Fuel Cell ASAP: Two Iterations of an Automated Stack Assembly Process and Ramifications for Fuel Cell Design-for-Manufacture Considerations

Polymer-electrode membrane fuel cell technology, a low-emission power source receiving much attention for its efficiency, will need to progress from low-volume production to high-volume within the course of the next decade. To successfully achieve this transition, significant research progress has already been made toward developing a fully functional fuel cell automatic stack assembly robotic station. Lessons can be drawn from this research with regards to design-for-manufacture (DFM) and design-for-assembly (DFA) considerations of fuel cells; however, more work still remains to be done. This document outlines both iterations of the robotic fuel cell assembly stations, other work to date, DFM and DFA lessons learned, and the anticipated future progression of automatic fuel cell stack assembly stations. Two individual robotic fuel cell assembly stations were constructed, including custom-built end effectors and part feeders. The second station incorporated numerous improvements, including overlapping work envelopes, elimination of a shuttle cart, software synchronization, fewer axes, and a better end effector. Consequentially, the second workcell achieved a fourfold improvement in cycle time over the previous iteration. Future improvements will focus in part upon improving the reliability of the overall system. As the stack assembly workcell continues to improve, research will focus upon the ramifications and interplay of tolerances, stack failure modes, sealing, reliability, and the potential for component redesign specifically to optimize fuel cell manufacturing throughput.

Download Full-text

Fuel Cell ASAP: Two Iterations of an Automated Stack Assembly Process and Ramifications for Fuel Cell Design-for-Manufacture Considerations

ASME 2009 7th International Conference on Fuel Cell Science, Engineering and Technology ◽

10.1115/fuelcell2009-85231 ◽

2009 ◽

Cited By ~ 1

Author(s):

Christina Laskowski ◽

Stephen Derby

Keyword(s):

Fuel Cell ◽

Failure Modes ◽

Scale Up ◽

High Volume ◽

Lessons Learned ◽

Research Progress ◽

Cell Assembly ◽

Production Scale ◽

Design For Manufacture ◽

Fuel Cell Stack

Polymer-electrode membrane (PEM) fuel cell technology, a low-emissions power source receiving much attention for its efficiency, will need to progress from low-volume production to high-volume within the course of the next decade. To successfully achieve this transition, significant research progress has already been made towards developing a fully-functional fuel cell automatic stack assembly robotic station. Lessons can be drawn from this research with regards to design-for-manufacture (DFM) and design-for-assembly (DFA) considerations of fuel cells; however, more work still remains to be done. This document outlines both iterations of the robotic fuel cell assembly stations, other work to date, DFM and DFA lessons learned, and the anticipated future progression of automatic fuel cell stack assembly stations. A literature search reveals numerous patents pertaining to equipment and processes for fuel cell assembly as well as a great number of patents pertaining to fuel cell stack features to aid in manufacture or assembly. However, most of this is focused upon proper compression of the membrane material, with little thought given to overall assembly and throughput. Journal articles have begun to consider real-world manufacturing considerations pertinent to production scale-up, but much remains to be done. Therefore, there is a need for more contributions to stack manufacture and assembly. Work already completed (by the authors and their lab) towards the manufacturing workcell specifically includes the design and construction of two individual robotic fuel cell assembly stations, including custom-built end effectors and parts feeders. The second station incorporated numerous improvements, including overlapping work envelopes, elimination of a shuttle cart, software synchronization, fewer axes, and a better end effector. Consequentially, the second workcell achieved a four-fold improvement in cycle time over the previous iteration. Future improvements will focus in part upon improving the reliability of the overall system. Close study of the manufacturing workcell indicated that stack component design features are key for production and scale-up of fuel cell stack manufacturing processes. Critical features are discussed in this article, as well as their ramifications for the overall stack design. As the stack assembly workcell continues to improve, research will focus upon the ramifications and interplay of tolerances, stack failure modes, sealing, reliability, and the potential for component redesign specifically to optimize fuel cell manufacturing throughput.

Download Full-text

Fuel Cell ASAP: Two Iterations of an Automated Stack Assembly Process and Ramifications for Fuel Cell Design-for-Manufacture Considerations

ASME 2009 International Manufacturing Science and Engineering Conference, Volume 2 ◽

10.1115/msec2009-84104 ◽

2009 ◽

Author(s):

Christina Laskowski ◽

Stephen Derby

Keyword(s):

Fuel Cell ◽

Failure Modes ◽

High Volume ◽

Lessons Learned ◽

Cell Assembly ◽

Fuel Cell Stack ◽

Volume Production ◽

End Effectors ◽

Electrode Membrane ◽

Previous Iteration

Polymer-electrode membrane (PEM) fuel cell technology will need to progress from low-volume production to high-volume within the course of the next decade. To successfully achieve this transition, a fully-functional fuel cell automatic stack assembly robotic station is being developed. This document outlines both iterations of the robotic fuel cell assembly stations, other work to date, DFM and DFA lessons learned, and the anticipated future progression of automatic fuel cell stack assembly stations. Two individual robotic fuel cell assembly stations were constructed, including custom-built end effectors and parts feeders. The second station incorporated numerous improvements, including overlapping work envelopes, elimination of a shuttle cart, software synchronization, fewer axes, and a better end effector. Consequentially, the second workcell achieved a four-fold improvement in cycle time over the previous iteration. Future improvements will focus in part upon improving the reliability of the overall system. As the stack assembly workcell continues to improve, research will focus upon the ramifications and interplay of tolerances, stack failure modes, sealing, reliability, and the potential for component redesign specifically to optimize fuel cell manufacturing throughput.

Download Full-text

Automated Fuel Cell Stack Assembly: Lessons in Design-for-Manufacture

ASME 2010 8th International Fuel Cell Science, Engineering and Technology Conference: Volume 2 ◽

10.1115/fuelcell2010-33222 ◽

2010 ◽

Author(s):

Christina Laskowski ◽

Ryan Gallagher ◽

Andrew Winn ◽

Stephen Derby

Keyword(s):

Fuel Cell ◽

Proton Exchange Membrane ◽

High Volume ◽

Proton Exchange ◽

Robotic Assembly ◽

Automated Assembly ◽

Design For Manufacture ◽

Fuel Cell Stack ◽

High Volume Production ◽

Exchange Membrane

Within the next decade, proton-exchange membrane (PEM) fuel cell technology will need to progress from low-volume to high-volume production. The second of two fully-functional fuel cell stack assembly robotic stations is being developed to meet the requirements for this transition; meanwhile, a fuel cell stack is being modified to ease the challenges of automated assembly. This document outlines the most recent iteration of the robotic fuel cell assembly station, challenges encountered, stack design features which impair automation efforts, stack modifications and their impact on assembly success, and a methodology for designing successful stacks in tomorrow’s automated assembly plants. Numerous design aspects of the stack, intended for manual assembly, proved challenging for robotic assembly: in particular, those pertaining to component tolerances, stack compliance, fasteners, environmental requirements, overall stack alignment, MEA handling, and part alignment verification. Each of these challenges was addressed during the refinement of the second robotic station, in many cases via modification of the stack. Nonetheless, each of these factors represents a continuing liability, both in cost and time, to rapid, accurate, reliable stack assembly. Methodology for incorporating these critical design-for-manufacture considerations into future stack designs is therefore addressed as well. As the stack assembly workcell continues to improve, research will focus upon further stack redesign specifically to optimize fuel cell manufacturing throughput.

Download Full-text

Review of the Durability of Polymer Electrolyte Membrane Fuel Cell in Long-Term Operation: Main Influencing Parameters and Testing Protocols

Energies ◽

10.3390/en14134048 ◽

2021 ◽

Vol 14 (13) ◽

pp. 4048

Author(s):

Huu Linh Nguyen ◽

Jeasu Han ◽

Xuan Linh Nguyen ◽

Sangseok Yu ◽

Young-Mo Goo ◽

...

Keyword(s):

Fuel Cell ◽

Polymer Electrolyte ◽

Failure Modes ◽

Polymer Electrolyte Membrane ◽

Durability Test ◽

Term Operation ◽

Electrolyte Membrane ◽

Transportation Applications ◽

Testing Protocols

Durability is the most pressing issue preventing the efficient commercialization of polymer electrolyte membrane fuel cell (PEMFC) stationary and transportation applications. A big barrier to overcoming the durability limitations is gaining a better understanding of failure modes for user profiles. In addition, durability test protocols for determining the lifetime of PEMFCs are important factors in the development of the technology. These methods are designed to gather enough data about the cell/stack to understand its efficiency and durability without causing it to fail. They also provide some indication of the cell/stack’s age in terms of changes in performance over time. Based on a study of the literature, the fundamental factors influencing PEMFC long-term durability and the durability test protocols for both PEMFC stationary and transportation applications were discussed and outlined in depth in this review. This brief analysis should provide engineers and researchers with a fast overview as well as a useful toolbox for investigating PEMFC durability issues.

Download Full-text

A Review of Hydrogen Purification Technologies for Fuel Cell Vehicles

Catalysts ◽

10.3390/catal11030393 ◽

2021 ◽

Vol 11 (3) ◽

pp. 393

Author(s):

Zhemin Du ◽

Congmin Liu ◽

Junxiang Zhai ◽

Xiuying Guo ◽

Yalin Xiong ◽

...

Keyword(s):

Fuel Cells ◽

Fuel Cell ◽

Carbon Emission ◽

High Efficiency ◽

Impurity Content ◽

Fuel Cell Vehicle ◽

Research Progress ◽

Hydrogen Purification ◽

Fuel Cell Vehicles ◽

Low Carbon

Nowadays, we face a series of global challenges, including the growing depletion of fossil energy, environmental pollution, and global warming. The replacement of coal, petroleum, and natural gas by secondary energy resources is vital for sustainable development. Hydrogen (H2) energy is considered the ultimate energy in the 21st century because of its diverse sources, cleanliness, low carbon emission, flexibility, and high efficiency. H2 fuel cell vehicles are commonly the end-point application of H2 energy. Owing to their zero carbon emission, they are gradually replacing traditional vehicles powered by fossil fuel. As the H2 fuel cell vehicle industry rapidly develops, H2 fuel supply, especially H2 quality, attracts increasing attention. Compared with H2 for industrial use, the H2 purity requirements for fuel cells are not high. Still, the impurity content is strictly controlled since even a low amount of some impurities may irreversibly damage fuel cells’ performance and running life. This paper reviews different versions of current standards concerning H2 for fuel cell vehicles in China and abroad. Furthermore, we analyze the causes and developing trends for the changes in these standards in detail. On the other hand, according to characteristics of H2 for fuel cell vehicles, standard H2 purification technologies, such as pressure swing adsorption (PSA), membrane separation and metal hydride separation, were analyzed, and the latest research progress was reviewed.

Download Full-text

Electromagnetic-launch-based method for cost-efficient space debris removal

Open Astronomy ◽

10.1515/astro-2020-0016 ◽

2020 ◽

Vol 29 (1) ◽

pp. 94-106

Author(s):

Chongyuan Hou ◽

Yuan Yang ◽

Yikang Yang ◽

Kaizhong Yang ◽

Xiao Zhang ◽

...

Keyword(s):

Space Debris ◽

Orbit Space ◽

Low Earth Orbit ◽

Research Progress ◽

Area Of Interest ◽

Electromagnetic Launch ◽

Debris Removal ◽

Significant Research ◽

Electromagnetic Launcher ◽

Cost Efficient

AbstractThe increase in space debris orbiting Earth is a critical problem for future space missions. Space debris removal has thus become an area of interest, and significant research progress is being made in this field. However, the exorbitant cost of space debris removal missions is a major concern for commercial space companies. We therefore propose the debris removal using electromagnetic launcher (DREL) system, a ground-based electromagnetic launch system (railgun), for space debris removal missions. The DREL system has three components: a ground-based electromagnetic launcher (GEML), suborbital vehicle (SOV), and mass of micrometer-scale dust (MSD) particles. The average cost of removing a piece of low-earth orbit space debris using DREL was found to be approximately USD 160,000. The DREL method is thus shown to be economical; the total cost to remove more than 2,000 pieces of debris in a cluster was only approximately USD 400 million, compared to the millions of dollars required to remove just one or two pieces of debris using a conventional space debris removal mission. By using DREL, the cost of entering space is negligible, thereby enabling countries to remove their space debris in an affordable manner.

Download Full-text