Fuel Cell Solutions

The entire value chain - fast, flexible, in series

Electric drives with fuel cells as energy suppliers will play a major role in the emission-free vehicles of the future. The advantages are long ranges and short refuelling times, similar to combustion engines. When it comes to making freight and passenger transport more eco-friendly, the fuel cell is superior to a battery in terms of availability of raw materials, weight and size. We can provide you with the right production system for your requirements in terms of component variance, variable or fixed production quantities. With our assembly and test solutions for fuel cells, you can safely process more than 10,000,000 cells per year. Based on our experience from projects realized worldwide, we will find the right solution for you.

The alignment of the MEA to the bipolar plate and the fast, precise stacking of these cells represent the challenge in the assembly of fuel cells. We have optimized these processes.

Thomas Kuschel, Senior Manager Fuel Cell Assembly & Test, thyssenkrupp Automation Engineering

^{Our solutions for fuel cell assembly}

Our production systems for fuel cells are based on both clocked and flow processes. In order to enable the provision of materials, partial productions of the individual components become assembly processes. Bipolar plates, both stainless steel and graphene based, and MEAs (membrane electrode assemblies) are first assembled and then delivered to the line. The CCM (Catalyst-Coated-Membrane), the GDL (Gas-Diffusion-Layer) and the Sub-Gasket as components of the MEA are processed, aligned and assembled e.g. as roll material.

Our production systems for fuel cell stacks are based on clocked processes. In order to enable the provision of materials, partial productions of the individual components become assembly processes. Bipolar plates, both stainless steel and graphene based, and MEAs (membrane electrode assemblies) are first assembled and then delivered to the line. The CCM (Catalyst-Coated-Membrane), the GDL (Gas-Diffusion-Layer) and the Sub-Gasket as components of the MEA are processed, aligned and assembled e.g. as roll material.

^{Test and conditioning}

Fuel cell assembly MEA — Safe transport of the sensitive MEA.

A defective part in the stack can lead to a total failure of the system in the vehicle. Our test benches and in-process test concepts monitor the quality of production and ensure the performance of the fuel cell stacks.

The current conditioning times of the stacks of up to 12 hours require extensive technical equipment in the manufacturing process. Together with partners we are working on a solution to reduce the conditioning times to 2 hours.

Turnkey line portfolio

With our equipment you can manufacture MEA elements in series with a high and reproducible accuracy. You receive these turnkey, manual, semi- or fully automatic, including means of transport.

Our portfolio includes the automated production of bipolar plates (in cooperation with a partner), sealant application and end-of-line testing. Developed transport solutions between production and stack assembly enable the efficient transfer of components.

Camera system solutions check the elements for geometry and contamination in the µ-range every second. This way, you can detect manufacturing errors in 2D or 3D for fast correction directly at the point of origin and ensure your quality.

With our systems you stack cell elements, consisting of a pair of MEA/BPP, in ½ Hz technology. At present these lines are accelerated to 1 Hz technology. With these systems you can produce at least 50,000 stacks at 300-400 cells per stack per year.

At the end of the stack production, our systems test your fuel cells for leaks. This is followed by end-of-line testing and conditioning.

Are you planning the manual or fully automatic final assembly of the unit? Profit from our standard solutions. If required, we can also adapt them to your individual requirements.

Analog to the end-of-line inspection of the stack, we have solutions for the final inspection of the entire unit. This ensures that you only deliver 100% OK-tested systems.

Both the transport of the entire system and the individual components require sensitive handling. Therefore, our systems are individually designed for the components in manual and fully automatic processes.

^{Quantity scenarios from prototype production to series}

Fuel cell assembly Bipolar plates and MEA — Bipolar plates and MEAs are assembled and delivered to the line.

For prototype and small series assembly, we offer our customers scalable and individually tailored solutions. Product understanding and variant competence are our top priority. The selection of the required test processes and technology is part of our DNA

We enable you to enter into large series production with clocked 1 Hz cell stack technology for at least 50,000 fuel cell stacks per year. The next step is flow production, as the key to producing significantly larger quantities.

Contact

Thomas Kuschel

Phone:+49 421 6888 41455

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