Assembly Automation
for SUSTAINABLE
Energy Solutions
Assembly lines and test equipment for fuel cells and electrolyzers
A sustainable mobility and power supply depend on new energy sources and carriers. Climate change is forcing politics, science and industry to rethink and is driving the development of innovative technologies to a considerable and sustainable level.
Hydrogen as an energy carrier and fuel cell systems as alternative forms of propulsion can pave the way to climate neutrality.
XENON is committed to proactively shaping the energy transition. As a leading automation specialist, we design and develop automation equipment for the series production of fuel cell systems.
To meet this goal, we rely on an extensive process know-how and a broad technology portfolio and cover the entire value chain: from component manufacturing to stack and system assembly.
Hydrogen Technology & Stack Components
HOW IT WORKS
An electrolyzer uses electrical energy to break down water or water vapour into its components hydrogen and oxygen.
Common technologies for hydrogen production by electrolysis are
- Alkaline electrolysis
- Proton exchange membrane electrolysis (PEM)
- High-temperature electrolysis
Contributing our expertise of more than 30 years in fast-cycle assembly lines and changeable production systems to the new business area and helping to solve one of the most important problems of our time is a rewarding challenge.
Dr. Hartmut Freitag
Senior Vice President, XENON Dresden
Model: TU Chemnitz - Open Source Stack
Application fields for electrolysis and fuel cells
STATIONary
INDUSTRy supply
- Hydrogen generation
- Uninterruptible power supply (UPS)
- Energy and heating systems for homes
- Industrial energy supply
MOBILe
Drive Technology
- Passenger cars
- Commercial vehicles (CMV)
- Buses
- Trains
- Ships
transPORTABle
Energy Storage
- Emergency power generators
- Energy supply for systems and machines
Assembly and Test Automation for the entire Value Chain
As a leading automation specialist, we design and develop automation equipment for the series production of fuel cell and electrolysis systems.
STACK-Assembly
Automation Processes
- Feeding, positioning and stacking of the cellss
- Compressing and tensioning of the stack
- Assembling media connections
- Testing for leaks
- EOL test
PEM
Polymer Electrolyte Membrane Electrolysis uses a thin membrane made of thermoplastic (ionomer) as electrolyte. Anode and cathode are separated by this gas-tight membrane, only positive hydrogen ions can pass through the membrane. Due to ion migration, this process of electrolysis belongs to the acidic processes. This makes the use of precious metals necessary for the catalysts in order to avoid corrosion.
Advantages
The good load change behaviour. It can react quickly to fluctuations in the energy supplied and can be operated at partial load without any problems. The efficiency of PEM electrolysis is currently around 63%, which is slightly lower than that of alkaline electrolysis. Since the technology is still relatively new, the investment costs are considerably higher than for alkaline electrolysis. The power range of the plants reaches values of up to 6 megawatts.
SOC
Solid Oxide Electrolysis uses a solid ceramic material as the electrolyte, which separates the two half cells. The water is fed to the reaction chambers in the form of steam. This type of electrolysis is currently in transition from research to industrial application.
Advantages
This technology belongs to the high-temperature electrolysis, is operated at temperatures of 600-900 °C and can achieve a very high efficiency of over 80%. The investment costs are about the same as for PEM electrolysis. Recently, the largest SOE electrolyser in the world with a power of 250 kW was commissioned by our strategic partner Sunfire.
Component Production
Automation Processes
- Separating and feeding the bipolar plate (BPP) and the membrane electrode assembly (MEA)
- Injection stamping/injection molding of the BPP
- Applying the seal
- Testing
SYSTEM Assembly
Automation Processes
- Feeding and assembly of peripheral components
- System test
High-Speed Stacking and Testing Technologies for Fuel Cells and Electrolyzers
Maximum Speed – Maximum Accuracy & Modular Plant Concepts – Scalability on Demand
"Investing in hydrogen is investing in our future. In climate protection, in qualified jobs and in energy supply security."
Robert Habeck, Bundesminister für Wirtschaft und Energie
Our Key Technologies for Fuel Cells and Electrolyzers
Feeding
Linear-Transfer-System, Band Transfer System, SCARA Robots, 6-axis robots
Stacking
SCARA robots, 6-axis robots, Multi-axis gantry systems, High-speed pick and place systems
Testing
Vision control (AOI), Quality control, Leak tests, Flow-rate tests, Electrical tests, End-of-line tests, Force and distance measurement
Screwing
Member- and Partnerships
Together we work with a wide range of partners from industry and research. This enables us to find new innovative approaches for a faster, more efficient and more cost-effective large-scale production of green hydrogen.
Only through collaboration and joint efforts we will be able to continue to push the current boundaries of hydrogen technologies to reach the goal of a more sustainable future.
Reference Projects
Fully automated assembly of a fuel cell stack
Customer product
Fuel cell stack
Automation requirements
- Handling of extremely thin material / flexible components
- High precision in positioning the stack / individual layers
- Mechanical centering of thin-walled fuel cells without breakage
- Automated clamping of the stack in the workpiece carrier
- 100% quality and traceability
