Engineering Education Scheme Wales Cynllun Addysg
Transcription
Engineering Education Scheme Wales Cynllun Addysg
66586_2016_WELSH Cover:Layout131/3/1618:44Page1 Engineering Education Scheme Wales For more information go to Am rhagor o fanylion ewch i www.stemcymru.org.uk Cynllun Addysg Peirianneg Cymru EESW Waterton Centre Waterton Bridgend CF31 3WT Tel: 01656 669381 Fax: 01656 662402 E-mail: [email protected] The Engineering Education Scheme Wales is grateful to the Welsh European Funding Office and the Welsh Government for their support. Mae Cynllun Addysg Peirianneg Cymru yn ddiolchgar i Swyddfa Cyllid Ewropeaidd Cymru a Llywodraeth Cymru am eu cefnogaeth. Engineering Education Scheme Wales Ltd Registered Charity / Elusen Gofrestredig 1144651 Company limited by guarantee / Cwmni cyfyngedig drwy warrant 07776138 PROJECT BROCHURE 2015 -16 66586_2016_WELSH Cover:Layout131/3/1618:44Page2 Noddwyr Gwobrau EESW Ein Noddwyr Dydd Iau Mawrth 24ain, 2016 Cynllun Arloesol neu Addasedig Gorau Gwerthfawrogiad Gorau o Wyddoniaeth Y Perfformiad Cyffredinol Gorau gan Dîm Y Cyflwyniad Mwyaf (IIHLWKLRO R¶U $WHE D Ddewiswyd Gwobr Proses Cemegol neu Dylunio Peiranneg Prototype neu'r Model Gweithredol Gorau Defnydd Gorau o Beirianneg a Thechnoleg Gwerthfawrogiad Gorau o Faterion Amgylcheddol Gwerthfawrogiad Gorau o Faterion Diogelwch Yr Ateb Mwyaf Arloesol i Brosiect Yr Ateb Gorau gan Goleg Adroddiad Ysgrifenedig Gorau Y Defnydd Mwyaf Effeithiol o TG Y Defnydd Mwyaf Arloesol o Dechnoleg sydd yn bod Eisoes Dydd Mercher Ebrill 13eg, 2016 Defnydd Gorau o Beirianneg a Thechnoleg Yr Ateb Mwyaf Arloesol i Brosiect Gwerthfawrogiad Gorau o Faterion Amgylcheddol Defnydd Gorau o Egwyddorion Peirianneg Mecanyddol First Hydro Y Gwerthfawrogiad Gorau o Ynni Cynllun Arloesol neu Addasedig Gorau Adroddiad Ysgrifenedig Gorau Academi Wyddoniaeth Genedlaethol Engineering Education Scheme Wales The Engineering Education Scheme Wales (EESW) is a not-for-profit, educational charity offering a range of activities to inspire and motivate young people to choose a career in Science, Technology, th Engineering or Mathematics (STEM). EESW enjoyed a very successful 25 anniversary last year and we are continually finding professional engineers in Welsh companies who participated in EESW themselves and who speak very highly of the positive influence the scheme had on them. Following the success of the STEM Cymru Project, we are pleased to have received new funding from the European Social Fund through the Welsh Government to operate in West Wales and the Valleys. We also receive funding through the National Science Academy from the Welsh Government to undertake activities in other areas of Wales. th This annual brochure gives details of the EESW 6 Form Project which encourages the most able young people to consider engineering as a career. A professional engineer from a link company has worked with the teams of Year 12 students and their teacher for 5-6 months on a real engineering th problem. For the first time this year, students engaging with the EESW 6 Form Project have been able to use their EESW experience for the Enterprise and Employability Challenge in the Welsh Baccalaureate. This adds further value in addition to the opportunity to gain a Gold CREST Award and developing the range of skills developed through participation. The EESW Project concludes with an annual Awards and Presentation Day in North and South Wales which we are combining with the Big Bang Fair Wales. We are very pleased to be holding the Big Bang South Wales event in the exciting, new Swansea University Bay Campus. Teams will be nominated to represent Wales for The National Big Bang Fair UK in March 2017. Our events also feature the F1 in Schools Secondary Schools Regional Finals, interactive activities and exhibitions by companies and organisations including Welsh universities and professional engineering institutions. We are also hosting a full size replica of the Bloodhound Super Sonic car which is currently being built in Bristol and will attempt to break the current land speed record reaching an incredible speed of 1,000 miles per hour. We are delighted that a number of organisations have sponsored a variety of awards categories again this year. We gratefully acknowledge the support of all the companies and sponsors shown on the following pages and the engineers involved with the scheme. We would also like to thank the schools and teachers for continuing their partnership with us and the Welsh universities and colleges for their help in hosting the welcome events and workshops to facilitate the scheme. Finally congratulations to all students who have participated this year and good luck for the future. Robert Cater EESW CEO EESW Teams 2015-16 Big Bang South Wales Thursday 24th March 2016 – Swansea University Bay Campus Team School/College Company Page Northern Automotive Systems 1 Northern Automotive Systems 1 Blaenau Gwent 1 2 Coleg Gwent, Blaenau Gwent Learning Zone 1 Coleg Gwent Blaenau Gwent Learning Zone 2 Caerphilly 3 Heolddu Comprehensive School Continental 2 4 Lewis Girls School University of South Wales 2 Cardiff University High Voltage Laboratory & The National Grid Cardiff University ‘The Shakers’ 3 Cardiff University 4 Cardiff University High Voltage Laboratory 4 9 Bishop of Llandaff Church-in-Wales High School 1 Bishop of Llandaff Church-in-Wales High School 2 Bishop of Llandaff Church-in-Wales High School 3 Bishop of Llandaff Church-in-Wales High School 4 Cardiff High School Solviq 5 10 Cardiff Sixth Form College Associated British Ports 5 11 Fitzalan High School Arriva Trains Wales (Cardiff) 6 12 Howell's School 1 PDR 6 13 Howell's School 2 Viridor 7 14 Llanishen High School 1 GE Aviation 7 15 Llanishen High School 2 GE Aviation 8 16 St David's Catholic College Yard Digital 8 17 St Teilo’s CIW High School Western Power Distribution 9 18 Whitchurch High School Cardiff University 9 19 Ysgol Gyfun Gymraeg Glantaf 1 AECOM 10 20 Ysgol Gyfun Gymraeg Glantaf 2 AECOM 10 21 Ysgol Gyfun Gymraeg Plasmawr BBC 11 Cardiff 5 6 7 8 3 Merthyr Tydfil 22 The College Merthyr Tydfil 1 Merthyr Tydfil County Borough Council 11 23 The College Merthyr Tydfil 2 Merthyr Tydfil County Borough Council 12 Team School/College Company Page Monmouthshire 24 Haberdashers’ Monmouth School for Girls Renishaw PLC 12 25 Monmouth Comprehensive School General Dynamics 13 26 Monmouth School Renishaw PLC 13 Newport 27 Caerleon Comprehensive School Zodiac Aerospace 14 28 Caldicot School Orb Electrical Steels - Cogent Power 14 29 Rougemont School 1 Zodiac Aerospace 15 30 Rougemont School 2 Zodiac Aerospace 15 31 Rougemont School 3 Jacobs Engineering Group 16 32 St Joseph’s Roman Catholic High School 1 Eastman Chemical Company 16 33 St Joseph’s Roman Catholic High School 2 Eastman Chemical Company 17 Rhondda Cynon Taf 34 Aberdare Community School Rhondda Cynon Taff County Council 17 35 R-TEK 18 36 Cardinal Newman RC Comprehensive School Coleg y Cymoedd, Ystrad Mynach Renishaw 18 37 Treorchy Comprehensive School Allied Aerosystems 19 38 Ysgol Gyfun Garth Olwg 1 FSG Tool & Die 19 39 Ysgol Gyfun Garth Olwg 2 FSG Tool & Die 20 40 Croesyceiliog Comprehensive School 1 ZF TRW Automotive 20 41 Croesyceiliog Comprehensive School 2 ZF TRW Automotive 21 42 Croesyceiliog Comprehensive School 3 ZF TRW Automotive 21 43 Croesyceiliog Comprehensive School 4 ZF TRW Automotive 22 44 Croesyceiliog Comprehensive School 5 ZF TRW Automotive 22 45 St Alban’s Roman Catholic High School Meritor 23 46 Brynteg School Ford 23 47 Cynffig Comprehensive School Sony UK Tec 24 48 Maesteg Comprehensive School 24 49 Pencoed Comprehensive School Capita Symonds & Bridgend County Borough Council CGI Bridgend 25 Team School/College Company Page Carmarthenshire 50 Coleg Sir Gar National Botanic Garden of Wales 25 51 Queen Elizabeth High School 1 Carmarthenshire Council 26 52 Queen Elizabeth High School 2 Carmarthenshire Council 26 53 Ysgol Dyffryn Taf Magstim 27 54 Ysgol Gyfun Maes Y Gwendraeth 1 National Botanic Garden of Wales 27 55 Ysgol Gyfun Maes Y Gwendraeth 2 National Botanic Garden of Wales 28 56 Pembroke School Valero 28 57 Pembrokeshire College 1 Valero 29 58 Pembrokeshire College 2 Valero 29 59 Pembrokeshire College 3 GD Harries & Son 30 60 Pembrokeshire College 4 GD Harries & Son 30 61 Pembrokeshire College 5 GD Harries & Son 31 62 Ysgol Y Preseli Pembrokeshire County Council 31 Ysgol Maesydderwen Weartech International 32 Powys 63 Swansea 64 Bishop Vaughan School University of Wales Trinity St David 32 65 Tidal Lagoon 33 66 Gower College Swansea- Gorseinon Campus Gower College Swansea - Tycoch Campus 1 University of Wales Trinity St David 33 67 Gower College Swansea - Tycoch Campus 2 Tongfang Global 34 68 Gower College Swansea - Tycoch Campus 3 Tongfang Global 34 69 Gower College Swansea - Tycoch Campus 4 TWI 35 70 Gowerton School Materials Live 35 71 Ysgol Gyfun Gwyr Schaeffler 36 72 Ysgol Gyfun Gymraeg Bryn Tawe Power & Water 36 Vale of Glamorgan 73 Cowbridge Comprehensive School 1 Aerospace Wales 37 74 Cowbridge Comprehensive School 2 RWE Npower 37 75 St Cyres School GE Aviation 38 Big Bang North Wales Wednesday 13th April 2016 - Venue Cymru, Llandudno Team School/College Company Page Conwy 1 Eirias High School Siemens Healthcare 39 2 Rydal Penrhos School North and Mid Wales Trunk Road Agency 39 3 Ysgol Aberconwy RWE Innogy Gwynt Y Môr 40 4 Ysgol Bryn Elian 1 RWE Innogy Gwynt Y Môr 40 5 Ysgol Bryn Elian 2 RWE Innogy Gwynt Y Môr 41 6 Ysgol John Bright RWE Innogy Gwynt Y Môr 41 Denbighshire 7 Denbigh High School Dŵr Cymru Welsh Water 42 8 Ysgol Dinas Bran Qioptiq 42 9 Ysgol Uwchradd Glan Clwyd 1 PPM Technology 43 10 Ysgol Uwchradd Glan Clwyd 2 PPM Technology 43 Flintshire 11 Alun School 1 Toyota 44 12 Alun School 2 JCB Transmissions 44 13 Alun School 3 JCB Transmissions 45 14 Coleg Cambria Airbus UK 45 15 Flint High School Toyota 46 16 Ysgol Maes Garmon Brake Engineering 46 Gwynedd 17 Coleg Meirion-Dwyfor 1 First Hydro Company 47 18 Coleg Meirion-Dwyfor 2 First Hydro Company 47 19 Coleg Meirion-Dwyfor 3 First Hydro Company 48 20 Coleg Menai Photonics Academy of Wales at Bangor 48 Isle of Anglesey 21 Ysgol David Hughes Siemens Healthcare 49 22 Ysgol Gyfun Llangefni 1 RAF/Babcock 49 23 Ysgol Gyfun Llangefni 2 RAF/Babcock 50 Welshpool High School Morgans Brew Tea 50 Brother Industries UK Ltd 51 Powys 24 Wrexham 25 Ysgol Y Grango Blaenau Gwent Team 2 Team 1 Coleg Gwent – Blaenau Gwent Learning Zone 2 & Northern Automotive Systems Coleg Gwent – Blaenau Gwent Learning Zone 1 & Northern Automotive Systems Re-design the frame and shoot for the mould machine process Re-design the frame and shoot for the mould machine process Team: Myles Davies Cameron Goode David Morgan Spencer Rooke Emma Rose Hallum Woolrich Team: Ellis Delaney Morgan Bridge Gavin Nash Samuel Pritchard Karl Young Teacher: Mentor: Dr Shaun Andrews Christian White Teacher: Dr Shaun Andrews Engineer: Sara Jones Engineer: Sara Jones Northern Automotive Systems is a manufacturing company which is situated in Gilwern, Abergavenny. Northern Automotive Systems is a world leader in the manufacture and supply of decorative aluminium trim for the automotive industry. With a history dating back to 1908, NAS have mastered the art of transforming a concept into reality. Their ultimate focus is to produce innovative and unique decorative aluminium trim for the automotive industry. Northern Automotive Systems is a manufacturing company which is situated in Gilwern, Abergavenny. Northern Automotive Systems is a world leader in the manufacture and supply of decorative aluminium trim for the automotive industry. With a history dating back to 1908, NAS have mastered the art of transforming a concept into reality. Their ultimate focus is to produce innovative and unique decorative aluminium trim for the automotive industry. There is a problem as damage is caused to parts when they are travelling down the shoot following moulding. There is a problem as damage is caused to parts when they are travelling down the shoot following moulding. The task is to re-design the frame and shoot for the mould machine process, taking into consideration the cost, ease of implementation, user friendliness, and sustainability. The task is to re-design the frame and shoot for the mould machine process, taking into consideration the cost, ease of implementation, user friendliness, and sustainability. 1 Caerphilly Team 4 Team 3 Lewis Girls School & University of South Wales Heolddu Comprehensive School & Continental Develop a Hydro based energy generation system that gives 24v DC even in power failure Scrapping Spanner Stereotypes Team: Jasmine Warrell Megan Price Emily Spoor Maya Yeung Sara Yorath Shayleigh Lanzarotti Team: Jessica Barber Kyle Greenland Lewis Hurley Morgan James Jay Moon Aled Rees Keira Waite Nataleaha Willey Teacher: Owen Griffiths & Leah Brinkworth Teacher: Steve Pole Engineer: Matthew Price & Lee Curtis Engineer: Dr Kathryn Franklin Getting students, particularly females, interested in engineering is difficult. As CTUK have special permits that allow Continental to treat their own waste from their plating process, it is required that Continental constantly monitors the amount of waste that is discharged. If this requirement is not met, the NRW can impose heavy fines. The team’s brief is to design a 'scheme' that could be taken to schools to educate and inspire students to follow a career in engineering. The brief was ultimately to provide a service that encourages young people- with a focus on females- to take an interest in the field of engineering. The intricacies of the service itself was left to the team to decide upon, however it was specified that the service must include some sort of visual/auditory material to support a tangible, physical engineering activity. The concept in mind was that the service would be an entire package that a teacher, for example, could use to present a workshop to a class of young people, and thus create or stimulate an interest in engineering. The output flow sensor should be operating at all times. 24V DC must be generated to charge a battery that enables constant power to the flow sensor. In the event of a power outage at the factory, the Hydro generation system will continue to power the sensor. The task is to build a desk top prototype system that can be scaled up to the correct size, enabling the out flow sensor to have constant power, even when the factory has total power loss. The system must be deemed to be robust. Prototype costs should be kept to a minimum with a £250.00 maximum budget. A scaled up version is then to be costed on completion of the prototype. It is important that the system is not too complicatedsimplicity facilitates maintenance and repair. 2 Cardiff Team 6 Team 5 Bishop of Llandaff Church-in-Wales High School 2 & Cardiff University ‘The Shakers’ Bishop of Llandaff Church-in-Wales High School 1 & Cardiff University High Voltage Laboratory & The National Grid Smart Plug Team: Pacemaker lead testing following intensive radiotherapy treatment Grace Hope-Gill Nathan Tarr Michael Tuthill Sam Critcher Jacob Hodges Teacher: Ben Hughes Engineer: Dr Stephen Robson The brief was to design and build a 'smart plug' which will measure and control the input of current in a mains power socket. Both internally and external; creating designs where the case can be 3D printed. Team: Freya Morris Georgie Bradshaw Ilhaam Selih Alexander Phillips Nick Dickson Dan Nkiko Teacher: Ben Hughes Engineer: Mr Richard Perks The team have been tasked with designing a device that will allow them to clamp pacemaker leads so they can simulate a heartbeat and test to see if radiation has any effect on the leads. This would be used to reduce energy consumption in a household, thus relieving pressure from the National Grid and overall reducing the maximum usage across the UK. By being able to monitor how much energy is being used at a certain time, the national grid can then accurately know how much energy is required and needs to be supplied to the network. The device would then increase the efficiency of the network and save wasted power. The overall aim is to check pacemaker cables are still effective after a patient has been treated with chemotherapy. 3 Team 7 Team 8 Bishop of Llandaff Church-in-Wales High School 3 & Cardiff University Bishop of Llandaff Church-in-Wales High School 4 & Cardiff University High Voltage Laboratory App & Server Development: Smart Plug Testing pacemaker leads for the degradation of polymers Team: Rosie Hughes Shannon Phillips Adriel McForrester John Lee Alex Woodman Owen Evans Teacher: Ben Hughes Engineer: Mr Richard Perks Team: Sebastian Cheer Samuel Liu Callum Hole Daniel Lewis Owen Lewis Dafydd Herdman Teacher: Ben Hughes Engineer: Dr Stephen Robson There is a large economic drive towards flattening the peak electricity usage at a daily, weekly and annual level. Given the right economic incentives, many customers would be willing to change their electricity usage to flatten peak demand and respond to local grid conditions and requirements. The project was to test pacemaker leads for the degradation of polymers using microwave resonance. To design a system that will hold the pacemaker leads securely in the microwave resonator. The company has provided a resonator that they would like to be used; therefore the stand will have to be designed to fit this specific resonator. The company has specified that they would like the pacemaker leads to be easily replaced in the system as the team will be testing many different leads. This project contains two parts. The first is the physical design and build of a plug-in current sensor which will communicate with a user interface. The second part, which is the part relevant to this group, focuses on three main points: firstly, the construction of a web-based server, responsible for processing and storing incoming and outgoing data; secondly, the design and build of the user interface, allowing customers to see their electricity usage and optin or opt-out of certain plans; finally, development of an economic and marketing plan. 4 Team 10 Team 9 Cardiff High School Cardiff Sixth Form College & Solviq & Associated British Ports An Automated System to Control Heating and Lighting at Cardiff Port Frequency Alteration Team: Bethan Wilkinson Yuchen Fu Chloe Smith Max Taylor Evan Turner Matthew Fry Julian De Silva Rhushda Amir Teacher: Ian Davies Engineer: Carwyn Balch Solviq is a digital product development company based in Cardiff that provides software development, API-based software design, filtering, analytics and consultancy. When someone who is partially deaf uses headphones with a hearing aid it can become very uncomfortable after a short period of time. It also affects the quality of the sound. Many people may also feel self-conscious about being deaf and having to use special equipment to hear properly. Team: Leon Khalmetov Matthew Wong Isabella Dao Li Ting Sun Jin Kim Isaac Teng Gordon Ka Yeung Lee Tze Leung Wong (Gordon) Justin Tse Liang Wong Changmao Huang Ka Ying Elsa Ma Maria Zagorulko Maria Rossich Akhil Sagar Beatrice Ong Teacher: Alex Kampas Engineer: Nathan Evans Currently a number of buildings, cranes, storage rooms etc are powered 24/7 to provide for lighting and heating. This translates to wasted power on lights and heating for sites that are not occupied by personnel. The aim is to design an automated system that only powers these sites when personnel are on location, with the aim to reduce costs significantly. The brief is to investigate the prevalence of deafness in the UK and design a suitable solution that allows a partially deaf person to have a better perception of music by making a device tailored to their needs. The solution should be easy to use on a regular basis. 1. Lighting: Lights should only be on when personnel are on site. 2. Heating: Heating should be provided when personnel are on site. 3. Sensory data: Humidity and other data should be made available for each site to the port authority. There is a special focus on the project researching deafness in the UK and how the product may be able to improve how people feel about being partially deaf. There is also potential for it to be used by the general public to alter music for an extremely high quality sound. The sites are located around the Cardiff area. The control centre of the port is located at the southeast side of the Queen Alexandra Dock but the central system can be located anywhere in the port area. 5 Team 11 Team 12 Fitzalan High School Howell's School 1 & Arriva Trains Wales (Cardiff) & PDR Finless Radiator Noise Reduction PDR Lower Arm Prosthesis Team: Louie Hext Ruby Thomas-Collins Connor Woodcock Abo Al- Quassim Mohamad Team: Teacher: Robert Morgan & Laura Speake Engineer: Sean Cadogan Jessica Cooper Alexandra White Nia Moseley-Roberts Isabelle McTaggart Caitlin Davies Olivia Murray Olivia Davies Gem Pipps Teacher: Dr Andrew Ford Engineer: Emily Bilbie Finless radiator, despite being more efficient causes a high-pitched droning sound at full speed. There are an estimated 11.4 million lower arm amputees worldwide, most have no prosthesis, some have hooks, a few have robotic hands. When a person becomes a limb amputee they face staggering lifestyle changes. The amputee requires a prosthetic device(s) and services which become a lifelong event. There is a need to analyse the problem to find out exactly what causes this noise and to propose innovative solutions to the noise. The team will test and evaluate how effective each of the solutions is. 3D printable prosthetics are changing the face of medicine as engineers and physicians are able to develop prosthetics that are fully customisable to the wearer. The project involves developing a lower arm prosthesis which will be 3D printed using technology called stereo lithography (SLA). The prosthesis must not only be functional but also aesthetically pleasing. The product will involve research into relevant ergonomic and anthropometric data with adequate methods of attaching the prosthesis to the amputee before considering the design. The team will need to highlight key considerations that the user would require from prosthesis. 6 Team 14 Team 13 Howell's School 2 Llanishen High School 1 & Viridor & GE Aviation Fan and frame dimension tool design project Waste Screening System Team: Alex Grieve Alex Hamzelou Henri Hicks Henry Jones Teacher: Andrew Ford Engineer: Ross Clifford Tom Kynaston Abid Miah Michal Oleszuk Zachary Stone Viridor are a waste management company. They recover energy from non-recyclable domestic and commercial waste, handling 350,000 tonnes of black bag and post recycling waste per year, generating 30 MW of energy. Team: Rhys Bartlett Henry Edwards James Duffy Sam Voyce Joe Jenkins-Delf Teacher: Philippa Wallington Engineer: Glen Atherton, Wayne Kwenda & Lloyd Taylor GE Aviation is a Turbofan Jet Engine overhaul facility based just North of Cardiff and is one of the largest aircraft engine maintenance facilities in the world. They have a current capacity to work 350 + engines a year and employ over 1200 members of staff. The task is to improve the separation of incoming commercial residual waste and increase resource efficiency by developing a system capable of distinguishing size variance, unauthorised waste and other large bulky waste items. Measurements on the fan hub frame can be taken either vertically or horizontally. Measuring the FHF vertically can cause inaccurate measurements and measuring horizontally can cause health and safety issues. The brief was to design a tool to improve this process. The team will research and design a system for screening incoming residual waste to a specified size. The investigation of the screening system should take into account the following: The team will have to take 3 depth measurements on the fan hub frame and it is very important that these measurements are accurate. This is because of the efficiency of the engine, oil consumption, a fuselage oil odour, and damage to the ball bearing in the engine. The team were advised to improve on the way GE Aviation take the measurements already; they had to be more accurate, safer and cost effective. It was also important to consider the ergonomics of the tool they would be creating as they were already using a heavy metal bar to level the measurements to the datum which required 3 people to measure (two holding the bar and one with the depth micrometre). 1. Screening of sizes 2. Transportation and movement of segregate waste on site 3. Potential metals separation Key points to consider: Variety of incoming waste, volume (processing capability- tonnes/hour), cost and resources, footprint (designed within the envelope of the building), robustness (ability to handle waste streams), traffic management (awareness of traffic and vehicle turnaround times). 7 Team 16 Team 15 Llanishen High School 2 St David's Catholic College & GE Aviation & Yard Digital Fan and frame dimension tool design project Interactive Raspberry Pi School Kit Team: Lucy Dicken Jack Griffiths Rhys Melvin Peter Snook Team: Teacher: Philippa Wallington Rhys Greenslade Rachel Bamford Christy Nganjimi Jacob McCarthy Slawek Jankowski Gracjan Zagorksi Engineer: Glen Atherton, Wayne Kwenda & Lloyd Taylor Teacher: Craig Hillard Engineer: Lisa Fryer, Sam Rogers & Paul Newburry GE Aviation is a Turbofan Jet Engine overhaul facility based just North of Cardiff and is one of the largest aircraft engine maintenance facilities in the world. They have a current capacity to work 350 + engines a year and employ over 1200 members of staff. Yard Digital is one of Europe's leading online marketing agencies with clients including Sainsbury's Bank, British Gas and Legal & General. Measurements on the fan hub frame can be taken either vertically or horizontally. Measuring the FHF vertically can cause inaccurate measurements and measuring horizontally can cause health and safety issues. The brief was to design a tool to improve this process. They specialise in recommending profitable action based on the data-driven analysis of customer behaviour. They have expertise in a range of analytics solutions and meeting clients' requirements through both common and bespoke solutions. The team will have to take 3 depth measurements on the fan hub frame and it is very important that these measurements are accurate. This is because of the efficiency of the engine, oil consumption, a fuselage oil odour, and damage to the ball bearing in the engine. The team were advised to improve on the way GE Aviation take the measurements already; they had to be more accurate, safer and cost effective. It was also important to consider the ergonomics of the tool they would be creating as they were already using a heavy metal bar to level the measurements to the datum which required 3 people to measure (two holding the bar and one with the depth micrometre). The task is to design and produce an educational tool that can be used to get children interested in coding and provide them with a willingness to learn either python or scratch. 8 Team 18 Team 17 Whitchurch High School & Cardiff University St Teilo’s CIW High School & Western Power Distribution Waste Energy Recovery from a Transformer Educational Interactive Display Team: Team: Liam Clements-Pope Max Harding Christos Michael Ethan Giordano Teacher: Mike Williams Engineer: Dr Richard Perks Umar Qazi Kobi Hazel Mei Soun-Wong Ensty Mathew Wojciech Kwiatkowski Mitchell Williams Zach Williamson Teacher: Leighton James Engineer: Andrew Roderick, Michael Rego & Liam Aldron Whitchurch High School’s Design and Technology department has a large foyer area welcoming pupils, parents and staff. In this space, Whitchurch High School require an Educational Interactive Display unit that can be used by the pupils as they are waiting for the lessons to begin and for the parents to also use on open evenings. Western Power Distribution is owned by PPL Global LLC, a subsidiary of PPL Corporation, Allentown, Pennsylvania. Western Power also delivers electricity to South Wales, the South West and Midlands area of England. With increasing requirements for legislative bodies to improve efficiency, WPD is searching for innovative solutions to minimise losses. The cost of a desired display will be in the region of £80,000- far too much on a state school’s budget. The solution is to build an Educational Interactive Display unit that is inspirational and informative but is also cost effective. Currently, as the load increases on a transformer, its copper loss increases which accounts for predominate heat loss in a transformer. If the heat is not dissipated properly it can cause damage to the transformer. The transformer cooling system is responsible for ensuring the transformer does not exceed critical temperatures, but makes no attempt to recover this waste heat. The team will investigate methods to recover the waste heat from transformers at Western Power’s primary substation sites and use this to heat onsite buildings and investigate alternative uses. It will be necessary to research and design a heat recovery system that can capture waste heat from an oil cooled transformer and explore options and recommend how this recovered heat can be used or stored onsite. 9 Team 20 Team 19 Ysgol Gyfun Gymraeg Glantaf 1 Ysgol Gyfun Gymraeg Glantaf 2 & AECOM & AECOM Improve Road safety in an urban area while also including an innovative system that generates electricity in a sustainable manner Design a Sustainable Street within an Urban Setting Team: Rhys Rickard-Frost Rhys Hopkins Sara Davies Hanna George Phoebe Marshall Cian Moriarty Teacher: Haydn Pritchard & Gareth Jones Engineer: Zoe Thompson AECOM is a premier, fully integrated professional and technical services firm positioned to design, finance, build and operate infrastructure assets around the world for public and private sector clients. The firm’s global staff serves clients in over 150 countries across the world. Team: Dafydd Davies Rhodri Davies Joseph Parry Iestyn Dallimore Guto John Iwan Rogers Teacher: Haydn Pritchard & Gareth Jones Engineer: Zoe Thompson & Siân Lewis The team were tasked with designing an environmentally as well as efficient roadway which would look at developing the roads which we have today into effective roads which could cope with the overgrowing demand for fossil fuels. Water is a finite resource. Developments require a holistic, sustainable approach and in the future must consider the prevention of excess water loss combined with the promotion of utilising waste water in a recycled form. The challenge is to design a sustainable street within an urban setting. There are various types of waste water including grey water, black water and in the form of runoff whether from roads or roofs. There are points to consider such as incorporating a sustainable urban drainage system in addition to the sustainable solutions that can be added to the buildings and the surrounding environment. The brief was to design/develop an environmentally friendly roadway which incorporated an element of safety to it. The team and AECOM came to the decision that it would be better to design one aspect in particular rather than developing many aspects and not doing them to a high standard. Not only did the team have to answer the brief through providing a more efficient energy source from the road they also had to maintain a high safety objective. This is one of the most important aspects of British roads that they are some of the safest roads in the EU, and the team want to maintain these high standards throughout the project. It is necessary to consider the fabric make up of particular elements within the design and may also wish to include features to encourage the user to reduce their carbon footprint. 10 Merthyr Tydfil Team 22 Team 21 The College Merthyr Tydfil 1 & Merthyr Tydfil County Borough Council Ysgol Gyfun Gymraeg Plasmawr & BBC Design an Efficient Office Layout and Structure for a Technology Service Department Team: Elis Williams Laura Satterly Thomas Bowen Daniel Lloyd- Evans Teacher: Gareth Huw Williams Engineer: David Williams New and Affordable Lighting for Merthyr Tydfil Team: The problem is to improve the support department’s work area in order to improve the department’s efficiency. The brief is to reorganise the support department’s work area in order to achieve maximum efficiency and allow effective communication between members. Teacher: Ian Griffiths & Mark Richards Engineer: Chris Ridout Merthyr Tydfil County Borough Council’s Highways Division have worked closely with The College Merthyr Tydfil for a number of years, designing innovative ways to improve the quality of life of many of its citizens through new road designs, lighting and energy saving ideas. In order to come up with an effective design it will be important to understand a number of key issues: Brandon Jones Gareth Sullivan Morgan Bennett-Mahoney Ryan Peeke Jack Elford Morgan Page Aaron Thomas We live in an age where energy consumption and our ‘Carbon Footprint’ are problems that every one of us faces in the 21st century. Many of us face the problem of trying to save valuable non-renewable energy sources (coal, oil and gas) by reducing our energy consumption. This problem is amplified for County Borough Councils as they have to provide services such as street lighting for the entire community. This costs County Councils millions of pounds every year to provide lighting for the safety and convenience of road and foot traffic in the area. The College Merthyr Tydfil have been asked to design lighting for roads and pathways that are activated when road or foot traffic are present. This design would ensure that the lighting system for the borough would only become activated when it is needed, saving valuable nonrenewable resources and saving money. The work the BBC do. How they work. The priority of the work. How support staff interact with each other. How they interact with customers (other departments). How they interact with contractors and suppliers. How technologies interact and their dependencies. The key areas of interest for staff. Where technologies are located within the building. To understand the important interactions it will be important to understand the technology and how one technology relies on another. 11 Monmouthshire Team 24 Team 23 Haberdashers’ Monmouth School for Girls & Renishaw PLC The College Merthyr Tydfil 2 & Merthyr Tydfil County Borough Council Redesign of a Renishaw assembly jig New and Affordable Lighting for Merthyr Tydfil Team: Kyle Breen Brody Donovan Niall Rowland Jack Forrest Benjamin Ryan Liam Morgan Teacher: Ian Griffiths & Mark Richards Engineer: Chris Ridout Team: Emily Owen Hannah Green Gabrielle Du Toit Mia Stanger Teacher: Anne Kavanagh Engineer: Holly Summerton Davies & Mike Beasant Renishaw is one of the world's leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as metal 3D printing). It is the only UK business that designs and makes industrial machines which ‘print' parts from metal powder. Merthyr Tydfil County Borough Council’s Highways Division have worked closely with The College Merthyr Tydfil for a number of years, designing innovative ways to improve the quality of life of many of its citizens through new road designs, lighting and energy saving ideas. We live in an age where energy consumption and our ‘Carbon Footprint’ are problems that every one of us face in the 21st century. Many of us face the problem of trying to save valuable non-renewable energy sources (coal, oil and gas) by reducing our energy consumption. This problem is amplified for County Borough Councils as they have to provide services such as street lighting for the entire community. This costs County Councils millions of pounds every year to provide lighting for the safety and convenience of road and foot traffic in the area. The task is to design lighting for roads and pathways that are activated when road or foot traffic are present. This design would ensure that the lighting system for the borough would only become activated when it is needed, saving valuable non-renewable resources and saving money. Renishaw employ a wide range of assemblies in their products. Some of these assemblies are currently labour intensive due to the complexity of the process leading to long lead times and relatively high costs. One such assembly process is threading wires around a set of pins, using a custom jig. This project is to review the current process of threading the wires with the aim of redesigning the jig. The redesign will aim to reduce the labour intensity of the process and hence the lead time and cost of the assembly. Manufacturing, materials and the cost associated with this, along with the ergonomics of the jig, must be considered. 12 Team 26 Team 25 Monmouth School Monmouth Comprehensive School & General Dynamics & Renishaw PLC Journey Incident Monitor Team: Automated Ball Bearing Selection and Placement Harry Burge Rory Gordon Florence Mayo James Ralph Theo Rook Bradley Smith Harry Dalrymple Alexander Allen Teacher: Colin Brown Engineer: Kieran Young Team: Louis Robinson Omar El Hammamy Lennon Wong Jason Ingamells Teacher: Gareth Dunn & Nick Goodson Engineer: Phil Sutton & Erik Danielsen Renishaw is one of the world's leading engineering and scientific technology companies, with expertise in precision measurement and healthcare. The company supplies products and services used in applications as diverse as jet engine and wind turbine manufacture, through to dentistry and brain surgery. It is also a world leader in the field of additive manufacturing (also referred to as metal 3D printing). General Dynamics UK are a prime systems integrator specialising in Mission and Land System capabilities for the British Army. GD UK require a one box vehicle incident recorder that will provide data to allow evaluation of performance and investigation of incidents when a vehicle is being tested in challenging environments; whether it has been driven badly or mishandled. During the assembly of a number of products ball bearings of various sizes (2-5mm) are assembled into a number of different housings. Currently the adhesive is dispensed using an automated dispensing machine but the balls are placed manually using a vacuum pick-up system. This process is time consuming and the operators would benefit from a semi-automated solution following the automated adhesion. To design and develop a semi-automated solution to select, pick up and dispense ball bearings ranging from 2-5mm diameter into different housings of the highest volume products. This will be a bench-top system that will allow the operator to select the appropriate ball size and dispense the balls correctly within several housings on a jig using existing vacuum pick-up system using compressed air. This tooling and air supply can be used as part of the solution. Another application for a similar device is when a delicate or valuable object (or living creature) is in transit; there is a risk of mistreatment. A company may wish to know how reliable a courier is at obeying certain instructions such as “fragile”, “this way up” etc. They would require a cheap, reusable, robust device that could record any relevant incidents during the journey for analysis and display on a base computer on arrival. 13 Newport Team 28 Team 27 Caldicot School & Orb Electrical Steels- Cogent Power Caerleon Comprehensive School & Zodiac Aerospace Disappearing Headrest PLC Test Rig and Diagnostics System Team: Callum Ewins Brandon Fox James Strong James Tillett Jed Andrew Savannah Beaumont Jenny Chan Team: Alexander Moras Naoise Williams Cameron Lillie Benjamin Lewsey Emlyn Ashley Teacher: Richard Scott Teacher: Natalie Gibbs Engineer: Howard Smith Engineer: Peter Carr & Alvy Muriuki Orb Electrical Steels creates electrical steel for use in transformers. Cogent Power is a global supplier of electrical steels and part of Tata Steel. The business works closely with customers at a local level to support their business development through optimisation of logistics and slitting to reduce inventory as well as continuous product development and innovation. Through the application of innovation and technology development, Zodiac Seats UK is a world leader in First and Business Class aircraft seats. Zodiac Seats UK is an industry leader in the design and development of First and Business Class aircraft seating, cabin furniture, monuments, bar & stowage units; supplying to the world's major airlines and OEMs The problem is to test and diagnose issues with a variety of PLC’s used within the manufacturing line and then create a small diagnostic board capable of testing 16 digital I/O ports and 8 analogue ports on a PLC. Integrating state of the art in-house production techniques with the capabilities of their global network of suppliers allows them to deliver bespoke solutions, limited only by the imagination and vision of the airline and the design team. Zodiac are a lead producer in First and Business Class aircraft seats who are always seeking ways to produce new and innovative concepts to attract their target market. Currently Zodiac have head rests that attach to the air craft seats, but are unnecessary when passengers set the seat to bed mode. Storage of these head rests are an issue and not always considered as aesthetically pleasing. Caerleon Comprehensive have been given the task to research and design a head rest that would disappear within the seat showing consideration to safety, aesthetics and comfort for the client. 14 Team 30 Team 29 Rougemont School 1 Rougemont School 2 & Zodiac Aerospace & Zodiac Aerospace Develop a waste disposal system for use on a premium aircraft seat Develop a child seat system for use on a premium aircraft Team: Elliot Quigley Lauren Dunn Jasper Zatman Ellie Morris Zoe Groves Lauren Hill Team: Sam Griffiths Harry Wynne Ibrahim Yusuf Tom Stockton Josh Winn Alex Davies Teacher: Jane Goodwin Teacher: Jane Goodwin Engineer: Louis Flanagan & Balaji Ilangovan Engineer: Oliver Davies & Tania Kyriakogkona Zodiac Aerospace designs and manufactures premium aircraft seating and cabin furniture. Zodiac Aerospace produces ‘standard’ aircraft seats along with bespoke solutions. Due to the nature of air travel, passengers require regular hydration and feeding to remain comfortable. The waste commonly gets stored in seat pockets causing reduction in space. Children can often find aircraft seats uncomfortable and un-accommodating. The task is to design a child seat system whilst considering safety, comfort and ease of use. It should be acknowledged that this concept is to be placed in a luxury seat. The brief is to develop a concept for a waste disposal system. Ease of recycling, ease of removal and ease of use should be considered. It should be acknowledged that this concept is for placement in a luxury aircraft seat and appropriate considerations should be made. 15 Team 32 Team 31 Rougemont School 3 St Joseph’s Roman Catholic High School 1 & Eastman Chemical Company & Jacobs Engineering Group Rag/oil/water separation improvements Design a detector of induced voltages that can be used from a safe distance Team: Nathan Grimsteed Megan Pritchard Izaak Dew Rhianna Robinson Alexander Kennerley Bhoomika Gandhi William Rattenbury Teacher: Jane Goodwin Engineer: Iwan Watkin & Freddie van der Linde Team: Jerrin Baby Callum Doughty Jake McDonald Ewen Cook Teacher: Cerys Corbett Engineer: Carrie Thomas & Jack Levy Eastman is a global specialty chemical company that produces a wide range of advanced materials and functional products, specialty chemicals, and fibers that are found in products that people use every day. The company distribute electricity across the Midlands, South West and Wales. They supply over 7.8 million customers with electricity. Their network of wires consists of 220,000km of overhead lines and underground cables, and 185,000 substations. As part of the manufacturing process crude Santicizer oil is washed with water and sodium hydroxide to remove impurities, phenol and partial esters, which are formed by a side reaction during the process. The wash water flows to a settling tank, along with the partial esters and some oil that is carried over. The problem is that the partial esters are good emulsifiers and so create an emulsion with some of the oil and water. This creates two problems. The first problem occurs when trying to separate the oil and partial esters in the storage containers. Maximum amount of oil needs to be recovered, without any partial ester contamination. The second problem involves partial ester carry over with the water to the bio treatment plant. This is a problem as the partial esters attack some components of this plant. In high voltage and extra high voltage substations metallic conductors left on the ground during installation or removal can have a voltage impressed on them due to the high electric fields and currents. This can create danger for anyone handling the conductors. Normally the conductors are earthed to reduce the danger but it would be useful to have a small portable detector that can tell a fitter if the metal has an impressed voltage on it. It could also be useful to detect impressed voltages in metallic structures such as fences in substations or in open fields under power lines. The task is to create a reader to show whether a piece of metal is dangerous or not for somebody to handle. The aim of the project is to evaluate the current methods of separation and identify improvement opportunities. The team will also identify and design different methods of separation to compare. 16 Rhondda Cynon Taff Team 34 Team 33 Aberdare Community School St Joseph’s Roman Catholic High School 2 & Eastman Chemical Company & Rhondda Cynon Taff County Council Rag/oil/water separation improvements School Bus Pass Alternative Team: Joyal Benny Jakub Dziechciarz Nikhil Jacob Team: Teacher: Cerys Corbett Daniel Loring Harriet Miller Cameron Carey James Ashford Engineer: Carrie Thomas & Jack Levy Teacher: James Thomas Engineer: Roger Waters & Geraint Roberts Eastman is a global specialty chemical company that produces a wide range of advanced materials and functional products, specialty chemicals, and fibers that are found in products that people use every day. Rhondda Cynon Taff County Council were looking in to developing the bus pass system. There are several reasons why the Bus Pass System was not now considered effective, for instance; As part of the manufacturing process crude Santicizer oil is washed with water and sodium hydroxide to remove impurities, phenol and partial esters, which are formed by a side reaction during the process. The wash water flows to a settling tank, along with the partial esters and some oil that is carried over. The problem is that the partial esters are good emulsifiers and so create an emulsion with some of the oil and water. This creates two problems. The first problem occurs when trying to separate the oil and partial esters in the storage containers. Maximum amount of oil needs to be recovered, without any partial ester contamination. The second problem involves partial ester carry over with the water to the bio treatment plant. This is a problem as the partial esters attack some components of this plant. Expense- Nearly £1 per card People lose/break cards- costs to produce more. Cards may be given out but not used by every pupil that has one- wasting money. Fraud- One card often used by more than one pupil- causes buses to be cramped as they are not meant to cater for so many. Does not track any information about the pupil getting safely on or off the busalmost a worthless process. Does not retain any information about the bus’s situation itself- is there any point having a certain stop when no children get on it? Hard to know this as the cards track no information. With an average of 10,000 bus passes being produced each year, it is neither financially or environmentally friendly as so many materials are used to make these cards. The aim of the project is to evaluate the current methods of separation and identify improvement opportunities. The team will also identify and design different methods of separation to compare. 17 Team 36 Team 35 Cardinal Newman RC Comprehensive School & R-TEK Coleg y Cymoedd, Ystrad Mynach & Renishaw Cable Measurement Cutting Device Investigate the properties of waste material and design a product/system that could be manufactured using the off cuts. Team: Lewis Alexander Nathaniel James Thomas Penman Kieran Murphy Joseph Jones Abigail Willshee Natalie Denisiuc Ryan Williams Rhodri Taylor James Bunney Liam George Team: Caitlin Dallison Savannah Rivera Clyde Leal Teacher: Dr Helen Mason Teacher: Phil Jones Engineer: Darren Hooper, Andrew Thomas & David Rees Engineer: Samuel Thomas & Rhys Jones At present, Renishaw have to manually cut and measure the required length of wire and this creates a lot of waste within the industry. The team will have to build a device to solve this problem. The team broke the problem down into three sections. Solution A had ideas like; portable, cable manually fed into the machine, controlled by a Raspberry pi, battery powered and rechargeable. Solution B had ideas of being portable, handheld; an LCD display with buttons, cable manually fed and pulled out, battery operated with a manual cutter. Solution C is to have a belt system, using the mains power, a tube to feed cable in and a laser measuring the cable. Currently R-TEK has a problem with the inefficiency of their multi-board’s ability to cut fabrics in a way that uses up most of the material’s surface area. This leads to excessive waste material that is costly to dispose of. The group decided to address the dilemma of the waste product as they could see the solution profiting R-TEK, as they’d spend less money on skip hire, while also having a positive impact on the environment by reducing the volume of waste sent to landfill. The aim is to reduce the issue with the waste material that R-TEK produces after manufacturing panels for cars. The material is polypropylene (PP) plastic mixed with fibre. This is used as the carpet lining for car boots. As the material is a mix of plastic and fibre it cannot be sent for recycling to be made into something else as the two materials, PP and fibre, cannot be separated leaving the product contaminated. The team wanted to devise a solution whereby the company could make profit by selling the material off or giving it away to be utilized for free in a way that does not damage the environment. They aim to make the project as eco-friendly and profitable for the business as possible by reducing the amount sent to a landfill. The group researched about hydraulic and pneumatic to aid in the cutting of the cables. As a group they looked at different cutting methods, however the only one that will actually work is a guillotine. They also worked on a transistor circuit. This circuit was needed to control the pneumatics driver. The circuit was built on Circuit Wizard and simulated it. The team then built it on bread board, and then tested it. With the resistors and the transistors, they compared the practical results and the electronic results and calculated weather they are in tolerance or not. 18 Team 38 Team 37 Treorchy Comprehensive School Ysgol Gyfun Garth Olwg 1 & Allied Aerosystems & FSG Tool & Die Stopwatch Calibration Conundrum Control of coolant Team: William Grenter Jack Ayres Thomas Allen Caelan Bradley Team: Teacher: Owen Nelson Engineer: Callum Matthews, Philip Ashurst & Matt Thomas Iwan Cavil Oliver Kittridge Daniel Thomas Robbie Mears Harriet Hooper Morgan Riella Tirion Welsby Teacher: Gareth Humphreys Engineer: Ian Slaughter, Aled Price & Aaron Johnson Simrit Bains Jordan Jenkins Rhys Dyer Iwan Dyer Allied Aerosystems is a company that specialises in the calibration of equipment in all the basic SI units for the commercial sector (including kg for mass and strain on industrial equipment and seconds to be used in timing equipment of aircraft). They calibrate to a bare minimum of 95% accuracy but aim for 98%. Founded in 1961 FSG Tool and Die is the largest privately owned toolmaking company in Europe. Their facility in Llantrisant, South Wales contains the very latest technology for design and manufacture of high precision tooling. They have a reputation for training young engineers and have trained apprentices for over 50 years. Many of the current employees joined them as apprentices and they are very proud of growing their own talent. Allied Aerosystems calibrates stopwatches but currently the process takes six hours per stopwatch. The team have been challenged to design a more efficient process that retains the current 95% accuracy requirement. Problems occur with the delivery of coolant to the machining centre at the correct dilution and there is also an issue with the disposal of waste coolant. The team was given the challenge to: research, design, finance, construct and finalise a more efficient process for the calibration of stopwatches as currently it takes six hours per stopwatch. It is also important to make sure that the design is able to be easily commercialised. The team also had to ensure that the accuracy must remain at 95% or higher. The task is to design a cost effective system to supply, monitor and dispose of the coolant. The project should also look at safe storage of new and old product. The design also had to be able to be used with a range of stopwatch designs as the display, shape, and buttons can be located in different places.Finally, as technology is constantly improving the design must be adaptable to fit with this constant change and as such it is important to label theoretical future improvements for the project. 19 Torfaen Team 40 Team 39 Ysgol Gyfun Garth Olwg 2 Croesyceiliog Comprehensive School 1 & FSG Tool & Die & ZF TRW Automotive Sealing Face Damage of Automotive Braking Systems Control of coolant Team: Adam Evans Elliot Jones Ioan Payne Tom Swayne Olivia Sieniawski Matthew Villis Sam Nibblett Evan Rayner Teacher: Gareth Humphreys Engineer: Ian Slaughter, Aled Price & Aaron Jones Team: Dylan Boyer Jonny Mundy-Jones Ross Walters Sam Levy Teacher: Lisa Taylor & Nicola Quiller Engineer: Simon Blunsdon & Steve Josling ZF TRW, Pontypool, South Wales, have been manufacturing braking systems since the early 1970’s. Today they manufacture for companies such as Nissan, BMW & Jaguar Land Rover. Founded in 1961 FSG Tool and Die is the largest privately owned toolmaking company in Europe. Their facility in Llantrisant, South Wales contains the very latest technology for design and manufacture of high precision tooling. They have a reputation for training young engineers and have trained apprentices for over 50 years. Many of the current employees joined them as apprentices and they are very proud of growing their own talent. During the machining and assembly process it is possible to introduce damage to the sealing face, which results in a leak. The product is therefore deemed unfit for purpose. The task is for a system to be developed that can identify “reject” or “suspect” parts before adding value through the assembly process. The solution must be in the form of a non-destructive system that shows a high level of repeatability and low maintenance costs. Problems occur with the delivery of coolant to the machining centre at the correct dilution and there is also an issue with the disposal of waste coolant. The best in class production cycle time of 18 seconds is to be aimed for and no foreign body or material must be introduced to system. The task is to design a cost effective system to supply, monitor and dispose of the coolant. The project should also look at safe storage of new and old product. 20 Team 41 Team 42 Croesyceiliog Comprehensive School 2 Croesyceiliog Comprehensive School 3 & ZF TRW Automotive & ZF TRW Automotive Sealing Face Damage of Automotive Braking Systems Sealing Face Damage of Automotive Braking Systems Team: Ffion Morgan Georgia Bailey Rhiannon Chilcott Gwennan Ward Hannah Godfrey Team: Briony Allen-Betts Alex Elias Rhiannon Phillips Alex Burridge Teacher: Lisa Taylor & Nicola Quiller Teacher: Lisa Taylor & Nicola Quiller Engineer: Simon Blunsdon & Steve Josling Engineer: Simon Blunsdon & Steve Josling ZF TRW, Pontypool, South Wales, have been manufacturing braking systems since the early 1970’s. Today they manufacture for companies such as Nissan, BMW & Jaguar Land Rover. ZF TRW, Pontypool, South Wales, have been manufacturing braking systems since the early 1970’s. Today they manufacture for companies such as Nissan, BMW & Jaguar Land Rover. During the machining and assembly process it is possible to introduce damage to the sealing face, which results in a leak. The product is therefore deemed unfit for purpose. During the machining and assembly process it is possible to introduce damage to the sealing face, which results in a leak. The product is therefore deemed unfit for purpose. The task is for a system to be developed that can identify “reject” or “suspect” parts before adding value through the assembly process. The solution must be in the form of a non-destructive system that shows a high level of repeatability and low maintenance costs. The task is for a system to be developed that can identify “reject” or “suspect” parts before adding value through the assembly process. The solution must be in the form of a non-destructive system that shows a high level of repeatability and low maintenance costs. The best in class production cycle time of 18 seconds is to be aimed for and no foreign body or material must be introduced to system. The best in class production cycle time of 18 seconds is to be aimed for and no foreign body or material must be introduced to system. 21 Team 44 Team 43 Croesyceiliog Comprehensive School 4 Croesyceiliog Comprehensive School 5 & ZF TRW Automotive & ZF TRW Automotive To detect surface defects on a cast iron surface via a non-contact method Sealing Face Damage of Automotive Braking Systems Team: Dewi Taylor Jacob Bridgeway Daniel Williams Joseph Pugh Team: Teacher: Lisa Taylor & Nicola Quiller Thomas Magor Jacob Gordon Joshua Travers Iestyn Price Samuel Partridge-Wilson Thomas Spokes Engineer: Simon Blunsdon, Steve Josling& Bill Jones Teacher: Lisa Taylor & Nicola Quiller Engineer: Simon Blunsdon & Steve Josling ZF TRW, Pontypool, South Wales, have been manufacturing braking systems since the early 1970’s. Today they manufacture for companies such as Nissan, BMW & Jaguar Land Rover. ZF TRW, Pontypool, South Wales, have been manufacturing braking systems since the early 1970’s. Today they manufacture for companies such as Nissan, BMW & Jaguar Land Rover. During the machining and assembly process it is possible to introduce damage to the sealing face, which results in a leak. The product is therefore deemed unfit for purpose. During the machining and assembly process it is possible to introduce damage to the sealing face, which results in a leak. The product is therefore deemed unfit for purpose. The task is for a system to be developed that can identify “reject” or “suspect” parts before adding value through the assembly process. The solution must be in the form of a non-destructive system that shows a high level of repeatability and low maintenance costs. The task is for a system to be developed that can identify “reject” or “suspect” parts before adding value through the assembly process. The solution must be in the form of a non-destructive system that shows a high level of repeatability and low maintenance costs. The best in class production cycle time of 18 seconds is to be aimed for and no foreign body or material must be introduced to system. The best in class production cycle time of 18 seconds is to be aimed for and no foreign body or material must be introduced to system. 22 Bridgend Team 46 Team 45 St Alban’s Roman Catholic High School Brynteg School & Meritor & Ford Continuous load monitoring device Rainwater Harvesting Team: Trixica Kapdee Abigail McFadden Jade Williams Leigh Akehurst Team: Teacher: Chris Powell & Richard Everson Engineer: Daniel Jenkins Brogan Thomas Emily Williams Connor Gannon Adam Hogan Jaye Parry Samuel Thomas Jardin Bold Emma Hobby Teacher: John Catton & Paul Webber Engineer: Brian Vicker & Brett James Jake Green David Jones Harry Walbyoff Morgan Raynsford Meritor is recognised as being the market leader in advanced drivetrain, mobility, breaking and aftermath solutions for the global commercial vehicle and industrial markets. The Cwmbran site specialises in the design and manufacture of air disc brakes. The Ford engine plant in Bridgend is a major employer in the area and manufactures around 3000 engines per day. The Ford engine plant in Bridgend currently uses around 127,000,000 litres of water per year. In order to make cost savings, a concept should be developed to use the rainwater falling on the factory roof to reduce the overall water consumption from the mains supply. The company’s test facilities are continually looking into improving their existing methods. One such test involves the continuous application of an air disc brake, fatiguing the part till failure. The need has arisen to better understand and monitor the output load that brake assembly experiences throughout the duration of this particular test. The Ford engine plant has a large water consumption and cost of water from the mains supplier. The task required is to make use of the large area of roof on the factory to reuse as much of the rainwater as possible within the factory to reduce the water bill and improve the environmental credentials for the company. A device is to be designed which can fit an array of air disc brakes on test, which is both robust and effective at providing an accurate indication of the test load. The design must fit all standard brakes, and be fitted with an appropriate sensor which gives an electrical output which is proportional to the output load experienced. The design must fit within the following space envelope: 255mm length, 55mm width & 38mm depth. It is advised that the device is capable of dual sensing (to accommodate the dual pistons arrangement): 109.6mm centre-centre distance & capable of sensing up to a total of 280kN force. 23 Team 48 Team 47 Maesteg Comprehensive School & Capita Symonds & Bridgend County Borough Council Cynffig Comprehensive School & Sony UK Tec Increasing the efficiency and safety of the access road leading to Maesteg Comprehensive School Cosmetic Inspection of a Broadcast Camera Team: Lucy McArthur James Douglas Lauren Parry Thomas Howe Dafydd Attwood Cameron Sim Teacher: Richard Daniel & Daniel Morrish Engineer: Warren James Sony UK Tec is located at Pencoed adjacent to J35 of the M4. High value / highly complex Broadcast Cameras are manufactured here for a worldwide market. The company offer a Service repair operation for all Sony products, consumer and professional. Team: Aled Batchelor Kieran Hood Zoe Lee Kieran Collins Nathan Lloyd Katie Rees Teacher: Adrian Davies Engineer: Ian Walsh & Chloe Cadreman At present the access road leading to Maesteg Comprehensive School is inefficient and unsafe for pedestrians. The team will need to create a model of Maesteg Comprehensive School, along with its surrounding land – This is essential for the project as this will create an ideal image of the final solution so that it will be easier to convey the current problems within the school. They will be using polystyrene and foam blocks to create the structure of the school then completing the model by adding several layers of acetate depicting our possible solutions. Sony UK Tec manufacture high value broadcast cameras. Once a broadcast camera has been built, it must be inspected for faults to meet the high expectations of Sony customers. This process is entirely manual and as a consequence is a very repetitive and mundane operation. The aim of the project is to reduce the time it takes to manually inspect a camera to confirm that its cosmetic appearance is identical to the standard Sony camera setup. The objective is not to remove the human element completely but to aid the inspection process To be successful, it will be necessary to appraise the current operation in order to understand the diversity of the product line up, build process and the ‘cycle time’ in which to manage the task. 24 Carmarthenshire Team 50 Team 49 Pencoed Comprehensive School Coleg Sir Gar & CGI & National Botanic Garden of Wales Utilising wasted heat & reducing energy costs Bat Preservation Project Team: Daniel Morris Callum Johnson Jasmine Greene Ewan James Caitlin Sweet Team: Cerys Williams Samuel Austin Owen Wastell Hannah Leyshon Teacher: Mark Avaient Teacher: Bethan Norman Engineer: Emily Bristow & Steve Thomas Engineer: Nancy Hardy & Jamie Sutherland The National Botanic Garden of Wales covers an area of 578 acres in Carmarthenshire and includes a nature reserve, an ornamental garden and the largest single span glasshouse on the planet. CGI delivers a range of outsourcing, application services and infrastructure services to clients in the public and commercial sectors across the UK from South Wales. Their Welsh team are at the heart of delivering cutting edge services to their clients that help them become more efficient and focus on growing their businesses. This includes CGI’s Secure Government Cloud and Commercial cloud services, the new Cyber Security Operations Centre and developing mobility solutions, healthcare and smart meter technology. Every year when bats are very young they fall from the nest at the top of the Stable Block building and the mothers are unable to collect them. It is necessary to devise a solution to this problem that requires minimal or no human input. This issue is seasonal so it should not reduce the aesthetics of the building. It is important to bear in mind that the Stable Block Building is a listed building and that bats are protected by law in the UK. It is thought that the bats are Soprano Pipistrelle Bats. The company have given the team the problem that heat is wasted through their venting ducts in the data room. The team have been asked to find a way of making use of this heat while reducing energy costs for the building. 25 Team 52 Team 51 Queen Elizabeth High School 1 Queen Elizabeth High School 2 & Carmarthenshire Council & Carmarthenshire Council Design a new sustainable science classroom. Investigate methods of chlorine removal for pools Team: Alex Pilkington Georgia Hall Haitham Saeid Caradog Hanna-Davies Damian Muzal Rachel Jones Sam Hitchcock Teacher: Sharon Magill Engineer: Kristy Tillman Team: Jared Samuel Owen Griffiths Ela Griffiths Rachel O’Donoghue Thomas Watkins Indeg Crane Amber Randall Teacher: Sharon Magill Engineer: Kristy Tillman Carmarthenshire County Council is responsible for the construction and maintenance of all schools in Carmarthenshire. Like all other local authorities in Wales, they are charged by the Welsh Assembly to ensure suitable environments are provided for children to learn and flourish to their full potential. Many of the buildings are old and although the authority has invested a considerable amount of money to build new schools, it is important to explore how we can improve and maintain resources in existing schools. With this in mind the council have been consulting schools, parents and pupils to identify their requirements, and as part of their research have asked sixth formers from Queen Elizabeth High to identify potential improvements to their school. Carmarthenshire County Council is responsible for the construction and maintenance of all schools in Carmarthenshire. Like all other local authorities in Wales, they are charged by the Welsh Assembly to ensure suitable environments are provided for children to learn and flourish to their full potential. Many of the buildings are old and although the authority has invested a considerable amount of money to build new schools, it is important to explore how we can improve and maintain resources in existing schools. With this in mind the council have been consulting schools, parents and pupils to identify their requirements, and as part of their research have asked sixth formers from Queen Elizabeth High to identify potential improvements to their school. The team was asked to identify a construction, environmental or engineering issue within their school and then research possible solutions and design a prototype to overcome the problem. The team was asked to devise ways in which a new sustainable science classroom could be developed. It is important that the new classroom is designed in such a way as to aid pupils’ learning and be an environment where they can learn effectively. The team identified a problem with the chlorine gas levels in the pool and the potentially harmful chemicals that could enter nearby classrooms. The project involved investigation into alleviating this problem. 26 Team 54 Team 53 Ysgol Dyffryn Taf Ysgol Gyfun Maes Y Gwendraeth 1 & Magstim & National Botanic Garden of Wales Environmental Monitoring System Bat Preservation Project Team: Verity Baulch Sean Coaker Ieuan Griffiths Team: Teacher: Mark Smith Chelsie Walters Ffion Griffiths Owain Walters Rhys Lewis Engineer: Tim Facer Teacher: Jonathan Williams Engineer: Nancy Hardy & Jamie Sutherland Rhys Davies Kerris Goble Joel Rees Magstim provides quality medical devices for both research and clinical practices in neuroscience, psychiatry and intra-operative neuromonitoring and imaging. The company provides the means for neuroscientists to work with the human brain in awake subjects by manufacturing and supplying state-of-the-art clinical and research instruments. Manufacturers and developers in Magstim’s field face strict monitoring of their process tolerances. Data has to be available for a range of parameters as a site visit may occur at any time. Most of the equipment manufactured requires specific humidity and temperature constraints. A monitoring system is needed to gather, store and present this data at any time. The National Botanic Garden of Wales covers an area of 578 acres in Carmarthenshire and includes a nature reserve, an ornamental garden and the largest single span glasshouse on the planet. Every year when bats are very young they fall from the nest at the top of the Stable Block building and the mothers are unable to collect them. It is necessary to devise a solution to this problem that requires minimal or no human input. This issue is seasonal so it should not reduce the aesthetics of the building. It is important to bear in mind that the Stable Block Building is a listed building and that bats are protected by law in the UK. It is thought that the bats are Soprano Pipistrelle Bats. The aim is to design and develop an environmental monitoring system, gathering temperature and humidity data using two wireless monitoring stations. The data must be stored in a central log, and line graphs of varying types must be producible on demand. These graphs must be time scale adjustable, and allow for simple printing. The network for these stations will need to be self-contained, not interfere with other works networks and be able to reach over 50m at its greatest transmission range. The project will be constrained by price, with £50 allocated to the network, £100 allocated to each of the two stations, and £300 allocated to the logging station. 27 Pembrokeshire Team 56 Team 55 Ysgol Gyfun Maes Y Gwendraeth 2 Pembroke School & National Botanic Garden of Wales & Valero Bat Preservation Project Cooling Water Exchanger Project Team: Kieran Evans Harri Jones Manon Rees Aled Treharne Team: Teacher: Jonathan Williams Engineer: Nancy Hardy & Jamie Sutherland Holly Maynard Hannah Perry Tom Watson Will de Graaf Ben Newton Charlie Garrard Edward Davies Jordan Davies Teacher: Jon Jones Engineer: Gareth Thomas The National Botanic Garden of Wales covers an area of 578 acres in Carmarthenshire and includes a nature reserve, an ornamental garden and the largest single span glasshouse on the planet. On the crude unit, cooling water is used to cool lubrication oil systems via heat exchanges from multiple pumps and two overhead gaskets. Lubrication oil is needed to ensure all rotating parts can move freely at high speeds. Typical rotation speeds are 3,000 to 4,00rpm, heat needs to be removed from the lubrication oil so that it can be recirculated back to the pump / compressor seals and not cause rotating parts to overheat. Every year when bats are very young they fall from the nest at the top of the Stable Block building and the mothers are unable to collect them. It is necessary to devise a solution to this problem that requires minimal or no human input. This issue is seasonal so it should not reduce the aesthetics of the building. It is important to bear in mind that the Stable Block Building is a listed building and that bats are protected by law in the UK. It is thought that the bats are Soprano Pipistrelle Bats. Some of the old cooling water lines to the crude unit are fouled meaning the supply pressure and hence flow is lower than required for effective heat transfer and cooling of lubrication oil. Fire water supplied by hoses has been used to splash water on the outside of the heat exchanger – this is ineffective so there is a need to redesign a more efficient system. The task is to create an alternate means of cooling the system. 28 Team 58 Team 57 Pembrokeshire College 1 Pembrokeshire College 2 & Valero & Valero Hydrostatic testing device Valve Leakage Testing Team: Jordan Gough James Griffiths Thomas Preece Team: Dan Griffiths Thomas Wood Aaron John Teacher: Jason Pointer Teacher: Jason Pointer Engineer: Paul Evans Engineer: Paul Evans Valero’s Pembroke refinery is one of the leading employers in South Wales and is one of Europe’s largest and most complex refineries. Valero Energy Ltd, markets fuel in the UK and Ireland under the Texaco brand. There are around 850 Texaco-branded service stations in the UK and 230 Texaco-branded service stations in Ireland. Valero Energy Corporation, through its subsidiaries, is an international manufacturer and marketer of transportation fuels, other petrochemical products and power. Valero subsidiaries employ approximately 10,000 people, and assets include 15 petroleum refineries with a combined throughput capacity of 2.9 million barrels per day, 11 ethanol plants with a combined production capacity of 1.3 billion gallons per year, a 50-megawatt wind farm, and renewable diesel production from a joint venture. Valero’s Pembroke refinery is one of the leading employers in South Wales and is one of Europe’s largest and most complex refineries. Valero Energy Ltd, markets fuel in the UK and Ireland under the Texaco brand. There are around 850 Texaco-branded service stations in the UK and 230 Texaco-branded service stations in Ireland. Valero Energy Corporation, through its subsidiaries, is an international manufacturer and marketer of transportation fuels, other petrochemical products and power. Valero subsidiaries employ approximately 10,000 people, and assets include 15 petroleum refineries with a combined throughput capacity of 2.9 million barrels per day, 11 ethanol plants with a combined production capacity of 1.3 billion gallons per year, a 50-megawatt wind farm, and renewable diesel production from a joint venture. Valero has requested a method that will take the human involvement out of hydro testing. Hydro testing on site usually requires somebody to go back and forth between the test and any other tasks to record the pressure over an hour. We are going to remove the need to walk back and forth and let the test run automatically. Valves performing a safety critical function on the refinery require testing to ensure the leakage rate is within specified limits. This is currently performed manually via a procedure. Design a portable device with self-contained power supply and on board test medium that will automate the test on the valve leakage rate and indicate if valve meets the criteria as defined in the company test standard. The task is to design a machine which will record the pressure exerted by water inside a piece of pipe over an hour. The idea is to remove the need of human involvement and allow the machine to do it automatically, meaning that the worker can continue with other tasks. 29 Team 60 Team 59 Pembrokeshire College 3 Pembrokeshire College 4 & GD Harries & Son & GD Harries & Son Saltwater Lido at Saundersfoot Harbour Saltwater Lido at Saundersfoot Harbour Team: Megan Evans Sam Richards Mike Thomas Daniel Rudd Jordan Chapman Team: Cameron Edwards Connor McGarvie Greg Murrow Morgan Summons Josh Wilkinson Teacher: Antony Davies Teacher: Antony Davies Engineer: Richard Burton Engineer: Richard Burton Design a new saltwater lido for the Saundersfoot Harbour development to include solutions to sea wall defences, lido construction, temporary works, operation and added value to the local community. Design a new saltwater lido for the Saundersfoot Harbour development to include solutions to sea wall defences, lido construction, temporary works, operation and added value to the local community. Investigate the following regarding the construction of a saltwater lido at Saundersfoot Harbour: Investigate the following regarding the construction of a saltwater lido at Saundersfoot Harbour: Planning requirements including aesthetics, environment impact assessment and licences required. Location of the lido and the level of the tide at that location and at what height the rim of the lido will be set at. Design of the lido to include its appearance, sea defence strategy and the effect on the existing harbour wall, erosion strategy, floor level design, cleaning strategy, access for disabled users, access from the existing car park. The construction phase, looking at aspects such as temporary works, plant and machinery movement, site compound, impact on visitors to the town and harbour/boating activities. 30 Planning requirements including aesthetics, environment impact assessment and licences required. Location of the lido and the level of the tide at that location and at what height the rim of the lido will be set at. Design of the lido to include its appearance, sea defence strategy and the effect on the existing harbour wall, erosion strategy, floor level design, cleaning strategy, access for disabled users, access from the existing car park. The construction phase, looking at aspects such as temporary works, plant and machinery movement, site compound, impact on visitors to the town and harbour/boating activities. Team 62 Team 61 Pembrokeshire College 5 Ysgol Y Preseli & GD Harries & Son & Pembrokeshire County Council Saltwater Lido at Saundersfoot Harbour Newgale Coastal Adaptation Team: George Davies Iwan Davies Mark Jones Jeswin Shibu Pinnakatu Tom Phillips Joe Poole Sion Thomas Team: Teacher: Antony Davies Carys Thomas Rosie Evans Morgan Davies Megan Noakes Lowri James Rhodri Sollis Rhys Edwards Rhys James Iwan Cole Engineer: Richard Burton Teacher: Ceri Evans Engineer: Darren Thomas & Emyr Williams Design a new saltwater lido for the Saundersfoot Harbour development to include solutions to sea wall defences, lido construction, temporary works, operation and added value to the local community. Pembrokeshire County Council is the unitary authority responsible for the management of flood and coastal erosion risk management as well as being the highways authority. Investigate the following regarding the construction of a saltwater lido at Saundersfoot Harbour: The main road to the St. David’s peninsular runs at sea level behind a shingle bank at Newgale. A recent report has identified this bank as being unsustainable within a 10-20 year timeframe requiring the provision of a new transport link within 10 years. The site is a steep-sided valley with a marsh on the valley floor that floods when the stream outfall is blocked by shingle. This situation will deteriorate rapidly with sea level rise. Planning requirements including aesthetics, environment impact assessment and licences required. Location of the lido and the level of the tide at that location and at what height the rim of the lido will be set at. Design of the lido to include its appearance, sea defence strategy and the effect on the existing harbour wall, erosion strategy, floor level design, cleaning strategy, access for disabled users, access from the existing car park. The construction phase, looking at aspects such as temporary works, plant and machinery movement, site compound, impact on visitors to the town and harbour/boating activities. There is a requirement to identify a preferred sustainable and affordable solution to the problem either by work to stabilise the shingle bank or the provision of a new road. Any new alignment should meet environmental constraints and not incur excessive costs. 31 Powys Swansea Team 63 Team 64 Ysgol Maesydderwen Bishop Vaughan School & Weartech International & University of Wales Trinity St David Packaging and shipping design project Team: Glass Recognition Environmental Engineering Nucleation Joshua Davies Rhys Jones Lloyd Handley Akhil Johnson Brandon Jones Team: Keefe Montebon Joseph Robinson Phoebe Hughes Eloisa Maristela Joel Baiju Baptin Syriac Rhys Brannan Morgan Thomas Teacher: Matthew Jones Teacher: Engineer: Dyfyr Davies, James Vallery, Geo Joseph & Lee Derrick Kevin Widlake, Andrew Smith & Ann Lawrence Engineer: Richard Morgan Weartech International is a producer of cobaltbased hardfacing and wear-resistant welding consumables and castings, headquartered in Anaheim, CA with an additional manufacturing facility in Port Talbot, Wales. For over 20 years, Weartech has provided technical solutions to customers facing significant wear problems. A glass recycling company would like to automate some of their operations. In order to improve efficiency and competitiveness, they wish to develop an automated system which would be able to separate glass into different colours in preparation for further recycling operations. Weartech ships products throughout Europe. Currently, this is achieved by in-house construction of wooden shipping crates. Although this allows for a safe and effective means of transporting products, the crates are not returned to Weartech and the majority are not reused by customers. This project challenges the team to develop a conceptual, proof-of-principle, automated system which is capable of mechanically sorting bottles into distinct colour groups. The team have been instructed to assume that the glass bottles (of various colours) will be travelling along a conveyor belt in single file and that an automated colour recognition and mechanical sorting system should be developed. The team should work together to develop a practical solution to the problem stated above. The team may investigate a variety of potential technologies and solutions. However, they should consider the following points: Robust and reusable packaging designs could be utilised, allowing the customer to return the packaging to Weartech and improve the environmental impact of delivering goods. Other key factors such as cost, protection, quality, materials, and feasibility would all need to be considered. • • • Packaging solutions for two forms of Weartech product have been specified. Dimensions and additional specifications have been provided to the team. • 32 Cost effectiveness of implementation Operational reliability Operational costs / maintenance or repair costs Health and Safety Team 66 Team 65 Gower College Swansea - Tycoch Campus 1 & University of Wales Trinity St David Gower College Swansea - Gorseinon Campus & Tidal Lagoon Mechanised Component Sorting System Design and Development Lighting the Tidal Lagoon Swansea Bay breakwater access routes using renewably sourced electricity Team: Carys Evans Bailey Evans Aran McConnell Steven Edwards Peter Dyer Ieuan Edwards Mary Jones Teacher: Stewart McConnell Engineer: Jordan Nelson & Rebecca Stone Team: Thomas Hopkins Jordan Passmore Keelan Smith Daniel Hawkins Kai Pickman Teacher: Mark Row Engineer: Richard Morgan A manufacturing company would like to develop a mechanised system to facilitate the sorting and distribution of four variants of component. The team are instructed to assume that the components will travel along a conveyor belt in single file and need to be distributed into separate bins or containers. Tidal Lagoon Power brings together an experienced team specialising in renewable energy, all sharing the same ambition to see the UK successfully shift towards clean and sustainable energy that is locally owned. Tidal Lagoon Power plan to deliver the Swansea Bay Tidal Lagoon, the world’s first man-made energygenerating lagoon with a 320 MW installed capacity during 120 years of operation. The team are tasked with the design and development of a conceptual, proof-of-principle, prototype system which is capable of mechanically sorting and distributing the four variants of component. The system can be fully automated or semi-automated (remotely controlled by an operator). Planning conditions require Tidal Lagoon Swansea Bay to ensure the Eastern & Western breakwaters are lit at all times of darkness. The current proposal is to power the lighting electricity demand from the UK national grid. Providing power for the lighting in this way is expensive, and due to the nature of the project a sustainable system would be preferred. The team should work together to develop a practical solution to the problem stated above. The team may investigate and consider a variety of potential technologies and solutions. However, they should consider the following points: The task is to design a renewable energy powered lighting system for the Eastern and Western breakwaters. The lighting system must; provide enough light for safe transit along the access routes, minimise relevant concerns and be proven with a scale model. 33 • Cost effectiveness of implementation • Operational reliability • Operational costs / maintenance or repair costs. • Health and Safety Team 67 Team 68 Gower College Swansea - Tycoch Campus 2 & Tongfang Global Gower College Swansea - Tycoch Campus 3 & Tongfang Global Quality Testing Room Smart TV Testing Team: Kieran Belton Ryan Thomas-Close Ryan Wilkins-Williams Adam Wilkins- Williams Sameer Ullah Gareth Whitcombe Team: Cody Wilks Sara Vonk David Osbourne Kaleb Thomas Teacher: Steve Williams & Brian Lewis Teacher: Steve Williams Engineer: Simon Lucas & Richard Morris Engineer: Richard Morris Tongfang is a Chinese worldwide company that specialise in producing televisions. The company sells high quality TV’s at a competitive price. Based in china and with a manufacturing plant in Port Talbot, this company offers modern smart television sets at a competitive price compared to other brands. Tong Fang is a progressive international company; it focuses on different areas of the electronics market such as Consumer Electronics, Information Appliances, Multimedia Terminals and Educational Electronics. With plenty of investment their company has grown hugely. In recent years by putting their research investment into flat panels TV’s it has made the company a powerful presence when it comes to colour TV. Tongfang Global have tasked the team with making a testing station for smart televisions to test the capabilities of the smart TVs they produce. The task is to develop the testing facility located at Tong Fang. It needs new temperature control, sound testing facilities including sound proofed walls and then all new smart TV testing facilities. The aim is to test the functions of the smart TV’s on the assembly line of Tongfang Global. The team will need to research things like how Smart Televisions are tested, the cost of sound proofing and the most efficient ways to control temperature. A big key factor is the need to present the project to an audience. 34 Team 70 Team 69 Gower College Swansea - Tycoch Campus 4 & TWI Gowerton School & Materials Live Dehydration of faeces for fuel The Re-design of a probe holder in its casing, of a jet water system Team: Abdel Benamer Juned Hassan Robyn Betson Teacher: Kevin McNamara Engineer: Mentor: Nick Couling & Martyn Lindop Callum Thornhill Team: Neave Jefferys Morganna Davies Wai Yin Wong Matthew Pitson Ethan Lee Ewan Brown Joshua Smith Chloe Weatherley Teacher: Amy John Engineer: Dr Ian Mabbett Gareth Brown Mateus Ligocki TWI Technology Centre Wales specializes in the development and application of state of the art non-destructive testing methods. Through applied research and development in response to requests for assistance from member companies they provide real world solutions to inspection challenges across a broad range of industries. These technologies are particularly important for industry, where there is potential growth in sectors such as aerospace, petrochemical, road and rail transport, energy, and healthcare. Robust, cutting edge inspection technologies are vital to underpin the structural integrity required to ensure that industry can provide safe, reliable and cost effective products. SPECIFIC is an Innovation and Knowledge Centre led by Swansea University with three core Industrial partners: Tata Steel Europe, NSG Pilkington and BASF and 14 University partners.. The aim is to rapidly develop and commercialise ‘world class’ functionally coated metal and glass products. The vision is to transform buildings into power stations; generating renewable solar energy from coatings used in the built environment. This will enable energy to be generated, stored and consumed at the point of use delivering significant economic and environmental benefits. Currently in the jet system at TWI there are pressure issues with the water jets on the automated inspection system. They are finding that when the pumps are pumping water through the nozzles, there is a back flow of water leaking back down the casing of the probe in the nozzle. This is causing a loss of water pressure which is essential to these machines. The task is to redesign the probe casing in the nozzles so that it will prevent the back flow of water down this channel. However, the team must ensure that the original dimensions listed on the section below remain the same. Therefore preventing the loss of water pressure and solving the problem. Up to 40% of the world’s population practice open defecation. Drying faeces can produce a more useful product. Removing water would leave a solid that could be economically transported and even used as a fuel. It’s estimated that one year’s worth of average human faeces could fit in a suitcase if fully dewatered. This brief involves the dewatering of a ‘model’ faeces, similar in solids content and viscosity, but without posing a biohazard. The solution must be cheap, simple, robust and ideally be locally sourced. It’s important to consider the energy use of any solution and where that energy is supplied from. 35 Team 72 Team 71 Ysgol Gyfun Gwyr Ysgol Gyfun Gymraeg Bryn Tawe & Schaeffler & Power & Water Solar powered drinking water treatment system Energy recovery system for roof rain water Team: Tenzin Perkins Jessica Harrison Rhys Chambers Ciaran Parkhouse Carys Havard Cai Owen William Turner Teacher: Tomos Jones Engineer: Derrick Lewis & Paul Griffiths Team: Daniel Greenway Finlay Gunneberg Oliver Evans Tomos King Romek Shadrach Teacher: Rhun Llwyd Engineer: Philip G Morgan & Simon Conway Power & Water is a technology company working in the renewable energy and advanced water treatment market. Schaeffler UK is a manufacturer of high precision components for the automotive industry. While being part of a larger organisation, with some thirty plants worldwide. It has particular focus at the Llanelli Plant in high volume mechanical tappets for the automobile engine, which is complimented by lower scale manufacturing of precision bearing components also predominantly for the same markets. Sustainable conversion of sunlight to controlled DC current to treat 'dirty' water by sonoelectrochemistry means to produce potable drinking water. The project will include the following: The company has been highly focussed over the last few years with regards to Energy reduction and recovery systems to employ in the Plant. The company is also striving towards ISO 50001 accreditation and ESOS compliance within this calendar year. One of the ideas proposed from the Schaeffler team was to harness the ‘lost’ energy that existed as a result of water running down the discharge pipes from the roof. The project brief is focussed on using the potential energy of rain water on the roof of the factory and to generate electricity as it falls to ground. The use of the energy is entirely open to the team as to whether they wish to use it immediately or to store the energy for use later. It is suggested that storage would be the better option though. It should not have any detrimental effect on the operation of the plant. 36 Market analysis and sector application; Design and fabrication of a low cost solar panel; Design and fabrication of a sonoelectrochemical water treatment system to match energy production from solar panel; Bench trial to evaluate energy efficiency and water treatment performance; Report writing with future recommendations for design and commercialisation. Vale of Glamorgan Team 74 Team 73 Cowbridge Comprehensive School 2 & RWE Npower Cowbridge Comprehensive School 1 & Aerospace Wales Measuring Aberthaw Power Station's Coal Mill Levels Preventing and Detecting Strikes on a Composite Material Aircraft Team: Hannah Mitchell Katy Walden Genevieve Kirk Teacher: Tony Cooke Engineer: Paul Lindsay Composite materials are becoming increasingly important in the construction of modern aircraft. ‘Next generation’ aircraft are composed of over 50% composite materials. The primary advantages are their high strength, relatively low weight, and corrosion resistance. Team: William McCormack Toby Nye Michael Hain Luke Wybar Josh Evans Dylan Kennett Callum Marlor Cai Evans Teacher: Tony Cooke Engineer: Glyn Cox, Daniel Peters & Ben Denton RWE is a German electric utilities company and the parent company to RWE npower, which operates Aberthaw power station. RWE npower is a UK-based electricity generating firm which supplies approximately 5.4 million residential and business customers across Britain. However, in this case, the greatest asset flexibility, is also the biggest downfall. If hit the material often returns to its original shape, giving no indication of possible damage to its layers underneath unless marked on paintwork. In busy turnover times at airports work is undertaken both day and night in a variety of weather conditions. The aircraft, even when professionals are involved, is highly susceptible to being hit by equipment such as conveyor belts for cargo. The worst affected areas are around luggage holds. A key stage in the combustion process is the grinding of coal in the mills to form powder and dust. The task relates to these mills and their reliability. Currently, coal is remotely added to the mills in an attempt to maintain a certain level. If there is too little coal, not enough powder is produced and output falls. If there is too much coal, it builds up and blocks the pipes leading to the furnace, which results in temporary shutdown of the mill. Whenever this occurs it leads to a loss of revenue and as such should be prevented. The system presently in use is to measure backpressure from level lines within the mill. However, the coal, as stored outside, often has a high moisture content, which causes them to produce false readings. Therefore, the problem was to either create a new way to measure the volume of coal in the mill or to improve upon the current system. Unknown or undeclared damage to the internal layers of the aircraft’s structure is extremely dangerous. 37 Team 75 St Cyres School & GE Aviation B Nut Torque Transformer Tool Team: Felix Peterken Dion Petherick Matthew Jackson Rhys MacFarlane Callum Gandy Nabil Khan Veerain Patel Teacher: Richard Lawson Engineer: Richard Morfoot, Pavlos Giannakou & Yolanda Hoi GE Aviation is a world-leading provider of jet engines, components and integrated systems for commercial and military aircraft. GE Aviation has a global service network to support these offerings. Due to the limited space available in the Turbine Rear Frame, it is ergonomically hard to tighten the Oil Scavenge B Nut at 115.2 Nm and the Vent Drain B Nut at 150.5- 174.9 Nm as per engine manual. The task is to create a tool that can be used in combination with existing GE tools (Drive torque wrenches etc) to allow the technicians to tighten the B nut bolts outside the Turbine Rear Frame area. The product will improve the quality of the overhaul services and will further improve the health and safety aspects of the operation. 38 Conwy Team 2 Team 1 Rydal Penrhos School & North and Mid Wales Trunk Road Agency Eirias High School & Siemens Healthcare Siemens Assessment Tool Road/Structure Stabilisation Design Team: Annie Layhe Jacob Kingsley Iwan Mitchell Ethan Lopez Team: Ellys Gudger Jack Sissons Ieuan Franssens Teacher: Mike Hodges Teacher: Phil Sutton Engineer: Emily Williamson Engineer: David Cooil, Mark McNamara & Mike Evans Siemens is a multi-national company employing over 340,000 people worldwide, across several different divisions including Healthcare, Energy Management, Digital Factor, transport etc. In Llanberis, Siemens Healthcare produces medical diagnostic kits around the world. Their products are instrumental to diagnose and treat more than 83 million people every year in a wide range of diseases and allergies. Employees receive continuous training through different methods of delivery. The North and Mid Wales Trunk Road Agency (NMWTRA) is a partnership between Gwynedd County Council, Conwy County Borough Council, Isle of Anglesey Council, Denbighshire County Council, Ceredigion County Council, Powys County Council, Flintshire County Council and Wrexham County Borough Council for the purposes of managing, maintaining, and improving the network of trunk roads in their respective areas on behalf of the Welsh Government. A trunk road is a major road, usually connecting two or more cities, ports, airports and other places, which is the recommended route for long-distance and freight traffic. One method for certain courses including Health and Safety will be a classroom based session followed by a paper based assessment. This paper based assessment is not always the most effective method as the results then need to be marked individually and then uploaded electronically. The task is to create a computer based system that allows trainers to create assessments electronically that also allows participants to complete the assessment online where the results are automatically generated. An original Roman Road which was upgraded by Thomas Telford in the 1800’s forms part of a major strategic route through Wales. It has come apparent from periodic inspections that a retaining wall along this road has started to show signs of deterioration/failure. The failure consisted of movement of the retaining wall and carriageway subsidence. The retaining wall is a traditional stone structure and has not been part of any major upgrades. The carriageway alignment remains the same and the only major works undertaken has been resurfacing since it was built. A desktop study is required to identify the cause of this failure. The company would like the ability to: • Have individual log in’s for each user to verify the results • The opportunity to view results quickly and send on to their managers/ supervisors. 39 Team 3 Team 4 Ysgol Aberconwy Ysgol Bryn Elian 1 & RWE Innogy Gwynt Y Môr & RWE Innogy Gwynt Y Môr Tether line attachment/tool Tether line attachment/tool Team: Alisha Daniels Lewis Carlisle Jones Michael Hewitt Ieuan Williams Team: Teacher: Tomos Dennis Tom Aldous Amy O’Hare Daniel Harding Liam Herbert Rawan Hariri Natasha Perdiki Engineer: Liam Llewelyn Edwards & Giles Sims-Williams Teacher: Kim Web Engineer: Liam Llewelyn Edwards RWE Innogy Gwynt Y Môr is a 576 MW wind farm which at full power supplies 40% of welsh homes. The farm consists of 160 wind turbines, 2 offshore sub stations and 8km towers with 107m blade diameters. RWE Innogy Gwynt Y Môr is a 576 MW wind farm which at full power supplies 40% of welsh homes. The farm consists of 160 wind turbines, 2 offshore sub stations and 8km towers with 107m blade diameters. The tether lines that attach to the fall arrest system and the lower rungs of the ladder keep snapping. The tether lines that attach to the fall arrest system and the lower rungs of the ladder keep snapping. The company need a tool that can fit some sort of holding device to the lower rungs of the ladder at least 3m underwater. They then need for it to be able to withstand the harsh underwater conditions. The company need a tool that can fit some sort of holding device to the lower rungs of the ladder at least 3m underwater. They then need for it to be able to withstand the harsh underwater conditions. 40 Team 6 Team 5 Ysgol Bryn Elian 2 Ysgol John Bright & RWE Innogy Gwynt Y Môr & RWE Innogy Gwynt Y Môr Tether line attachment/tool Tether line attachment/tool Team: Lauren Holmes James McGhee Caitlin Keefe Dorothy-Jane Gough Isaac Hastings Robyn Watt Team: Teacher: Kim Web Engineer: Liam Llewelyn Edwards Marlon Allison James Culshaw Matthew Hill Konrad Jastrzebski Jack Lynch Ellen Richards Eryk Siembab Jack Strefford Dalton Wier Teacher: Dylan Williams Engineer: Liam Llewelyn Edwards RWE Innogy Gwynt Y Môr is a 576 MW wind farm which at full power supplies 40% of welsh homes. The farm consists of 160 wind turbines, 2 offshore sub stations and 8km towers with 107m blade diameters. RWE Innogy Gwynt Y Môr is a 576 MW wind farm which at full power supplies 40% of welsh homes. The farm consists of 160 wind turbines, 2 offshore sub stations and 8km towers with 107m blade diameters. The tether lines that attach to the fall arrest system and the lower rungs of the ladder keep snapping. The tether lines that attach to the fall arrest system and the lower rungs of the ladder keep snapping. The company need a tool that can fit some sort of holding device to the lower rungs of the ladder at least 3m underwater. They then need for it to be able to withstand the harsh underwater conditions. The company need a tool that can fit some sort of holding device to the lower rungs of the ladder at least 3m underwater. They then need for it to be able to withstand the harsh underwater conditions. 41 Denbighshire Team 8 Team 7 Denbigh High School Ysgol Dinas Bran & Dŵr Cymru Welsh Water & Qioptiq Welsh Water Challenge Qioptiq Scope Team: Tabitha Lewis Harry Gilbertson Dan Dallalio John Roberts Meg Gabarda Team: Elinor Barnett India Wynn Thomas Bell Joshua Williamson Teacher: Gareth Jones Teacher: Sion Jones & Gethin Williams Engineer: Sion Pritchard & Stephne Puddy Engineer: Ceri Chang Qioptiq designs and manufactures photonic products and solutions for markets such as life science, defence and aerospace. Qioptiq attend lots of conventions and science fairs with a target audience of 12-16, however they do not have any demonstrators which they can use to show people what they create, as well as how it operates. Dŵr Cymru Welsh Water requested for a new dwelling to be built 20m above an existing DCWW Service reservoir. The team had to evaluate the best cost benefit solution for supplying the house with water. Things to take into consideration include: Ways of elevating water The cost of different solutions Any construction complexities Any mechanical complexities The geography/ terrain of the land The height of the dwelling – 2 story house The costs of the materials The task is to create a demonstrator for young people so that they have the opportunity to experience how a scope would work, along with the various lenses. They must be able to achieve various outcomes with the lenses. The demonstrator should be approximately 300mm long, allowing it to house a selection of up to 4 lenses being utilised at their unique focal lengths. The dwelling should be as cost efficient as possible and should have a minimum of 20m pressure on their supply. The demonstrator should come with an additional case which is suitable for the transportation of the demonstrator. The combined weight of the demonstrator and the case should allow it to be light enough to be carried. In order for people to gain knowledge of lenses and scopes an ‘answer and question’ scheme has been requested. 42 Team 10 Team 9 Ysgol Uwchradd Glan Clwyd 1 Ysgol Uwchradd Glan Clwyd 2 & PPM Technology & PPM Technology System to alarm and monitor CO2 levels within a building Air Exchanger Refresher: System to alarm and monitor CO2 levels within a building Team: Dylan Easton Alex Yates Natasha Maitland-Davies Rhys Harper Ethan Hodge Owen Roberts Elin Mars Jones Erin Lindsay Team: Mathew Baines Harry Evans Elin Mair Jones Elinor Sheridan Carwyn Roberts Joshua Arch Tudur Owens Teacher: David Williams Teacher: David Williams Engineer: Huw Davies & John Jones Engineer: Huw Davies & John Jones PPM Technology is a leading manufacturer of portable and fixed gas detection instruments for formaldehyde and other toxic gases in any indoor environment. PPM Technology is a leading manufacturer of portable and fixed gas detection instruments for formaldehyde and other toxic gases in any indoor environment. PPM Technology would like the team to build an air conditioning unit for them. CO2 is a good indicator of the indoor ventilation accuracy. Levels above a 1000ppm can cause building occupants to feel sluggish and in terms of a working environment this leads to low productivity. In the Far East where air legislation is much stricter, 1000ppm is set to be the maximum exposure level for CO2. Over the last 30 years atmospheric CO2 has risen to 400ppm.The air conditioning unit should have the following features: PPM Technology would like the team to build an air conditioning unit for them. CO2 is a good indicator of the indoor ventilation accuracy. Levels above a 1000ppm can cause building occupants to feel sluggish and in terms of a working environment this leads to low productivity. In the Far East where air legislation is much stricter, 1000ppm is set to be the maximum exposure level for CO2. Over the last 30 years atmospheric CO2 has risen to 400ppm. The air conditioning unit should have the following features: A controller unit in a box with touch screen display The ability to turn a fan on and off depending on the air quality The ability to receive data from various positions in the room The ability to process this data The ability to measure from multiple CO2 sensors located in various positions in the room/building. 43 A controller unit in a box with touch screen display The ability to turn a fan on and off depending on the air quality The ability to receive data from various positions in the room The ability to process this data The ability to measure from multiple CO2 sensors located in various positions in the room/building. Flintshire Team 12 Team 11 Alun School 2 Alun School 1 & Toyota & JCB Transmissions Machine Safety Circuit Training Simulator Oil Seal Removal Device Team: Scott Morgan Jamie Wilson Dan Gaunt Owen Evans Team: Teacher: Matthew Firth Laura McNally Nicola Topliss Andrew Shaw James Norbury Jac Rushforth Engineer: Yian Baty & Ian Laundy Teacher: Neil McBain Engineer: Sion Lloyd Sam Robinson Matthew Pritchard Jamie Waite Toyota has two manufacturing plants in the UK representing a total investment in excess of £2.1 billion and currently approximately 3,800 members (including Agency) are employed. The vehicle manufacturing plant is located in Derbyshire; the engine manufacturing plant is located at Deeside in North Wales. In 2007, production of Auris, the new Toyota hatchback, started replacing Corolla. Production of the Auris Hybrid, the first full mass-produced hybrid in Europe, began in 2010. The processes at Burnaston include stamping, welding, painting, plastic mouldings and assembly and at Deeside machining, assembly and aluminium casting. JCB Transmissions is a company that helps to create over 300 machines with other JCB companies in many other countries. JCB is a very large and well known company. The problem is that currently JCB must use a hammer and chisel to remove seals from the swivel board which is time consuming and dangerous. The task is to produce a tool to remove the seal from the swivel board easily, safely and quickly without damaging the machinery around the seal. Modern machines used in the industrial environment have modular safety circuits which are used to monitor the start-up and running conditions of the machine. If any of these conditions are not met then the machine will either fail to start or stop running. These safety circuits are very reliable and as a result, maintenance members get little practice working on these circuits. The task is to manufacture a training rig to enable the simulation of OK and No Good conditions to allow maintenance members to practice their fault finding skills. The rig should be able to simulate as many fault conditions as possible and should have a user manual included. 44 Team 14 Team 13 Alun School 3 Coleg Cambria & Airbus UK & JCB Transmissions Develop a new Design and Manufacturing Method for Airbus A320 Wing Covers Cassette Seal Removal Tool Team: Sian Pearce Dominic Neave Harry Speakman Jamie Hogg Matt Gilsenon Eleri Davies Teacher: Ali McLellan Engineer: Connor Griffiths JCB Transmissions is a global company pioneering in mechanical engineering. They are world leaders in the manufacture of large scale earth moving and constructional equipment. Team: Jack Turner Jamie Ellison Phillip Richardson Ethan Williams Ian Howey Teacher: Marcus Hodges, Paul Thomas & Nick Tyson Engineer: Jake Owen & Michael Mosley The current A320 top cover is one of the main components of the aircraft wing. It makes up the majority of the upper outer surface of the wing. Maintaining the profile of the wing is crucial for producing lift and enabling the aircraft to function as designed. JCB are testing a new seal for their axle. The design of the seal means that it is more efficient but it also means that it is difficult to remove. Currently JCB engineers are attempting to remove the seal using a hammer and screwdriver which may be damaging to the gear bearing so they need a piece of equipment which will remove it efficiently whilst causing minimum damage. The A320 top cover is currently labour intensive and costly to manufacture. It is made up of individually machined aluminium components which are fastened together with thousands of bolts and rivets. The fasteners are installed in one of two ways; manually by skilled operators or automatically by numerically controlled bolting and riveting machines. Both of these processes are time consuming and require specialist equipment. The project is to create a tool or mechanism that can remove the new steel cassette seal. The tool must be safe, durable and sturdy, re-useable, portable and easy to use, cost effective, sustainably sourced and manufactured. The proposed project is to design and develop a new top cover for the A320 aircraft wing which reduces the number of parts in the assembly, the time taken to assemble the panel, and therefore the cost of the manufacture. Other secondary benefits could include a reduction in weight, or other performance enhancing features. The seal may be destroyed in its extraction, but no damage is permissible to the bore surfaces or tail bearing. This new cassette seal is being used in the hope of improving the efficiency of the entire axle. 45 Team 16 Team 15 Flint High School & Toyota Ysgol Maes Garmon & Brake Engineering 3 Phase AC Motor Fault Finding Test Rig Team: Ben Hughes Jake Bradley Ryan Logan James Davison Joseph Lewis Wesley Evans Teacher: Engineer: Design a test station to protect workers from potential danger Team: Tomos Hughes Luke Jackson Matthew Allen George Johnson Osian Jones Russell Davies Teacher: Adrian Evans & Iwan Williams Steve Carney Engineer: Stephen Whiting, Paul J Davies & Phil Thomas Toyota (at Deeside Plant) manufacture engines for a range of models in the Toyota range, exporting the product worldwide. The team have been working together with TRW of Wrexham to help design a new testing facility for the factory. There are many 3 phase motors used in the production process. Maintenance engineers need to be trained to find and predict faults. Presently, there are many rigs dedicated to specific faults – This needs to be reduced to one multifunctional rig. During the production of brake callipers, products need to be tested to ensure correct performance. The callipers need to be tested at a high pressure therefore the workers need to be protected in order to keep them safe whilst completing the test. The task is to design and make a single rig which can be used to model a range of problems re. The 3 Phase AC Motor. The challenge was to design the test station to protect the workers from the potential dangers of high pressure testing. 46 Gwynedd Team 18 Team 17 Coleg Meirion-Dwyfor 1 Coleg Meirion-Dwyfor 2 & First Hydro Company & First Hydro Company Remotely Operated Vehicle for inspection of Afon-y-Bala bypass Culvert Remotely Operated Vehicle for inspection of Afon-y-Bala bypass Culvert Team: Adam Barry Connor Duenas Bari Jones Steffan Jones Team: Connor Barratt Tobias Bavin Jessica Owen Teacher: Marius Jones Teacher: Marius Jones Engineer: Geraint Wyn Jones, Kevin Brookes & Arwel F Jones Engineer: Geraint Wyn Jones, Kevin Brookes & Arwel F Jones Declan Mason Jonathan Owen Jago Priestly Huw Williams John Roberts Eilir Thomas Matthew Williams First Hydro is one of the UK's most dynamic electricity generators, responsible for the management and operation of the pumped storage plants at Dinorwig and Ffestiniog. The ideal pumped-storage system has equal volumes of water available in the upper and lower reservoirs. This however is impossible due to rainfall and natural run-off into both reservoirs. When run-off enters the system it is called ‘excess water’. The station system must be managed so the ‘excess water’ can be returned to the surrounding natural system. Excess water is to be discharged from Llyn Peris via the Afony-Bala by-pass culvert and/or the Bascule gates. The Afon-y-Bala bypass culvert contains three 1m internal diameter steel pipes fitted with a valve which can be operated electrically from a remote position or electrically and manually from a local position. In recent years there have been problems with these valves and due to the nature of the installation it is extremely difficult to assess the condition of their internal components without removing them completely, which can be time consuming and expensive. First Hydro is one of the UK's most dynamic electricity generators, responsible for the management and operation of the pumped storage plants at Dinorwig and Ffestiniog. The ideal pumped-storage system has equal volumes of water available in the upper and lower reservoirs. This however is impossible due to rainfall and natural run-off into both reservoirs. When run-off enters the system it is called ‘excess water’. The station system must be managed so the ‘excess water’ can be returned to the surrounding natural system. Excess water is to be discharged from Llyn Peris via the Afony-Bala by-pass culvert and/or the Bascule gates. The Afon-y-Bala bypass culvert contains three 1m internal diameter steel pipes fitted with a valve which can be operated electrically from a remote position or electrically and manually from a local position. In recent years there have been problems with these valves and due to the nature of the installation it is extremely difficult to assess the condition of their internal components without removing them completely, which can be time consuming and expensive. The company require the design and construction of a water resistant ROV (Remotely Operated Vehicle) for internal condition assessment of the Afon-y-Bala bypass valves. The company require the design and construction of a water resistant ROV (Remotely Operated Vehicle) for internal condition assessment of the Afon-y-Bala bypass valves. 47 Team 20 Team 19 Coleg Menai & Photonics Academy of Wales at Bangor Coleg Meirion-Dwyfor 3 & First Hydro Company The Design of a Musical Tone generating device capable of being activated and played by a severely paralysed handicapped person. Remotely Operated Vehicle for inspection of Afon-y-Bala bypass Culvert Team: Grady Elliott Dyfan Pritchard Dyfed Parry Sion Jones Peter Stewart Teacher: Marius Jones Engineer: Geraint Wyn Jones, Kevin Brookes & Arwel F Jones Team: Stephanie Harris Bryn Jones Robyn Vaughan-Williams Teacher: Iolo Williams Engineer: Ray Davies The Photonics Academy of Wales at Bangor operates from within the School of Electronic Engineering of Bangor University, and has a long standing history of working with student groups involved with the design and construction of working Prototype outcomes which utilize Photonics concepts in highly original achievements. First Hydro is one of the UK's most dynamic electricity generators, responsible for the management and operation of the pumped storage plants at Dinorwig and Ffestiniog. The ideal pumped-storage system has equal volumes of water available in the upper and lower reservoirs. This however is impossible due to rainfall and natural run-off into both reservoirs. When run-off enters the system it is called ‘excess water’. The station system must be managed so the ‘excess water’ can be returned to the surrounding natural system. Excess water is to be discharged from Llyn Peris via the Afony-Bala by-pass culvert and/or the Bascule gates. The Afon-y-Bala bypass culvert contains three 1m internal diameter steel pipes fitted with a valve which can be operated electrically from a remote position or electrically and manually from a local position. In recent years there have been problems with these valves and due to the nature of the installation it is extremely difficult to assess the condition of their internal components without removing them completely, which can be time consuming and expensive. The task is to design and construct the components suitable for adaption within a Musical Note generating Instrument, activated by optical input signals, which would open up the potential for a severely paralysed person being capable of participating in creating some musical sounds. The design will require the creation of an empirically developed system, in which the body movement of the paralysed operator might be confined only to simple body movements, in the absence of any more normal finger movement input. These simple body, and perhaps even head, movements will enable a Low Powered Laser Diode signal to be directed towards an optical sensing system which, in turn, can activate the different Musical Notes of the Instrument device – with the anticipated potential that a paralysed person can still create some personal input towards creating Musical sounds. The company require the design and construction of a water resistant ROV (Remotely Operated Vehicle) for internal condition assessment of the Afon-y-Bala bypass valves. 48 Isle of Anglesey Team 22 Team 21 Ysgol David Hughes & Siemens Healthcare Ysgol Gyfun Llangefni 1 & RAF/Babcock Improvements to the current V mixer cleaning process Team: Airfield Environment Warning Sign Jo Anderson Grace Eickmann Anna Hume Manon Stonehewer Shon Alud Roberts Osian Gruffydd Luke Harris Matthew O’Hanlon Elms Akira Lowther Teacher: Geraint Llyn Engineer: Emily Williamson Team: Rhian Jones Daniel Summers-Jones Chloe Bulkeley Cara Evans Catrin Owen Teacher: Llion Dafydd & Zoe Jones Engineer: Bob Godin & Tony McLoughlin The Airfield Environment Warning Sign (AEWS) will provide proximity warnings of hazards and provide basic warnings or instructions to personnel within the airfield operating area and aircraft maintenance environment. RAF Valley operating environment is coastal and the product is to be designed to withstand the harsh operating conditions and will be sufficiently robust to operate within a maintenance engineering environment. The product should be self-contained from an operating perspective and, although portable, have the facility to be mounted on a wall, post etc. It should be powered independently without reliance on mains or hydrocarbon based fuels and any power source should not risk or constitute a hazard to functional safety or flight safety (ie Foreign Object Damage – FOD). It can however interface with other devices for information storage of any operating system management if required. Siemens was established in 1847 by Werner Von Siemens, they are a conglomerate company contributing to many aspects of industry. The branch in Llanberis specialises in medical diagnostics. Siemens produce immulite beads used in diagnostic blood tests. Each bead requires a specific protein coat depending on what it will be testing for. V mixers used to coat immulite beads are not cleaned thoroughly enough between batches, resulting in cross contamination and fail to give accurate blood test results. The project is to devise a way of cleaning the V mixers between batches of beads to eliminate cross contamination between the different coatings. The team must also come up with a way of testing the cleanliness of the mixer and therefore the effectiveness of their methods. • There should be limited technical expertise required to set up and operate the product. • The product should sufficiently robust to operate in the relevant environments. • There should be minimum maintenance required although scheduled inspection and oncondition maintenance would be appropriate. 49 Powys Team 24 Team 23 Welshpool High School & Morgans Brew Tea Ysgol Gyfun Llangefni 2 & RAF/Babcock Develop a solution for dispensing and packaging instant tea powder Airfield Environment Warning Sign Team: Jack Pleasant Osian Jones Owen Evans Jacob Sands Kieron Salter Teacher: Llion Dafydd & Zoe Jones Engineer: Bob Godin & Tony McLoughlin Team: Robert Flowers William Rhys Farmer Oliver Pritchard Teacher: Bob Cannon Engineer: Geoff Meredith Philip Evans Caitlin Perry Connor Gill Morgan’s Brew looks to develop new and innovative ways to merchandise instant tea in ways that will appeal to the young who are not traditionally thought of as heavy tea drinkers. The team have been asked to look at the problem of merchandising a tea flavoured drink that combines Welsh spring water and Morgan’s Brew instant tea. The Airfield Environment Warning Sign (AEWS) will provide proximity warnings of hazards and provide basic warnings or instructions to personnel within the airfield operating area and aircraft maintenance environment. RAF Valley operating environment is coastal and the product is to be designed to withstand the harsh operating conditions and will be sufficiently robust to operate within a maintenance engineering environment. The product should be self-contained from an operating perspective and, although portable, have the facility to be mounted on a wall, post etc. It should be powered independently without reliance on mains or hydrocarbon based fuels and any power source should not risk or constitute a hazard to functional safety or flight safety (ie Foreign Object Damage – FOD). It can however interface with other devices for information storage of any operating system management if required. The aim is to develop a method of presenting bottled Welsh spring water and the correct quantity of instant tea powder in a way that the two components are kept separate only to be mixed at the time the customer is ready to drink the product. The system should be self-contained and not require any additional equipment for the customer to enjoy the drink when they are out and about. This is a complex problem that extends into many areas including materials handling, packaging and promotion. There are several ‘off the peg’ solutions to the problem of selling a drink that needs to be mixed just before it is consumed. These existing solutions would require considerable investment in plant and equipment making them unsuited to the short production runs associated with product development. The team has elected to focus on the problems associated with dispensing accurately measured quantities of fine hydroscopic powders in a food production environment. • There should be limited technical expertise required to set up and operate the product. • The product should sufficiently robust to operate in the relevant environments. • There should be minimum maintenance required although scheduled inspection and oncondition maintenance would be appropriate. 50 Wrexham Team 25 Ysgol Y Grango & Brother Industries UK Ltd Automatic Box Opening of Toner Return Cartridges Team: Emily Davies Chloe Evans Jodie Williams Milly Williams Teacher: Mark Harmsworth & Angela Hughes Engineer: Harry Deakin & Paul Jepson Brother Industries has been based in Wrexham North Wales for the last 30 years. The core function of the Wrexham factory is the recycling of toner cartridges that are returned by the customer, they also have recycling factories in both Slovakia and USA. On average they receive and recycle 3.5 million toner cartridges per year. As part of the recycling process over 16,000 boxes are opened per day across the three recycling factories. It takes approximately 5 staff just to open the boxes before the toners and packaging materials can be sorted ready for recycling. Currently the process is carried out manually using box opening knives. This process can cause health and safety issues due to knife cuts and repetitive strain injuries The brief is to design an automatic box opener that can be used on the full range of boxes that are returned under the cartridge return system. The only operator interaction should be the feeding of the machine, with the machine presenting the box to the downstream operator fully opened ready for them to remove the toner and its internal packaging. Currently we have about 11 different carton designs which would require the machine to self-adjust in order to open each type of carton on a continuous production line. The cycle time for opening one carton needs to be 4 seconds. 51