3. Marktplatz Zulieferer Wasserstoff-und Brennstoffzellentechnologie · 2018-06-05 · ElringKlinger Company History 10.03.2016 3. NOW Marktplatz Zulieferer H2-und BZ-Technologie

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


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


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

Group Sales


ElringKlinger

Divisions


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


Sheet metal forming Injection molding In house tooling

Industrial processes Quality assurance

Joining technologies Coating technologies Assembly

ElringKlinger

Know-How


Industrial

production,

Process-

Know-how,

Technology-/

product-Know-how,

simulation (stamping, FEM),

tooling, process optimisation, …

ElringKlinger

PEMFC Stack NM 5


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


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


Cell voltage distribution 200 cell stack, 45 kW

ElringKlinger

Component Production


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


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


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


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


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


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


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


cell assembly

stack assembly

ElringKlinger

Cell/Stack Assembly - Challenges


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

[email protected]

Documents

3. Marktplatz Zulieferer Wasserstoff-und Brennstoffzellentechnologie · 2018-06-05 · ElringKlinger Company History 10.03.2016 3. NOW Marktplatz Zulieferer H2-und BZ-Technologie