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A Sixth Form engineering team’s innovative design project aimed at reducing the risk of injury from band saws is in the running for a major construction industry award.

The Year 12 team’s suggested improvements to band saw guards and dust extraction systems have been nominated for an Innovation Award in the annual Constructing Excellence SECBE Awards 2020 finals, where their fellow competitors include professional firms working in the industry. They are also hoping to win a new award introduced this year – the People’s Choice award, which is decided by popular vote.

The four boys – Brandon Ionev, Thomas Mgbor, Kai Sethna and Hugh Westcott – worked with office design specialists Morgan Lovell on the project. With the nomination, the four are following in the footsteps of other QE EES teams of recent years whose inventions under the Engineering Project Challenges initiative have achieved regional and national success.

Their entry was one of just two in their category to be selected by the judges to be interviewed in a ‘head-to-head’ at the virtual awards ceremony on Thursday 2nd July.

QE’s Head of Technology, Michael Noonan, said: “My congratulations go to these four students, who worked hard to come up with innovative designs that fulfilled the brief and were based on sound engineering principles. With the support of the Elizabethan community, they also stand a good chance of clinching the People’s Choice Award. We think they thoroughly deserve it, so please cast your vote now! Thank you.”

The deadline for voting is 5pm on Thursday 2nd July. To vote, visit the awards page describing the boys’ entry, scroll to the bottom and click the People’s Choice button.

During visits to construction sites, boys saw that workers often fail to use the blade guard fitted to existing band saws, because it is tedious and time-consuming to reset the guard manually each time to adjust it for different thicknesses of material.

To address the issue, the boys conducted extensive research over six months. They came up with three designs, all with the same basic idea. The material pushes against the bottom of the blade guard, causing a force that pushes upwards and adjusts the blade guard automatically to the correct and ideal height for cutting. Two of the designs use simple rails and sliders to autonomously adjust the height, while the third uses a rack and pinion. With no user input needed, saw operators can work in the same way as before, but much more safely.

An additional benefit of the designs is that they incorporate significant improvements to the existing dust extraction systems of saws, thus reducing dust exposure – another health & safety concern – and allowing a more precise cut to be made because of the enhanced visibility of the cutting service.

The designs would work with different types of saw and, unlike existing guards, they cover the blade from multiple angles, which is another safety improvement. Because they can be retrofitted to existing machines, the guards hold out the promise of improving safety without huge expenditure. The boys were assisted by their industry mentor, representing Morgan Lovell, Health Safety & Wellbeing Manager Alex Wood.

During the spring, just before the COVID-19 social distancing measures were put in place, the Morgan Lovell team and a second QE team working with Morgan Lovell’s sister company, Overbury, gave presentations on their projects to members of the Institution of Occupational Safety and Health (IOSH, a UK-based global chartered body for health & safety professionals),  at UBM’s centre, close to Blackfriars Bridge in London.

Year 10 pupil Ashwin Sridhar’s design for a doorstep smart box to stop delivery packages being stolen has won a top prize in an international competition.

Ashwin’s device, which he named the Raptor Adversus, uses a host of measures to thwart thieves trying to gain access to packages inside – and even sounds the alarm if anyone tries to steal the whole box.

The Raptor Adversus won him the Best in Show, Senior Division Europe award, in SAM Labs’ STEAM and Coding Creators Competition. Through the global competition, SAM Labs – a UK-based company making app-enabled construction kits widely used in education – challenged pupils in Covid-19 lockdown to showcase their coding projects.

Ashwin’s award was announced in a global awards livestream broadcast.

Congratulating him, QE Head of Technology Michael Noonan said: “Ashwin’s competition entry was well illustrated and included an account of the three different iterations of his device, thus demonstrating that he had worked very methodically to tackle the problem of package-stealing.”

The competition submission began by outlining the problem. “Online delivery has been integrated into our society,” Ashwin wrote. “Forbes estimates the average person in the United States receives up to 21 packages a year. However, with online delivery’s increase in popularity, a new epidemic has arisen – package-stealing.”

Using CAD software, Ashwin designed a device aimed not only at preventing thefts, but also at deterring thieves from even making the attempt.

His Raptor Adversus (meaning ‘against a thief’) design features:

• A motorised safe door opened with a passcode known to the homeowner and shared with the postman or delivery person
• An audible alarm
• A camera
• A tilt-and-pressure sensor
• Coloured indicator lights coded to indicate whether or not the box is empty and whether a letter or parcel is inside.

His initial iteration was designed to take a photo and send it to the homeowner’s phone when anyone used, or attempted to use, the passcode system. The alarm would sound – drawing the attention of people in the area, in case the person at the box was a would-be thief. Only then, after a delay, would the box open.

Ashwin realised that this would only deter thieves who were actually attempting to open the box, so his first refinement was to include a proximity sensor (with a range that could be adjusted by the owner) that would sound an alarm and take a photo of anyone who got close.

In the third iteration, he added the tilt sensor to sound an alarm if anyone tried to remove the whole box.

Two Sixth Form teams devised innovative engineering solutions to workplace safety challenges and successfully presented them to the world’s largest health & safety organisation.

The presentations were part of this year’s QE submissions under the Engineering Excellence Scheme (EES). The Year 12 boys are hoping to follow in the illustrious footsteps of other QE EES teams of recent years whose inventions under the Engineering Project Challenges initiative have achieved regional and national success.

They gave their presentations to members of the Institution of Occupational Safety and Health (IOSH, a UK-based global chartered body for health & safety professionals), just before the COVID-19 social distancing measures were put in place The venue was UBM’s centre close to Blackfriars Bridge in London.

QE’s Head of Technology, Michael Noonan, said: “The teams had been set engineering challenges to work on by two major office fit-out companies, Morgan Lovell and Overbury. QE has achieved brilliant things in recent years in this initiative, and this year’s boys did not disappoint: after six months’ work, they came up with carefully thought-through solutions based on sound engineering principles. They then presented these ideas fluently and with some confidence to the assembled IOSH members and other guests.”

The Engineering Project Challenges started off with a project tour and introduction to site conditions and equipment by industry sponsors Overbury and Morgan Lovell, both part of the Morgan Sindall construction group.

After seeing demonstrations of equipment and operatives at work, the boys were charged with finding innovative solutions to two specific problems.

The Overbury team had the challenge of creating an easy-to-use, hand-held, non-intrusive tool to check if an electrical steel wired armoured cable is live. The team members are: Enoch Hitchcock, Yai Sagolsem, Pranay Surana and Ukendar Vadivel.

The Morgan Lovell team were tasked with making health & safety improvements to a portable band saw, including blade protection and extraction of dust, to ensure that users could cut material both safely and quickly. The blade protection had to be designed in such a way that it could be retrofitted to existing machines. The team comprises: Brandon Ionev, Thomas Mgbor, Kai Sethna and Hugh Westcott.

Both teams were required to undertake analysis through extensive research to find the best practical and innovative engineering methods, and to solve these challenges without involving excess manufacturing costs. They were assisted by their industry mentor, representing Overbury and Morgan Lovell, Health Safety & Wellbeing Manager Alex Wood.

In their 15-minute presentation, team leader Ukendar and his fellow team members working on the project with Overbury explained their solution – a device featuring a hinged clamp and a handle with red and green LEDs to indicate whether the cable being worked on was live or not. In a question-and-answer session with members, they confirmed that the device could readily be manufactured to accommodate different sizes of steel wired armoured cable.

The Morgan Lovell team explained that their guard could be easily and quickly fitted to a band saw in a busy workplace environment. Questioned as to why they had made it in opaque materials, they confirmed that this was just for the prototype and that production models could be made in transparent ABS plastic.

Overall, the objective of the challenges is to introduce young people to careers in the construction and building fit-out and office fit-out industries and to help them apply what they have learnt about STEM (Science, Technology, Engineering and Mathematics) in the classroom into the real world.

The two teams will be hoping to emulate the successes of predecessors, including a 2018 QE team who devised a stair-climbing robot for transporting large sheets of material up staircases on construction sites. This was Highly Commended in the Contribution to the Business Award at the Celebration and Assessment Day of the Engineering Excellence Scheme (EES). And in the year before that, a QE project for the EES – a helmet which warned construction workers when workplace noise was exceeding safe levels – was among the national engineering prize-winners at The Big Bang, the UK Young Scientists & Engineers Fair.

In a video filmed for The Times newspaper, QE’s Head of Technology Michael Noonan explains how he is leading urgent work to 3D-print face shields ahead of a predicted UK peak to the COVID-19 virus in the next few days.

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Mr Noonan is spearheading a London-wide effort to 3D-print the Personal Protective Equipment.

And with QE’s own machines running around the clock and several pupils following suit on their home 3D printers, hundreds of face shields are currently being despatched from the School.

“We have material, we have manufacturing facilities, we have knowledge and skill and we have the ability to create sanitary environments, so we are putting our skill and all of our facilities into solving [the PPE shortage] problem right now,” Mr Noonan told the team from The Times when they visited to film him at work (while maintaining safe social distancing).

“And there are makers and engineers, designers, consultants and DT departments all over the country that have answered this call and that have pitched themselves into volunteering to help with this effort.”

The video explains how the face shields can be put together from two 3D-printed frame parts, combined with a transparent plastic shield and an elastic strap, or even a rubber band.

• Click here for more information on how Mr Noonan and the pupils got involved and on how the face shields are being distributed locally.
• Click here to support the fundraiser by 3DCrowd UK.

Head of Technology Michael Noonan is putting the School’s 3D printers and laser-cutters to good use by manufacturing protective visors for the NHS – part of a co-ordinated effort to support the national fight against the Covid-19 virus.

In addition to coming into School twice a day to set up and run the machines, which would otherwise be idle, Mr Noonan is also co-ordinating 3D-printing efforts among volunteers from schools and individuals. The face shields and ventilator components are being produced for hospitals, GP surgeries and social care organisations.

He is being supported remotely by boys (many from the School’s robotics teams), who are working from home using their own 3D printers to boost production still further.

Mr Noonan says: “It’s a wonderful example of how design and innovation can help solve some of the big problems we face in the world.”

Headmaster Neil Enright added: “We are very proud to be able to play our part in supporting doctors and other medical staff – who include many of our old boys – working on the frontline to combat the virus and save lives. At a time of great national uncertainty, it is good to be able to report on something positive.”

QE staff are currently working from home because of the crisis, but Mr Enright was happy to grant Mr Noonan’s request to make short, twice-daily visits to use the machines in the School’s Fern Building.

The face shields are part of the Personal Protective Equipment (or PPE, in medical jargon) which are currently in short supply because of the heavy demand as the number of people confirmed as having the virus continues to grow rapidly.

Welsh engineer David Sims initially came up with the idea of using his home 3D printer to make the shields after a discussion on Facebook with others around the world working on designs to help health workers. He was quickly contacted by NHS doctors from around the country who placed orders with him.

The idea was then picked up by Tony Ryan, Chief Executive of the Design & Technology Association, who appealed to school Design & Technology departments to help.

Mr Noonan, who is a specialist in Computer-aided Manufacture and Rapid Prototyping using 3D printers, 3D routers and laser-cutters, immediately stepped in, not only producing the specialist masks and ventilator components, but also setting up dedicated a Facebook page and Twitter feed  (‘Design and Technology Education – Helping to fight the spread of coronavirus’) to guide other teachers.

“The idea is simple”, says Mr Noonan. “Individuals or schools use their 3D printers to print the visors using one of the many files that have been developed by teachers and designers around the country.”

After filling in their details on an online spreadsheet, they are then paired with a hospital close to them through the 3dcrowd, a volunteer group who are leading the national effort.

“I was one of the first London people involved, so I just kind of fell into coordinating,” Mr Noonan added.

“So far we here at QE have printed 20 visors, but now that we have the design finalised we are hoping to ramp up production to about 50 per day.

“We even have some of our wonderful QE students who have 3D printers at home helping us out.”

Eight QE boys are currently 3D-printing at home to help the effort: Year 9’s Niyam Shah and Soumil Sahjpal; Dillan Shah, of Year 11; Year 12’s Thomas Mgbor, Ukendar Vadivel, Deshraam Ganeshamoorthy and Devin Karia, and Akram Ahmad, of Year 13.

Several of these boys were recipients of this year’s Arkwright Engineering Scholarships and used their award money to fund the purchase of their 3D printers. Thomas is pictured, above, at work.

UPDATE: 3rd April 2020. Mr Noonan has now donated the first consignment of face shields to the NHS locally, handing over the supplies to Dr Ahmer Farooqi, Director, Barnet Federated GPs (and a QE dad), who have posted a thank you message on their website.

In recent days, the School has also donated its supply of 228 pairs of eye protection glasses to Dr Farooqi for use by GPs in Barnet.

To read more about the story of how and why Mr Noonan got involved, read Technology teacher Sean Kelly’s account, Designing a better tomorrow.

For more information on the national scheme, visit http://3dcrowd.uk

Two QE boys are among the prizewinners in a national competition aimed at finding better designs for electric vehicle charging points.

Year 8’s Tharsan Nimalan won a prize in the seven–14 category, while Ashwin Sridhar, of Year 10, achieved success in the 14-–19 age group in the Eco-Innovators Competition run by the Government’s Office for Low Emission Vehicles (OLEV).

Their success came as the Government announced that a ban on selling new petrol, diesel or hybrid cars in the UK would be brought forward from 2040 to 2035 at the latest. Prime Minister Boris Johnson made the announcement as the country plans to host the annual United Nations climate change summit, COP 26, which is being held in Glasgow in the autumn.

The brief for the competition was to create a design for on-street electric vehicle (EV) charging points that were innovative, iconic and beautiful. At QE, entries were handled jointly by the Geography and Technology departments.

Geography teacher Nilisha Shah said: “I congratulate Tharsan and Ashwin on their success. As the Government’s announcement shows, universal use of electric vehicles is an idea whose time has clearly come, yet there is still much work to be done in making our cities ready. Innovative, creative thinking such as Tharsan’s and Ashwin’s is likely to prove essential if the UK is to get the infrastructure right.”

Tharsan went through a number of design ideas and drafts before settling on his submitted design, which was based upon a large tree. The trunk had a spiral staircase which users could walk up to reach lounge-style leisure facilities – perhaps a restaurant – at the top of the “tree”.

The intention behind this, he explained, was to help EV users pass the time whilst their vehicle charged and even make the charging point a desirable destination – thus overcoming the perceived drawback of electric vehicles that users would have nothing to do while re-charging. Tharsan wanted, in fact to make non-electric car users “jealous of the experience they could be having”.

His design involved the use of lightweight, more sustainable and recyclable metals and other materials, with green planting on the roof. Vehicles would be parked around the base for charging, with cables pulled down from the trunk and plugged in wherever the connection point is on a vehicle.

Ashwin designed a charging station with a “contemporary aesthetic” and a “self-maintaining garden to absorb pollution”. He envisaged a vertical garden some 3 metres high which would collect rainwater and self-irrigate, featuring green plants and mosses that are good at capturing carbon.

Ashwin envisaged targeting high-pollution areas in terms of locations for his charging station, which would also be designed to provide easy access.

Even before learning about the competition, Ashwin had already been thinking about charging point designs, having seen existing ones around London and thought that they could be made better. “They should be more than charging points,” he said, pointing out that ones created according to his designs would not only help “green” the urban landscape, but could usefully act as a source of information, for tourists, for example. Since so many charging points were going to be needed, it was important to get more functionality out of the space.