To establish research, development and design frameworks deploying advanced uncertainty modelling in decision making processes for the development of future ultra-low emission off-highway powertrains

The collaboration between Perkins Engines Company Limited, Equipmake, and Loughborough University is to design, develop and demonstrate an innovative 'drop-in' pre-integrated, highly configurable electric hybrid power system capable of operating using hydrogen or lower carbon intensity fuels that a wide-range of customers can readily incorporate into their off-highway vehicles and machines. Many off-highway vehicle and machine manufacturers lack the scale and resources to integrate advanced power systems into their products. This is limiting the penetration of reduced carbon power systems in the UK Non-Road Mobile Machinery (NRMM) markets. This will impact the ability of industry to support the UK government's targets for net zero in industrial sectors such as construction and infrastructure. As outlined in the Advanced Propulsion Centre's roadmap 2040 report, the energy transition for off road vehicles will require a diverse range of alternative fuels \[including hydrogen and lower-carbon intensity fuels,\] combined with varying degrees of electrification. The most appropriate solution for each application will be determined by the operational profile of the machine, as well as availability of different energy sources at the work site. Many of these different fuel types require significant differences in engine design and can produce different power characteristics which effect transmission and machine design. This makes integrating them into the thousands of machine types used to perform different job functions, a big challenge. Using the vast skills of project partners, this project proposes that through an innovative combination of power system design and electric hybridisation, a flexibly fuelled drop-in replacement powerpack is possible, greatly reducing the barriers to change and accelerating the transition to net zero for many non-road mobile machine applications.

Perkins Engines Company Limited and the University of Nottingham are working together to improve capability in virtual process development (VPD) and virtual product validation of Power Electronics, Motors and Drives (PEMD). Significant advancements in processes for assessment of lifecycle and embedded carbon, remanufacturing, refurbishment and recyclability analysis of PEMD will be realised, supporting the development of the circular economy.

Perkins Engines Company, AVID Technology and Imperial have joined together to develop a new battery storage system. This will significantly improve battery life through advanced controls and monitoring and thermal management. The consortium will implement this technology breakthrough in a Caterpillar wheel loader. Utilising sophisticated simulation techniques the team will also demonstrate that integrated powertrain systems utilising battery storage can be commercially viable for Electric and Hybrid vehicles in the commercial on-highway as well as off-highway sectors.

This project is a collaboration between Caterpillar’s Engine Division - Perkins Engines Co Ltd (based in Peterborough), Loughborough University, Imperial College London and CMCL Innovations to develop innovative engine technology for off-highway diesel engine applications. The project is focussed on engine performance, fuel economy and exhaust emission improvements

Caterpillar UK Engines Company Ltd in partnership with Grainger & Worrall Ltd and Loughborough University will launch a 22 month program of research into the localised material property dependance of the casting process for key engine components. The consortium aims to harness the combined capabilities of as-cast material property prediction, cycle dependant property evolution and advanced Computer Aided Engineering (CAE) processes to simultaneously and synergistically optimise engine component design and production processes to significantly impact engine capabilities for increased efficiency and productivity at reduced cost. This research project, scheduled to start in 2015, is enabled by an £623,000 grant from the UK government’s Innovate UK and builds on a previous project co-funded by the TSB (now Innovate UK). The programme of research will be performed across the consortium members' facilites in Peterborough, Bridgnorth and Loughborough.

Caterpillar UK Engines Company Ltd in partnership with Concentric Birmingham Ltd and Loughborough University will launch a 24 month program of research into engine and driveline disconnection to enable engine downsizing and stop-start technology. This research project, scheduled to start mid 2015, is enabled by an £599,168 grant from the UK government’s Innovate UK and complements previous projects co-funded by the TSB (now Innovate UK). The programme of research will be performed across the consortium members' facilities in Peterborough, Birmingham and Loughborough.

In a project co-funded by Innovate UK, Perkins Engines Company Ltd, DENSO Marston Ltd, AVID Technology Ltd and Imperial College London are collaborating to demonstrate a highly efficient diesel-electric hybrid powertrain in which waste heat energy from the engine is recovered through an Organic Rankine Cycle system. When coupled with electrification of the engine’s ancillary devices (coolant and oil pumps for example) to reduce the parasitic loads on the engine, the system is expected to deliver significant fuel consumption reductions over real-world operating conditions. This £5.2M, 3-year project encompasses software, hardware, and control system design and development, and will culminate with a heavy duty on-engine demonstration. System cost, performance and packaging will be targeted to meet requirements of selected on-road and off-road applications. The project was launched in January 2015.

Caterpillar UK Engines Company Ltd, in partnership with Ford Motor Company Ltd, BP, Oxford Lasers Inc. and Nottingham University, will launch a 2-year program of research in which the basic principles of friction will be re-examined using a novel test rig which will replicate conditions in conventional powertrains, specifically, between the piston rings and the cylinder liner walls. The consortium aims to extend the capabilities of this novel, but practical, test rig to fully validate the new friction models that will be derived. Further, the outcome of this work will include the development of a lubricant formulated to interact with the topography and material of the cylinder and piston rings. In the long term, if all powertrain bearing surfaces are considered, it is believed that a significant improvement in fuel economy is possible by the reductions in friction that will be demonstrated in this project. This research programme, scheduled to start in late 2013, is enabled by an £812,000 grant from the UK government’s Technology Strategy Board (TSB), and builds on an earlier programme, led by Ford, which was also co-funded by the TSB. The programme of research will be performed across the consortium members' facilites in Peterborough, Basildon, Reading, Oxford and Nottingham.

Awaiting Public Summary

ATKINS will investigate a holistic solution to energy minimisation in product manufacture, distribution & use by creating an energy-efficient design, manufacture and distribution technology platform based on the unique characteristics of Rapid Manufacturing (RM) technologies. Such an approach will enable novel design & supply chain methods for the manufacture, via a digital supply chain for reduced transportation, of fully optimised products using energy efficient & waste minimising RM processes. This holistic approach is unique &, for maximum benefit, it is vital that UK manufacturers are closely involved with the specification & development of this new system to achieve more energy efficient processes and products. ATKINS will deliver a completely new RM based technology platform for the environmental manufacture of lightweight, energy efficient, automotive & aerospace metallic components.