Jaguar Cars Research Articles

Innovative groundwater management in industrial park: Optimization and modelling of extraction system

The research presented in this paper focuses on the optimization and modelling of an innovative groundwater extraction system and addresses the challenge of managing the increased groundwater level in Nitra Industrial Park, where the Land Rover Jaguar car manufacturer is located. The primary objective of this research was to determine the optimal pumping rate of the system, ensuring the maintenance of the groundwater level at the required elevation without depleting the surrounding water resources. To achieve this goal, a numerical groundwater modelling approach was utilized, employing the TRIWACO simulation package and the finite element method (FEM). The study involved various simulations under steady and unsteady flow conditions, using hydrological, geological and hydrogeological data, including the results of three proposed pumping tests conducted by INGEO, Ltd. Company, as well as measured groundwater level data from boreholes monitored by the Slovak Hydrometeorological Institute (SHMI). Implementing transient groundwater flow simulations considered the impact of a 1000-year flash flood wave (Q1000). This paper presents results of numerical modelling results, offering insights into maintaining the required groundwater elevation while considering key parameters and uncertainties for design purposes. Additionally, on-site optimization was performed to ensure efficient system operation and minimize associated costs. In conclusion, this research contributes to sustainable groundwater management in the Nitra Industrial Park, addressing the challenge of the increased groundwater level and providing valuable findings to optimize the extraction system’s performance.

MARINA DISTRICT DEVELOPMENT COMPANY LLC., DOING BUSINESS AS BORGATA HOTEL CASINO & SPA V. AC OCEAN WALK LLC, DOING BUSINESS AS OCEAN CASINO RESORT

MARINA DISTRICT DEVELOPMENT COMPANY LLC., DOING BUSINESS AS BORGATA HOTEL CASINO & SPA V. AC OCEAN WALK LLC, DOING BUSINESS AS OCEAN CASINO RESORT

Benchmark 2 – Springback of a Jaguar Land Rover Aluminium

The aim of this benchmark is the numerical prediction of the springback of an aluminium panel used in the production of a Jaguar car. The numerical simulation of springback has been very important for the reduction of die try outs through the design of the tools with die compensation, thereby allowing for the production of dimensionally accurate complex parts at a reduced cost. The forming stage of this benchmark includes one single forming operation followed by a trimming operation. Cross-sectional profiles should be reported at specific (provided) sections in the part before and after springback. Problem description, tool geometries, material properties, and the required simulation reports are summarized in this benchmark briefing.

Hybrid Vehicles: The System and Control System Challenges

Hybrid electric vehicles are expected make a significant contribution to the environmental needs of the premium vehicle sector and there is currently extensive industrial and academic research ongoing in this area. Combining an internal combustion engine with electric traction, managing electrically powered ancillaries and meeting the high expectations of the premium market, presents new problems in the area of Systems Engineering and Control. Some of the main system and control system challenges will be discussed in the context of hybrid research being undertaken in Jaguar Cars and Land Rover.

Project Omnivore: A Variable Compression Ratio ATAC 2-Stroke Engine for Ultra-Wide-Range HCCI Operation on a Variety of Fuels

The paper describes the principal features of Omnivore, a spark-ignition-based research engine designed to investigate the possibility of true wide-range HCCI operation on a variety of fossil and renewable liquid fuels. The engine project is part-funded jointly by the United Kingdom's Department for the Environment, Food and Rural Affairs (DEFRA) and the Department of the Environment of Northern Ireland (DoENI). The engineering team includes Lotus Engineering, Jaguar Cars, Orbital Corporation and Queen's University Belfast. The research engine so far constructed is of a typical automotive cylinder capacity and operates on an externally scavenged version of the two-port Day 2-stroke cycle, utilising both a variable charge trapping mechanism to control both trapped charge and residual concentration and a wide-range variable compression ratio (VCR) mechanism in the cylinder head. This approach permits individual control of retained and compression heat as separate inputs to the ATAC combustion process (now commonly referred to as HCCI), an ideal situation which is not possible when attempting to operate a traditional fixed compression ratio, variable valve timing 4-stroke engine in HCCI combustion. The ease of application of the VCR system due to the elimination of poppet valves for gas exchange is fundamental to the concept and this feature is discussed in detail, together with the very wide range of compression ratios that the chosen solution permits (from 10:1 to 40:1 in this initial configuration). In addition to describing the engine and its technologies, test results from its initial operation on 98 RON gasoline are presented, including stable operation at idle load and 450 rpm in true HCCI (i.e. without spark assistance).

Jaguar lifts XF robot total to 179

PurposeThe purpose of this paper is to describe how Jaguar Cars in the UK has increased the number of industrial robots at its XF body‐in‐white (BIW) facility at its Castle Bromwich site in the UK. This site has three BIW shops – one each for the XK sports car, the XF sports saloon and the XJ saloon. Both XK and XJ use aluminium‐intensive BIW structures. Castle Bromwich is Jaguar's principal manufacturing site alongside Halewood on Merseyside where the X‐Type continues to be built.Design/methodology/approachDescribes the major production line techniques that are used in the manufacture of the BIW structure of the XF vehicle, Jaguar's latest car. The BIW techniques include spot‐welding and ultrasonic weld inspection for parts assembly.FindingsOver the space of the last three or four years, Jaguar has increased significantly the stature of its UK manufacturing units with the aim of increasing productivity.Research limitations/implicationsJaguar Cars, part of the Indian conglomerate TATA, continually assesses all of the functions involved in the manufacture of a motor vehicle, and in this context is working both with its own plants as well as with suppliers of equipment and components to enhance production and quality processes. This includes all of the processes of joining steel and other materials using spot welding and adhesives. There is also much to be gained from the interchange of information between the various plants in the Jaguar/LandRover group with a view to implementing continuous improvement. The benefits achieved from one process in one particular plant are communicated to other facilities, again with the object of improving quality and productivity.Practical implicationsArising out of greater plant integration and utilization, it is likely the management of Jaguar Cars can further increase manufacturing efficiency at the Castle Bromwich site.Originality/valueJaguar Cars continues to rationalise its manufacturing processes, further integrating these production facilities with those of major component suppliers to produce a finished vehicle. There is a heavy concentration of robots within the BIW manufacturing facilities.

A Critical Assessment of Two-Stage Group Screening Through Industrial Experimentation

Screening is the process of sifting through a set of factors through experimentation to determine the few important factors that have a substantial effect on a response. When the set of factors is large and interactions are anticipated, screening methods using single fractional factorial designs may require too many observations to be feasible. The methodology of two-stage group screening has been suggested as an alternative. This article gives the first description of practical aspects involved in running a two-stage group screening experiment for investigating interactions. Issues involved in the design and analysis of such an experiment are discussed in the context of a study run at Jaguar Cars on cold start optimization. The analysis of this experiment provides insight into how group screening works in practice and how the factorial effects of the individual factors relate to those of the grouped factors. Elicitation of information from subject specialists, choice of factor groups, and selection of designs for two-stage group screening are discussed. Through the analysis of the experimental data, it is shown that the process of group screening can provide an efficient method of detecting interactions among large numbers of factors.

Laser sensor helps to guarantee safety of pedestrians at Jaguar Cars

Laser sensor helps to guarantee safety of pedestrians at Jaguar Cars

Should a quality sub-brand be located before or after the parent brand? An application of composite concept theory

The author examines the effectiveness of quality sub-brands in creating quality images through the formation of inferential quality beliefs for both weak and strong brands. The sub-brands are examined as either headers (placed before the parent brand) or modifiers (placed after the parent brand). In Study 1, alpha-numeric sub-brands show that both header (e.g., XL500 Hyundai car) and modifier (e.g., Jaguar XL500 car) sub-brands enhance the perceived quality of weak and strong brands but provide greater enhancement for weak brands. Ratings of the 141 subjects indicate that a header sub-brand is more effective than a modifier sub-brand for weak brands (e.g., XL500 Hyundai car > Hyundai XL500 car), whereas a modifier sub-brand is more effective for strong brands (e.g., Jaguar XL500 car > XL500 Jaguar car). The findings indicate greater differences between the header and modifier sub-brands for weak brands than for strong brands. In Study 2, foreign sub-branding stimuli result in similar findings.

Jaguar uses adaptive MIG welding to join C‐pillars to an aluminium roof section in a new sports car

PurposeTo describe how Jaguar Cars in the UK is making use of a robot‐based intelligent adaptive metal inert gas (MIG) welding process incorporating laser diode measurement of the gap in the joint between the aluminium C‐pillars and the aluminium roof structure of its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.Design/methodology/approachDescribes the sensor technology that is used to guide the robot in order to undertake the MIG welding path.FindingsThe use of MIG welding in this particular application is essential if a perfect surface is to be achieved in a critical area of the car body before the aluminium body shell enters the paint shop. The introduction of MIG welding in this particularly exposed region of the car's body shell has proved to be a challenging experience for a wide range of engineers at jaguar cars in the UK, from manufacturing engineers through to process engineers and metallurgists, and others. The MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as staff at Warwick University. This work is likely to continue in order to achieve a complete understanding of the entire production process, as well as to reduce cycle times and improve overall product performance, both to the benefit of the manufacturer and the end‐user – the customer.Practical implicationsIt is likely that arising out of development work into new MIG welding techniques and processes, new standards will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover Volvo could all benefit from the technologies developed at Jaguar Cars.Originality/valueThis is the first time that Jaguar Cars has used an ABB 2400‐16 robot in conjunction with a laser diode sensor to measure the true position of a seam prior to welding, allowing the robot's path to be optimised for each individual vehicle. This paper provides a unique insight into the development of a root‐based intelligent adaptive MIG welding process to produce a perfectly finished body shell.

ABB robots form part of islands of automation to build body shells at Jaguar Cars

PurposeDescribes how Jaguar Cars in the UK is using robots to manufacture aluminium car bodies for its new XK sports car that is being built in the company's plant in Castle Bromwich, UK.Design/methodology/approachDescribes the major production line techniques that are used in the manufacture of the body‐in‐white structure. These include self‐piercing rivets (SPRs), self‐tapping screws, MIG welding and adhesives.FindingsThe use of SPRs and self‐tapping screws are proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings.Research limitations/implicationsThe introduction of SPRs and self‐tapping screws, adhesive bonding and MIG welding of cosmetic aluminium skin panels is the result of considerable research work on the part of Jaguar engineers and the company's suppliers, as well as Warwick University. Three of these techniques require the services of robots with their integrated controls. This work is likely to continue in order to reduce cycle times and improve overall product performance, both to the benefit of manufacturer and end‐user – the customer. This paper provides a unique insight into the development of a facility with islands of automation to produce aluminium body shells.Practical implicationsIt is likely that arising out of development work into new techniques, processes and standards that will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Aston Martin, Land Rover and Volvo could all benefit from the technologies developed at Jaguar Cars.Originality/valueThis is the first time Jaguar Cars has used ABB robots in significant numbers to apply SPRs and self‐tapping screws to join aluminium components. ABB robots are also used for body shell inspection and MIG welding aluminum skin panels.

Jaguar uses castings, extrusions to reduce parts count in new sports car

PurposeDescribes how Jaguar Cars in the UK is assembling aluminium car bodies for its new XK sports car that will be manufactured with a production time of 12 hours.Design/methodology/approachDescribes the major production line techniques that are used in the assembly of the body‐in‐white structure. These include adhesive bonding, self‐piercing rivets (SPRs) and self‐tapping screws.FindingsThe use of SPRs and self‐tapping screws is proving essential in the joining of aluminium components manufactured as extrusions, castings and pressings.Research limitations/implicationsThe introduction of adhesive bonding, SPRs and self‐tapping screws is the result of considerable research work on the part of Jaguar engineers and the company's suppliers. This work is likely to continue in order to reduce cycle times and improve overall product performance, both in terms of manufacture and for the user.Practical implicationsIt is likely that arising out of development work into new assembly techniques that the technology will be used throughout the Ford organization, including other companies that form the Premier Automotive Group. Both Aston Martin and Volvo could benefit from the technologies developed at Jaguar Cars.Originality/valueThis is the first time that Jaguar Cars has used self‐tapping screws to join aluminium components although it has been used before within Lotus Group for the Elise sports car.

Jaguar “Roadmap” rethinks self‐piercing technology

PurposeDescribes how Jaguar Cars is evaluating a technology roadmap to assess future manufacturing processes.Design/methodology/approachDescribes the major production line technologies that are under close scrutiny for the next ten years for use in the Jaguar Cars' production plants at Castle Bromwich and at Halewood, Merseyside, both in the UK. Technologies under review include ultrasonic welding, friction stir spot welding, laser welding and self‐piercing rivets.FindingsThe use of self‐piercing rivets is already used in production at Jaguar for the aluminium‐bodied XJ saloon. But developments of the process are already underway in readiness for the next new model. However, at the same time, engineers are examining other techniques including ultrasonic joining and friction stir spot welding, both of which at the subject of research work in the US and the UK. Use of pedestal guns and blow feeding devices is expected to bring improvements in cost.Research limitations/implicationsEngineers at Jaguar are carrying out research and development, both in‐house and with various research bodies and universities to establish the most beneficial processes for the joining of aluminium sheet, extrusion and cast components that go to form an aluminium car body. For successful joining aluminium requires low heat input solutions. At present, self‐piercing rivets offer the best solution, but Jaguar engineers are looking at other processes including ultrasonic joining and friction stir spot welding. The aim is to find processes that are fast and cost‐effective. In the meantime, Jaguar will continue to use self‐piercing rivets for aluminium structures.Practical implicationsThe practical implications of the work will lead to reduced cycle times which in turn will help to make the manufacture of aluminium car bodies more cost‐effective.Originality/valueBMW claims it is the first car maker to make use of bowl‐feeding self‐piercing rivets for the manufacture of aluminium body‐in‐white.

A Web-Based Knowledge Elicitation System (GISEL) for Planning and Assessing Group Screening Experiments for Product Development

When planning experiments to examine how product performance depends on the design, manufacture and environment of use, there are invariably too few resources to enable a complete investigation of all possible variables (factors). We have developed new algorithms for generating and assessing efficient two-stage group screening strategies which are implemented through a web-based system called GISEL. This system elicits company knowledge which is used to guide the formulation of competing two-stage strategies and, via the algorithms, to provide quantitative assessment of their efficiencies. The two-stage group screening method investigates the effect of a large number of factors by grouping them in a first stage experiment whose results identify factors to be further investigated in a second stage. Central to the success of the procedure is ensuring that the factors considered, and their grouping, are based on the best available knowledge of the product. The web-based software system allows information and ideas to be contributed by engineers at different sites and allows the experiment organizer to use these expert opinions to guide decisions on the planning of group screening experiments. The new group screening algorithms implemented within the software give probability distributions and indications of the total resource needed for the experiment. In addition, the algorithms simulate results from the experiment and estimate the percentage of important or active main effects and interactions that fail to be detected. The approach is illustrated through the planning of an experiment on engine cold start optimization at Jaguar Cars.

Fire protection pumps installed at Jaguar production plant

A new range of fire protection pumps and associated equipment has been installed at Jaguar Car’s Halewood production facility in the UK, where the prestigious new Jaguar X-Type car is manufactured. The fire pumps were selected because they enable prompt, reliable and effective fire control in the facility’s vehicle trim and assembly line, which processes up to 100,000 vehicles a year.

Mix of robots used for Jaguar's aluminium‐bodied XJ luxury car

Jaguar Cars has invested millions of dollars in two new facilities – a press shop and a body‐in‐white shop – to produce aluminium bodies for the next generation XJ luxury passenger car.

Mayflower part of GT40 ‘Dream Team’

A British company is playing a key role in the design, development and production of the latest version of Ford’s legendary GT40 ‘supercar’, which will be built using an aluminium space frame structure and skin panels. The GT40 will be a new technology demonstrator, watched closely by Jaguar Cars’ engineers at Whitley, Coventry, UK.

Jaguar uses game‐show techniques to get dealers up to speed

Techniques based on popular television game‐show culture and online gaming psychology were used to train car dealers around the world in the features of the new Jaguar X‐Type. The CD‐ROM‐based training, designed to appeal to the competitive spirit of the Jaguar dealer, was commissioned by Jaguar Cars Ltd as a practical, fun and user‐friendly bespoke e‐learning tool that could be sent to dealers ahead of the “traditional” launch training.

Improving the Competitiveness of Companies in the UK Automotive Sector

It has been recognized that there is a lack of competitiveness in the UK-based automotive supply chain and that knowledge and creativity at all levels within a company are a source of competitive advantage. It is against this background, and in light of the increasing demands placed on the automotive supply chain through globalization and over-capacity that a number of initiatives have been established with support from the UK government – including the Society of Motor Manufacturers (SMMT) Industry Forum and The Automotive College. To improve the competitiveness of companies lower down in the automotive sector supply chain it is necessary for the original equipment manufacturers (OEMs) and first-tier suppliers to lead any initiative. With this mind, a Merseyside Automotive Group (MAG) was established, chaired by Jaguar Cars with representation from other Merseyside-based automotive companies. Its activities are managed and coordinated from the Centre for Automotive Studies at Liverpool John Moores University. The model developed by the Group consists of an integrated programme with three elements: a Manufacturing Improvement Programme, which aims to transfer the best practice from the OEMs into the supply chain, an Automotive E-Community Programme in which companies can trade, share and learn, and an E-Tools for Industry Programme to raise awareness of the benefits of information and communications technology. The paper describes this integrated programme and its impacts.

Polynorm looks set to manage new Jaguar press shop

Polynorm Group of Bunschoten, Holland, looks set to manage the new press shop at Jaguar Cars’ Castle Bromwich car-making facility in the West Midlands. The plant already makes the S-Type saloon.