Bloodhound SSC: Inspiring the next generation of Engineers Pt 2

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound SuperSonic Car project

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound SuperSonic Car project

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound SuperSonic Car project.  As an Aircraft Engineering Officer in the Royal Electrical & Mechanical Engineers (REME), his technical background on Apache is used to good effect to provide the Bloodhound team with technical advice on Engineering Assurance. In addition to his engineering role, he is also responsible for recruiting each six-month attachment of personnel and managing the team on a day-to-day basis.

Opening Bloodhound SSC’s Technical Centre

This summer Minister for Universities and Science, David Willetts MP, formally opened the new Bloodhound Technical Centre in Avonmouth, Bristol. It was a fantastic event with the Minister talking about the importance of UK skills and the increasing demand for Scientists, Engineers and Mathematicians.

REME Corporal Lisah Brooking keeping a keen eye on Minister David Willetts MP. Image by Stephan Marjoram

REME Corporal Lisah Brooking keeping a keen eye on Minister David Willetts MP. Image by Stephan Marjoram

And it’s this challenge that Bloodhound SSC intends to tackle – to inspire kids into STEM subjects by building a car capable of 1000 mph and allowing the student population to be able to engage and follow the project.

Bloodhound SSC’s new technical centre has been occupied for a few months while the team have been commissioning the site and getting all the workshop machines ready to go. The new centre looks impressive and provides the design team as well build engineers/fabricators with a great facility in which we will build the car. A special mention must go to SSgt Neil Gallagher who received a commendation from Director Richard Noble for his part in managing the move to the new Avonmouth site.

SSgt Neil Gallagher with his commendation. Image by Stefan Marjoram

SSgt Neil Gallagher with his commendation. Image by Stefan Marjora

SSgt Gallagher got permission to extend his attachment by 2 months to see the move through to completion. He has since handed over to his successor SSgt Ben Richards who continues the role of Workshop Manager supporting Chris Dee (Build Manager) to ensure the machines are fit and are available at all times.

Introducing the new REME team

SSgt Ben Richards. Image Stefan Marjoram

SSgt Ben Richards. Image Stefan Marjoram

The composition of the second team of REME tradesmen has developed to reflect the changes and demands of the build as it continues. As we move into the assembly of the rear upper chassis, SSgt Ben Richards’ experience repairing aircraft on Operations comes to the fore. He has been helping to build the chassis rails that connect the carbon fibre monocoque to the rear lower chassis.

Ssgt Henry Breed. Image Stefan Marjoram

Ssgt Henry Breed. Image Stefan Marjoram

SSgt Ben Richards is one of two Artificers on the Army team. Artificers are the REME’s technical fast track managers and are amongst the most respected soldiers in the British Army. Alongside Ben, is SSgt Henry ‘H’ Breed who is an Electronics Artificer and works with Joe Holdsworth on the Bloodhound’s electronic control systems. He has continued AQMS Mark Edwin’s work prototyping EJ200’s control system as well as developing the electronics of a number control systems.

On the mechanical side of the project, Corporal Lisah Brooking has been working with Lee Giles on the rocket development system. She has done a fantastic job and has developed her technical knowledge testing the F1 engine’s custom gearbox at X-trac near Reading.

LCpl Lisah Brooking. Image Stefan Marjoram

LCpl Lisah Brooking. Image Stefan Marjoram

The last member of the team – and certainly not least, is Craftsman Andy Pike who is an Armourer and the youngest engineer on the whole project. Cfn Pike is normally found working in patrol bases repairing weapon systems with the Infantry. He has used his technical knowledge and manufacture skills to support some of the more senior fabricators assembling the car.

Cfn Andy Pike. Image Stefan Marjoram

Cfn Andy Pike. Image Stefan Marjoram

Project update…the build story so far

So what is happening with the vehicle build at the moment? We have been lucky that we could continue building the car whilst the building has been commissioned.

All of the workshop machines supplied under Bloodhound contract with the Army have been delivered (thanks SEAE and SEME) and the machine shop is now ready to start production of smaller components. The machine shop, with lathes, mills, folding and cutting machines, to mention a few, is an important addition to the Technical Centre. It will save time and provide agility when essential components are needed that can’t be sent to suppliers.

Positioned in the centre of the workshop, not far from the machine shop, is a huge surface table that the Bloodhound SSC car will be built on. So why do we need to build it on a metal surface 30 cm off the ground?

Surface table. Image Stefan Marjoram

Surface table. Image Stefan Marjoram

We need an incredibly flat surface to build on to ensure that we can accurately measure the car as it is assembled – you wouldn’t want us to put it together wonky! Dan Johns, who has spent much of his career working with Airbus as a Manufacturing Engineer is using a laser scanning system to ensure that the car’s components are placed as accurately as possible in the X, Y and Z axis. David Willetts MP had the honour of tightening up the bolts that connect the lower chassis and monocoque together – all under the watchful eye of Cpl Lisah Brooking!

The most recent work has been the arrival of the chassis rails which have come back from the autoclave and are now fitted to the car. The fabrication team have done a great job, delivering ahead of time to assemble, Kephos (black anti corrosion paint), re-assemble/glue and cure – and with an accuracy of 0.4 mm variation over 6 metres.

So what’s coming next?

Bloodhound cuttaway. Image Stefan Marjoram

Bloodhound cuttaway. Image Stefan Marjoram

The lattice structure on the side of the car (where the red dot is) has been dry assembled to ensure that all of the resources required to complete the work package are ready to go. The combination of the chassis rails (green dot at either end) and the lattice will provide increased stiffness to the body of the car – in a similar way to that of a bridge.

Infantry bridge. Crown copyright

Infantry bridge. Crown copyright

Chassis rails and lattice. Image Jules Tipler

Chassis rails and lattice. Image Jules Tipler

Now that Dan Johns has laser scanned and measured the mating surfaces, we have the assurance that we will be building on an accurate and level plane which means that the jig can be made available to start to receive the initial sections of the upper chassis which has been designed similar to the construction of an aircraft. Within this structure, the EJ200 developmental engine will be suspended beneath the structure, with the fin supported on top!

The upper chassis is going to be a big job with over 11,000 holes to drill, prepare and rivet – I will keep you updated when the job starts and how it progresses.

Next blog I will be writing about the REME team and our time at Goodwood Festival of Speed talking to kids about engineering and science and Bloodhound SSC!

Read more about the Bloodhound Supersonic Car

Yes Minister! REME team forges ahead with 1000mph car project

Major Oli Morgan is the Team Leader for the Army’s involvement in the Bloodhound Super Sonic Car project.  As an Aircraft Engineering Officer in the Royal Electrical & Mechanical Engineers, his technical background on Apache is used to good effect to provide the Bloodhound team with technical advice on Engineering Assurance. In addition to his engineering role he is also responsible for recruiting each 6 month attachment of personnel and managing the team on a day to day basis.

Defence Minister visits

It was great to see the Minister for Defence Equipment Support and Technology last week at the Bloodhound SSC Technical Centre in Bristol. Philip Dunne MP visited the Army Team from the Royal Electrical and Mechanical Engineers (REME) working on Bloodhound SSC to see what we had been doing since we saw him at the signing of the MoD-Bloodhound Concordat in Oct 2012.

Minister was impressed how we had integrated into the civilian team building the 1000 mph car and the ground breaking work the guys had been doing. I took the Minister around the workshop to allow each of the REME team to explain their role and what they had achieved during their attachment, which is fast coming to an end in March 13 (Details of the new team coming soon).

Left to Right: Philip Dunne MP, Cfn Rob Fenn, WO2 (AQMS) MarkEdwin, Maj Oli Morgan. Image by Stefan Marjoram

Left to Right: Philip Dunne MP, Cfn Rob Fenn, WO2 (AQMS) Mark Edwin, Maj Oli Morgan. Image by Stefan Marjoram

Craftsman Rob Fenn, our most junior tradesman (his rank is equivalent to Private Soldier), showed Philip Dunne MP the work that been done on the Super Sonic car’s lower chassis. Cfn Fenn has been part of a small group building this section of the car and he has also had the opportunity to work with Lee Giles, a very experienced mechanic formerly at McLaren R&D. The Minister was impressed by how much exposure Cfn Fenn had to wider engineering and his goal to work towards a Degree in Automotive Engineering.

Cfn Rob Fenn working with Lee Giles. Image by Stefan Marjoram

Cfn Rob Fenn working with Lee Giles. Image by Stefan Marjoram

Bloodhound Team working on the rear lower chassis at the Bristol Technical Centre. Image by Stefan Marjoram

Bloodhound Team working on the rear lower chassis at the Bristol Technical Centre. Image by Stefan Marjoram

As a footnote to Cfn Rob Fenn’s role on the project, I must put his experience into perspective – he is 20 years old and has recently completed his apprenticeship after completing training at the Army’s School of Electrical and Mechanical Engineering. He was selected as an outstanding candidate in the REME interview process and has impressed Bloodhound’s F1 engineers and designers with his work ethic, willingness to muck in and drive to expand his knowledge. This knowledge transfer – in essence rocket powered professional development – is one of the key benefits of the MOD’s Concordat with Bloodhound. It will create a lasting legacy in each REME soldier’s career and have a positive impact on the Army’s ability to support equipment maintenance and repair, especially on Operations.

Origins of the Ministry’s Concordat with Bloodhound

The origins of the MOD Concordat go back to last year at a chance meeting between Peter Luff MP, then Minister for Defence Equipment Support and Technology, and Richard Noble. The meeting at DE&S’s Defence Vehicle Demonstration event led to an agreement being proposed that would draw together the various strands of collaborative work that already existed between the MOD and Bloodhound. This would provide a platform for deepening the relationship and express the Department’s and the Minister’s own belief in this ground breaking education project and the benefits that it will return to the Department and the Armed Forces.

Image by Ashleigh Kane Photography

Peter Luff MP and Richard Noble. Image by Ashleigh Kane Photography

But nothing in politics is straightforward and before we knew it we had a new Min(DEST). Fortunately, the new Minister, Philip Dunne MP was just as excited about the project and progress on the agreement continued at pace. On 1 October 2012 we were all present in the Officers’ Mess at Wellington Barracks in London to witness the signing of the Concordat by the Minister and Richard Noble amongst a throng of broadcast and newspaper journalists. BFBS TV Report

ARMY ENGINEERS LOOKING TO SPEED INTO THE RECORD BOOKS

From Philip Dunne MP: “This is a great opportunity for the Army’s Electrical and Mechanical engineers to share experience and develop their skills whilst working on this innovative technology here in the UK; their experience will feed directly back into the front line as they progress through their Army careers.”

At last week’s visit to Bristol, the Minister got to see an example of REME tradesmen working at the cutting edge of technical development when I handed him over to WO2 (AQMS) Mark Edwin to explain his role developing the primary control system for the developmental EJ200 TYPHOON engines. The control avionics will allow Bloodhound’s driver, Wing Commander Andy Green, to control the engine and get the car up to speed before the rocket kicks in and blasts the car through the sound barrier.

In the next blog I will touch on the work the electronic systems team have been doing with the EJ200 engine and the Minister’s reaction to the news that the WO2 (AQMS) Edwin and the team have built a system to control the engine which has been successfully tested on Rolls Royce’s engine simulator.