GERMAN FUEL CELL COOPERATION

Process

• Vacuum Coating of metal strip substrate
• Process component options:
  • Plasma Pretreatment (surface activation / cleaning)
  • PVD-Coating by magnetron sputtering or electron beam evaporation
  • Heating / Cooling

Benefits from coating metal substrates

• Mechanical and chemical stability
• Low interfacial contact resistance
• Low coating costs
• Electrical and thermal conductivity
• Corrosion resistance
• Long lifetime

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By using laser technology, you avoid the use of high-maintenance tools and react flexibly to contour changes.

System advantages

• Cutting speed up to 50 m/min
• Highest dynamics through linear direct drives
• Contour accuracy up to +/- 0,02 mm
• For standard plate format up to 500 x 165 mm, a doubled mold is possible
• Highest cutting quality due to real-time controlled power regulation
• Automated loading and unloading from KLT or belt system

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• Optical inspection of the coating for homogeneity/defects
• Checking the orientation of the plate before loading

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System advantages

• Patent-pending welding modules with large working area of 500 x 350 mm
• Dual field scanner technology for an absolute welding speed of 1000 mm/s for maximum output
• Reduced thermal distortion due to symmetrical heat input with Butterfly Weld
• Double panel loading is possible for panel sizes up to 500 x 165 mm
• Low space requirement

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• Use of all common test methods possible (pressure drop, detection gas test with helium)
• High flexibility due to easily exchangeable sealing devices as well as the use of the modular ZELWANGER measuring inserts ZEDcore
• Scalable test systems incl. semi- to fully-automatic loading and unloading process
• Achieving the shortest possible test times through the use of specially developed measuring circuits and test fixtures
• Preliminary tests as well as measuring equipment capability tests in our own application laboratory or at the customer’s site

Process

• V- Vacuum Coating of metal bipolar plates
• Process component options:
  • Plasma Pretreatment (surface activation / cleaning)
  • PVD-Coating by magnetron sputtering or electron beam evaporation
  • Heating / Cooling

Benefits from coating metal substrates

• Mechanical and chemical stability
• Low interfacial contact resistance
• Low coating costs
• Electrical and thermal conductivity
• Corrosion resistance
• Long lifetime

Learn more or contact us directly

Automated application of sealing compound

• 1K or 2K sealants

Process monitoring

• Volume flow monitoring
• Visual inspection of the sealing bead „on the fly“

Hardening

Advantages

• Automated process for high productivity
• Highly accurate dosing of the sealing
  material possible
• Optical inspection of the sealing lip after
  application optional

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Speed

• Stacking rate up to 2.9 seconds per cell
• Optical positioning „on the fly“

Accuracy

• Positioning accuracy +/- 0.10mm
• Optical tests
• After grabbing
• After discarding
• Position correction after measuring the component using optical contours of the components
• Straight or inclined stacking device

Flexibility

• Freely adjustable number of cells (up to 500 cells)
• Standardized for component dimensions up to 250mm x 500mm
• Handling of bipolar plates made of metal or graphite
• Expandable with integrated leak test, bracing module and pre-assembly processes

Pressing of the stacked fuel cell stack

• Force-displacement monitored pressing of the stack by means of servo presses​
• Free parameterization of the force and/or displacement over time

Leak testing of the fuel cell stack

• Fully automatic testing of external and internal leakages of the individual test chambers to each other (anode, cathode, cooling)
• Allocation of the leakage channel possible using highly accurate flow measuring circuits

​Clamping of the fuel cell stack

• ​Manual or automatic clamping of the stack possible by means of metal straps or threaded rods

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Manual and semi-automated assembly workstations for the production of fuel cell systems

• Mounting of the stack in a housing incl. bracing
• Assembly of media supply circuits

Assembly of peripheral components

• Humidifier
• Recirculation unit
• Air treatment
• Inverter

Test station for fuel cell systems

• Leak testing of the anode, cathode and cooling circuits with air and helium
• Leak detection through the use of helium sniffing processes
• EOL isolation tests

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Leak test with air / nitrogen

• Cooling channel
• Anode channel / hydrogen
• Cathode channel / air
• External and internal leakage (cross-over)

Leak test with helium

• H2 circuit (robotic sniff test for leakage measurement and leak localization)

HV test / Isolation test

Filling and venting of the cooling circuit