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ElringKlingerElringKlinger
Montagetechnologie und Automatisierungskonzepte für die Brennstoffzellenfertigung 3. Marktplatz Zulieferer Wasserstoff- und Brennstoffzellentechnologie
Dr. Jürgen Kraft, ElringKlinger AGMar 10, 2016
ElringKlinger
content
110.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
� Overview ElringKlinger AG
� PEMFC products
� PEMFC assembly andcomponent production
ElringKlinger
Company History
210.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
1879 Foundation of Paul Lechler in Stuttgart, Germany (later: Elring GmbH)
1885 Foundation of Richard Klinger in Vienna, Austria
1994 Merger of Elring GmbH and Richard Klinger Automotive to Elring Klinger GmbH
2000 Merger of Elring Klinger GmbH and ZWL Grundbesitz- und Beteiligungs-AG
(former Holding Company of Elring Klinger GmbH), renaming as ElringKlinger AG
2008 Acquisition of Sevex AG based in Sevelen, Switzerland
2011 Acquisition of the Static Flat Gaskets business of the Freudenberg Group
(Germany, France, Italy)
2011 Takeover of a 66,7% interest in the Swiss Hug Group based in Elsau, Switzerland
2011 Takeover of a 90% interest in the Hummel Group based in Lenningen, Germany
2014 Takeover of a 75% interest in New Enerday GmbH based in Neubrandenburg, Germany
ElringKlinger
Employees ElringKlinger Group
310.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
As of December 2014 (py)
Group7,255 (6,716)
+ 8.02%
AG2,488 (2,301)
Domestic subsidiaries854 (754)
International subsidiaries3,913 (3,661)
Germany3,342 (3,055)
ElringKlinger
Divisions
510.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Cylinder-head
gaskets
Specialty
gaskets
Plastic
modules
Lightweight
plastic
components
Shielding
systems
Aftermarket
E-Mobility Fuel cells Exhaust gas
purification
Engineered
plastics
Engine testing
services
Tooling
technology
ElringKlinger
Core Competences
610.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Sheet metal forming Injection molding In house tooling
Industrial processes Quality assurance
Joining technologies Coating technologies Assembly
ElringKlinger
Know-How
710.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Industrial
production,
Process-
Know-how,
Technology-/
product-Know-how,
simulation (stamping, FEM),
tooling, process optimisation, …
ElringKlinger
PEMFC Stack NM 5
810.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Stack based on metallic bipolar plates
� Produced by high volume processes
Lifetime test ongoing, currently > 6500 hrs
Frreze start capability
Power density pressurized
(2,5 bara, 340 A @ UC=0,6 V):
� 7,2 kW/l (active area),
� 6,4 kW/l (CCM size),
� 4,0 kW/l (cell stack w/o end plates)
i.e. stack NM 5- 48 cells
10 kW @ 2,5 bara
6,5 kW @ 1,2 bara
L /W/H (mm): 243/161/73 (w/o end plates)
picture showing 200 cell module
(stack with integrated media
supply unit)
ElringKlinger
PEMFC Stack NG 3
910.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Application Material Handling, low pressure operation
Cathode: λ < 1.7, 85 % r.H. , 150 mbarg
Anode: dry, with recirculation, 300 mbarg
U/I Characteristics: 160 A @ 600 mV
Prated(24/48 Z/72 Z): 2.3 kWel/4.6 kWel/6.9 kWel
(pressurized up to 10 kWel)
Cooling: Glysantin
Operating temperature: > 0 to 73°C/ 83°C (TCooling in/out)
Storage temperature: -25 … 70°C
TÜV approval accord. to DIN EN 62282-2,
Vibration-/Shock Resistance accord. to DIN EN 60068-2-27/-64
(e.g. 50 g single shock in all three directions)
ElringKlinger
Stack design and -assembly ↔ Component design and -production
� Cell/component design defines stack design and assembly process, e.g.
• Flowfield and MEA design define requirements for assembly tolerances
• Function integration on component level allows simplified assembly processes
but requires innovative component production processes
Quality in component production and cell and stack assembly is
� key requirement for cell homogenity and
� crucial for failure modes on individual component level
and thus basis for stable stack performance
� Production technology has to be main aspect of technology development
Cell/Stack Design
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Cell voltage distribution 200 cell stack, 45 kW
ElringKlinger
Component Production
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Serial production status achieved
� Housing, thermal shielding parts (deep drawing)
� Modules for fluid system (Injection molding)
� Metallic bipolar plates (Stamping)
e.g. metallic bipolar plate:
High volume • Serial production equipement available
• Progressive die set, production rate > 40 pcs/min
• Process capability proven
Prototyping • step by step processing: stamping, laser cutting, …
high throughput processes,
high tooling cost
e.g. repeatability better
than 4 µm (batch to batch,
tooll changing in betwenn)
> 350.000
parts per week
ElringKlinger
Fuel cell module
� Function integration in media supply unit - integrated on endplate
(e.g. sensors, actuators, bypass ducts etc.)
� Innovative production technology, proven in automotive serial
production
• Injection moulding
• Joining technology
� Production technology enables integration
� Low cost, low weight
� Reduced system complexity
� Thermal integration, optimized water management
� Reduced system assembly effort
Function Integration on Stack Level
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ElringKlinger
Production Technology ↔ Product Technology
� Production processes have to be adapted to product technology requirements
� Manufacturability has to be major aspect of product design
Stack/cell concepts have to prove in production process:
� Process stability/control and quality assurance (all relevant steps)
Approach:
1. Manual production using devices compatible to automated production
2. Pilot production, partly automated
3. Throughput optimised pilot line
4. Serial production (low volume)
5. Mass production
But: Different stages may require different concepts/solutions
Cell/Stack Assembly
1310.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
Early learning for automated production,
process development and
preparation for transfer,
high yield at an early stage
ElringKlinger
Requirements:
Cost efficient design� Integration of components/functions
- sealing on BPP or GDL
- endplate with media supply unit
� Simple configuration
- no subgasket
� Design with acceptable tolerance requirements
� Failure tolerant/compensating processes
Process capability on all levels of cell and stack assembly
Certification of stacks includes
assessment of production processes
Cell/Stack Assembly
1410.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
ElringKlinger
Development of manufacturing technology is in line with growing volume
� Scalable production concept
Scalability:
� Parallelisation
� Throughput optimisation� simplyfied concepts
� Processing speed, e.g. faster robotics
� Continous processing (e.g. progressive die set)
Production concepts and equipment should be suitable for
the transition to high volume production
Cell/Stack Assembly – Step by Step Approach
1510.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
ElringKlinger
� Process
� Process linking
� Automation technology
� QA concept
� Analysis of crucial assembly steps
� Definiton of cost efficient automation/ robotic solutions
� Definition of component supply configuration
� Definition of transfer systems
� Inline geometrical measurement/QA
� Traceability
� Throughput optimisation, scalability
Cell/Stack Assembly – Realisation
1610.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
ElringKlinger
Two stack formats
- NM 5 (metallic bipolar plate, typ. 5 - 50 kW)
- NG 3 (graphitic bipolar plate, typ. 2 - 7 kW)
with different component design but
compatible design concepts (e.g. sealing concept, cell configurations)
� similar manufacturing processes
Cell/Stack Assembly - Products
1710.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
ElringKlinger
Flexible manufacturing cell (mc):
� Fixed concept for basic setup and process linking� first mc for cell assembly
� second mc for stack assembly (mounting of compression unit manually assisted)
� Flexibility in component size and material � stacks with metallic and graphitic bipolar plates
� cell format/size, roll width
� Flexibility in component supply� different component configurations
� interfaces for feeding adaptable
Target:
� Development of process, automation concept
and plant-/machine technology
� Validation/revision of component design
� Approaching the requirements for high volume production
Cell/Stack Assembly - Realisation
1810.03.2016 3. NOW Marktplatz Zulieferer H2- und BZ-Technologie
cell assembly
stack assembly
ElringKlinger
Cell/Stack Assembly - Challenges
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Membrane� process: flatness, free of wrinkles
� supply, feed: properties and condition,
� quality assurance: failure marking and detection
Bipolar plate� process: flatness (�clicker)
Supply chain:� general: consistent understanding of high volume requirements and
approach to realisation
� process: standards for state and conditions of supplied components
ElringKlinger
Thank you for your attention!
Experience mobility – Drive the future.
development supported by:
Dr. Jürgen Kraft
Head of PEM Fuel Cell Development
+ 49 7123 724 9921