Second research project fuels AME’s growing R&D reputation

The Institute for Advanced Manufacturing and Engineering (AME) – the collaboration between Coventry University and Unipart Manufacturing Group  - is set to play a major role in the development of cleaner and more efficient engines after securing its involvement in another major R&D contract.

More than £900,000 of funding from Innovate UK (the new name for the Technology Strategy Board) has been allocated to Unipart Eberspächer Exhaust Systems (UEES) for its part in a project to help design, develop and prototype build new fuel rail systems for the Ford 1.0-litre EcoBoost engine.

The global manufacturer will work closely with AME on the simulation, analysis and metrology aspects of the work, utilising an eight strong team of engineers, designers, quality experts and material specialists.

Together, they will form an important part of a consortium that is looking to create a three cylinder, 1 litre high-pressure gasoline turbo engine for future Ford models.

“This demonstrates the trend for powertrain solutions that offer the same level of performance but a reduced engine capacity,” explained James Simester, Technology Director at AME.

“It’s definitely the next big advancement in this field and gives the car manufacturers the chance to offer motorists improved efficiencies, cleaner vehicles and a host of cost savings without detracting from the driving experience.”

He continued: “Our role will be to work with UEES on developing a new fuel rail system that is able to offer the high pressure performance required by the gasoline turbo engine.

“We will then be responsible for manufacturing the prototypes and coming up with processes and strategies for long-term volume production.

“It’s a massive challenge, but one we know we can make a difference with. The fact this funding follows the recent ‘Towards Zero Prototyping’ project also shows our reputation is spreading across industry.”

Dennis Witt, Ford Project Manager: Advanced Propulsion Centre, added his support:

“Ford is delighted to be actively involved in this project, which will ultimately see benefits for consumers through even further improved engine efficiency - reduced CO² emissions and improved performance.”

AME is set to pioneer a new higher education model for manufacturing degrees, offering a blend of innovative activity-led teaching, product development and research.

Construction work on the 1,700 square metre, state-of the-art manufacturing and R&D space at UEES is gathering pace and will deliver the UK’s first ‘Faculty on the Factory Floor’ for 30+ undergraduates and postgraduates in the first year.

It will also house over £2m of state-of-the-art automation, joining technology and testing equipment, which, alongside Unipart’s extensive manufacturing operation, will play a key role in the development of the Ford 1.0-litre EcoBoost fuel rail systems.

“We’ll certainly be making the most of AME and its world class research and development capabilities,” continued Andy Davis, Managing Director of Unipart Eberspächer Exhaust Systems.

“As part of the R&D, we will be investigating joining techniques, simulating various design models and developing how we actually test the physical design and geometry more effectively.”

He concluded: “There will also be a major focus on product verification through pressure and hydropulse testing. We need to prove this system works time and time again so it is ready to go into volume production at the end of the project.”

AME is supported by the Higher Education Funding Council for England’s Catalyst Fund.