VTE March 2023

VEHICLE TECHNOLOGY ENGINEER

The sky’s the limit March 2023 RMIT Hydrogen: RMIT turns Blue hydrogen Green DT Engineering: Ray tracing tech for AV and ADAS Technical: An Autonomous Vehicle at the Handling Limit

Issue 35 Representing mobility engineers since 1927 www.saea.com.au

VTE | Contents

Contents March 2023

Ampol to go electric with SEA

8

University of Auckland engineers working at McLaren

11

RMIT turns Blue hydrogen Green

15

Avalon Airshow 2023

16

Ray tracing tech for AV and ADAS

24

Special Features 15

RMIT Hydrogen – RMIT turns Blue hydrogen Green

16

Avalon Airshow 2023 – The sky’s the limit

24

DT Engineering – Ray tracing tech for AV and ADAS

VTE News 7

General News

9

Automotive News

12

Bus News

13

Truck News

14

Overseas News

Society News 4

Notes from the Chair - Welcome from Adrian Feeney

5

SAE-A News

Technical Feature 25

Technical – An Autonomous Vehicle at the Handling Limit: A Hierarchical Controller Based on the Quasi-Steady-State Model

About the cover After four years the air show returned to Avalon and it was massive

About the SAE-A SAE-A was founded in 1927 to address the need for further education for all facets surrounding Automotive Engineering, and now encompasses all mobility engineering industries in the Australasian region. The SAE-A is a non-profit organisation that works to serve the needs of its members and to promote the relevance of mobility related technologies to governments, industry and the community in general.

The editor, publisher, printer, the Society of Automotive Engineers – Australasia (SAE-A) and their employees, directors, servants, agents and associated or related entities (Publishing Entities) are not responsible for the accuracy or correctness of the text, pictures or other material comprising the contributions and advertisements contained in this publication or for the consequences of any use made of the products, services and other information referred to in this publication. The Publishing Entities expressly disclaim all liability of whatsoever nature for any consequences arising from the use or reliance on material contained in this publication whether caused to a reader of this publication or otherwise. The views expressed in this publication do not necessarily reflect the views of the Publishing Entities. The responsibility for the accuracy or correctness of information and other material is that of the individual contributors and the Publishing Entities do not accept responsibility for the accuracy or correctness of information or other material supplied by others. To the extent permissible by law, the Publishing Entities exclude all liability pursuant to the Competition and Consumer Act 2010 (Cth) or other applicable laws arising from statute or common law.

Readers should make their own inquiries prior to the use of, or reliance on, any information or other material contained in this publication, and where necessary seek professional advice. All rights reserved. Reproduction in whole or part without the written permission of SAE-A is strictly prohibited.

www.saea.com.au

VTE | 3

Introduction | Secretary, CEO and Chairman Society of Automotive Engineers

VTE Published By: Society of Automotive Engineers - Australasia ABN:

95 004 248 604

Adrian Feeney

Address: PO Box 103, Werribee Vic 3030

Chairman and CEO Society of Automotive Engineers – Australasia

Phone: 0403 267 166 Email: info@sae-a.com.au Web: www.saea.com.au Membership & Subscriptions Rose De Amicis Email: rose@sae-a.com.au Events Cara Coughey Email: events@sae-a.com.au

Board of Directors: Chairman & CEO Adrian Feeney Board Mohammad Fard – Technical Director Bernie Rolfe – FISIT & SAE Liaison Greg Shoemark – Gov’t & Industry Liaison James Soo – Autonomous/EV Vehicles Richard Taube – Board Director Michael Waghorne – Finances Gary White – Board Director

Magazine Production: Editor Mandy Parry-Jones Trading Terms Media Email: mandypj@optusnet.com.au Mobile: 0409 806 986 Design Brigid Fraser Email: fraseram@optusnet.com.au Mobile: 0413 009 122 Advertising Jill Johnson Jill Johnson Media Email: jj@jilljohnsonmedia.com.au Mobile: 0409 217 624

VTE Industry Partner: Excellerate Australia

4 | March 2023

Welcome to the first VTE edition for 2023, all of us at SAE-A trust you had an enjoyable break over Christmas and the New Year period.

As with each year, the Board of SAE-A has been hard at work developing programs for 2023.

This started in January with an unofficial board meeting to review what SAE-A stands for and what we should be doing to ensure our members get value for their investment in us.

I will have more to say in the coming weeks but one decision we have already made to bring the role of events manager back in-house and to increase the number of days per week that person will be working in order to achieve the additional workload to bring these events to reality. The process is well advanced, and I hope to make the announcement as to who we have selected very soon.

Another significant announcement regarding staffing is to reiterate the announcement I made at last year’s AGM, that I will be standing down as chairman this year and so we are seeking a replacement. I encourage all loyal SAE members to consider this position and if you are interested in the role make your intentions known directly to me if you wish.

It is not overly time consuming, and you will have an excellent board to help you. Please think about it and if interested, I am more than happy to discuss the role with you over the next few weeks.

The 2023 AGM date has not yet been determined, but assume late May to early June as the most likely timeframe.

Another initiative I wish to daw to your attention is that in Victoria the Engineers Act comes into effect in December this year and so engineers must register to be able to practice, it’s the law.

We have been working closely with the Victorian Government over the last three years to ensure we

become a Registered Assessing Agent, so much so that we have now submitted our application and are awaiting confirmation that we have been accepted.

Once that is done, we will provide more details to our members as to exactly what this means to you as SAE members and how we will be able to help you in the process.

Briefly recapping on last year, a non-Covid year that allowed us to function more normally than was possible over the preceding 2+ years.

Formula SAE successfully returned to the Winton Raceway with the first ever driverless car providing attendees with a demonstration of its capabilities, the future direction for Formula SAE and the associated university teams.

We also had a number of face-to-face events, including the highly successful APAC 21 conference, an event that has been the traditional domain of SAE and will continue to be in the future.

And just to reiterate our Mission and Vision Statements Mission statement Our mission is to advocate for, develop and connect Australasian mobility engineers for the future of global mobility Vision Statement Our vision is to foster a thriving mobility engineering industry within the Australasian region.

And finally, just a reminder that for many of you, your membership renewal is now due, and I urge you to sign up as soon as possible so we can continue our journey together.

SAE | News

New Members The SAE-A would like to welcome the following new members:

SAE-A moves towards Mechanical Engineers registration in Victoria

Professional Member Nathan Pring Student Members

SAE-A has officially submitted its application to become an assessment entity for Mechanical Engineers in Victoria under the Professional Engineers Registration Scheme (PERS).

The culmination of more than three years’ work since the legislation was passed in August 2019, our submission is timed to be ready for mechanical engineers to be registered by the 1 December 2023 registration deadline.

Importantly, SAE-A is the only organisation focussed specifically on providing registration assessment for automotive engineers. Of the seven assessment entities confirmed to date, most are focussed primarily on assessing engineers in the building and construction sectors but SAE-A is ensuring that the particular circumstances of automotive engineers are taken into account, we are best placed to understand this sector of engineering.

SAE-A chairman and CEO Adrian Feeney said Consumer Affairs Victoria had confirmed the scheme covered engineers in the automotive sector, not just the building industry.

“Ever since our first meeting with the Victorian Government in 2019, our focus has been solely on the particular needs of engineers in the automotive sector,” he said.

Chidalu Chukwuneke Nathan Clark Tim Collier

“We have emphasised that many of our members come from a background where continuing professional development (CPD) has traditionally been handled internally by their employers, unlike most other professional sectors. With this in mind, SAE-A has focussed on ensuring that we can help engineers in our sector to meet the on-going CPD requirements under the Act.”

Jett De leon Yianni Giannakopoulos Olivia Heaton Luke Howard Imraan Matthews Adithep Phaktham Charles Sewell Charles Sharpe

Mr Feeney said it was likely that SAE-A members of full member grade or higher could meet the requirements for registration by having already met the member requirements but membership is not a requirement for engineers to seek assessment through SAE-A.

Daniel Smith James Talkington MILESTONE MEMBERS 40 YEARS (1983) Brian Brady

PERS covers five cohorts of engineers, with the implementation timetable staged over two years. Fire safety engineers were required to be registered by 1 December 2021, followed by civil and structural engineers on 1 October 2022. Electrical engineers will be due for registration by 1 June this year, followed by mechanical engineers by 1 December.

Russell Brown Lee Kernich 30 YEARS (1993) Keith Knapp Edward Kopinski 20 YEARS (2003) Michael Dudley

More information: https://www.consumer.vic.gov.au/

James Hurnall

licensing-and-registration/professional-engineers

SAE International Dictionary of Automotive Engineering SAE’s new International’s Dictionary of Automotive Engineering is a comprehensive automotive engineering reference for professionals and students alike.

This authoritative reference provides clearly written, easy-to-understand definitions for over 1,800 terms used in automotive engineering worldwide.

Unlike a standard dictionary that provides only definitions, the SAE International’s Dictionary for Automotive Engineers provides a unique level of detail including: • In-depth definitions including formulae and equations where appropriate.

• More than 300 full-colour illustrations provide clarity for definitions, component, or system identification.

• References to relevant SAE Standards to direct the reader to additional information beyond practical definitions.

•

Coverage of newer technologies such as electric vehicles, automated vehicles, hydrogen fuel.

•

Organised in alphabetical order, readers will find most acronyms are listed first followed by the term then the definitions to mimic conventional usage of acronyms within the industry.

This book is available from SAE-A in print and ebook formats.

The List price for the either book is $206.80 (SAE-A Member $185.90) plus $22 delivery if ordering the print copy.

Go to https://www.saea.com.au/publications-catalogue VTE | 5

News | SAE

Vale: Max Chanter Mr Chanter was involved in the automotive industry for more than 45 years of which 25 years were spent managing his own motor body repair company.

Graeme Palmer honoured at Motorsport Australia National Awards A full house was on hand at the Melbourne Convention and Exhibition Centre to witness a busy night of celebrations as the Motorsport Australia (MA) National Awards were presented.

In addition to the champions of 2022, a number of individuals were recognised for their contributions on and off the track throughout the night, including those who were awarded Life Membership.

Those honoured for their services to the sport with Life Memberships included well known SAE-A member Graeme Palmer who has been working at the FSAE-A event since it began.

Mr Palmer has been involved with MA, previously CAMS, for 47 years.

He held the position of CEO of SAE-A from 2009-2012 after holding board positions for a number of years.

During his career, Mr Chanter participated in many industry initiatives.

He started his working life at Spalding’s before moving on to Woods panel shop.

He then started Lemax Body Repairs and created the Independent Body Repairers group to discuss what was happening in the industry with other panel shop business owners.

After closing Lemax Body Repairs, Mr Chanter went to work for the SAE-A and then on to the Collision Repair magazine.

He passed away 20 January 2023.

On behalf of the SAE-A Board of Directors, CEO, staff and members our deepest condolences go out to Mr Chanter’s family.

“After I became a scrutineer, I was unhappy with the ‘old scrutineers’ method of presenting the scrutineer’s course, which for me was three Friday nights in the Shell city building auditorium listening to ‘the old scrutineers’ reading from the CAMS Manual of Motorsport,” explained Mr Palmer.

“So, I assisted the training presentation with the introduction of my own slides of the different categories of racing vehicles and a guest speaker (Russell Stuckey) this time held in the BP House auditorium over a weekend, and I continued presenting the Victorian Scrutineering Course in various venues including the country for the next 30 years.

“Then, I somehow (I couldn’t say no) became the first Victorian State Training Co-Ordinator for quite a few years travelling the State presenting the Level 3 Officials’ generic course to the Victorian car clubs.

HVAC seminars for automotive Tickets are now on sale for 26 industry-supported refrigerant education events aimed at those working in the automotive and stationary HVAC/R sectors.

A lot of change has emerged in the world of refrigerants since the highly successful future: gas refrigerant seminar roadshows of 2016 and 2017. So, it’s time for another.

Refrigerants are still changing, with some changes happening faster and some slower. There are also some unexpected developments and curveballs in the mix.

Everyone in the industry needs to be aware of what is happening in the market, what the laws are and how they could be changing.

The 2023 future:gas roadshows will assemble expert speakers to discuss and explain the latest on the recovery and handling of new refrigerants, the laws that will influence each 6 | March 2023

part of the industry and what this will mean for the day-to-day life of those in the business of handling refrigerants.

At least 3000 delegates from the automotive and stationary HVAC/R sectors are expected to attend the 26 events across Australia, New Zealand, Papua New Guinea and Vanuatu.

Tickets to future:gas seminars in Australia and New Zealand are just $20, making it a very affordable event, which will take place on weekday evenings during the winter, beginning at 5pm with complimentary welcome drinks, food and trade displays.

For more information including the seminar timetable: https://futuregas.ac

“I also served on the Victorian Rally Panel for many years and then the Victorian Scrutiny Panel becoming a committee member, which I still am. Then serving roles on the Victorian Rally Scrutineers’ Panel as chairman, secretary and to this day I am currently in the secretary role again.”

To add to his busy schedule Mr Palmer fulfils the role of a Vehicle Log Book inspector and Rally Permit Inspector on the Mornington Peninsula, which involves rally pre-event scrutineering and circuit competitor car audits if required.

For Mr Palmer Life Membership is a tangible reminder of the pleasure and memories that motorsport has given him over the years and continues to do.

General | News

Jobs and tech will be big winners from the AUKUS deal Australia’s industrial base will be just the second in history to be granted access to highly sensitive US nuclear propulsion capability and afforded the ability to access, handle, build and sustain this sensitive technology.

The program will create around 20,000 direct jobs over the next 30 years across industry, the Australian Defence Force and the Australian Public Service including trades workers, operators, technicians, engineers, scientists, submariners and project managers.

At its peak, building and sustaining nuclearpowered submarines in Australia will create up to 8,500 direct jobs in the industrial workforce.

With hundreds of thousands of components, nuclear-powered submarines will present a unique opportunity for Australian companies to contribute to the construction and sustainment of Australia’s new fleet and to the supply chains of partner nations.

Australians have already commenced training and working on UK and US nuclear-powered submarines and in UK and US facilities.

Between 2027 to 2032, an additional 500 direct jobs are expected to be created to sustain the Submarine Rotational Force-West US and UK presence in Western Australia.

This will mean Australia has a trained and experienced sovereign workforce for the arrival of Australia’s Virginia class submarines from as soon as the early 2030s.

At its peak, up to an estimated 4,000 Australian workers will design and build the infrastructure for the new submarine construction yard in South Australia.

A further 4,000 to 5,500 direct jobs will be created to build the nuclear-powered submarines when the program reaches its peak in 20 to 30 years, almost double the

workforce the former Government forecast for the Attack class program.

To support delivery of the submarine program, the Government has commenced developing the AUKUS Submarine Workforce and Industry Strategy to: •

Attract, recruit, develop, qualify and retain a highly-skilled trades, technical, scientific and engineering workforce.

•

Invest in new infrastructure for sustaining and building nuclear-powered submarines in Australia.

•

Support and build the capabilities of Australia’s world-leading defence industry.

•

This will involve working closely with state and territory governments, industry, unions, education and training institutions and the scientific and technical sectors.

Key elements of the strategy the Government is planning include national engineering and technology facilities. The South Australian Government will work on a dedicated skills and training academy to deliver tailored education, training and skilling for Australia’s submarine and naval shipbuilding.

For industry there will be opportunities for Australian companies to carry out maintenance for US Virginia and UK Astute class submarines during rotational presence in WA. And opportunities to embed Australian industry in the UK and US nuclear-powered submarine construction and sustainment programs and supply chains.

Four Australian engineers take home the QEPrize

General Briefs Hydrogen hub for Townsville The Albanese Government has said it will contribute $70 million investment to support the development of a hydrogen hub in Townsville.

With matched funding, the region will see a $140 million investment in renewable hydrogen.

The Government’s investment in hydrogen hubs is now more than $525 million, including the $454 million Regional Hydrogen Hubs program for projects in places like Gladstone, the Hunter Valley, the Pilbara, Port Bonython and Bell Bay. The Government is also investing $89.5 million to help the transport sector make the switch to hydrogen, including through hydrogen refuelling stations along Australia’s busiest freight routes.

Australian engineers honoured Mining and resources engineer Dr Stuart McGill and Warrant Officer Brett Hooper of the Royal Australian Air Force were awarded a Member of the Order of Australia (AM).

Dr Ernest Evans was given the medal for service to engineering. Graeme Haussmann was recognised with an Order of Australia medal.

Royal Australian Air Force’s Wing Commander Rachael Quirk was recognised with an Order of Australia Medal.

Other engineers recognised with honours were RMIT University Professor Sylvester Abanteriba, Rob Gehling of the Royal Institution of Naval Architects, University of Technology Sydney Distinguished Professor Dr Jie Lu, University of Sydney Professor David Hensher, Princeton University Professor Alexander Smits and DoricGroup Chair Hariolaos Xydas.

Aircraft maintenance scholarships CASA is offering three aircraft maintenance engineers (AME) scholarships worth $5,000.

“There’s a shortage of aircraft maintenance engineers in Australia, and one of the ways we are supporting the industry is to offer a financial incentive to those AMEs who’ve started structured training towards a licence,” Andreas Marcelja, Executive Manager Stakeholder Engagement, says.

The 2023 Queen Elizabeth Prize for Engineering (QEPrize) was awarded to four Australians; Professor Martin Green, Professor Andrew Blakers, Dr Aihua Wang and Dr Jianhua Zhao for their research work and development of Passivated Emitter and Rear Cell (PERC) solar photovoltaic technology that has underpinned the recent growth of high performance, low-cost solar electricity, to harness the power of the sun.

Awarded annually, the Queen Elizabeth Prize for Engineering is presented to engineers responsible for ground-breaking innovations that have been of global benefit to humanity.

Celebrating its 10th year in 2023, the prize announcement was made by Lord Browne of Madingley, Chairman of the Queen Elizabeth Prize for Engineering Foundation.

The 2023 laureates greatly improved the energy conversion efficiency of commercially dominant silicon cells by improving the quality of both the top and the rear surface of www.saea.com.au

standard silicon solar cells. PERC introduced an additional layer on the back surface that helped prevent recombination and further, reflected unused photons back into the silicon to generate more electrons.

Recognising the important role PERC technology plays in the development of solar energy, the awardees published their findings with no patent, encouraging further developments within the field and driving down the cost of production to the benefit of wider society.

The scholarships are aimed at those who haven’t gone through formal training but are currently working in the industry gaining experience.

“We know that $5,000 doesn’t cover all the associated costs of AME licence training, but the funding will provide some support in continuing education and training towards getting a CASR Part 66 AME licence.”

VTE | 7

News | General

Ampol to go electric with SEA Recharging has partnered with Australian commercial electric vehicle manufacturer SEA interest in battery Ampol Electric to support the transition of companies to zero-emissions commercial electric vehicle technology. tech for Geelong Recharge Industries is a leading provider of battery technology, specialising in production and research and development..

Based in Geelong, Australia, the firm is currently developing Australia’s first largescale lithium-ion cell production facility to provide safer, more efficient and recyclable batteries, as well as investing in research and development of next-generation solutions to real-world and emerging energy storage solutions.

Through the partnership, SEA Electric and Ampol will be working together to develop flexible, sustainable and seamless charging options to support the uptake of lower emissions commercial vehicles in key parts of the transport sector.

Recharge Industries has retained Jacobs to lead the design of its Australian advanced battery manufacturing production facility in Geelong.

Jacobs is globally recognised as one of the top firms in designing advanced manufacturing facilities and the company has delivered large scale facilities such as these in the EV industry and is well suited to design one of the world’s largest “Gigafactories” in Australia.

Additionally, the partnership will focus on building an integrated charging solution for SEA Electric customers on the road at Ampol forecourts, at destinations and solutions at the workplace.

“Ampol is evolving to provide a range of fast and reliable charging solutions. We know our business customers are looking for lower emissions solutions and want to ensure their

Construction will be phased to begin at 2GWh annual production and ramp up to 6GWh, 12GWh and then to 30GWh. As operations expand to 30GWh, the factory will employ an estimated 1,500 to 2,000 workers.

8 | March 2023

“Ampol is committed to developing an open access national charging network as well as home and business charging solutions to ensure vehicles can be on the road whenever needed.”

For SEA Electric, the partnership provides flexible charging options for electric truck owners, with many Ampol customers moving into the EV space in cars and now with light trucks. The partnership will help reduce range anxiety for businesses looking to invest in electric trucks to reduce their emissions.

Siemens and Swinburne’s Energy Transition Hub Siemens and Swinburne University of Technology have agreed to set up the most advanced future Energy Transition Hub of its kind in Australia in at the University’s Hawthorn campus in Melbourne.

Featuring some of the most advanced digital energy technology from Siemens and the technical, R&D and teaching expertise of Swinburne, the $5.2 million hub aims to build a future energy grid laboratory accessible to students and industry.

At full capacity, Recharge Industries large scale lithium-ion battery cell production facility in Geelong will generate up to 30 gigawatt hours (GWh) of storage capacity per year for electric vehicles and stationary energy storage markets.

investment in commercial electric vehicles can be supported with efficient and reliable charging technologies,” James Myatt, Ampol’s General Manager, Energy, said.

When fully operational, the hub will also offer researchers and industry the opportunity to work on solutions for greener, more efficient future energy systems using Siemens Xcelerator, a new open digital business platform and marketplace.

Deputy Vice-Chancellor, Research, Professor Karen Hapgood said the new Siemens Swinburne Energy Transition Hub will be working on new technologies to improve energy efficiency, supply, integration, storage, transport and use, as well as how we can improve existing technologies and frameworks.

The hub will enable users to leverage digital

twins of energy grids, map scenarios, research new findings, develop original and creative hypotheses, and test results. It will be home to a digital twin of Australia’s energy grid that commercial research teams can use to run simulations of new, innovative solutions and software.

As well as R&D and commercialisation projects, the hub will deliver short courses for industry professionals.

In addition to microgrid and planning stations, the Hub will also feature Siemens’ microgrid management system (MGMS) and decentralised energy optimisation platform (DEOP) software.

The microgrid technologies include Sicam A8000 and Siprotec 5 devices for control and protection. The planning stations feature Siemens PSS software which is used by over 70% of utilities and independent system operators including AEMO and grid operators.

Auto | News

World Car Person of the Year

Drive Car of the Year the Australian Ranger

The World Car Awards jury panel representing 100 journalists from 32 countries have voted Sang Yup Lee, Executive Vice President, Head of Hyundai and Genesis Global Design Centre, Hyundai Motor Company (HMC), as the 2023 World Car Person of the Year.

Ford’s Ranger 4x4 dual-cab ute is the overall winner of the 2023 Drive Car of the Year awards, a first for any LCV. Ranger topped the voting among 13 DCOTY category winners that were eligible for the outright award.

Last year 4x4 utes made up 18 percent of total new vehicle sales and nearly 13 percent of all private sales.

Ford Australia designed and engineered the global Ranger (and its SUV partner, Everest), which is now offered in upward of 180 markets. The car, developed with our local roads, climate, and driving conditions in mind, was the result of work conducted by Ford’s design and engineering teams in Melbourne and Geelong. It was significantly tested at the Ford Proving Grounds just outside of Melbourne and in the Victorian High Country and South Australian desert.

It’s not just the Ranger and Everest either, as

Australia remains a global development hub for Ford. The local team sees more than 2300 personnel working on cars predominantly for China, India, and South American markets.

So, while Australian market Rangers may be built in Thailand, in nearly every other way, this is an Australian car.

The Ranger’s win isn’t the first Drive Car of the Year overall winner award on the Ford mantlepiece either, with the previous generation Ford Everest SUV securing top honours in 2015.

SEA to electrify Hilux and LandCruisers for mining SEA Electric has signed a Memorandum of Understanding with MEVCO, a leading systems integrator focused exclusively on electric light commercial vehicles within the mining industry.

The partnership will see specialist all-electric Hilux and LandCruiser models made available for the mining industry, with MEVCO making a commitment to order 8,500 units over the next five years.

The deal has a total value of close to $1 billion.

At the heart of the arrangement is SEA Electric’s proprietary SEA-Drive power-system.

Thanks to its medium voltage architecture and electronic thermal management, SEA Electric’s solution is light, cost effective, and efficient, with the system tested in the field across eight countries with over 2.5 million kilometres of real-world use registered to date.

Available in various mining-specific designs for 4x4 and 4x2 configurations, the vehicles can be

specified with two SEA-Drive options, namely an 88kWh battery which provides 380km of range, or a 60kWh battery delivering up to 260km of use.

Fast DC to DC charging is available for the system, which provides up to 80 percent battery power in less than one hour, with a fiveyear factory warranty on the batteries supplied.

For SEA Electric, the announcement is the logical next step in the company’s expansion in the commercial vehicle space, opening up possibilities for the technology on a global scale for a wide variety of applications.

This is the second consecutive World Car Person of the Year win for Hyundai Motor Group. Luc Donckerwolke, President for Design and Chief Creative Officer, Hyundai Motor Group was last year’s winner.

To be eligible for this award, candidates must have made a significant contribution to the global automotive industry with global repercussions. That contribution could include a significant impact to their brand or company, or a significant safety, engineering, design or technical advancement or other significant benefit for the consumer.

Sang Yup Lee was chosen by the jury panel on the basis that as Head of Hyundai and Genesis Global Design Centre, he is the creative mind behind some of the most stunning and innovative concept and production cars unveiled in 2022, including Hyundai IONIQ 6, the KONA and N Vision 74.

Sang Yup Lee

The top five finalists for this year’s award represent some of the best and most accomplished men and women in the industry, in very personal and different ways. The top five finalists are, in alphabetical order: 1. Wang Chuanfu, Chairman and President of BYD Co., Ltd 2. Dr. Stella Clarke, Research Engineer Open Innovations, BMW Group 3. Sang Yup Lee, Executive Vice President, Head of Hyundai and Genesis Global Design Centre, Hyundai Motor Company (HMC) 4. Peter Rawlinson, CEO and CTO, Lucid Motors 5. Naoyuki Sakamoto, Chief Engineer, GR Corolla, GAZOO Racing Company, Toyota Motor Corporation.

www.saea.com.au

VTE | 9

News | Auto

Auto Briefs EV Recap report Australia’s Electric Vehicle Council recently published the Australian Electric Vehicle Industry Recap 2022 Report that shows that last year was good in terms of EV sales in Australia. Sales of new EVs in Australia almost doubled in 2022, compared with 2021. The market is trailing the global average estimated to be 12 percent to 14 percent in 2022. EVs still represent less than 0.5 percent of Australia’s passenger and light commercial vehicle fleet.

BMW bringing man and machine closer The BMW Group shared its vision of the future digital experience at the Consumer Electronics Show (CES) 2023 in Las Vegas with its i Vision Dee.

SA drops tax for electric cars South Australia has abolished its controversial road user tax, the per kilometre charge for electric cars.

The SA Parliament voted to repeal the tax which was due to come into force in July 2027 or when electric cars reached 30 percent of new car sales. The tax was to pay 2.5 cents for every kilometre and was meant to offset lost revenue from fuel excise. Victoria is the only state to have a road user tax with electric and hydrogen cars charged 2.5 cents per kilometre and plug-in hybrids charged at 2 cents per kilometre.

Michael Filazzola MD for Stellantis Stellantis Australia has appointed Michael Filazzola to the role of Managing Director, Australia, encompassing the Jeep, Alfa Romeo, Fiat, Fiat Professional and Abarth brands.

Mr Filazzola replaces Kevin Flynn, after 47 years in the automotive industry. Over three decades, Mr Flynn worked across multiple countries and brands including Lexus, BMW, Jaguar Land Rover and Porsche.

Mr Filazzola has worked in the automotive and aftermarket industry for more than 28 years, working across Australia, China and the Southeast Asia markets. He has extensive knowledge of the automotive ecosystem, holding a variety of roles as a senior executive across sales, aftersales, customer experience, purchasing and supply chain, and product development while at General Motors, Holden Australia and Bapcor.

Deakin pinpoints reason for lithium battery degradation Deakin University research has pinpointed a crucial mechanism inside lithium-metal batteries that could prevent battery degradation.

In a paper published in the Journal of Power Sources, Institute for Frontier Materials researchers based at the ARC Training Centre for Future Energy Storage Technologies (StorEnergy) have revealed the adverse effect of ‘lithium metal creep’ deformation on the performance of Li-metal pouch cell batteries and their safety. The research shows how ‘Li creep’, which is the slow deformation of lithium metal, contributes to the degradation of the separator within a Li-metal pouch cell. The separator plays an important role in preventing a short circuit inside a battery.

This study shows that current commercial separators are not mechanically compatible with the next generation of high-energy density batteries, and novel battery separators should be developed to meet the mechanical requirements. The next step in this line of research is a closer investigation of separators.

10 | March 2023

The name “Dee” stands for Digital Emotional Experience, the aim is to create an even stronger bond between people and their cars going forward.

to driving-related information, to the contents of the communications system, to augmented-reality projection, right up to entry into virtual worlds.

Future digital functions will go far beyond the level of voice control and driver assistance systems. The BMW Head-Up display extends across the full width of the windscreen, providing a glimpse of the next vehicle generation.

In parallel, dimmable windows can also be used to gradually fade out reality.

From 2025 onwards, this innovation will be available in the models of the NEUE KLASSE (new class of vehicles).

The headlights and the closed BMW kidney grille also form a common phygital (fusion of physical and digital) icon on a uniform surface, allowing the vehicle to produce different facial expressions.

“With the BMW i Vision Dee, we are showcasing what is possible when hardware and software merge. In this way, we are able to exploit the full potential of digitalisation to transform the car into an intelligent companion,” said Oliver Zipse, Chairman of the Board of Management of BMW AG. With its intelligent, almost human capabilities, BMW i Vision Dee accompanies drivers not only through real-life situations on the roads, but also in their digital environment.

The BMW Mixed Reality Slider, in combination with the advanced Head-up display, is the digital highlight and central operating control of BMW i Vision Dee. Using shy-tech sensors on the instrument panel, drivers can decide for themselves how much digital content they want to see on the advanced Head-Up display.

The five-step selection ranges from analogue

The digital experience begins outside the vehicle, with a personalised welcome scenario that combines graphical elements, light and sound effects.

This means BMW i Vision Dee can talk to people and, at the same time, express moods such as joy, astonishment or approval visually. BMW i Vision Dee can also project an image of the driver’s avatar onto the side window to further personalise the welcome scenario.

“With BMW i Vision Dee, we are showing how the car can be seamlessly integrated into your digital life and become a trusty companion. The vehicle itself becomes your portal to the digital world with the driver always in control,” said Adrian van Hooydonk, head of BMW Group Design.

“Implemented the right way, technology will create worthwhile experiences, make you a better driver and simply bring humans and machines closer together.”

Auto | News

Soft target AB Dynamics has launched the Soft Scooter 360, a highly realistic Powered Two-Wheeler (PTW) test target. It enables vehicle manufacturers to safely test and develop ADAS and autonomous vehicle systems.

It has been developed in response to the significant growth of PTWs globally, which is being driven in part by the increased environmental, economic and practical benefits of electric PTWs. The motorcycle, moped and scooter market is projected to increase by more than 37 percent over the next five years reaching 65.2 million annual sales.

The target is highly-realistic and features speed-matched rotating wheels that provide a micro-Doppler effect, which is important for radar sensors. A photorealistic vinyl skin enhances camera detection and a comparative radar signature to a real scooter and rider also increases realism for sensor characterisation.

It uses a lightweight tubular skeleton surrounded by highly durable foam pieces.

The hard points of the target have also been minimised to reduce possible damage to the test vehicle. For example, the ends of the handlebars are hollowed rubber to provide better compliance if it comes into contact with the vehicle.

Unlike some alternatives, the rider is a separate piece that is mounted to the scooter rather than being an integrated section, this also helps to reduce damage to the test vehicle during a collision. The scooter section of the target has been wrapped in a hard-wearing and easily replaceable vinyl

skin meaning the cost of maintaining it is minimised.

The Soft Scooter 360 meets the ISO/WD 19206-5 standard and is compatible with C-NCAP’s latest protocols. It is capable of withstanding front and side impact speeds of 40kph and 60kph respectively.

The type of test scenarios it will be used

for include; lane cut-in where the scooter overtakes and cuts into the same lane as the test vehicle; blind spot where the test vehicle attempts to change lanes with the scooter positioned in the test vehicle’s blind spot; intersections where the scooter and test vehicle cross the intersection perpendicular to each other at the same time.

University of Auckland engineers working at McLaren Sixty years after Bruce McLaren made the journey from New Zealand to England to establish the company that still bears his name today, two young engineers followed in his footsteps as part of a scholarship established in his honour.

University of Auckland (UoA) mechanical engineering students Sabrina Yarndley and Joshua Cates are the latest Bruce McLaren engineering scholars to be welcomed to McLaren to hone their skills at the Woking-based UK supercar company.

They were greeted at the McLaren Technology Centre (MTC) in Woking by former UoA alumna Lizzy Grant, herself a former Bruce McLaren engineering scholar in 2019 and now working on battery technologies crucial to the company’s future electrified powertrains.

They were also joined by fellow Kiwi Piers Scott, the company’s executive director of PR, and Jim Marsh, chief transformation and people officer.

Ms Yarndley and Mr Cates will be completing a three-month scholarship that will see them working in multiple departments across the company.

Born in Auckland, New Zealand, Bruce McLaren studied there and went on to become an accomplished engineer and innovator as well as a successful racing car driver. www.saea.com.au

Joshua Cats and Sabrina Yarndley VTE | 11

News | Bus

BusTech electric bus to hit the roads Australia’s first designed and manufactured electric bus the BusTech ZDI-450 represents the next generation in connected zero emission transit and will soon be a familiar sight in public and private bus services around the country.

The ground-breaking design has been tailored for Australian conditions with a 452kWh battery capacity that is the most powerful of its kind in the Australian market, and a rapid charge time of just two hours.

The durable, marine-grade stainless steel chassis has been tested over 300 million km.

Its lightweight integrated structure has room for 45 seated and 21 standing passengers in a stylish interior designed for safety and comfort.

Ten of the innovative new electric coaches are currently on order and the first one has been delivered to the Clarks Logan City Bus Service, in Queensland.

The ZDI-450 is the centrepiece in BusTech’s manufacturing strategy which aims to fast track the clean energy transformation in the public transport sector with innovative designs made to suit Australian conditions.

“Public transport is one of the biggest producers of greenhouse gas emissions. If

Bus Briefs Mercedes-Benz out of bus and coach arena in Australia Mercedes-Benz is hitting the pause button on sales of new buses and coaches in the Australian market and has not indicated when the company will return to that arena.

The company said in a statement that it was pausing sales because its future products were not the best fit for Australia. M-B will continue to support existing products with parts and technical support.

It is touted that the reason that this has happened is Australia’s peculiar and outdated design regulations.

Fuso buses are not affected.

ARCC, a NSW manufacturer of buses announced that it has made the first hydrogen cell bus, the prototype is to go into service in autumn. ARCC was started just six years ago.

Queensland’s government is boosting local manufacturing by making buses in that state.

The government said it would work with manufacturers to assist them to that end.

The next step in developing the state’s bus manufacturing policy is to work with industry to better understand the capacity.

Transit Systems has won a major contract that will help the company expand offering 400 new jobs and 230 buses to its line-up. An additional 18 electric vehicles are being added.

12 | March 2023

we want to protect the environment, we need to move on that now,” said BusTech Chief Operating Officer and General Manager of Queensland operations Martin Hall.

“We are partnering with world class technology providers to build Australia’s manufacturing capability and grow the local supply chain.

“Our target is to produce 200 vehicles a year, initially to meet the need for efficient, low emission public transport in urban areas.

“We have already had a lot of inquiry from the

mining resource sector, and we expect to see significant uptake there as more infrastructure becomes available.”

Bus Tech has been developing the new electric bus for the past three years and has completed extensive testing at the company’s depots in Adelaide, South Australia, and at Burleigh Heads, on the Gold Coast.

The company’s integrated architecture is designed with cost-efficiency and sustainability in mind enabling the transition from diesel to electric to hydrogen power over the life of the vehicle.

Foton partners education for skills transition Foton Mobility Distribution (FMD) has signed Deeds of Collaboration with a number of major national education and vocational training Institutions to facilitate the upskilling of trades to support the uptake of zero emissions vehicles, with particular focus on the Bus and Heavy Transport Industries.

FMD will partner with TAFE NSW, TAFE Queensland, South West TAFE (Vic), Federation University, Deakin University (Victoria) TAS TAFE, TAFE SA, South Metropolitan TAFE WA, MTA (NSW) and MTA (Qld) to work on developing training programs and accreditations to meet the needs of the transport industry.

While acknowledging that skills shortages exist across the broader economy, the partnerships intend to address this by creating a pathway for already technically trained workers to maintain and upgrade their skills in the repair and maintenance of both battery electric and hydrogen fuel cell zero emissions vehicles (FCEV’s), while offering entry-level skills training to attract workers across to the new opportunities in the green economy of the future.

Transit Systems recently acquired its first two

Hydrogen Fuel Cell City buses from Foton Mobility.

Foton Mobility Distribution (a part of the TrueGreen Impact Investment Group) is the exclusive Australian Distributor of Foton New Energy commercial transport vehicles, including the T5 Light Duty Electric truck, Electric Vans, Battery Electric and Hydrogen Fuel Cell City buses, soon to be joined by Hydrogen Prime Movers.

FMD has acquired the exclusive Australian distributorship for Asiastar New Energy Commercial vehicles, including the about to be launched Eurise D11 5.9m electric van.

Truck | News

SEA Electric forges ahead in the US Global e-Mobility technology company SEA Electric has appointed Justin Gil Palmer to the position of President – North America.

Truck Briefs Kenworth turns 100

Mr Palmer comes to the role with extensive electric truck industry experience, focusing on the delivery and final mile segments.

Since 2017, Mr Palmer has been the President and CEO of Mitsubishi Fuso Trucks America (MFTA-Daimler Trucks), which included oversight of the global launch, sales and support for the brand’s industry-disrupting alternate powertrains, including the e-Canter line.

The role encompassed the brand’s distribution network and market strategy in the USA and Canada, extending to sales, communications and marketing, CS operations and logistics, retail network development and product management.

Previous to that role, Mr Palmer was Director of Business Operations at MFTA-Daimler Trucks and has held various other executivelevel positions.

With Mr Palmer joining the expanded SEA Electric team, Mike Menyhart, who had led the North America business, will now head global marketing, strategy and business

development, in his new role as Chief Commercial Officer.

Now headquartered in Los Angeles, CA, SEA Electric was founded in Melbourne, Australia, in 2012, with the proprietary all-electric SEA-Drive power-system at the heart of the business’s offering for trucks and buses.

Adaptable to a wide array of commercial applications, the company has grown its footprint to cover five continents, with extensive deployments across a wide crosssection of industries.

Mighty good for last mile deliveries The zero-emission Hyundai Mighty electric will be added to the company’s existing fleet of EVs later in 2023. Mighty electric follows on from XCIENT Fuel Cell, the brand’s firstever hydrogen-powered heavy truck, currently deployed in Switzerland and California with an estimated laden range of approximately 240km and is an ideal zero-emission workhorse for metropolitan and last-mile deliveries.

Mighty electric’s 120kW, 320Nm traction motor is powered by a 114.5kWh battery system with rapid charging capability with 10 percent to 100 percent in under 70 minutes.

In addition to its efficient EV technology the Mighty electric represents the latest in cabs, including comfort and convenience features such as a digital dash display, a multi-function steering wheel and a suspended driver’s seat.

Mighty electric comes packed with safety technology features including: •

Forward Collision-avoidance Assist (FCA)

•

Lane Departure Warning System (LDW)

•

Electronic Stability Control (ESC)

•

Electronic Air Brake System (EBS).

Mighty electric is classed as a Light Duty Heavy Truck (3,501 - 8,000kg GVM) and has

Kenworth is celebrating its 100-year anniversary in 2023. The company started in the US as a logging truck maker in 1923 and then became part of Paccar in 1946 but retained the Kenworth name which is the K in Kent (Harry Kent) and the W in Worthington (Edgar Worthington) the founders.

Volvo FE put to work in Sydney

GEODIS is the first Australian global logistics provider to take delivery of the Volvo FE Electric in Sydney. The 6x2 FE Electric will be put to work transporting parts from Geodis’s Matraville NSW headquarters to Volvo Group Australia’s Minto NSW Parts Distribution Centre on the Southwestern outskirts of Sydney.

With 50kw AC charging at the depot end of the 47-kilometre route, the 10 pallet FE curtainsider will take advantage of opportunity charging while loading during the working day and is capable of hauling a 7-tonne payload.

Volvo electric trucks made in Australia In 2027 Volvo Group Australia plans to start manufacturing all-electric trucks at its Wacol facility in Queensland. The ability to make the vehicles hinges on Australia’s design rules that have heavy restrictions on what is able to be used on the road. an approximate cargo capacity between one and 3.5 tonne, depending on the variant and upper body specification.

From launch, the Mighty electric line-up will be available in a single 7,300kg Gross Vehicle Mass (GVM) variant, in 4x2 configuration with a 3,300mm wheelbase.

Bare cab-chassis, tray or pantech (regular or refrigerated) versions will be offered for Australian customers with a tipper variant also under review.

Hyundai is also looking at its heavy load XCIENT Fuel Cell prime mover for a potential trial in Australia.

www.saea.com.au

VTE | 13

News | Overseas

Australia’s Recharge buys Britishvolt Australia’s Recharge Industries has bought Britishvolt, the collapsed start-up that had struggled to fund a major electric vehicle (EV) battery factory in northern England.

Recharge Industries, privately owned by New York-based investment fund Scale Facilitation, was selected as the preferred bidder for Britishvolt, which had outlined plans for a gigafactory.

Britain’s ambitions of building a homegrown EV battery industry that can support domestic car production were thrown into doubt when Britishvolt failed to raise enough funding for the factory in Cambois.

“Backed by our global supply chain, strategic delivery partners and a number of significant customer agreements in place, we’re confident of making the Cambois Gigafactory a success and growing it into an advanced green energy project,” Scale Facilitation Chief Executive David Collard said.

“We have the right plan in place, to match and support the region’s energy and ambition to become a major player in the international battery market.”

Sustainable car materials in the circular economy A consortium of 19 leading industrial companies and research institutes, including the BMW Group, Evonik, Thyssenkrupp, the Fraunhofer Institute, and the Technical University of Munich, has set itself the goal of developing new processes for using sustainable materials for circular automotive production.

The project, which is funded for three years by the German Federal Ministry of Economics and Climate Protection (BMWK), was launched at the end of last year.

The core of the “Future Sustainable Car Materials (FSCM)” initiative launched by BMW is to develop innovative process routes and material concepts for large parts of the value chain, thus enabling a circular economy in vehicle production.

According to the principle of the circular economy, materials must be kept in the value chain after they have reached the end of their useful life so that new objects, such as

Australian Tritium DCFC, a global leader in direct current (DC) fast chargers for electric vehicles (EVs), announced that bp has placed the largest ever order from a single customer in Tritium’s history. bp will install the chargers for fleets and the general public in the United States, the United Kingdom, Europe, and Australia as bp expands its EV charging business, bp pulse.

Tritium’s high-powered and modular 150kW PKM charger leverages a pool of shared

The British government under former Prime Minister Boris Johnson had touted Britishvolt’s project as a major milestone toward building an EV industry as the country heads toward a ban on combustion engine cars in 2030.

Recharge Industries, which is building a lithium-ion cell factory in Australia expects to begin production next year.

14 | March 2023

Due to the high complexity of automotive manufacturing, the participants in the FSCM project are optimistic that the knowledge gained can also be applied to other industrial products in the future, such as commercial vehicles, electrical and household appliances, and will thus be a decisive impetus for future circular economy systems in the German economy.

bp places largest ever order for fast chargers

bp’s order includes a mix of Tritium’s 50kW RTM and 150kW PKM chargers. Tritium’s RTM is the company’s first modular charger and one of the most advanced DC fast chargers on the market. Ideal for network operators, dealerships, and the retail and hospitality industries, the RTM uses a single person lift power module system for easier power upgrades, maintenance, and serviceability.

The planned plant site is regarded as Britain’s best “shovel-ready” location to make EV batteries at scale, with the land already acquired and planning permission in place.

automotive parts, can be produced without the use of fossil resources. It is particularly challenging to keep these materials in the cycle while maintaining the same quality and safety properties.

power to deliver higher charger availability and power output, through Tritium’s innovative micro-grid design. The model is popular across fleets, network operators, heavy commercial units, retail and hospitality.

Tritium anticipates manufacturing the chargers destined for bp’s European and American markets in the company’s Lebanon, Tennessee US facility, which opened in August 2022 and is expected to reach a production capacity of 30,000 units per year at full maturity.

The chargers for bp’s Australian market are expected to be manufactured in Tritium’s Brisbane factory, which has a capacity of 5,000 units per year.

Auto companies that have exited Russia •

British car distributor Inchcape (INCH.L) sold its Russian business to local management

•

Italian truck and bus maker Iveco (IVG.MI) transferred its 33% stake in its AMT truck assembly joint venture in Russia to a local partner

•

French tyre maker Michelin (MICP.PA) intends to transfer its activities in Russia to a new entity under local management

•

Japanese automaker Nissan (7201.T) is transferring its Russian assets to

state-owned NAMI, the Russian Central Research and Development Automobile and Engine Institute •

French carmaker Renault (RENA.PA) sold its majority stake in Avtovaz (AVAZI_p.

MM) to NAMI, and transferred all shares in Renault Russia to the city of Moscow

•

MAN Truck & Bus and Scania, units of German truck maker Traton (8TRA.DE), expect to sell their sales companies in Russia to local partners along with Scania’s Russian financing business by Q1 2023.

RMIT Hydrogen | Feature

RMIT turns Blue hydrogen Green Engineers in Melbourne have used sound waves to boost production of green hydrogen by 14 times, through electrolysis to split water.

They say their invention offers a promising way to tap into a plentiful supply of cheap hydrogen fuel for transportation and other sectors, which could radically reduce carbon emissions and help fight climate change.

By using high-frequency vibrations to “divide and conquer” individual water molecules during electrolysis, the team managed to split the water molecules to release 14 times more hydrogen compared with standard electrolysis techniques.

Electrolysis involves electricity running through water with two electrodes to split water molecules into oxygen and hydrogen gases, which appear as bubbles. This process produces green hydrogen, which represents just a small fraction of hydrogen production globally due to the high energy required.

Most hydrogen is produced from splitting natural gas, known as blue hydrogen, which emits greenhouse gases into the atmosphere.

The Associate Professor Amgad Rezk from RMIT University, who led the work, said the team’s innovation tackles big challenges for green hydrogen production.

“One of the main challenges of electrolysis is the high cost of electrode materials used, such as platinum or iridium,” said Rezk from RMIT’s School of Engineering.

“With sound waves making it much easier to extract hydrogen from water, it eliminates the need to use corrosive electrolytes and expensive electrodes such as platinum or iridium.

“As water is not a corrosive electrolyte, we can use much cheaper electrode materials such as silver.”

The ability to use low-cost electrode materials and avoiding the use of highly corrosive

Yemima Ehrnst

electrolytes were gamechangers for lowering the costs of producing green hydrogen, Mr Rezk said.

new acoustic platform for other applications, especially where bubble build-up on the electrodes was a challenge.

The research is published in Advanced Energy Materials. An Australian provisional patent application has been filed to protect the new technology.

“Our ability to suppress bubble build-up on the electrodes and rapidly remove them through high-frequency vibrations represents a major advance for electrode conductivity and stability,” said Ms Yeo.

First author Yemima Ehrnst said the sound waves also prevented the build-up of hydrogen and oxygen bubbles on the electrodes, which greatly improved its conductivity and stability.

“Electrode materials used in electrolysis suffer from hydrogen and oxygen gas build-up, forming a gas layer that minimises the electrodes’ activity and significantly reduces its performance,” said Ms Ehrnst, a PhD researcher at RMIT’s School of Engineering.

As part of their experiments the team measured the amount of hydrogen produced through electrolysis with and without sound waves from the electrical output.

“The electrical output of the electrolysis with sound waves was about 14 times greater than electrolysis without them, for a given input voltage. This was equivalent to the amount of hydrogen produced,” Ms Ehrnst said.

Distinguished Professor Leslie Yeo, one of the lead senior researchers, said the team’s breakthrough opened the door to using this

www.saea.com.au

“With our method, we can potentially improve the conversion efficiency leading to a netpositive energy saving of 27 percent.”

While the innovation is promising, the team needs to overcome challenges with integrating the sound-wave innovation with existing electrolysers to scale up the work.

“We are keen to collaborate with industry partners to boost and complement their existing electrolyser technology and integrate into existing processes and systems,” Ms Yeo said.

You can read the article: AcousticallyInduced Water Frustration for Enhanced Hydrogen Evolution Reaction in Neutral Electrolytes (https://onlinelibrary.wiley.com/ doi/10.1002/aenm.202203164)” is published in Advanced Energy Materials (DOI:10.1002/ aenm.202203164). The co-authors are Yemima Ehrnst, Amgad Rezk and Leslie Yeo from RMIT and Peter Sherrell from the University of Melbourne.

VTE | 15

Feature | Avalon Airshow 2023

The sky’s the limit for Avalon After four years the show returned to Avalon and the massive turnout of exhibitors, trade, media and, during the weekend show goers, proves it’s a drawcard event.

There was no doubt that the Avalon Airshow was on; telling signs were everywhere – the traffic jam on the Geelong freeway, the sounds of jets flying overhead, the raft of international visitors to Melbourne and of course, ministers of every denomination – Labor, Liberal, State and Federal.

16 | March 2023

It was no wonder since it had been four years since the last show was held with Covid interrupting what is by far the biggest air show in the southern hemisphere.

The show had been moved from its original venue at the Royal Australian Air Force Base in Richmond, New South Wales to Victoria in 1992 and then attended by 175,000 visitors.

Back in 2019 it attracted around 40,000 industry professionals with 698 participating companies. This year the show was bound to break records as it was a long time between flights.

For the first time all exhibition space was sold out with 798 exhibitors, which was a 14 percent increase over the 2019 show

Avalon Airshow 2023 | Feature

STRIX

Systems Australia teamed with local industry to present Australia’s first domestically designed, manufactured and armed VTOL (Vertical Take-Off and Landing) Uncrewed Air System (UAS).

STRIXTM is being developed by BAE Systems Australia and Perthbased Innovaero and launched at the 2023 Avalon Airshow in Geelong, Australia. The collaboration brings together BAE Systems’ global expertise in autonomous platforms and its vehicle management system (VMS) technology with Innovaero’s knowledge of aeronautical product design and manufacture in the Australian market.

A hybrid, tandem wing, multi-domain and multi-role UAS capability, STRIX could be used for a variety of missions including air to ground strike against hostile targets and persistent intelligence, surveillance and reconnaissance (ISR). It could also act as a ‘loyal wingman’ for military helicopters.

Designed to carry up to a 160kg payload over 800km, STRIX will be capable of operating in high-risk environments. With a collapsed footprint of 2.6m x 4.5m, it could be easily transported. Its VTOL capability means STRIX could be used without relying on an airfield. It could also be operated from a helicopter to expand the mission set and protect aircrew in high-threat environments.

and there were 50 percent more industry, government, defence and scientific delegations.

As well as the exhibitions there was a program of around 59 conferences and for the first time the Republic of Korea Air Force Black Eagles display team arrived, what did not arrive was China or Russia with both nations excluded from the event.

Not only is this event an important economic driver for the region, generating millions of dollars in economic activity and creating jobs it is also a platform for displaying and launching products and BAE was on top of that pyramid with the unveiling of its STRIX and RAZOR. www.saea.com.au

VTE | 17

Feature | Avalon Airshow 2023

Young Innovators Awarded In a first for the Avalon Innovation Awards both the National and the SME Innovation Awards have been won by the same company.

Melbourne-based 1MILLIKELVIN Pty Limited was named winner of both the National Innovation Award and SME Innovation Award at the presentation ceremony.

1MILLIKELVIN won both awards for its worldleading work developing a stress imaging camera system which provides a full-colour representation of the stress on a mechanical structure under loads, such as the airframes of crewed and uncrewed aircraft and helicopters.

The panel of eight judges, led by former Deputy Chief Defence Scientist Dr Bill Schofield AM, agreed that 1MILLIKELVIN’s entry was a deserving winner for both awards.

The Young Innovator Award was presented to BAE Systems Australia Melbourne engineer, Callum Rohweder, for his work on developing the core guidance, navigation and control algorithms at the heart of the Australian-developed Vehicle Management System (VMS) for the Boeing MQ28A Ghost Bat uncrewed aerial vehicle.

This year, for the first time, the winners of the SME Innovation Award and Young Innovator Award were presented with a cheque for $50,000 each.

Jobs Plus to support digital engineering in NSW

Defence sector engineering, professional services, and business advisory consultancy ADROITA will receive New South Wales Government Jobs Plus support to assist them to expand their service offering in the state.

The female-led and veteran-owned company is based in Sydney, with employees in Canberra, Melbourne, Wollongong, and Adelaide.

will create more than 30 new skilled jobs over the next two years and improve the productivity of the NSW economy by leading the transition to digital engineering.

ADROITA will use the Jobs Plus support to assist them to develop a New South Wales-based Defence-digital engineering capability with a globally competitive service offering that will include modelbased systems engineering, digital sovereign test and evaluation, modelling and simulation, digital twin development, and other advanced data analytics such as machine learning, artificial intelligence, and decision support.

“Digital Engineering is to the engineer what Industry 4.0 is to the manufacturer.

Digital engineering requires the integration of modern digital enterprise systems with data driven techniques such as decision support and data engineering, modelling and simulation and digital systems engineering, to provide a modern, integrated approach to manage the lifecycles of complex defence systems from concept through to disposal,” said CEO of ADROITA, Ms Sarah Pavillard.

The company anticipates that the grant

BAE jobs for the boys, and girls

BAE Systems Australia aims to recruit 6,500 people over the next five years and kicked off a national recruitment drive at the air show.

Two events showcased the diverse career opportunities available in the defence industry.

On Wednesday 1 March (at the AMDA Tech Zone), BAE Systems hosted an event with Right Management, With You With Me and the Department of Veteran Affairs.

On Thursday 2 March, BAE launched the recruitment for its 2024 graduate program.

There are more than 100 graduate roles available across its national business next year.

BAE on the RAZER’s edge

RAZER is a low cost air-launched precision guided munition designed to transform a 40-50kg standard non guided munition into a precision air launched weapon at low cost.

The winners are: •

AVALON 2023 National Innovation Award: 1MILLIKELVIN Pty Limited (VIC)

•

AVALON 2023 Defence SME Innovation Award ($15,000): 1MILLIKELVIN Pty Limited (VIC)

•

AVALON 2023 Young Innovator Award ($15,000): Mr Callum Rohweder, BAE Systems Australia Limited (VIC)

In addition, three Award contenders won a High Commendation: •

AVALON 2023 National Innovation Award HIGH COMMENDATION: DMTC Limited (VIC)

•

AVALON 2023 SME Innovation Award HIGH COMMENDATION: MicroTau Limited (NSW)

•

AVALON 2023 Young Innovator Award HIGH COMMENDATION: Mr Michael J Scott, RMIT University (VIC)

18 | March 2023

The RAZER system consists of a wing/ body kit and tail unit equipped with a powered GPS/INS guidance control and navigation system, aimed at operations from Uncrewed Combat Air Vehicles (UCAV) and Rotary Wing aircraft.

“RAZER can meet urgent local and overseas demand for low-cost sovereign munition solutions that could be deployed

from the air. It could deliver a powerful and affordable battlefield strike capability for users globally,” BAE Systems Australia Chief Executive Officer Ben Hudson said.

The ability to deploy RAZER from an airborne platform and glide to target would dramatically increase the weapon’s range and provide a significant stand-off range for the launch platform.

Avalon Airshow 2023 | Feature

Ghost Bat Boeing’s MQ-28A Ghost Bat Australian supplier base has increased by 60 percent – to 55 suppliers – just four years after initial concept unveiling.

Making its public debut at Avalon 2023, the MQ-28 is the first Australian-designed, developed and manufactured military combat aircraft in half-a-century.

“The support of agile local suppliers has been vital to the rapid manufacture of this revolutionary uncrewed aircraft and its payloads, which will support a range of missions,” said Glen Ferguson, director MQ-28 Global Program, Boeing Australia.

“The Boeing MQ-28 program proves Australian industry can create a seamless link between airpower capability needs, local innovation and job opportunities.”

Lovitt Technologies Australia and Marand Precision Engineering are two suppliers applying innovative solutions to develop the fighter-like aircraft with Boeing.

Program capability partner, BAE Systems Australia has also signed an extension of a Memorandum of Understanding (MOU) as a

shared commitment to the development of a sustainable, sovereign MQ-28 program.

More than 35 Australian companies have contributed to the Ghost Bat program. It is the first military combat aircraft to be designed, engineered and manufactured in Australia in more than 50 years.

BAE Australian Cluster

BAE Systems Australia has become the first Defence prime to enter a partnership with Advanced Fibre Cluster, a group of organisations leading the innovation of advanced fibre and composite technology capabilities in Australia. The partnership was made official at a signing ceremony at Avalon Airshow.

The Advanced Fibre Cluster is pioneering a sovereign capability. Its innovations will complement BAE Systems’ work in the Guided Weapons and Explosive Ordinance (GWEO) Enterprise.

Led by companies located in the Geelong region, the Advanced Fibre Cluster (AFCG) provides investment opportunities for the Victorian economy and local industry.

“The AFCG was established with funding from Deakin University and a world leading group of domestic manufacturers situated in WaurnPonds, with a mission to enhance knowledge, innovation and collaboration within Composites and Carbon Fibre materials,” said AFCG CEO David Buchanan. www.saea.com.au

Deputy Prime Minister and Minister for Defence Richard Marles with Advanced Fibre Cluster CEO David Buchanan and BAE Systems Australia CEO Ben Hudson.

“Many of those members now lead the world in both product, design and capability from Victoria, exporting product and research innovation globally. Examples include Carbon Revolution, Quickstep, Sykes who are all founding members.

“The mission for the AFCG is to continue to collaborate, innovate and lead development of

Advanced Fibres with the world’s top scientific and manufacturing minds.

“We are excited that the addition of BAE Systems Australia to the group will ensure the continuation and focus on domestic capability and the growth of Geelong and Victoria as a national centre of excellence for research and domestic production programs.”

VTE | 19

Feature | Avalon Airshow 2023

Airshow Briefs Gilmour Space Technologies (“Gilmour”) and Atomos Space (“Atomos”) have announced the signing of a Memorandum of Understanding (MOU) to explore a multi-year contract for Gilmour and Atomos to mutually purchase services for launch and in-space transportation.

Melbourne-based critical communications SME, C4i, has been awarded a nationwide voice communication control system (VCCS) contract. Following a successful initial system delivery on behalf of C4i, this contract will expand on what is already one of the largest systems in Asia Pacific.

CGI the worldwide IT and business consulting services firm, has been awarded a Smart Sat Cooperative Research Centre (CRC) project alongside domain experts from both Swinburne University of Technology and the Royal Melbourne Institute of Technology (RMIT), to develop a space domain awareness technology demonstrator. The demonstrator will explore the application of artificial intelligence and advanced data visualisation techniques to enhance space domain awareness (SDA) and related mission systems.

Advanced Air Mobility in Morwell

Working collaboratively to co-design the future of advanced air mobility (AAM) will be the focus of a new partnership between Latrobe City Council and Swinburne University of Technology.

The partnership will explore how advanced air mobility can be established at the Latrobe Aerospace Technology Precinct to drive economic growth in the region.

Researchers from Swinburne’s Aerostructures Innovation Research Hub (AIR Hub) will work with Latrobe City Council, local research and industry partners, and certification organisations such as CASA, to pioneer new technologies in AAM for the

region and develop green aviation solutions to address real-world problems.

The Latrobe Aerospace Technology Precinct is located at Latrobe Regional Airport in Morwell.

Swinburne’s AIR Hub is one of Australia’s largest and most active industry-research collaborations, driving the future of air mobility and developing the next generation of aerostructures in Australia.

The Department of Defence announced its intent to “replace and expand” its fleet of C-130J-30 Super Hercules tactical airlifters in November 2022.

According to Defence, “the C-130J-30 represents the only option that meets all of Australia’s capability requirements and will be the only option that Defence will progress for Government approval under Project AIR 7404 Phase 1 in 2023.”

Airbus Defence and Space has selected Blacktree Technology Pty Ltd of Perth, Australia, to provide the ground segment for the Airbus funded UHF military communications hosted payload onboard a commercial telecommunications satellite manufactured by Airbus.

Lockheed Martin Australia and New Zealand announced partnerships with Marand, Survitec and TRCalibration to provide instrumentation, calibration and repair services for its aircraft ground support equipment as part of Lockheed Martin’s Product Support Provider network (PSPn).

Lockheed Martin technical hub for Victoria

For the first time, Boeing will hire Australian companies to supply parts for its AH-64E Apache helicopters.

Suppliers will provide components for these aircraft including Australia’s future fleet of 29 Apaches.

Australian companies Cablex and Thomas Global Systems respectively will manufacture cabling, and design and manufacture cockpit avionics components for the global fleet of Apaches. For the Australian fleet, four companies – Cablex, Ferra, Axiom Precision Manufacturing and Mincham were selected to supply wire harnesses, electrical panels, vertical spar box, machined parts, fairings and composites.

Under its proposal, Lockheed Martin Australia would invest in infrastructure and programs in Victoria to support the delivery of a Military Satellite Communications (MILSATCOM) solution for Defence.

GE Aerospace and Asia Pacific Aerospace (APA) signed an agreement for APA to provide GE-authorised T700 engine line maintenance training to operators in the region. This agreement expands an existing arrangement between the two companies that named APA as a GE- authorised Engine Maintenance, Repair and Overhaul (MRO) provider for T700 engines.

20 | March 2023

Lockheed Martin Australia announced its intent to work with the Victorian Government to establish Victoria as the engineering and technical hub for its proposed JP9102 solution. This investment would create more than 200 advanced space industry jobs in Victoria.

Lockheed Martin Australia and New Zealand Chief Executive, Warren McDonald, commented on Lockheed Martin Australia’s commitment to Victoria and the relationship with the Victorian Government.

“We have a well-established presence in Victoria, including our STELaRLab HQ in Melbourne – Lockheed Martin’s first multidisciplinary research and development laboratory outside of the United States,” he said.

“Through STELaRLab we are currently partnering with universities from across Australia in critical areas such as spacebased image exploitation, automated AI-based knowledge generation using nuero-symbolic reasoning and developing world-leading sovereign technologies for space domain awareness.

“The proposed investments in infrastructure, skilled jobs and STEM initiatives are designed to contribute significantly to ensuring Victoria’s space economy grows sustainably for decades to come.”

Avalon Airshow 2023 | Feature

Honeywell aims to create a better local presence Honeywell is a diverse company with interests in four areas of business: aerospace, building technologies, performance materials and technologies, and safety and productivity solutions.

Over the duration of the Avalon Airshow the company made several announcements one of which concerned Rosebank Engineering.

Honeywell and Rosebank Engineering signed three agreements to appoint Rosebank Engineering as a Maintenance, Repair & Overhaul (MRO) Authorised Service Centre for the F-35 Joint Strike Fighter Wheels and Brakes program in the Asia-Pacific (APAC) region.

a long history of partnering with Honeywell on various Defence platforms and programs.

As the Product Support Provider this will strengthen the sovereign capability of Rosebank Engineering and its ability to deliver on customer requirements.

During the event the company also announced an agreement with BAE Systems Australia to supply aircraft parts and component repair services for 33 Hawk 127 aircraft.

The establishment of the Honeywell MRO Authorised Service Centre will be exclusive to Rosebank Engineering in the APAC region.

This is the first of several F-35 sustainment assignments to be awarded to the company.

The five-year, non-exclusive agreement will be exercised for the Royal Australian Air Force (RAAF) Hawk 127 fleet. It will support the maintenance, repair, and overhaul of the fleet to meet the training requirements of the RAAF’s military modernisation program.

To meet its agreement, Rosebank Engineering will transition its skilled and experienced defence and aerospace technical staff from current legacy programs into the F-35 Global Support Systems. Rosebank Engineering has

We talked with John Guasto Vice President, Defense and Space International for Honeywell Aerospace who was at the show about the opportunities for engineers with Honeywell.

“We have everything from aerospace products, we have our building technologies, we have our safety equipment and then we have our petrochemicals and they could possibly have everything from chemical and process engineers to electrical and aeronautical engineers,” he said.

“We’re putting a lot of focus around alternative aircraft fuels and so a lot of hydrogen capabilities. And so we see a very large demand for chemical engineers and electrical.”

Mr Guasto said that the company was continuing to look at Australia as a growing market and sees the need for a larger footprint.

In Australia the company is focused on providing systems to manufacturers, he cited as an example the Boeing Loyal Wingman stating that the company is bidding to put content onto that platform and being a “successful partner on that platform is to have Australian development”.

Another focus Mr Guasto described centred around aftermarket support saying that the company sees a need to increase the amount of MRO capability in Australia.

“And as part of doing that, not only does it create jobs for technicians or engineers, depending on the complexity of the part to be able to do those repairs. But there’s also engineering requirements for folks that basically design the sub component,” he said.

Engineering resources will be needed locally to support the growing MRO capability.

“And number one is around our auxiliary power units, which is a small engine that used to provide auxiliary power ... It’s basically a mini jet engine,” Mr Guasto explained.

“So, we’ll need a lot of engineering resources to support the repair and overhaul of those components. And then also we have the engines, basically on the Abrams tank and on the Chinook helicopter. And we already do some of the AGT 1500 here locally but we’re looking to do T-55, as well. And so, we will need propulsion engineers and process engineers … It’s really about creating a local presence.”

John Guasto Vice President, Defense and Space International for Honeywell Aerospace www.saea.com.au

VTE | 21

Feature | Avalon Airshow 2023

Wings and Wheels for Australian Pegasus A three-hour commute to attend the Avalon Airshow on day one was especially auspicious as Australian company Pegasus was displaying its latest iteration of a flying car. In case this seems a bit ‘pie in the sky’ there’s plenty of companies vying for a slice of the sky in this domain.

Pegasus appears to be the only Australian company that is in that space but there are overseas companies – more about one of those later. However, it should also be said that many competitors to Pegasus do not offer identical craft with many making passenger craft that take off and land but are not capable of being driven on a road.

Pegasus is one of only two flying car manufacturers globally who have obtained national airworthiness certification.

Jacky Yang who is the Pegasus Chief Technical Officer was at the Avalon Airshow with two versions of the Pegasus.

According to the company a unique integration of modern automobile and rotorcraft technologies enabled it to create the Pegasus E, a true VTOL-capable drivable flying car that can be parked in any general car park or garage.

“The Pegasus is a unique product made as practical as possible. Meaning we can go and register this particular aircraft already, and we can fly anywhere that we want. So, this is something that no other company can do at the moment,” said Mr Yang.

The transition between aircraft and car can be done in three seconds at the push of one button. When the Pegasus lands, the main rotors fold in half automatically using centrifugal force – this is a patented technology.

The Pegasus E controls are also very similar to cars and rotorcrafts and a patented threeJacky Yang, Pegasus Chief Technical Officer

foot paddle system integrates all driving and flight controls into one package, allowing driving controls to be the same as a normal car and flight controls to be the same as a rotorcraft.

Being a hybrid flying car, the Pegasus E has a range of three hours, equivalent to 420kms.

In flight, it has a top speed of 160km/h, and 120km/h (electronically limited) when driving on the road. Easy to obtain 95RON unleaded petrol is the standard fuel so users will not suffer from range anxiety – not something you want to experience while in the air.

“Pegasus is a hybrid so we can make it fly for more than three hours,” Mr Yang explained.

“That means between cities. Now we can also travel instead of just doing a short 10km range.”

The Pegasus E is built with advanced lightweight materials like autoclave prepreg carbon composites, titanium and aircraft grade 6061 T6 aluminium. The chassis construction aims to keep the Pegasus as light as possible. Race car style double wishbone front suspension enables the vehicle when on the road to mix it with normal traffic.

The front end is a very conventional front drive system. The rear drive is a swing-arm system, which takes all the landing load and the take-off load extremely well. This is where the innovation is because a flying car can’t be all conventional. The innovation is in the drive and the transition time.

Police ready Pegasus Alongside the passenger version of the Pegasus at the Avalon Airshow was a police version which is a great idea though one that can’t be totally attributed to this company as another company Italian Pal-V has also taken a leap into emergency vehicle space with their PAL-V – more about that later.

Mr Young said his company has released the Pegasus police version of the flying car because they see a great scope for a vehicle that can respond much quicker to emergencies than current police cars or helicopters and cheaper to run. Other uses could be to monitor traffic or incidents. You can also envisage the use of a Pegasus for other emergency services – again something that PAL-V has initiated.

Pegasus in the Olympics Another area that the company is considering is providing their vehicle for taxi services during the 2032 Brisbane Olympics. Mr Yang is enthusiastic about the prospect of an Australian made flying taxi used at the event, it will not only promote their company to the world but also Australia’s innovations in engineering.

To make that happen the company has opened the process of communication with federal agencies and CASA (Civil Avation Safety Authority – Australia) to ensure that current and future regulations are met.

While Pegasus is a small company it has a good base of Australian engineering talent onboard including Peter Schaefer a wellknown former team manager/engineer of Formula Brabham, former team manager of the Gibson Racing Team and former structural designer and aerodynamicists for the Holden Racing Team.

Alongside Mr Schaefer is a team of aeronautical, electrical, CAD and mechanical engineers. Jacky Yang, apart from his role as CTO, is also the test pilot and holder of a delta wing pilot’s licence and a civil helicopter licence, and he is an ex-open wheeler race driver.

22 | March 2023

Avalon Airshow 2023 | Feature

not just an aircraft, and neither is it just a car it’s both,” David Polo Marks, CEO/Airboss of SkyAngels, said.

“The fact that the aircraft can drive on roads means that it is not restricted by weather conditions and it’s a car that can fly which doesn’t need roads so makes it an ideal solution for our emergency response needs, especially in areas where ground infrastructure is limited. We are thrilled to have PAL-V as our partner and look forward to utilising their unique technology in our operations.”

The future is in the air

A Pal in the sky

Morgan Stanley has recently released a report based on the eVTOL market (available at: https://assets.verticalmag.com/wpcontent/uploads/2021/05/Morgan-StanleyURBAN_20210506_0000.pdf) that predicts that by 2040 the market will reach $1 trillion which is a substantial amount for what only yesterday seemed like something out of a Jetsons cartoon.

Italian company PAL-V is another company that has travelled down the road of designing and building a flying car with its PAL-V Liberty that the company says has the capacity to reach a maximum speed of around 180 km/h in the air and almost 160 km/h on the road.

Mr Yang said that he is convinced that this technology is on the way up because there is no longer room to expand in a 2-dimensional way.

This vehicle is about the same size as a car but transforms to a gyroplane at the press of a button. In the UK SkyAngels Air Ambulance has joined PAL-V in a partnership to provide fast transport solutions.

“We must elevate to the third dimension,” he said. “We can ease traffic on the ground. We can get people from point A to point B much faster.”

Its wind-powered rotors provide a range of around 1300 kilometres in the air and around 500 on road.

“Range, payload, and practicality are key factors when considering a flying car for our air ambulance service. The PAL-V Liberty is

The PAL-V Liberty will operate as one of SkyAngels’ fast response vehicles, with advanced paramedics and doctors able to utilise its unique abilities to get to the scene faster and more efficiently.

The PAL-V Liberty can be used on short flights over natural obstacles, such as flying to the Isle of Wright or the Isle of Man. But can also be used as quick transfer cross country, independent from the major highways and the congestion.

“The reservation of SkyAngels shows their trust in our product, and we look forward to further developing this partnership to make emergency response better,” Robert Dingemanse, CEO of PAL-V, said.

“SkyAngels Air ambulance has a unique use case for the Liberty, which also helps us to develop the business and governmental markets. Besides emergency response, it is also a tool which can be used for coast guarding, border patrol, policing and many more applications.”

Specifications: Pegasus Flying Car - E class Engine: Pegasus 800/160 hp Fuel type: #95 unleaded Dry weight: 265kgs Vehicle Height: 1900mm Wheelbase: 2900mm Front track: 1800mm Rear track: 1745mm Rotor diameter: 5285mm Fuel capacity: 60 litres Ground to air transition time: 3 seconds Ground top speed: 120 km/h Take-off and landing distance: 0 metres Max Air speed: 160km/h Max cruise speed: 130 km/h Max range: 420 km Max flight time: 3 hours Maximum flight altitude: 1800 metres Useful payload: 101 kgs Fuel economy: 20 litres per hour www.saea.com.au

VTE | 23

Feature | DT Engineering

Ray tracing tech for AV and ADAS New ray tracing rendering technology is the first to accurately simulate how a vehicle’s sensor system perceives the world.

UK software specialist, rFpro, has developed a new simulation technology that significantly reduces the industry’s dependence on real-world testing for the development of autonomous vehicles (AV) and ADAS (Advanced Driver Assistance Systems).

“The industry has widely accepted that simulation is the only way to safely and thoroughly subject AVs and autonomy systems to a substantial number of edge cases to train AI and prove they are safe,” said Matt Daley, Operations Director at rFpro.

“However, up until now, the fidelity of simulation hasn’t been high enough to replace real-world data. Our ray tracing technology is a physically modelled simulation solution that has been specifically developed for sensor systems to accurately replicate the way they ‘see’ the world.”

The ray tracing graphics engine is a superior fidelity image rendering system that sits alongside rFpro’s existing rasterisationbased rendering engine. Rasterisation simulates light taking single bounces through a simulated scene.

This is sufficiently quick to enable real-time simulation and powers rFpro’s driver-in-theloop (DIL) solution that is used across the automotive and professional motorsports industries.

Ray tracing is rFpro’s software-in-the-loop (SIL) solution aimed at generating synthetic training data. It uses multiple light rays

24 | March 2023

through the scene to accurately capture all the nuances of the real world.

As a multi-path technique, it can reliably simulate the huge number of reflections that happen around a sensor. This is critical for low-light scenarios or environments where there are multiple light sources to accurately portray reflections and shadows.

Examples include multi-storey car parks and illuminated tunnels with bright ambient daylight at their exits, or urban night driving under multiple street lights.

Modern HDR (High Dynamic Range) cameras used in the automotive industry capture multiple exposures of varying lengths of time. For example, a short, medium and long exposure per frame.

To simulate this accurately, rFpro has introduced its multi-exposure camera API. This ensures that the simulated images contain accurate blurring, caused by fast vehicle motions or road vibrations, alongside physically modelled rolling shutter effects.

“Simulating these phenomena is critical to accurately replicating what the camera ‘sees’, otherwise the data used to train ADAS and autonomous systems can be misleading,” said Daley.

“This is why traditionally only real-world data has been used to develop sensor systems.

Now, for the first time, ray tracing and our multi-exposure camera API is creating engineering-grade, physically modelled images enabling manufacturers to fully develop sensor systems in simulation.” rFpro’s ray tracing is applied to every element in a simulated scene, which has been physically modelled to include accurate material properties to create the highestfidelity images.

As this is computationally demanding it can be decoupled from real-time. The rate of frame rendering is adjusted to suit the level of detail required. This enables high-fidelity rendering to be carried out overnight and then played back in subsequent real-time runs.

This overcomes the usual trade-off between rendering quality and running speed.

“Ray tracing provides such high-quality simulation data that it enables sensors to be trained and developed before they physically exist,” explains Matt Daley, Operations Director, rFpro. “As a result, it removes the need to wait for a real sensor before collecting data and starting development.

This will significantly accelerate the advancement of AVs and sophisticated ADAS technologies and reduce the requirement to drive so many developmental vehicles on public roads.”

Technical | Feature

K. Tucker 1*, R. Gover 1, R.N. Jazar 1, H. Marzbani 1 1

RMIT University, Bundoora, VIC 3083. Australia

ABSTRACT

* Corresponding Author (E-mail: kyle.tucker@rmit.edu.au)

An Autonomous Vehicle at the Handling Limit: A Hierarchical Controller Based on the Quasi-Steady-State Model 1. Introduction

2.1 Path Planning

Safe autonomous vehicles must be reliably controlled in many situations, including in transient on-limit manoeuvres, e.g. obstacle avoidance. Many control algorithms used for autonomous vehicle control are founded on linear vehicle dynamics and sub-optimal control models [1,2], and thus their application in extreme vehicle manoeuvring tasks is limited. The main challenges associated with on-limit vehicle control are two-fold: The prediction accuracy of the vehicle response within the environment, and the computational effort of the control calculations.

Most path planning tools employed in vehicle modelling tasks are geometric in nature, due to their computational speed. Geometric paths provide a robust method for determining time optimal solutions to the minimum time path. Minimum curvature paths are often the choice of geometric solution [9,10] as this closely resembles the minimum time path of a racing circuit. Vehicle trajectory curvature is also importantly related to the vehicle acceleration as the normal acceleration (an) can be determined with vehicle speed (V) and the curvature of the vehicle trajectory (Kv).

This work attempts to bridge the gap between the prediction accuracy of the vehicle modelling task and the real-time implementation of Model-Predictive-Control (MPC). This paper presents the formulation of a hierarchical control framework which capitalises on the advantages of both vehicle models. A path planning model is used to assist with optimal control refinement. Racing car lap-time simulations [3-8] are used in this work for result comparisons as they provide a convenient platform to assess the performance of the controller in transient onlimit manoeuvres. Future developments of this controller may be more suited to specific autonomous vehicle control tasks.

This paper is organised as follows. Section 2 introduces the vehicle modelling techniques.

Section 3 will outline the hierarchical control framework employed in vehicle modelling tasks. Section 4 shows the results of the research and Section 5 concludes the paper.

2. Vehicle Modelling Three vehicle modelling formulations are presented in this section. The first is a geometric path planning tool which provides feasible trajectories to point mass minimum time problems. The second is a minimum time point mass vehicle model which accurately predicts vehicle behaviour in transient on-limit vehicle manoeuvring problems. Lastly, a short horizon 7 Degree-of-Freedom (DOF) transient vehicle model is used for path following.

The three models outlined in this section form a hierarchical control framework used to control a vehicle in minimum time manoeuvres. The unique contribution of each model is outlined in Section 3. www.saea.com.au

(1) Understanding the relationship between curvature and trajectory is therefore of fundamental importance. The curvature is presented in the global (inertial) coordinate frame.

(2) When the monotonic derivative indicator ( ̇) is defined w.r.t. trajectory arc length (Sv), eq.(2) is simplified with a denominator equal to 1. Whilst this simplification assists with computational effort, the resulting equation remains within the global framework and therefore curvature resolution is still challenging. By evaluating the trajectory curvature in a curvilinear coordinate frame (track), a new equation for curvature is presented [4].

Most approaches to autonomous vehicle control are focused on normal driving conditions and are not suitable for on-limit control due to the non-linear nature of on-limit behaviour. Situations which require on-limit control are also commonly constrained by hard boundaries and require fast computation times, providing a unique set of problem constraints that are challenging to fulfill.

Numerical simulation of on-limit manoeuvres often carries significant computational burden, precluding the direct use of full transient vehicle simulations in Model-PredictiveControl (MPC). Quasi-Steady-State (QSS) lap time simulation is a modelling method commonly found in motorsports, which uses point mass dynamics to control a vehicle within a set of predefined acceleration and jerk envelopes. QSS models are capable of accurately predicting the transient velocities and trajectories of on-limit vehicle motions, though vehicle controls such as steering and throttle cannot be formally tended to with this method. This paper presents a 3-tiered hierarchical control framework used to control autonomous vehicles in on-limit handling based on QSS motion. A simple constrained geometric path evaluation algorithm is used to determine a feasible path for initialisation, with QSS free-trajectory optimisation used to determine trajectory and velocity profiles.

Finally, a short horizon transient vehicle model optimisation is used to convert QSS motion into a set of autonomous vehicle controls. The controller is evaluated in a Model-in-the-Loop setup, where the ability of the hierarchical framework to control the vehicle in near realtime is demonstrated at the limits of handling.

Vehicle response is compared with a fixed horizon transient and fixed horizon QSS optimal control model, providing favourable results.

KEYWORDS: Autonomous vehicles; Lap-time simulation; Quasi-Steady-State; Hierarchical controller; On-limit control.

of the velocity (e.g. braking at constant acceleration along SC) therefore provides conservative feasibility assessments of the (3) motion along the path. The variables (DV, DV’ , an and jn) are then imposed as state/ control parameters in the development of the where Dv is the vehicle reference line offset, trajectory to determine feasible paths in a Kv is the reference line curvature and Q is the geometric format. vehicle to reference line translation ratio.

Track variables Xc and Yc, and vehicle reference line offset Dv are fitted with (4) piecewise polynomial splines to impose acceleration continuity across the path.

All are functions of the reference line arc length (SC).

The 2nd and 3rd derivatives of the parameterised eq.(3) are notably explicit forms of normal acceleration (an) and normal jerk (jn) if the velocity is known. Trivial developments

(5)

(6) VTE | 25

Feature | Technical

The track spline coefficients (c1 − c12) are developed during the environment mapping process and the reference line curvature KC is calculated directly with the numerator of eq.(2), employing track spline coefficients.

2.2 Point Mass Motion The point mass vehicle model has only two DOFs and is controlled with planar jerk variables [3]. As the equations of motion do not consider the yaw degree of freedom, the only non-inertial reference frame available is the natural coordinate frame, which is fixed at the centre of mass and orientated in the direction of the path of motion [11].

Accelerations and jerks are therefore presented in the natural coordinate frame. The state (X2) and control vector (U2) for the point mass vehicle is shown.

(14)

Figure 1.Track coordinate frame and vehicle positioning.

(7)

(11)

(8)

Equality constraints are calculated with state space derivative (XT’).

(9)

(12)

The state (XT) and control vectors (UT) are shown.

(15) The state derivative variables are presented.

(16)

The spatial derivative of an is.

(10)

(17) (13)

(18) As fixed distance problems require state space transformation, the spatial first order Runge-Kutta marching method is presented.

(19) The state space derivative is.

(20) 2.3 Transient Vehicle Motion The transient vehicle model has two distinct developments, those are the rigid body equations of motion which apply to the general plane motion of the chassis (3 DOF) and driveline equations of motion which are used to determine the wheel state for tyre force evaluation (4 DOF). Development of the complete set of equations of motion is outside the scope of this paper, thus the authors refer the reader to [3] for the full development. The state vector for the transient vehicle model is presented.

(21)

Figure 2.Vehicle coordinates and forces.

26 | March 2023

Where YC is the yaw rate of the chassis, w j is the anular velocity of each wheel, and T, and 8 are the normalised throttle/braking and steering positions respectively. The control vector is presented.

Technical | Feature

representation of the maximum quasi-steadystate (QSS) accelerations of the equivalent transient vehicle model. The acceleration envelope development is outside the scope of works but is outlines in [3]. The acceleration constraint is imposed on the point mass motion problem as a non-linear inequality constraint.

(28)

Figure 3.Hierarchical control framework.

(22) The spatial marching method presented in eq.(18) equivalently applies to the transient vehicle model, as does the state space transformation eq.(19). The remaining transient derivative variables are developed via a summation of wheel and chassis forces and moments.

As the transient vehicle model forces are evaluated in the body coordinate frame, NewtonEuler equations of motion are presented.

(23) (24)

implicit solver implementation will significantly improve computation time [13,14]. The current method therefore demonstrates the utility and feasibility of the framework.

3.1 Feasible Path Planning Control The path planning optimal control problem intends to provide minimum curvature paths. The minimum curvature path closely resembles the minimum time optimal control solution in a geometric format. Vehicle motion along the path is used as the QSS MPC initial guess. This initial guess is sufficiently close to the optimum for reliable solver convergence [4].

The cost function of the optimisation problem is shown as.

3. Hierarchical Control Framework As the use of full transient vehicle models is too computationally costly for real-time MPC [12], a hierarchical set of vehicle modelling tools, fig.(3), is sequenced here to control the vehicle at the limits of handling. First, a feasible path planning method is used to develop a minimum curvature trajectory with horizon length SC = 500m. Next is a QuasiSteady-State (QSS) point mass model is used to predict the minimum time response of the transient vehicle model. The horizon length of the QSS model is SC = 300m and has an T end state condition, DV and OV defined by the feasible path planning model, which ensures that the end state of the QSS manoeuvring problem is positioned close to the minimum time solution, improving initial control refinement.

The last stage of the hierarchical controller is the restricted horizon length transient vehicle path following controller. The horizon length is only SC = 10m, with end state constraints defined by the position T DV and heading angle OV from the QSS vehicle motion problem. The optimisation objective minimises a mean-square of the QSS and transient velocity profiles along the trajectory. The short horizon distance of the transient path following controller allows the control algorithm to run in near real-time.

It is expected that improvements to the controller, e.g. higher order explicit RungeKutta methods, discretisation refinement, or www.saea.com.au

Two acceleration envelopes are used in this work. The first is a Normal-TangentialAcceleration (NTA) surface [3], and the other is a friction ellipse (FE) surface (designed to match the NTA surface while remaining below to ensure control reliability).

A strategic set of jerk limits for this vehicle was also outlined in [4]. Appropriate jerk limits are one of the major driving factors behind the alignment of QSS and transient models.

Track position DV and track heading angle T OV are imposed on the QSS motion problem as an end state constraint and are derived from the feasible path planning solution at a horizon length of SC = 300m. The remaining permissible states are derived from track and vehicle parameters.

The minimum time cost for the QSS problem is presented.

(29)

(25) where the control segment is defined by (∆SU = 1m, : N = 500), and the analysis segment is defined by (∆SV = 0.05m, : n = 20). The permissible set of states and controls are determined by track and vehicle parameters.

The trivial velocity profile is evaluated with constant reference line acceleration.

Where the control segment is defined by (∆SU = 1m, : N = 300), and the analysis segment is defined by (∆SV = 0.05m, : n = 20). The formal optimisation problem for the QSS model is.

(26) (30) The formal optimisation problem for path planning is.

(27)

3.2 QSS Minimum Time Control The QSS model is used to accurately predict the minimum time response of the vehicle.

Improved computational efficiency of this simplified model provides a platform that is more suited to real time control.

The acceleration envelope that restricts the point mass accelerations is developed offline with an optimisation problem and is a

3.3 Transient Path Following with Restricted Horizon Length QSS vehicle motion is simplified to improve computational efficiency, but vehicle controls are untended. The receding horizon transient vehicle model, which does tend to controls, cannot be used due to its computational efficiency. Computational efficiency however, scales with problem size, thus the transient vehicle model can be used if the horizon length is sufficiently short (H<10m).

Reliability of open loop vehicle control with reduced preview distance however, cannot be guaranteed. The transient vehicle model must therefore have strict end conditions which ensure its forward-looking reliability when horizons are short, turning the problem VTE | 27

Feature | Technical

into a path following task. As the QSS point mass model can accurately predict the transient minimum time response, the strict end conditions placed on the transient vehicle model can be derived from here.

Consistent with the path planning and QSS vehicle models, the transient vehicle model is also restricted by a set of permissible states and controls. In addition to these, it is also beneficial to restrict sub-states, such as tyre slip ratios. Restricting tyre slip states reduces both tyre wear and the possibility of entering into unstable and/or unrecoverable vehicle manoeuvres, which is particularly important with short horizon lengths. These additional restrictions are presented in the optimisation problem as a nonlinear inequality constraint.

(31) Where k and k are the upper and lower bounds imposed on the slip ratios.

The objective function for the transient vehicle model is.

Figure 4.Berlin optimal trajectory comparison.

(32) Where w1 is the weigting factor applied to each analysis step, V(i) is the transient vehicle velocity, VQ(i) is the target vehicle velocity

defined from the QSS minimum time solution.

Where the control segment is defined by (∆SU = 1m, : N = 10), and the analysis segment is defined by (∆SV = 0.0125m, : n = 80).

The formal optimisation problem for transient path following is.

(33)

3.4 MIL Control The hierarchical controller can be simulated in the virtual space by using a vehicle model in place of the autonomous vehicle response where a virtual control loop is setup, referred to as Model-In the-Loop (MIL). Whilst this work employs identical prediction and control models (assuming a definite environment and accurate modelling), the MIL framework provides a platform for virtual validation of the control framework. Artificial implementation of response disturbance (through differences in precision and control modelling) will yield differences in the outputs of the models which can be used to assess the robustness of the controller. This is reserved for future work.

Figure 5.State results for QSS and MIL solutions.

28 | March 2023

Before proceeding to results, it is noted that the performance of the path following

Technical | Feature

Table 1.Optimal times for Berlin circuit

Vehicle

time - sec

∆t - %

Transient

67.49

-

1

QSS (NTA)

67.89

+0.6

0.01

QSS (FE)

72.72

+7.8

0.003

MIL (NTA)

68.93

+2.2

≈4

MIL (FE)

73.73

+8.6

≈ 71

controller should not exceed that of the QSS full length minimum time solution as the target is only to follow both the path and velocity profile. Receding horizon solution should also be slower than the full circuit problem as global optimisation characteristics are not observed in the local minimum time response [15]. It is therefore hypothesised that the MIL simulations will have slower optimal times than the comparative works.

4. Results This work compares five simulations on the Tempelhof Airport Street Circuit (Berlin).

The first three are full length minimum time optimisations with transient and QSS models (NTA and FE). The last two are minimum time hierarchical MIL simulations (NTA and FE).

Transient and QSS lap-time simulations are

Comp Time - [Norm]

developed with the methods presented in [3,4] including all vehicle model parameters. The hierarchical controller presented in this paper also utilises identical vehicle parameters for comparability. The initial state of all examples is equivalent in their respective forms and are fixed. All simulations are implemented in MATLAB and are solved using the FORCES PRO NLP solver presented in [16,17].

The optimal trajectories are presented in fig.(4). The reference line orthogonal offset (DV), fig.(5), shows the trajectory of the QSS and MIL simulations. The deviation of those trajectories from the transient response is also presented in fig.(6). The trajectories presented show a good alignment of the transient response for both the QSS and MIL simulations. As the FE models have a regions in the acceleration envelope with largely

different acceleration capabilities (due to the FE surface remaining exclusively beneath the NTA surface), large divergences between the FE and transient trajectory can be seen. The biggest difference in the trajectories of the vehicles occurs on the large sweeping left hand turn (circa SC ≈ 250m – 650m). In this section of the track, the racing line sensitivity to full lap manoeuvring time is low, so variability between the models is large.

The velocity states, fig.(5) and deviations, fig.

(6), also show a good alignment however there is a clear distinction between the NTA and FE models here. Peak deviations of the NTA lap-time simulation velocities are within 1m/s of the transient vehicle as compared to the FE lap-time simulation which have velocity deviations beyond 4m/s. This is explained by the differences in acceleration surfaces. The hierarchical controller deviations are higher for their respective QSS models.

T

The track heading angle ( OV) also shows a good alignment. Notable deviations in the final hairpin, however, indicate a different mode of operation for the QSS lap-time simulations.

This difference is not unexpected as when speeds are low (V<10m/s) the QSS vehicle model assumptions are less accurate.

The alignment of the vehicle response is important in the evaluation of the controller capabilities. One of the most important evaluations to make is the alignment between the MIL simulation and the QSS lap-time optimisation for the same vehicle model.

This comparison gives an indication to the performance of the transient path following controller. The relative comparison for NTA is +1.5% and for FE is 0.8%, which is slightly higher than the expected deviance due to the receding horizon effects. The direct comparison between the MIL (NTA and FE) and transient yielded a difference of +2.2% and +8.6%. Comparisons between the QSS and transient however are as expected at +0.6% and +7.8% respectively, thus the deficiencies in the MIL controller must be explained by deficiencies at the transient path following level.

When the MIL controller is entering a braking zone, the optimal jerks close to the current position (H<10m) appear not to align perfectly between the QSS and transient path following controller. This causes the velocity of the path following controller to overshoot the target QSS velocities. As the hierarchical control method is open loop, the overshoot cannot be recovered by the succeeding QSS model, resulting in a sub-optimal target path for path following. It is this overshoot that produces the comparative deficiencies of the MIL controller.

Figure 6.State result deviation from transient. www.saea.com.au

Noting this deficiency, the hierarchical controller still shows excellent control capabilities at the limits of handling. The local jerk sensitivities in the path following controller therefore provide an avenue for VTE | 29

Feature | Technical

future work to incrementally improve both the QSS and transient alignment.

The piecewise NTA surface requires significant computational effort to compute which limits its real-time applicability.

Comparatively, the FE model is much simpler and thus is much quicker to compute.

Normalised computation comparisons appear in Table 1, noting that the FE MIL controller is roughly one order of magnitude away from real-time implementation.

Real-time implementation of the control framework requires several improvements.

Potential examples include refinement of the control and analysis discretisation, acceleration envelope discretisation, and explicit/implicit modelling formulations provide an additional avenue for further research.

5. Conclusions Safe autonomous vehicles need to be accurately controlled in many situations, including in transient on-limit manoeuvres.

High fidelity controllers are however too computationally expensive to run in realtime. QSS models solve this problem and are sufficiently accurate to predict the transient response, but vehicle controls are untended.

A hierarchical control structure is presented in this work to solve these challenges.

Results of two Model-In the-Loop (MIL) simulations are presented for comparison against QSS and transient lap time simulations. Comparisons of QSS and transient lap-time simulations are in line with expectations, however the hierarchical control model deficiencies are slightly higher than expected.

Deficiencies in the controller are explained by velocity overshoots from the transient model at the point of braking initialisation. This is caused by a misalignment of the local jerk characteristics in the local problem horizon (H<10m). As the MPC form is open loop, this results in sub-optimal QSS trajectories that cannot be recovered. Noting this deficiency, the hierarchical controller still capable of 30 | March 2023

controlling the vehicle to a minimum time performance of +1.5% as compared to its maximum potential (defined by the QSS laptime simulation). The observed phenomenon provides an avenue for future work on the specification of the QSS jerk limits.

The computation time of the hierarchical controllers is also assessed. It is noted here that the NTA surface model is more computationally costly as compared with the FE model. It is expected that refinement of the optimal control structure will bring the hierarchical controller with FE to be real time capable.

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