Carnot engines - hydrogen fuelled ice
Project challenges
A key challenge the Virtual Build aimed to help with was getting better visibility on clearances between components particularly when following a glide-path into position.
Business challenge
Process Innovation
Sector
Hydrogen
Technology or capability
Process Design
Project Background
CARNOT developed an ultra-efficient thermally insulated internal combustion engine targeting auxiliary and main propulsion engines for all vessel types up to 10MW.
This includes container vessels and Ro-Ro ferries representing the major CO2 emitters in UK international and domestic shipping, respectively.
Conventional metal engines typically lose about ⅓ of fuel energy to water cooling.
Carnot is developing an engine with components manufactured from technical ceramics that can withstand combustion temperatures eliminating the need for cooling the combustion chamber.
This is predicted to produce a peak brake specific fuel consumption (BSFC) of 120 g/kWh compared to 195-200 g/kWh for state-of-the-art auxiliary engines.
The Challenge
With the CARNOT Engine still under development, additional refinement into the best approach to assemble the design was required. Building on the work done developing the assembly sequence and to better understand the assembly approach, Virtual Build Simulation was used to envisage the glide paths of the components that make up the assembly.
A key challenge the Virtual Build aimed to help with was getting better visibility on clearances between components particularly when following a glide-path into position. Understanding this could feed into fixture designs in addition to directing decisions on appropriate tooling.
MTC's Solution
- A Virtual Build simulation built of the whole CARNOT Engine following the assembly sequence. This represented the approach likely needed to build the assembly with each component coming together.
- The simulation was assessed using an agreed criteria with Carnot to identify any concerns highlighted by the simulation.
- Collated Recommended Actions from the output for Carnot to consider. The actions will help reduce the risk and/or severity of the concerns identified.
We see MTC as a global centre of excellence for the art of industrial manufacturing. They have been integral to our work of ensuring all our technology can be manufactured efficiently, at scale, and with a reliable supply chain. This is best demonstrated by the fact we include them as a key partner on all of our major grant awards.
Archie Watts-Farmer, CEO & Co-Founder, Carnot Engines
The Outcome
- Full Virtual Build Simulation
- Assessment of the whole assembly sequence with good understanding on how to assemble the engine via glide paths and their clearances
- Identification of challenges during assembly such as limited clearances, Human Factor risks such as reachability and vision
- Proposed actions to improve highlighted concerns
- Templates for Carnot to continue using during future engine development
Benefits to the Client
- Visual representation of the engine design following the assembly sequence
- Ability to see each component from a variety of angles throughout each the components’ trajectory and get better visibility of any issues
- Recommendation actions made for each identified concern which can be planned into future work to mitigate any issues
- Ability to build on analysis completed to date during future engine design and/or assembly sequence development
The MTC team have taken the Carnot product, and through the Virtual Build Process identified and de-risked multiple assembly challenges. This not only delivers immediate benefit to Carnot, it also builds their knowledge to ensure future iterations are designed with manufacture and assembly in mind.
Tom Cockerill, Chief Engineer, MTC
