Bearing condition monitoring is an important task in any rotary machine application, given that a bearing is a Single Point of Failure that can lead to catastrophic failure of an entire system. A variety of scenarios can arise from a bearing failure, ranging from only a little monetary loss to hard human fatalities. Accordingly to the risk presented by each system, a wide set of monitoring techniques may be considered, from a simple periodic monitoring routine, usually performed locally by an operator, to a permanently online system that triggers warnings or alarms when a fault is detected on a bearing. The ultimate aim of iBearing is to monitor the bearing in real-time, and directly in the structure of the bearing, being subjected to the same surrounding harsh environment defined by oil lubricant and high temperatures. Moreover, the proposed system will apply an advanced data fusion algorithm capable of integrating sensorial data from several sources simultaneously, namely temperature, low frequency accelerations, acoustic emission waves, and quality of the lubricant, in order to calculate the most reliable prediction of the time to failure, without intervention of any testing operator. The consortium composed by Active Space Technologies, Cranfield University, and Schaeffler intend study the best solutions to achieve the iBearing goal. The selected solutions will be designed, implemented and tested on the Schaeffler test rigs, in the framework of the present activity. The final iBearing product will be a miniaturized and integrated piece of equipment to install in any bearing, just requiring minimal adaptations to the shape of new bearings.

HERAQCLES stands for New Manufacturing Approaches for Hydrogen Electrolysers To Provide Reliable AEM Technology Based Solutions While Achieving Quality, Circularity, Low LCOH, High Efficiency And Scalability. Project HERAQCLES delivers an operational 25kW electrolyser stack including balance-of-plant based on AEM technology to validate both our novel design-for-manufacturing architecture and innovative components developed for automated production processes. AEM electrolysis offers a more attractive cost/performance ratio compared to state-of-art PEM electrolysis because these is no need to utilise precious group metals in stack components like catalysts, porous transport layers and bipolar plates for generating hydrogen at reasonably high current density. Current stack manufacturing processes face bottlenecks limited by many separate components, manual assembly and lack of tooling due to low production numbers. The project focusses on increasing Manufacturing Readiness Level from 4 to 5 by collectively advancing all components to comply with automated manufacturing processes at industrial scale: forming of metal plates, 3D-screen printing porous layers, pilot-scale synthesis of membrane polymers and catalyst. Validation occurs in three yearly loops using single cell, short stack and full 25kW stack configurations, where test results are benchmarked against commercially available options to highlight critical improvements of composition, functionality and recyclability. The experienced consortium brings together a unique combination of know-hows acquired in previous projects (e.g. Anione) and manufacturing capabilities provided by strong representation from industrial partners (6 out of 8). If successful, the final qualified stack prototype can be scaled-up quickly. Finally, a business plan is established comprising of a technology roadmap, an analysis of premium applications, an overview of product-market combinations and feasible market development plans.

In nearly every sector of industrial manufacturing surface processing techniques are used, e.g. for structuring or polishing of aesthetical or functional surfaces. In many applications laser based surface processing techniques already achieve highest precision and quality. But often the throughput is limited. State of the art for many applications in laser surface processing is the utilization of one round laser beam. The idea of ultraSURFACE is to increase the throughput for laser surface processing by at least a factor of 10 without any drawbacks in the quality of the processing results. Therefore, two different optics concepts will be realised and combined with a fast and synchronized machine, scanner and optics control. Optics Concept 1 refers to a dynamic and flexible beam-shaping approach with piezo-deformable mirrors which enables the realisation and the fast adaption of application specific intensity distributions. This will allow significant increase in feed speed and track offset and therefore of throughput. Optics Concept 2 is a beam splitting approach which allows simultaneous processing with multiple laser beams and thus a significant increase of throughput. For both concepts the implementation of prototypes is planned as well as their industrial validation in different fields of application (laser structuring, laser polishing, laser thin-film processing). The main ultraSURFACE Objectives are uSO1 Dynamic and flexible beam-shaping optics for laser surface processing uSO2 Multi-beam optics for parallel laser surface processing uSO3 Ultrafast synchronisation of optics and machine for 3D processing uSO4 Validation in industrial scenarios

The CO2EXIDE project aims at the development of a combined electrochemical-chemical technology for the simultaneous “200%” conversion of CO2 to ethylene at the cathode, water oxidation to hydrogen peroxide at the anode and a subsequent chemical conversion of both intermediates to ethylene oxide and oligo-/polyethylene glycol in a cascade, boosting this technology from TRL4 to TRL6. The CO2EXIDE technology combines a modular nature for the feasibility of a decentralised application, a high energy and material efficieny/yield and the substitution of fossil based production of ethylene oxide. The CO2EXIDE technology will be combinable with renewables and allows for the direct creation of products, which can be integrated into the existing supply chain. The reactions will be operated at low temperatures and pressures and forecast significant improvements in energy and resource efficiency combined with an enormous reduction of GHG emissions. All improvements will be quantitated using Life Cycle Assessment. The CO2EXIDE approach will bring together physicists, chemists, engineers and dissemination and exploitation experts from 5 universities/research institutions, 3 SMEs and 2 industries, innovatively joining their key technologies to develop and exploit an unprecedented process based on CO2, renewable energy and water to combine the chemical and energy sector. Within 42 months project duration, the CO2EXIDE technology will undergo a thorough material and component R&D programme. A 1kW PEM electrolyser for CO2-reduction and water oxidation in combination with an ethylene enrichment unit and subsequent chemical conversion cascade reactor will be manufactured to produce ethylene oxide as intermediate for oligo-/polyethylene glycol synthesis. This will prove the achievement of the quantified techno-economic targets of CO2EXIDE.

The UPGRADE project aims to support the transition to a high efficient, cleaner and affordable powertrain technology systems, based on Spark Ignited GDI (Gasoline Direct Injection) approach, suitable for future Light Duty applications. The project also includes a deep analysis of the phenomenon of the formation of the nanoparticles in relationship to the engine design and its operating conditions and, with regard to the after-treatment solutions, the study and development of new Gasoline Particulate Filter (GPF) technologies. To increase the engine efficiency under Real Driving conditions, the following steps will be carried out: - address stoichiometric combustion approach on the “small” size engine and lean-burn combustion approach on the “medium” size one - study and develop the best combinations of technologies, including advanced VVA/VVT capabilities, advanced boosting system (including electrically assisted booster operations), EGR (Exhaust Gas Recirculation) and thermal management systems - Explore and implement advanced fuel injection (direct) and ignition system supported by new dedicated control strategies that will be integrated in the ECU (Engine Control Unit) software. In order to demonstrate the call overall targets (15% improvement on CO2 emissions based on the WLTP cycle and compliancy with post Euro 6 RDE standards) the project will see the realization of two full demonstrator vehicles: one B-segment vehicle, equipped with the small downsized stoichiometric engine, and one D/E vehicle equipped with the medium size lean-burn engine. The vehicle will be fully calibrated and assessed by independent testing, according to on road test procedures, using the available best representative PEMS (Portable Emission Measurement System) technology and considering also PN measurement below 23 nm diameter.