Overcoming the Challenges for a Mass Manufacturing Machine for the Assembly of PEMFC Stacks

Porstmann Porstmann,Wannemacher Wannemacher,Richter Richter

doi:10.3390/machines7040066

Abstract

One of the major obstacles standing in the way of a break-through in fuel cell technology is its relatively high costs compared to well established fossil-based technologies. The reasons for these high costs predominantly lie in the use of non-standardized components, complex system components, and non-automated production of fuel cells. This problem can be identified at multiple levels, for example, the electrochemically active components of the fuel cell stack, peripheral components of the fuel cell system, and eventually on the level of stack and system assembly. This article focused on the industrialization of polymer electrolyte membrane fuel cell (PEMFC) stack components and assembly. To achieve this, the first step is the formulation of the requirement specifications for the automated PEMFC stack production. The developed mass manufacturing machine (MMM) enables a reduction of the assembly time of a cell fuel cell stack to 15 minutes. Furthermore the targeted automation level is theoretically capable of producing up to 10,000 fuel cell stacks per year. This will result in a ~50% stack cost reduction through economies of scale and increased automation. The modular concept is scalable to meet increasing future demand which is essential for the market ramp-up and success of this technology.

Highlights

Since the beginning of industrialization, the storage of large amounts of energy has been a challenge for our society
One of the major obstacles standing in the way of a break-through in fuel cell technology is its relatively high costs compared to well established fossil-based technologies
This problem can be identified at multiple levels, for example, the electrochemically active components of the fuel cell stack, peripheral components of the fuel cell system, and eventually on the level of stack and system assembly

Summary

Introduction

Since the beginning of industrialization, the storage of large amounts of energy has been a challenge for our society. More than ever before, we understand the importance of direct power generation by solar, wind, water, and hydrothermal power plants. Electricity generated from these energy sources is known as green electricity because of its zero CO2 balance and the absence of NOx emissions. The production of the power plant has some carbon footprint, its operation is emission free. These power sources are intermittent, and the off demand energy surplus has to be stored because the power grid cannot handle it. A challenge of using these energy sources is to store the electrical energy whenever it is available in the most efficient way

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