ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com BLOODHOUND SSC ATSM AIR INLET ASSEMBLY FOR THE AMAD GEARBOX The following explains the ATSM assembly and some of the essential design decisions made in completing this part of the car.

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD GEARBOX INTRODUCTION/BACKGROUND : AMAD GEARBOX ASSEMBLY (Diagram explained) AMAD Gearbox (blue) ATSM control Valve. AC Generator DC Generator ATSM LH chassis Rail mount position RH Chassis Rail mount position PTO Shaft Bulkhead mount position To Jet engine Hydraulic Pump Start Air in ATSM Exhaust Air out

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD GEARBOX INTRODUCTION/BACKGROUND : WHAT IS AN AMAD GEARBOX? The AMAD (Air Mount Accessories Drive) gearbox is a piece of equipment Bloodhound are reusing from the Typhoon aircraft. It is a multifunction item and is essential in starting the jet engine and then running auxiliary systems (AC & DC generators and hydraulic pump) once the jet engine is running. AMAD GEAR BOX FUNCTIONALITY: - Starting the Jet Engine: When starting the jet engine a compressed air source is connected to the car at the ‘air start couple’ on the left hand side of the car. The compressed air is fed via the ATSM inlet assembly to the AMAD gearbox at the ATSM control valve. The ATSM itself (Air Turbine Start Motor) is essentially an air turbine. The compressed air rotates the turbine which in turn rotates the power output of the AMAD gearbox. The power output from the AMAD gearbox is connected to the jet engine via the PTO shaft. This spins the jet engine up to the correct start speed allowing the engine to be fired up. -Auxiliary systems power: Once the jet is running under its own power the jet engine rotates the PTO shaft which back drives the AMAD gearbox. When the AMAD gearbox is back driven by the PTO shaft the power is directed to the AC generator, Hydraulic Pump and DC generator which are mounted on the AMAD gearbox. All of these items are used in the car. When the AMAD gearbox is being back driven by the Jet engine the ATSM inlet is unused. The ATSM inlet assembly is only used during Jet engine start up.

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ASSEMBLY LOCATION & THE DESIGN PROBLEM AMAD GEARBOX LOCATION: The AMAD gearbox assembly has to be mounted circa half way down the length of the car, level with the front of the EJ200 jet engine. It has to be here as this is where the PTO shaft engages with the Jet. THE AMAD ATSM INLET DESIGN PROBLEM: To design an air inlet system which will allow the compressed air source (off car) to be connected to the AMAD gearbox at the ATSM inlet. This will allow the AMAD gearbox to be spun up under jet start conditions. ABH – E0005

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ATSM INLET ASSEMBLY DESIGN CONSTRAINTS: AMAD ATSM Inlet assembly design constraints: The ATSM inlet assembly is used when starting the EJ200 jet engine. It connects the ATSM inlet on the AMAD gearbox to a compressed air source which will be connected to the side of the car during jet start up. The following are design constraints that effected the design of the assembly. Compact Geometry and accessibility - The ASTM inlet assembly has to fit in the tight space available in the car between the jet fuel tank, the Jet engine air intake and the Jaguar engine while still allowing as much access as possible. The ATSM inlet assembly has to connect the “Air in” from the ATSM on the AMAD gearbox to the LH side of the car and provide a suitable mounting point. The ATSM inlet has to be covered when not in use to prevent dust/dirt entering the AMAD. The Inlet must also have a similar bore size to the original Typhoon to minimise additional back pressure in the starting system. Heat resistant - The air entering the ATSM inlet is hot at circa 180deg C. All inlet components need to be able to cope with this heat so material selection is crucial. Design Flexibility - The AMAD inlet assembly needs to be adaptable to allow both gear box configurations to be used (Bloodhound have 2–off AMAD gearbox’s a LH and RH version which are mirror opposites of each other). Vibration Isolation - The inlet needs to Isolate any vibrations between the AMAD gearbox and the car structure. System monitoring - The pressure and temperature of the compressed start air needs to be monitored. Inlet pressure - The Input pressure used to start the Jet is circa 6 bar. Unknowns: No drawings were available from the MOD regarding the geometry of the AMAD gearbox and the ATSM inlet. Due to military secrecy there was also no information available on the existing clamps used on the AMAD assembly.

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ATSM INLET DESIGN SOLUTIONS: The following shows the final geometry for the ATSM Inlet assembly and how the design constraints were met. ATSM Inlet Assembly The ATSM Assembly is positioned above the ATSM exhaust above the jet fuel tank LH Chassis Rail ATSM output Exhaust exits in upper Chassis under stringer 1 AMAD gearbox assembly ATSM Input The connection point for the ATSM inlet assembly fixes on the LH side of the car

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com Flexi PARRAP hose between side fixing point and ATSM inlet AMAD ATSM INLET DESIGN SOLUTIONS: The following shows the final geometry for the AMAD gearbox exhaust assembly and how the design constraints were met. LH Chassis Rail LH side Car trellis structure The compressed air couple mounts to the side of the car via the AMAD start bowl and start car couple. This uses existing anchor bolt positions on the side trellis structure. Pressure/temperature sensor V-band clamp V-band clamps both ends of flexi hose allow easy installation ATSM Inlet Control valve AMAD start inlet couple – Reused part from Typhoon Start Bowl Start Car Couple

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ATSM INLET DESIGN SOLUTIONS: Design solutions to constraints on page 5 : Compact Geometry and accessibility: i.The ATSM assembly was routed from the ATSM air inlet to the side of the car with careful considering to the bend radius of the flexi hose being used, the available mounting point on the side of the car and the surrounding car structures. ii.To increase ease of installation two sets of V-band clamps were used allowing each end section of the flexi PARRAP hose to be removed/installed separately. iii.An lockable hinged flap on the side panel covers the compressed air inlet point stopping dirt ingress. iv.A custom fabricated ‘bowl’ mounts the inlet to the side of the car using existing bolt positions Heat resistant: i.The Inlet assembly is a fully metallic stainless steel assembly which is compatible with the heat requirements and also has corrosion resistant properties. The Parrap flexi hose is a mix of 316 and 304 stainless. This material is compatible with the v-band flanges/clamps required to connect with the existing AMAD gearbox ATSM inlet helping manufacturing welding/fabrication. Design Flexibility: i.If the other ‘handed’ gearbox is used the V-band connections on the assembly allow a longer piece of PARRAP hose to be installed in the car. The hose would be routed to the same compressed air connection point on the side of the car. Vibration Isolation: i.The Parrap flexi hose provides vibration isolation between the side panel and the AMAD ATSM inlet. System monitoring: i.A threaded boss is present in the Inlet assembly allowing a pressure/temperature sensor to be installed.

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ATSM INLET DESIGN SOLUTIONS: Design solutions : Output pressure : i.The 2.5” Parrap hose used in the assembly has a max working pressure of 31bar. Well above the 6bar required. Unknowns: i.The clamping features on the ATSM inlet exit gave a few clues to the type and size of clamp used on Typhoon. Due to military information confidentiality the defence specification v-band clamps and flanges we required were not available to purchase. Through a combination of measuring and research a civilian equivalent was eventually sourced and purchased. See the information pack. ii.Fortunately we managed to source a start car couple from a Typhoon which we can use in the car as the coupling point for the compressed air. This is the component mounted in the start bowl on the side of the car. Manufacture/Manufacturability: To decrease costs and lead times it is best to manufacture/fabricate components, construct assemblies, by using manufacturing techniques and raw materials that are readily available. With this in mind the following considerations were made for this assembly. i.The PARRAP pipe is an ‘off the shelf’ item with its length made to order from Pirtek (see information pack) ii.The bend in the inlet assembly is made from ‘off-the-shelf’ preformed bends. It was sized to match the V-band flange and Parrap end fitting requirements. Labelled in industry as a hygienic pipe fitting. These items are also available from a local supplier so lead times were short. iii.The start Bowl was hand fabricated/welded using laser cut profiles and off-the-shelf box section items iv.The start car couple (which mounts on the start bowl) was CNC machined.

ENGINEERING ADVENTUREwww.BLOODHOUNDSSC.com AMAD ATSM INLET DESIGN SOLUTIONS: The flexi hose to bend assembly was hand fabricated/welded. Conclusion: Once all items were manufactured the Inlet assembly was installed into the car and is ready for the first air start of the EJ200 jet engine.