sponsoredWorld premiere Fully automated fuel cell production

In China, the Palcan Group has launched a globally unique, fully automated production line for fuel cells. Stäubli robots prove to be true productivity boosters when it comes to handling sensitive components even in an acidic environment.

Will the fuel cell be the energy source of the future in stationary and mobile applications? For many experts, the answer is a clear "Yes" - especially since the current construction and expansion of a hydrogen infrastructure will facilitate the implementation of this environmentally friendly, compact, and proven technology.

The Palcan Group is driving this trend. The company, founded in Canada in 1998, merged with Boyuan Fuel Cell (Shanghai) Co., Ltd. in 2016. Since then, Palcan has invested in three modern production and R&D facilities in China: Suzhou (research and development), Changzhou (product service), and Cixi (production).

The goal is to cover the entire value chain with state-of-the-art and highly scalable technologies - from research and development, prototyping, and pilot testing to mass production with integrated testing capabilities.

All core competencies of cell production in one hand

Palcan has already developed a variety of methanol reforming hydrogen fuel cell systems with different performances for various markets. It is a major advantage that the manufacturing process of core components such as stacks, bipolar plates, and reformers is carried out in-house for both MR hydrogen production (methanol reforming) and high-temperature PEM fuel cells (Proton-Exchange Membrane).

The production of these components on a large scale poses a real challenge. Each "stack" - referring to the fuel cell stack - consists of a large number of thin and valuable materials with sensitive surfaces that are stacked on top of each other.

To efficiently fulfill this task, Palcan has built a facility in Cixi for the production of methanol reforming fuel cells (MRFC), which began operation in early 2021. The plant covers an area of 33 hectares and features fully automated production lines for bipolar plates (BPP) and membrane-electrode assemblies (MEA), as well as for their assembly into stacks and further into high-temperature fuel cell systems.

Handling under aggressive environmental conditions

Stäubli robots play an important role in the membrane electrode assembly (MEA) process. Liu Zhikang, the head of the production line, says, "Carbon foils are an important component of these MEAs. Once they have been formatted, meaning they are cut, coated, and sintered, a Stäubli TX2-90 six-axis robot transports the sheets quickly and precisely to the defined assembly position."

Another component of the stacks, the PBI (Polybenzimidazole) films, need to be soaked in a strongly acidic environment (pH >2) without causing corrosion or damage to the handling equipment. This is where a Stäubli SCARA robot TS2-80 he comes in for handling the films. The "HE" stands for "Humid Environment". The housing of these robots is carefully sealed, protecting their internal components from water or chemicals. They also provide a high level of corrosion resistance.

After stacking the thin and also coated sheets and foils, a second TX2-90 six-axis robot moves the MEA unit to a laser cutting system. Thanks to its high performance, the robot not only performs this task with precision but also with impressive dynamics.

Cell stacking: fast and precise

During the subsequent assembly of the stacks into cells, two Stäubli TS2-80 robots with a payload of 2.4 kg each take care of the handling. Once again, the Stäubli robots set the standard for speed and precision: the cycle time is only 0.8 seconds, and the positioning accuracy is +/- 0.01 mm. Liu Zhikang: "Thanks to this combination of speed and precision, we can assemble a complete stack in one hour: considering the large number of components involved, this is extremely fast."

This line was designed by a globally renowned system integrator. They specialize in developing and constructing not only complex production lines but also turnkey manufacturing facilities for fuel cells and lithium-ion batteries for electric vehicles.

With these robot-assisted lines, a continuous ramp-up is possible, aiming for 50,000 units per year. This is achieved by continuously upgrading and expanding the production line.

A production line that sets global standards

Palcan's production line in Cixi is a true world innovation, as Liu Zhikang explains: "We operate the first automated production lines for both membrane-electrode assemblies and stacks of high-temperature fuel cells here. These systems have quickly become a reference in the industry. The robots work in a strongly acidic environment, with high speed and precision, as well as high availability and scalability."

The positive experiences with this solution have already led to subsequent projects. Currently, the Palcan Group is preparing their project in Guangxi Nanning, which focuses on the production of components for the hydrogen industry with an annual capacity of 12 GW.

The project is expected to cover a total area of ​​over 214 hectares, and Stäubli robots will also be used here. Overall, Palcan's plant constructors anticipate a greater demand for Stäubli SCARA and six-axis robots for further automation of existing production lines at multiple locations, as well as for completely new production lines.

Yu Yiwen, Brand and Supply Chain Director of the Palcan Group: "The Stäubli robots ensure accuracy and stability in our production. They significantly reduce the failure rate of delicate components and lower production costs. Moreover, the Stäubli team has provided us with many professional suggestions and solutions during our initial collaboration. In the future, there will definitely be a broader space for cooperation."