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 in handling sensitive components, even in acidic environments.

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 as the current expansion of a hydrogen infrastructure will facilitate the implementation of this environmentally friendly, compact, and proven technology.
 The Palcan Group is driving this trend. Founded in Canada in 1998, the company 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 through prototyping and pilot tests 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 capacities for various markets. A significant advantage is 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 large-scale production of these components presents a real challenge. Each "stack," referring to the fuel cell stacks, consists of a large number of thin and valuable materials with sensitive surfaces that are stacked together.
 To efficiently meet this challenge, Palcan has built a facility for the construction of methanol reforming fuel cells (MRFC) in Cixi, which started operation in early 2021. The plant covers an area of 33 hectares and features fully automated production lines for bipolar plates (BPP) and membrane electrodes (MEA), as well as their assembly into stacks and further into high-temperature fuel cell systems.

Handling under aggressive environmental conditions

Stäubli robots play a crucial role in the Membrane Electrode Assembly (MEA). Liu Zhikang, head of the production line, explains: "Carbon foils are a crucial component of these MEAs. After being formatted, i.e., cut, coated, and sintered, a Stäubli TX2-90 six-axis robot swiftly and precisely transports the sheets to the defined assembly position.

"Another component of the stacks, Polybenzimidazole (PBI) foils, needs to be soaked in a highly acidic environment (pH >2) without causing corrosion or damage to handling equipment. Here, a Stäubli SCARA robot TS2-80 HE handles the foils. The "HE" stands for "Humid Environment," and the robot's housing is meticulously sealed to protect its internals from water or chemicals, providing a high level of corrosion resistance.
 After stacking the thin and coated sheets and foils, a second TX2-90 six-axis robot moves the MEA unit to a laser cutting machine. Thanks to its high performance, the robot not only accomplishes this task with precision but also with impressive dynamics.

Stacking the cells: fast and precise

In the subsequent assembly of the stacks into cells, two Stäubli TS2-80 robots with a payload of 2.4 kg each handle the operation. Once again, Stäubli robots set standards in terms of speed and precision: the cycle time is only 0.8 seconds, and the positioning accuracy is +/- 0.01 mm. Liu Zhikang says, "Thanks to this combination of speed and precision, we can assemble a complete stack in an hour: considering the high number of components, that is extremely fast."
 This line was designed by a globally renowned system integrator, known for developing and building 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 a production capacity of 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 global innovation, as explained by Liu Zhikang: "We operate the first automated production lines for both membrane electrodes and stacks of high-temperature fuel cells. These facilities have quickly become a reference in the industry. The robots work in a highly 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 its project in Guangxi Nanning, targeting 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 more than 214 hectares, and Stäubli robots will also be used here. Overall, Palcan's equipment manufacturers anticipate a greater demand for Stäubli SCARA and six-axis robots for further automation of existing production lines at multiple locations and for completely new production lines.
 Yu Yiwen, Brand and Supply Chain Director of the Palcan Group, states, "Stäubli robots ensure accuracy and stability in our production. They significantly reduce the breakage rate of sensitive components and lower production costs. Moreover, during our initial collaboration, the Stäubli team provided us with many professional suggestions and solutions. In the future, there will definitely be broader space for cooperation."