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Dyson Future Power Systems Lab

Lead Research Organisation: Newcastle University
Department Name: Sch of Engineering

Abstract

With an ever growing need to become carbon neutral as a society, and increasing concern about the harm of disposable products and the pollution they cause, the time is right to strive to change the domestic market for electrical consumer goods and deliver solutions that are more environmentally friendly and consume less energy. Dyson is well-placed to effect change in this industry with its experience in delivering efficient, lightweight power systems in collaboration with Newcastle University. Through optimisation and innovation of the power systems at their heart, Dyson has shown in recent years how vacuum cleaners and hairdryers can be made smaller, lighter and more efficient, reducing their material and energy usage. Newcastle University have been a key partner in the development of these systems and some of the key technologies that enable them; both in terms of academic contribution and in educating a significant portion of the Motor and Power Systems engineers in Dyson's Research department.

Traditionally, concepts such as efficiency, sustainability, and end of life impact have not been of major concern in smaller domestic appliances, where cost was the prime concern and the power system for the product was a bought-in component. However, with 1/3 of all UK electricity consumption being attributable to domestic use and an estimated 1 billion domestic appliances in the UK alone, both the efficiency and sustainability of these appliances need urgent reflection and improvement to help drive the UK and the world towards long-term sustainability goals. In particular, the environmental impact of domestic appliances is dominated by through-life electrical power consumption, which averages an annual 36TWh in the UK, thus even a modest 5% improvement in energy conversion efficiency (which we believe is achievable through improvements in motor efficiency alone) would represent a significant saving in grid generation requirement.

We will achieve our goal of improving the energy efficiency and reducing environmental impact of domestic products through a whole-systems-level integrated approach in which all subcomponents of the power system are considered, designed and optimised simultaneously. Additionally the typical modes of operation of the end appliances will be incorporated into the design procedure to maximise performance and efficiency gains at the most common (and therefore most important) operating points.

Planned Impact

The proposed Dyson Future Power Systems Laboratory aims to ensure the UK maintains a world leading position in electrical consumer goods, producing systems which are more efficient, smaller, lighter, lower cost and more environmentally sustainable than other existing and emerging solutions, thus providing long-term strategic value to the UK consumer goods industry.

The project makes a major contribution to three of the EPSRC Prosperity Outcomes:
Productive Nation
Healthy Nation
Resilient Nation

Impact upon Business will centre on:
driving the development of the market for more efficient electrical goods; contributing to a resilient nation by ensuring energy security and efficiency and sustainable management of resources.
overcoming significant technical challenges and generating intellectual property, which will be utilised by Dyson within their future products, maintaining the UK in general, and Dyson specifically, as the world market leader in the next generation of electrical consumer goods.

The impact to the UK as a whole will focus on:
Building links with the EPSRC Manufacturing hub on electrical machines, of which the academic investigators are also part of. The outputs of this project will feed into and the team will collaborate with these activities, with active participation in events organised.
The fundamental research on system efficiency and sustainability will have a major influence over other sectors, including:
o The aerospace sector, where there is intense interest in hybrid and all electric propulsion systems, along with the marine and rail sectors. We will engage through our overlapping links with the governments Aerospace Technology Institute
o The electric vehicle industry, where the academic investigators head the APC spoke on Electrical Machines.
o The industrial drives and process control industry. We will actively engage through the IET Professional Network on Power Electronics, Machines and Drives and through our existing links
Developing a fruitful collaboration in the North East of the UK; producing a resilient nation by enriching local communities and business and engaging with the 'Driving the Electric Revolution" initiative.
Aiding transformation of the UK to a sustainable society with a more efficient use of energy and materials.
Contributing to a Healthy Nation by supporting national efforts to hit climate change and clean air targets.
Outreach activities into schools, leading initiatives such as Greenpower and via participation in the APC.
Creating advantages to the consumer, through lighter, more efficient and higher performance products all achieved in a more cost effective manner.
Significant environmental advantages, contributing to a resilient nation by: managing resources more efficiently and sustainably; reducing emissions, contributing to carbon neutral targets much earlier than expected; reducing usage of rare earth metals via innovation in manufacture and improving recyclability


The Partners already have a strong track record in skills growth, with over twenty of Newcastle's most promising graduate electrical engineers now hold staff positions in Dyson, from Director down through senior managers to senior design and research engineers. UK wide skills will be Impacted by:
Giving Dyson staff the opportunity to spend time seconded to the project.
Encouraging all relevant Dyson staff to attend any of the university's specialist taught modules and take part in research forums and internal seminars. They will also be encouraged to deliver material to our taught course and research
 
Description Yes. Dyson are currently developing new products which contain many of the outcomes from this project. Our results are also feeding into sustainability corporate strategy within Dyson.
First Year Of Impact 2021
Sector Electronics,Energy
Impact Types Economic

 
Description Leverhulme scholarship award panel
Geographic Reach National 
Policy Influence Type Influenced training of practitioners or researchers
Impact award of fellowships to ur best academics
 
Description external examiner of MSc programme at Edinburgh university
Geographic Reach Europe 
Policy Influence Type Influenced training of practitioners or researchers
Impact changing of education given to about 250 students over 5 years
 
Description EPSRC Centre for Doctoral Training for Sustainable Electric Propulsion (CDT SEP)
Amount £5,388,053 (GBP)
Funding ID EP/S024069/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 03/2019 
End 09/2027
 
Description Collaboration with EPSRC Future Electrical Machines Manufacturing Hub 
Organisation University of Sheffield
Country United Kingdom 
Sector Academic/University 
PI Contribution The PI is a CI on the FEMM Hub and Dyson are industrial advisors. We are working with the FEMM Hub on life cycle analysis and sustainable manufacturing.
Collaborator Contribution Strathclyde university are proving expertise in the LCA of electrical machines. Sheffield University are providing expertise on the testing of electrical materials
Impact Greater understanding of LCA in electrical machines
Start Year 2021
 
Description Dyson 
Organisation Dyson
Country United Kingdom 
Sector Private 
PI Contribution This grant is collaborative between Newcastle University and Dyson. Newcastle University are inputting approx £1M.
Collaborator Contribution Dyson are funding 3 of their engineers to be based in the university, along with about £500k on equipment
Impact This funding, approx £1M of direct research funding to the university from Dyson. 10 PhD studentships, of which 7 were fully funded by Dyson. A series of patents Employment for graduates.
Start Year 2020
 
Description Sustainability advisor 
Organisation University of Exeter
Country United Kingdom 
Sector Academic/University 
PI Contribution Sustainabilty in the design and manufacture of electrical machines
Collaborator Contribution Broad perspective on directions of research
Impact new project directions
Start Year 2023
 
Title A bearingless motor 
Description A bearingless motor 10 includes a rotor 12 having p pole pairs 18, and a stator assembly 14 including stator core 20 and stator winding 22. The stator winding is energised to generate a first magnetic field having p pole pairs for generating torque to act on the rotor, and also energised to generate a second magnetic field comprising a component having q pole pairs for generating a translational force to act on the rotor, wherein q=p±1. Energising the stator winding to generate the second magnetic field includes applying a modulation factor to the stator winding, the modulation factor comprising a factor of 2p±1. The stator winding may comprise a first set of coils and a second set of coils, where the first and second sets of coils are energised in phase with one another to generate the first magnetic field, and may be energised out of phase with one another to generate the second magnetic field. The first and second sets of coils may each form a three-phase winding. The arrangement is suitable for use in an air moving device, such as a fan. 
IP Reference GB2628830 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Title HEATING SYSTEM 
Description A heating system is provided. The heating system comprises an induction heating assembly configured to generate varying magnetic fields, a heating target assembly comprising a plurality of heating targets, the plurality of heating targets being heatable by penetration with a varying magnetic field. A first subset of the plurality of heating targets has a first resonant heating characteristic and a second subset of the plurality of heating targets has a second resonant heating characteristic, and the first and second resonant heating characteristics are different. The system further comprises a controller configured to: control the induction heating assembly based on the first resonant heating characteristic to generate a first varying magnetic field to heat the first subset and control the induction heating assembly based on the second resonant heating characteristic to generate a second varying magnetic field to heat the second subset. 
IP Reference US2024430993 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Title Hair styling device 
Description A hair styling device for heating hair, such as a hair straightening device, comprises an induction heating plate 110 arranged to be heated by penetration with a varying magnetic field, and an induction heating assembly 116 to generate the varying magnetic field. The induction heating assembly is configured to generate an asymmetric magnetic field such that a magnetic field strength at a top side 118 of the assembly facing towards the heating plate is substantially greater than a magnetic field strength at a bottom side 120 of the assembly. The heating plate may be flexible and moveable between first and second positions, and may define multiple regions, separated by an insulating boundary, corresponding to independently controllable heating zones. The heating assembly may comprise a resonant circuit driven by a drive circuit to cause resonant heating of regions of the heating plate. 
IP Reference GB2610606 
Protection Patent / Patent application
Year Protection Granted 2023
Licensed No
 
Title Heating system 
Description A heating system 200, e.g. for a haircare appliance, comprises an induction heating assembly 102 having at least one driving coil 108a - 108e and configured to generate a varying magnetic field, an induction heating plate 104 spaced apart from the driving coil and heatable by penetration with the varying magnetic field, and one or more repeater coils 210a - 210e arranged between the driving coils and the induction heating plate, the repeater coils being electrically isolated from the driving coils. Use of the repeater coils may enhance the influence of the magnetic field generated by the driving coils, thereby extending the range of the magnetic field. Alternatively or in addition, one or more magnetically permeable elements (510a - 510e; figure 5) which may comprise ferrite particles, may be arranged between the driving coils and heating plate to guide magnetic flux therebetween. 
IP Reference GB2625113 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Title Heating system 
Description A heating system 500, e.g. for a haircare appliance, comprises an induction heating assembly 102 having at least one driving coil 108a - 108e and configured to generate a varying magnetic field, an induction heating plate 104 spaced apart from the driving coils and heatable by penetration with the varying magnetic field, and a compliant material 140 arranged between the driving coils and the induction heating plate and at least partially encompassing one or more magnetically permeable elements 510a - 510e, which may comprise ferrite particles, having a higher magnetic permeability than the compliant material. The magnetically permeable elements are configured to guide magnetic flux between the driving coils and the induction heating plate, thereby reducing leakage flux. Alternatively or in addition, one or more repeater coils (210a - 210e; figure 2) may be arranged between the driving coils and heating plate to enhance the influence of the magnetic field generated by the driving coils, thereby extending the range of the magnetic field. 
IP Reference GB2625114 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Title Heating system 
Description An induction heating system 100 comprises an induction heating assembly 102 configured to generate a varying magnetic field and a heating target assembly 104 comprising one or more heating targets, wherein the one or more heating targets are moveable relative to the induction heating assembly, the one or more heating targets being heatable by penetration with the varying magnetic field. The heating target assembly may be flexible and may be moveable between a first position and a second position closer to the induction heating assembly, for example due to contact with an entity 138 to be heated. Alternatively, an adjustment assembly (210; figure 2) may be provided to move the heating targets relative to the induction heating assembly. The heating targets may be resonantly heated when arranged in the second position. 
IP Reference GB2610607 
Protection Patent / Patent application
Year Protection Granted 2023
Licensed No
 
Title Induction heating 
Description An induction heating system with an induction coil 106 for generating a magnetic field and a heating target 104a, b spaced from the coil. The susceptor 104a, b is moveable varying the distance 134 between the coil and the heating target along a length of the heating target. This generates, in use, a varying amount of heating of the target along its length, by penetration of the heating target by the coil's magnetic field generated by the induction coil. The coil and heating target may be incorporated into a haircare appliance, such as a hair straightening apparatus (800, figure 8). The heating target may be a flexible plate, may be biased to be spaced apart from the coil and may be moveable by contact with an entity 138 for heating. 
IP Reference GB2622404 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Title Stator member and method of forming a stator member 
Description A tubular stator member for a rotary system (Fig.1, 100) comprises a longitudinal axis 124 and is formed from a conductive sheet 112. The sheet comprises a plurality of electrically insulating regions (Fig.2A, 120) located across and along the sheet to reduce eddy currents flowing through the formed tubular stator member in a direction parallel to the longitudinal axis. The stator member may have a plurality of rolled layers of the sheet (Fig.3A, 136a, 136b). Some of the insulating regions may comprise an (elongate) aperture extending through the sheet. The stator member may have a first and second rolled layer of the sheet, each with an aperture that aligns with the other in a radial direction (Fig.3A, 138a, 138b). The apertures may form cavities (Fig.3C, 142) with a greater depth than a component (Fig.3C, 140) of the rotary system, such that the component can be received in the cavity. Some of the insulating regions may comprise an electrically insulating material. The insulating regions may subtend between 10 and 300 degrees around a circumference of the stator member (Fig.2A, 132). Each sheet may be coated with an electrically insulating material. The insulating regions may be arranged across and along the sheet such that no straight-line eddy current flow path exists across the sheet (Fig.2A, 122). 
IP Reference GB2626143 
Protection Patent / Patent application
Year Protection Granted 2024
Licensed No
 
Description APC machines spoke 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Coordination of electrical machines activity for the automotive council
Year(s) Of Engagement Activity 2021,2022
 
Description CDT showcase event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact set of posters on PhD research given at annual event for academics and industry
Year(s) Of Engagement Activity 2022,2023
 
Description Career Development Workshop on WIE Career Path to Net Zero 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Dr Xu Deng was an invited speaker on Career Development Workshop on WIE Career Path to Net Zero organized by IEEE WIE UK & Ireland Affinity Group and IEEE WIE UKI Ambassador Network in November 2023.
Year(s) Of Engagement Activity 2023
 
Description Centre for Power Electronics Annual Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Annual conference on power electronics
Year(s) Of Engagement Activity 2023
URL https://www.powerelectronics.ac.uk/calendar_event/cpe-annual-conference-2023/
 
Description Centre for Power Electronics Conference 2024 (CPE) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact The Centre for Power Electronics (CPE) Annual Conference brought together the Power Electronics, Machines and Drives Community to review the latest Research and Development that will impact the Electric Revolution. This Conference featured Invited Keynotes and Presentations from Leading Academics and Industrialists, views of the Future Demands for Power Electronics and Drives and hearing about the latest research advances from the Centre for Doctoral Training in Sustainable Electric Propulsion and other Students and Post Doctoral Researchers.
Year(s) Of Engagement Activity 2024
URL https://www.imaps.org.uk/events/cpe2024-centre-for-power-electronics-annual-conference-8-9-july-2024...
 
Description ECCE Nashville 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presented at workshop session
Year(s) Of Engagement Activity 2023
URL https://www.ieee-ecce.org/2023/
 
Description EPSRC Prosperity Partners Showcase Event 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Poster at Prosperity Partnership event
Year(s) Of Engagement Activity 2023
 
Description Energy Conversion Congress and Exposition 2024 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The five-day IEEE Energy Conversion Conference and Expo is the pivotal international conference and exposition event on electrical and electromechanical energy conversion field. ECCE 2024 Conference featured both industry-driven and application-oriented technical sessions. ECCE brought together practicing engineers, researchers and other professionals for interactive and multidisciplinary discussions on the latest advances in various areas related to energy conversion.
Year(s) Of Engagement Activity 2024
URL https://www.ieee-ecce.org/2024/
 
Description Faraday 150 year celebration 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact Presentation to Royal Society to celebrate 150 years of Electrical Machines
Year(s) Of Engagement Activity 2022
 
Description Girls into Electronics Newcastle 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Public/other audiences
Results and Impact Dr Xu Deng presented at the event of Girls into Electronics in Newcastle to encourage more young girls to study electronics and to pursue engineering careers in the sector in June 2023.
Year(s) Of Engagement Activity 2023
 
Description Greenpower 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact Greenpower is an activity in which we provide schools with kits to make electric goblin race cars, aimed at 9-11 year olds. We assist with advice and help with construction, leading to a drag race.

The school we supported in 2021 was Corbridge Middle School. The school was overall champions of the day after coming first in the drag race and third in the slalom.
Year(s) Of Engagement Activity 2021
 
Description IEMDC San Francisco 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact presentation at IEEE International conference
Year(s) Of Engagement Activity 2023
URL https://www.iemdc.org/
 
Description Industrial Advisory Board 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Undergraduate students
Results and Impact Member of university industrial advisory board
Year(s) Of Engagement Activity 2022
 
Description International Conference Electrical Machines 2024 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact The technical program featured eleven high quality tutorials and insightful keynote presentations from world-leading experts, interactive sessions designed to foster collaboration on ground breaking research and innovation. The program offered special sessions, industry sessions and the student forum. All attendees had the opportunity to engage with leading experts, share their work, and explore the present and the future of electrical machines.
Year(s) Of Engagement Activity 2024
 
Description International Conference on Electrical Machines 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact presentation at leading international conference in Valencia
Year(s) Of Engagement Activity 2022
 
Description International Symposium on Magnetic Bearings 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Attended event.
Year(s) Of Engagement Activity 2023
URL https://ismb18.sciencesconf.org/
 
Description Interview for Newspaper article 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Interview concerning future trends and research in electrical machines
Year(s) Of Engagement Activity 2022
 
Description Motor CAD User Conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact presentation to industrialists and acdemics
Year(s) Of Engagement Activity 2023
 
Description PEMD Brussels 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Presentation at conference.
Year(s) Of Engagement Activity 2023
URL https://uobevents.eventsair.com/repm2023/
 
Description PEMD conference 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Industry/Business
Results and Impact presentation of research work
Year(s) Of Engagement Activity 2022
 
Description STEM for Britain 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Judging of UK's best postgraduate posters at the house of Commons
Year(s) Of Engagement Activity 2021,2022,2023,2024
 
Description STEM for Britain Judge 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact This activity, within the House of Commons, reviews and awards prizes for the best early career researchers in the UK. As a fellow of the Royal Academy of Engineering, I have attended as a judge.
Year(s) Of Engagement Activity 2021,2022,2023,2024
URL https://stemforbritain.org.uk/
 
Description Student open days 
Form Of Engagement Activity Participation in an open day or visit at my research institution
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Undergraduate students
Results and Impact Interviewing and enthusing students, provision of equipment and demonstrators
Year(s) Of Engagement Activity 2020,2021,2022
 
Description WEMDCD 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact presented keynote at an IEEE workshop
Year(s) Of Engagement Activity 2023
URL https://wemdcd2023.com/
 
Description Women in Engineering Day Leadership Day 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Professional Practitioners
Results and Impact Dr Xu Deng was invited to attend International Women in Engineering Day Leadership Day organised by Royal Academy of Engineering to discuss psychological safety in the workplace for WIE in June 2023.
Year(s) Of Engagement Activity 2023
 
Description Women in PEMD 2024 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact The event was attended by academics, industrial partners and students. The workshop session had 6 presenters and covered their journey being a woman in PEMD, the challenges they're facing and the solutions they've found, and positive changes that have happened in some of the areas. Toward the end of the session the speakers talked about how to promote gender parity in organisations and connecting and networking opportunities provided by IET and IEEE Women in Engineering UK and Ireland Affinity group.
Year(s) Of Engagement Activity 2024
 
Description open day talks 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Schools
Results and Impact talks and demonstrations at student open days
Year(s) Of Engagement Activity 2021,2022,2023