1

Consulting, Design and Engineering ServicesReduce costs, speed up development, improve product quality

Engineering Services

2

Romax provides you with expertise, tools and services for:

• Gearbox and driveline design, simulation, test and manufacture• New product development and product redevelopment• Problem solving – and process improvements

Enabling you to drive down costs, reduce risk and improve product quality, we are the world’s leading provider of integrated solutions for gearbox, driveline systems and bearings: combining consulting expertise, tools and technology, and services.

Giving you the power to succeed

3

We are the experts in gearboxes and driveline systems – which means we can provide you with specialist expertise, support and resources for all major design and development projects. Our integrated solutions address the critical issues and solve the business challenges you face.From dealing with specific technical problems to implementing end-to-end process improvements, we help our clients to reduce costs, improve the design process, remove risk and raise product quality in key sectors:

• Automotive

• Commercial Vehicles

• Off-highway

• Aerospace

• Marine

• Rail

• Renewable Energy

Our clients trust us to deliver innovation from our engineering centres around the world: global reach with a local presence.

Achieve forward motion in faster and smarter ways

“”

Romax has been a very important partner... not only because they have the most advanced technologies in the world but also for their willingness and ability to share and transfer those technologies, which enables our sustainable growth.

4

Romax clients benefit from multi-disciplined teams that combine deep engineering skills and industry experience with advanced simulation tools.We add value at every stage of design, development and production. Our proven skills and methodologies help you achieve measurable improvements and business advantage in:

• Concept Design and Detailed Design

• Design Review and Advanced Analytics

• Manufacturing, Testing and Problem Investigation

• Strategic Consulting

• Process Improvements

Solutions aligned with your business

”Engineering excellence is the heart of our business...we can help you solve any problem, reduce costs in multiple areas and speed up development in the smartest ways

“

5

Drawing on our expertise and experience means you can reduce costs throughout the design and development process, pre-or post-production. You can deliver better quality products more rapidly, streamlining the process and reducing risk.Our services enable you to address the critical efficiency and cost-based challenges that you face, including:

• Product cost via materials and weight savings, for example

• Development time scales through improved design, analytical insight, prototypes and testing

• Cost of production including manufacturing, and along the supply chain

• The financial implications of failures including warranty and downtime

• Issues around in-service running costs for your customers

• Compliance with legislation and industry regulators - avoiding penalties and carbon emission taxes

In terms of quality, brand equity and reputation, combining our intellectual property with industry best practice and simulation tools enables you to embed innovation across your design and development lifecycle right through to production. This allows you to focus on and improve product quality issues in critical areas including noise, vibration and performance, to ensure you fully address environmental considerations including carbon emissions, and to pre-empt durability issues to minimise problems or failures in the market.

Helping you deliver higher quality products faster - and at lower cost

6

We’ve grouped our services into eight key areas that are aligned with the design and development process - and the challenges you can face. There is no such thing as a “typical” engagement: each situation is different, and an individual project will often combine different elements across these service areas. Our project management expertise and project governance ensure whatever the requirement, we can deliver what you need.

Integrated services: aligned with your business and its requirements

Reduce time to market and bring down costs from concept to production, with the ability to assess and understand a wider range of design concepts and minimise risk

• Initial studies to determine best concepts and feasibility

• Fast and accurate assessment of multiple drivetrain concepts and layouts

• Initial component selection and design including gears and bearings

• Review of specifications, interfaces and gearbox packaging constraints

• Benchmarking existing products

• System-level analysis to judge suitability of different concepts

Concept Design

Case study in Concept Design

Requirement: design wind turbine drivetrain and study scalability to 10MW

Services provided: we were engaged to size and compare drivetrain concepts to enable our client to select appropriate technology for next-generation turbine development. Assessing technical risks, cost of energy and manufacturing limits for each concept, we enabled the client to make a genuinely informed choice of drivetrain layout.

CONCEPT DESIGN

7

Create optimised designs for greater durability, vibration and efficiency - and reduced prototype testing - through a combination of experienced engineers, our intellectual property and powerful simulations

• Supply detailed models and drawings

• Bespoke transmission design: from first concepts to prototype production

• Modify existing transmission for new applications

• Understand end customer requirements to fully develop design specifications

• Detailed analysis and optimisation leading to preparation of production drawings

• Static and fatigue finite element analysis (FEA) of structural components

Detailed Design

Case study in Detailed Design and Certification

Requirement: wind turbine gearbox design and development

Services provided: enabling more than 30 gearbox and drivetrain designs, with 25 achieving certification. We developed and delivered a best practice design process for fast right-first-time results. By late 2014 more than 1.5GW of Romax-designed gearboxes will have shipped.

DETAILED DESIGN & CERTIFICATION

8

Expert know-how plus fast and accurate simulations to explore designs in depth – to eliminate gear, bearing and synchroniser problems, providing weight savings and bringing down costs

• Complete review of designs, component drawings and specifications

• Verify design suitability based on advanced analysis and expert judgement

• Review customer design against specifications and for certification

• Sensitivity studies to understand effects of design changes on durability and vibration

• Appraisal of alternative designs and manufacturing methods

• Prepare design and analysis reports for end-clients and/or certification

Design Review

Integrated services: aligned with your business and its requirements

Case study in Design Review

Requirement: bearing supplier assessment

Services provided: assess if supplier ’s product was suitable for application including analysis of risk of changing, quality review completed benchmarking against current supply, use of measured data in analysis, audit and develop supplier manufacturing to meet product quality requirement. We enabled this client to reduce cost by 18% from changing supply source of bearings.

DESIGN REVIEW

9

Sophisticated methods verified across multiple successful engagements: optimise the performance of the whole system, improve efficiency, reduce CO2 – and avoid expensive prototyping and testing

• Assessing all critical aspects of performance on drivetrain and geared systems

• Analysing misalignment, durability and efficiency of components (gears, bearings, shafts)

• Duty cycle generation and studying the effects of operating and extreme component loads

• Parametric studies and sensitivity analyses for design parameters using Design of Experiments (DoE)

• Energy flow analysis for advanced hybrid and electric vehicle powertrains

• Dynamic analysis of complete drivetrain systems

• Transmission error analysis with gear geometry optimisation to reduce gear whine

• Validate simulation results with measured vibration test data

• Gearshift analysis and optimisation

Advanced Analysis

10

With proven expertise and experience across multiple sectors, our engineers and metallurgists will bring new perspectives on production processes, facilities, costs and success/failure rates

• Highly experienced experts on hand for advice and support

• Review and support improvements in production capability, facilities and equipment

• Advice on best practice for prototype and serial production

• Onsite due diligence on suppliers to ensure quality target compliance

• Advice on selection of materials and manufacturing/finishing processes

• Assess effects of manufacturing variability on product durability

• Documentation for improvements in QA processes, assembly and tooling design

Manufacturing Support

Integrated services: aligned with your business and its requirements

Case study in Manufacturing Process

Requirement: review, audit and gap analysis for prototype gearbox

Services provided: examining the manufacturing process (what went right / what didn’t) to identify issues, audit to ensure compliance with QA plan and verify specification, capability review, gap analysis of “what’s missing and what’s required”, with recommendations made on improvements and cost avoidance activity.

MANUFACTURING PROCESS

11

Minimise development testing time and costs: we offer proven expertise in test rig design combined with simulation and analytics to ensure the most representative procedures and equipment

• Informed advice across all testing procedures and test rig design

• Creating specifications and procedures for evaluation tests and instrumentation

• Install and commission instrumentation of drivetrain test systems

• Test rig design for components and complete drivetrains

• Validation using measured test data of simulation results

• Onsite support for completing all testing requirements

• Supplier audits, training and certification

As you would expect, we work with the most respected certification bodies around the world, including Germanischer Lloyd (GL), TÜV SÜD, DNV and DEWI-OCC Offshore and Certification Centre.

Romax is recognised by Germanischer Lloyd (GL) as the first company in the world to achieve 25 Gearbox designs for wind turbines with A-Design Certificates.

Testing and Certification Support

CCERTIFIERTIFICCAATE TE NNO.O. ZZZZ--001_a_001_a_RRomaxWIomaxWINNDD CCERTIFIERTIFICCAATE TE NNO.O. ZZZZ--GGLL-001-201-001-20111

12

Integrated services: aligned with your business and its requirements

Identify and solve problems, with experienced engineers handling design, analysis and physical inspections: eliminate gearbox, bearing and synchroniser failures and target reject rates in production

• Identify failure root causes and explore countermeasures

• Inspect and measure drivetrain components for expert assessments on condition

• Identify failure mode root causes via investigation and advanced simulation

• Optimise gear design and bearing selection to enhance performance

• Review the influence of manufacturing quality and metallurgy on durability

Problem Investigation

Case study in Problem Investigation

Requirement: investigate railway axle box failure

Services provided: examine the causes of bearing failures; explore analyses previously carried out by other companies/consultants. Our experts identified failure modes that indicated bearing misalignment was causing the problems; assembly tolerance errors had resulted in abnormal loading that previous analyses had not accounted for.

PROBLEM INVESTIGATION

13

Right first time: with a proven methodology that includes stakeholder interviews, root cause definition, process mapping, simulation optimisation, process design, pilots and specialist consulting, we deliver engineering process improvements for diverse clients in different sectors.Drawing on specialist skills and industry knowledge gained worldwide, the due diligence and measurable gains we provide have helped clients speed up product development, save millions of dollars and smooth their entry into new markets.

• Reduce the number of iterations: save time so you can get to market faster

• Drive down project costs – and total cost of development

• Improve staff utilisation, share learning and raise skill levels

• Implement and benefit from the optimum tools

• Deliver consistently high quality results

Getting it right first timeWe help you deliver products faster and at reduced cost through process improvement - so you can overcome the challenges you face in design and development.

• The drivetrain specialists: for transmission, gearbox and bearings

• Market surveys and benchmarking technology trends

• Feasibility studies on new product introduction and development

• Due diligence of suppliers and acquisitions

• Design and analysis process improvements

• Tailored education & training programmes

Strategic Consulting – Process Improvements

14

What makes Romax different?Solving the real-world problems and engineering issues you face, our solutions give you the expertise you need to improve your operations - with clearly defined outcomes.We are acknowledged experts in the design, analysis, testing and manufacture of gearboxes, drivetrains and bearings - combining many years’ hands-on operational experience with deep academic know-how. Few if any other providers in this area can match our expertise; 23% of our employees hold PhDs. 60% of staff are qualified engineers.

Our in-house R&D has also resulted in exceptional intellectual property, with advanced simulation methods that have been proven and validated over a 25-year period.

We combine these tools and technologies with industry best practice for design and development, again founded on many years’ expertise of successfully delivering for our clients.

You also have the assurance that we are flexible enough to meet whatever set-up and requirements you may have, working on projects from the relatively small-scale to global strategic initiatives – backed by our own global engineering resources. Crucially, we are 100% independent from manufacturers, suppliers and end users, so can offer you unbiased and objective viewpoints on the issues you face.

Our combination of expertise, tools and services mean we can help you:

• Move from concept to production faster

• Reduce design time and optimise development

• Speed up time to market

• Increase product quality

• Drive down manufacturing costs

• Reduce failures and warranty costs

• Build value and increase brand equity

15

Case study in Concept Design

Requirement: design a new transmission system for a marine application (marine)

Services provided: we were engaged by a client to provide Feasibility Studies for parallel, planetary and perpendicular gear types, as well as Concept Design selection, comparing bearing concepts and studying system packaging. We identified a number of designs that met the client’s requirements, and would fit inside the existing vessel hull in a short period of time.

CONCEPT DESIGN

Case study in Detailed Design

Requirement: design new manual transmission for GM Korea

Services provided: design services from concept to prototype drawings, UK prototyping with testing by a Romax partner, support for rig and vehicle testing. All targets met for gearbox development, and the transmission was produced in volumes of more than one million units per annum.

DETAILED DESIGN

Case study in Advanced System Analysis

Requirement: vibration analysis of railway axle

Services provided: assess the effect of Transmission Error on the system and of changes to housings and gear geometry, predict the response of the structure, accelerations, velocities, modal shapes and energies, and predict Sound Power Level across a given speed range. We identified key design changes to reduce noise at specific speeds and provided a rapid process to deliver recommendations; this has since been used on multiple projects for this client.

ADVANCED SYSTEM ANALYSIS

Case study in Design Review

Requirement: fully assess dual clutch transmission (DCT) design

Services provided: lubrication and assembly assessment, examine gear misalignment and load distribution factors, FE stress analysis of gearbox housing and shift forks, NVH assessment including gear micro-geometry, transmission error sensitivity analysis and mode shape prediction. We provided notable design changes to the transmission concept to improve gear durability, gear micro-geometry design and bearing support.

DESIGN REVIEW

Case study in Testing Support

Requirement: bearing test rig development

Services provided: test rig design for large size bearings, simulating behaviour in turbine operation, study skidding characteristics of High-Speed Stage (HSS) bearings and monitor bearing degradation using vibration and temperature measurements. Results from the rig were successfully applied in R&D activities to assess influences on bearing performance.

TESTING SUPPORT

We are proven – across multiple sectors and for the most demanding clients.

These are just a few examples of how we have delivered measurable value in design, development and production.

16

Romax Technology LimitedRutherford House

Nottingham Science & Technology ParkNottingham

NG7 2PZUnited Kingdom

T: +44 (0) 115 951 8800F: +44 (0) 115 951 8801

E: sales@romaxtech.com www.romaxtech.com

© Copyright Romax Technology Limited 2013. This document is for information only & is subject to change without notice. S-B-DT-R1

Solutions to drive business and sustainability

www.romaxtech.com