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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: info@stemcymru.org.uk
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