice and develop commercially viable approaches to achieving them which will be piloted on prototype units. Bladon Jets will supply the micro gas turbine range extenders, parts and gas turbine knowledge, Warwick University (UoW) will supply test facilities and manpower and Jaguar Land Rover (JLR) will provide the automotive knowledge and test procedures.

Lightweight powertrains are crucial if vehicle weight reduction targets are to be met in the longer term. New architectures, with the strength and stiffness to support downsizing, but without weight penalty, are essential. This project will deliver:- • A challenging translation of an existing concept study into a robust, functional, Application Ready demonstration engine. • An engine block mass reduction of circa 60% over an equivalent output conventional design. • A vehicle level CO2 benefit of circa 2.3% through a combination of mass reduction, and accelerated warm-up due to reduced thermal inertia. • An engine dynamometer based evaluation and functional sign-off.

The MSYS project aims to develop an electric powertrain for the next generation of electric and hybrid vehicles going into production in the 2015-2016 timeframe. The proposed powertrain will include a YASA motor and integrated multispeed transmission, which when combined will offer a solution of the lowest cost, weight and packaging volume. The YASA motor, developed through the TSB funded projects LIFECar and YAMOT, has been shown to have class leading torque density and power density, but can be further utilised by designing for a multispeed gearing system. The proposed output of the project will be a complete traction system that will attain class leading efficiencies over urban and motorway dutycycles.

VE-DRIVE is a £1.28m, 2-year collaborative research and development project co-funded by the Technology Strategy Board and the project partners. The 4 project partners from across market sectors and supply chain positions are BAE Systems, Theorem Solution and Holovis International with project lead Jaguar Land Rover, and Project Management support provided by Axillium Research. Digital tools are used daily to design, develop, produce, deliver and support products for global markets. From the ‘OEM’ and throughout the supply chain there is a common requirement to connect these digital processes to bring products to market, support them, and capture market input from concept through to the in-service environment. Through this project, the consortium partners aim to generate technology and expertise to connect digital technologies across supply chains and deliver the key innovation of directly linking digital product development approaches to the consumer in new digital and immersive environments. By applying a new generation of connected, digital environments to product life cycle, this project will add value directly at all stages through direct user interaction with virtual information, content and services in digital ‘showrooms’ and wider ‘virtual’ environments.

The essence of this proposal is to introduce innovative aluminium casting alloys and related processing know-how for the manufacture of advanced highly stressed large structures as found in aerospace, automotive and similar sectors. This innovation is expected to bring about a step improvement from current manufacturing methods and fully aligns with the TSB’s High Value Manufacturing strategy. A resource efficient, cost effective approach will displace expensive machine from solid methods ensuring the UK builds a strong competitive and sustainable position in these important global markets. The approach has been enabled by a patented new aluminium alloy –A20X – which has been developed and characterised by Aeromet International plc, the lead partner in this project. A20X has demonstrated characteristics which are far in excess of today’s commonly used high performance alloys; namely, high isotropic strength, double the fatigue life and properties that ensure levels of integrity not possible to achieve using current generation alloys. Application of this high value manufacturing technology is strongly supported by leading companies in the aerospace and automotive sectors seeking weight and cost reductions. The project sets out to develop and derisk the manufacture of large structures by developing and evaluating innovative casting and post casting processes using a range of virtual toolsets validated by test pieces based on real applications. Practical work will be underpinned by fundamental metallurgical characterisation and development and validation of models to optimise liquid metal and solidification behaviours.

REEVolution is an accelerated development and integration programme of new technologies, from concept through to validated components and systems intended to produce robust technology demonstrator vehicles. The aim has been to deliver high performance Range Extended Electric Vehicles (REEV) and Plug-in Hybrids Electric Vehicles (PHEV). Delivering 70-75% CO2 reductions through implementation of advanced technologies into three very different best in class premium vehicle applications, building on and using the skills of all the collaborative partners. The project has successfully developed key UK technology suppliers with novel Ultra Low Carbon (ULC) technologies towards tier 1 capability by working with three major UK vehicle manufacturers. The goal has been to lay the foundations for a robust and globally competitive UK supply base by drawing on the product development processes of the vehicle manufacturers. The REEVolution consortium, led by Jaguar Land Rover and consists of three suppliers: Axeon Technologies Ltd, EVO Electric Ltd and Xtrac Limited; and three vehicle manufacturers: Jaguar Cars, Lotus Cars and Infiniti along with Lotus Engineering. This acceleration development was made possible by the UK Government through the mechanism of the Technology Strategy Board.

As lighter vehicles require less energy (and emit less CO2) aluminium matrix composite materials (AMCs) are increasingly attracting the attention of vehicle manufacturers. AMCs combine the strength & stiffness of steel with the lightness of aluminium, enabling components to be redesigned in lightweight material, with no increase in size or loss of performance. Composite Metal Technology Ltd (CMT) have developed a revolutionary casting process known as Advanced Liquid Pressure Forming (ALPF), which enables AMC components to be produced quickly in high volume. Antich & Sons are leaders in the area of weaving technology relevant to the manufacture of fibre reinforcements for AMC's. Jaguar Land Rover possess wide knowledge of potential application areas and performance requirements in premium automotive products as well as bringing key component performance analysis skills to the project. AMCs have wide potential in vehicle manufacture and the objective of this project is to prove engineering, manufacturing & commercial feasibility of the materials, enabling Jaguar Land Rover to declare their production readiness.

Innovative micro gas turbine company Bladon Jets, in partnership with Jaguar Land Rover and switch reluctance generator specialists SRD, developed an ultra-lightweight 50Kw micro gas turbine powered, electric vehicle range extender. This technology enables small size range extenders to be developed with high power density, multi fuel capability, vehicle weight savings of over 100kg and further reductions in CO2 emissions. The micro gas turbine was developed based on Bladon Jets axial flow technology and the electrical generator on SRD’s switch reluctance technology. The key challenges were to develop a system operating at high rotational speeds which would ultimately be suitable following further research for low carbon vehicle automotive applications and help drive the greater adoption of these vehicle types. This project, in partnership with Jaguar Land Rover and part funded by the Technology Strategy Board has had a major impact in the race to develop lightweight range extenders for automotive use. At the date of writing, the Bladon Jets micro gas turbine powered range extender is the most advanced contender in the market for this technology, having the potential to deliver significant advantages over conventional internal combustion engine offerings.

The Syner-D project is a collaborative group working on the technologies and software required to significantly reduce the CO2 output and enhance the performance feel of a premium brand diesel passenger car. It will meet future worldwide emissions standards by use of engine and aftertreatment technologies. The partner contributions have further extended the knowledge of the benefits and constraints these respective technologies offer. Deploying these technologies into future mainstream programmes will bring a major competitive advantage to the project members.

The goal of the PLANET project was to deliver a novel process for manufacture of lightweight hybrid automotive body panels with a significant weight reduction compared to conventional monolithic metal panels. This was achieved by forming metal sheets by the injection of molten plastic in a conventional injection moulding machine in a similar way to hydroforming. This plastic both bonded to the metal bond and formed features on the metal. The hybrid combination of metal and polymer enabled a reduction in metal thickness with additional benefits including a minimisation of springback, reduced tooling costs, increased part complexity, part consolidation and improved impact/safety properties. In addition the polymer backing of the metal provided a corrosion protection of the metal. The technology requires only minor modification to existing injection moulding technology. The project evaluated the design and production of automotive panel systems to establish the most efficient and practical composite. The intention was to establish OEM confidence to apply the new material combination for future low carbon vehicles.

Jaguar Land Rover is now one of the global leaders in the manufacture of complete aluminium automotive body structures. Whilst delivering significant enhancement to final product performance this slrategy does have huge implication in terms of manufacturing investment, with up lo £200M spent wilh every vehicle programme on press lools & BIW (body-in-white) facilities. A proportion of this cost is due simply to the selection of aluminium rather than steel and its reduced formability driving simpler more numerous parts, wilh more sub-assembly lo create the required levels of complexity. This projecl will industrialise the innovative warm forming concept, in essence marrying the commercially existing worlds of super plastic forming for niche production with the conventional cold processing technique used in volume production today. It will provide a manufacturing process specifically optimised for Premium vehicle production, the aim being to achieve steel formability with aluminium and hence steel investmeni levels with savings of up to £20M per vehicle programme. In press tooling terms we envisage a 40% reduction in the capital & revenue costs associated with the consolidation of 30 key structural componenls through the application of this technology. Such a reduction in part count, tooling & facilities, will in addition, contribute towards JLR's improved Carbon Footprint, as they look lo further 'green' their manufacturing processes and in doing so achieve the target of a 25% reduction in Manufacturing Carbon Footprint by 2015.

The aim is to provide proof of concept for a high efficiency transmission (HET) which increases the cuslomer satisfaction (driving range and performance) of electric vehicles (EV's). This is achieved by enabling e-motors to operate in their most efficient speed range. Al the 2009 DETC conference (ref. University of Sunderland proceedings paper: DETC2009-87190) evidence was presented which shows a transmission will increase vehicle range by as much as 12% and increase the flexibUity of EV's through improved launch performance and higher cmising speed. This encourages faster market adoption of EV's by providing a more acceptable driving experience. Furthermore there is scope lo downsize the e-motor by up to 25%. To achieve these benefits, the transmission must have a very high efficiency, large ratio steps, small package and low cosl but no such transmission exists today. Anlonov Automotive Technologies Ltd will provide a solution for the HET which addresses this gap in the market to give the UK a lead in this technology area. The iimovation lies in the means of achieving high efficiency and and the conlrol slrategy. Jaguar-Landrover will supply a Limo-Green mule EV and set performance targets and MIRA will be responsible for vehicle integration and proof of concept testing. Limo-Green provides the firsl demonstration application for Antonov but the technology wUl be modular and can be applied to other new passenger and commercial vehicle applications. In addition there will be significant retrofit opportunities on exisling vehicles, providing business opportunities for both Antonov and MIRA thus increasing UK low carbon vehicle engineering

Kinergy delivers a hybridisation system with potential for 30% fuel/C02 saving at an on-cost of below £1000, which will strongly accelerate the mass-market uptake of hybrid vehicles. The program deploys technologies in which the UK has leadership, based on a first generation derived from motorsport. First generation flywheel-hybrids suffer from risks and issues associated wilh the vacuum seal on the high Speed flywheel shaft, and need expensive and energy-consuming vacuum equipment as a result. The Kinergy concept eliminates this problem by replacing the driveshaft and seal wilh a hermetically sealed vacuum chamber and magnetic coupling to transmit drive. This solution reduces engineering costs and operating costs, and has generated great interest globally in road transport and other sectors. Enabled by the hermetic concept, the project develops innovation in key subsystem technologies in the areas of flywheel design, bearings, magnetic couplings / gearing and power transmission, wilh the objectives of cost reduction, manufacturing compatibility and ultra-high efficiency. These innovations will be realised in integrated units with magnetic/mechanical and electromagnelic outputs through a comprehensive program of rig research. Further validation is delivered in one vehicle plus case studies for four further key applications. The program will be delivered by a consortium of the UK's strongest players at component and system level, who have proven track records in their areas of expertise

The Activel Project is a TSB collaboration between JLR and Brunel University. The team are examining how to apply phosphor coating to surfaces activated by a specific wavelength LEDs. This could potentially produce a uniform homogeneous light something JLR has struggled to do with single point backlit LED. JLR is focusing on production and how we might potentially apply it to switchgear and surfaces. Current learning centres about the inherent complexity in producing a specific phosphor that when matched with a given light source at a specific wavelength will produce the exact colour point required by JLR. The team has deconstructed a standard LED in to its basic elements and are reconstructing using developed phosphors. A number of other key automotive suppliers are supporting the project with production samples and key data and information. Understanding the characteristics of the Phosphor is an important element for JLR in understanding how the company can apply and manufacture these potential new technologies in the future.

The project will demonstrate key elements of an innovative new scalable modular hybrid system. The concept is based on an innovative variable ratio pulley (VR-Pulley) as part of a belt integrated starter-generator system (B-ISG) and a new approach to e-machine integration into an automated manual transmission which both enable increased electrical and economic efficiency by significantly reducing motor torque and speed range. Critical ancillaries can be driven from the front end accessory drive so that the same motor is used to drive, for example, the air conditioning compressor as well as being used to start and stop the engine. The pulley also provides 1:1 and 3:1 drive ratios. This gives: - Better package efficiency, machine utilizadon, motor and power electronics efficiency. - Reduced machine size, cost and parts count. The project will provide design, test and cost data to support commercialisation of the technologies by licensing. Jaguar Land Rover is a potential adopter of the technology and is a member of the consortium. A simulation and rig based demonstration of key elements of the system will be carried out. The consortium will investigate implementing the BISG variable pulley element of the design on an existing vehicle in the latter stages of the project. The consortium comprises key UK based providers of innovative teclmology for motors, power electronics, controls software, transmission engineering and vehicle manufacturing creating a team capable of delivering the project. Gateway Question: Scope

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To enable companies to successfully compete today and in the future, they need to develop the next generation of light weight environmentally friendly and sustainable transportation systems. As these products are subjected to demanding and repeated loadings, it is necessary to be able to predict the durability performance of the joints in the vehicle. The Bonded Car project has developed commercially available software simulation tools to predict the operating life of five joining technologies: - Structural Adhesive, Self-Pierce Rivets, Aluminium Spot Welds, Weld-Bonded and Riv-Bonded. This will enable the type of joint, location and number of joints required to be determined, to meet the durability operating performance of the structure, while reducing both cost and weight.

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The FHSPV (Flywheel Hybrid System for Premium Vehicles) project which bought together some of the UK’s most respected names in automotive engineering under the TSB umbrella has concluded its work to determine the viability of flywheel hybrids as a cost-effective and modular solution for production vehicle applications. The consortium, comprising Jaguar Land Rover, Flybrid Systems, Ford, engineering consultancies Prodrive and Ricardo, and transmission experts Torotrak and Xtrac investigated the benefits of flywheel hybrids in a number of applications. Compared to conventional electric hybrid systems, mechanical flywheel hybrids reduce the number of inefficient conversions during the recovery and re-use of braking energy. Instead of converting kinetic energy into electricity, energy is stored in a high-speed flywheel with power transfer controlled by a compact continuously variable transmission (CVT). The Jaguar XF premium saloon used as the research vehicle has the flywheel hybrid system integrated into the rear axle, occupying part of the space normally used by the spare wheel. Following conclusion of the programme the consortium has made the following statements with respect to outcomes: • The development vehicle has demonstrated that this technology can deliver significant CO2 reductions in real world conditions, building on established stop-start gains • In the industry-standard NEDC cycle, the flywheel hybrid and stop-start combined achieved an 11.9% percent benefit, a 6.4% improvement over start-stop alone. • In the new ARTEMIS test cycle, which represents typical real-world usage, the flywheel hybrid system yields an 11% improvement over stop-start only. • The system can be realised at significantly lower cost and weight than a typical HEV application. This is a positive outcome for an early development system. Further refinements and related optimisation of other vehicle systems are expected to yield additional gains.

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