scholarly journals Bridging the Gap between Automated Manufacturing of Fuel Cell Components and Robotic Assembly of Fuel Cell Stacks

Energies ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3604
Author(s):  
Devin Fowler ◽  
Vladimir Gurau ◽  
Daniel Cox
Keyword(s):  
Fuel Cell ◽  
Alternative Energy ◽  
Vision System ◽  
Department Of Energy ◽  
Robotic Assembly ◽  
Assembly Process ◽  
Work Cycle ◽  
Cell Components ◽  
Dual Arm Robot ◽  
Manufacturing Technologies

Recently demonstrated robotic assembling technologies for fuel cell stacks used fuel cell components manually pre-arranged in stacks (presenters). Identifying the original orientation of fuel cell components and loading them in presenters for a subsequent automated assembly process is a difficult, repetitive work cycle which if done manually, deceives the advantages offered by either the automated fabrication technologies for fuel cell components or by the robotic assembly processes. We present for the first time a robotic technology which enables the integration of automated fabrication processes for fuel cell components with a robotic assembly process of fuel cell stacks into a fully automated fuel cell manufacturing line. This task uses a Yaskawa Motoman SDA5F dual arm robot with integrated machine vision system. The process is used to identify and grasp randomly placed, slightly asymmetric fuel cell components, to reorient them all in the same position and stack them in presenters in preparation for a subsequent robotic assembly process. The process was demonstrated as part of a larger endeavor of bringing to readiness advanced manufacturing technologies for alternative energy systems, and responds the high priority needs identified by the U.S. Department of Energy for fuel cells manufacturing research and development.

Robotic Arm for Automated Assembly of Proton Exchange Membrane Fuel Cell Stacks

2014 ◽  
Vol 11 (5) ◽  
Author(s):  
Michael Williams ◽  
Kenneth Tignor ◽  
Luke Sigler ◽  
Chitra Rajagopal ◽  
Vladimir Gurau
Keyword(s):  
Fuel Cell ◽  
Proton Exchange Membrane ◽  
Proton Exchange ◽  
Membrane Electrode ◽  
Assembly Process ◽  
Automated Assembly ◽  
Component Alignment ◽  
End Effector ◽  
Cell Components ◽  
Exchange Membrane

We present an innovative, inexpensive end-effector, the robot workcell, and the fuel cell components used to demonstrate the automated assembly process of a proton exchange membrane fuel cell stack. The end-effector is capable of handling a variety of fuel cell components including membrane electrode assemblies, bipolar plates and gaskets using vacuum cups mounted on level compensators and connected to a miniature vacuum pump. The end-effector and the fuel cell components are designed with features that allow an accurate component alignment during the assembly process within a tolerance of 0.02 in. and avoiding component overlapping which represents a major cause of overboard gas leaks during the fuel cell operation. The accurate component alignment in the stack is achieved with electrically nonconductive alignment pins permanently mounted on one fuel cell endplate and positioning holes machined on the fuel cell components and on the end-effector. The alignment pins feature a conical tip which eases the engagement between them and the positioning holes. A passive compliance system consisting of two perpendicularly mounted miniature linear blocks and rails allow compensating for the robot's limitations in accuracy and repeatability.

scholarly journals Reinforcement learning for robotic assembly of fuel cell turbocharger parts with tight tolerances

2020 ◽  
Vol 14 (4) ◽  
pp. 407-416
Author(s):  
Franziska Aschersleben ◽  
Rudolf Griemert ◽  
Felix Gabriel ◽  
Klaus Dröder
Keyword(s):  
Reinforcement Learning ◽  
Fuel Cell ◽  
Learning Strategy ◽  
Measurement Data ◽  
Robotic Assembly ◽  
Assembly Process ◽  
Current Contact ◽  
Manufacturing Accuracy ◽  
The Individual ◽  
Insertion Process

Abstract The efficiency of a fuel cell is not only dependent on the stack, but also to a large extent on the turbocharger, which is responsible for providing the required airflow. Since the individual components, especially those of the rotor, are subject to high demands on manufacturing accuracy, it is crucial to ensure a precise and robust assembly. In order to achieve a scalable assembly process, this paper presents a method for a robot-based assembly of the rotationally symmetric components of the rotor. The assembly task has been reduced to the two essential problems: search and insertion. On this basis, a system was developed, which is able to learn the joining process independently and compensate for positioning inaccuracies with the help of reinforcement learning in combination with a position-controlled robot. The applied reinforcement learning strategy is based on the measurement data of a 6-axis force/torque sensor, with which the current contact state can be evaluated and a decision for the next step can be made. The experimental verification shows that an automation of the assembly process is possible with the proposed strategy. The robot is able to perform the search operation successfully, whereas limitations to the achievable accuracies of the insertion process could be found.

Development of a Cost-Effective Hydrogen Production System for Vehicle Fueling Stations

2007 ◽  
Author(s):  
Timothy M. Aaron ◽  
Joseph M. Schwartz
Keyword(s):  
Fuel Cell ◽  
Hydrogen Production ◽  
Alternative Energy ◽  
Internal Combustion Engines ◽  
Transition Period ◽  
Cost Effective ◽  
Department Of Energy ◽  
Hydrogen Fuel ◽  
The Impact ◽  
Fueling Station

The need to transition from oil dependency to an alternative transportation fuel has been well documented over the last 30 years. Many alternative energy sources have been researched and developed, but none, to this point, has been able to compete with the cost and versatility of gasoline. The use of hydrogen fuel cells for transportation is one of the concepts being highly supported as a potential environmentally clean alternative energy technology. Significant research and development has dramatically increased the feasibility of this technology, but many additional breakthroughs, including a cost effective supply of hydrogen at fueling stations, will be required for fuel cell vehicles (FCV) to compete with gasoline fueled internal combustion engines (ICE). This paper describes the development of an on-site hydrogen supply system based on steam methane reforming (SMR) that could easily be added to a typical fueling station. The system is not intended to fuel the equivalent of all the cars on the road today, but to provide enough hydrogen for the transition period from gasoline powered transportation to the hydrogen fuel cell. Opportunities exist for a significant reduction in hydrogen cost by introducing advanced design technologies, such as Design for Manufacturing and Assembly (DFMA), to the development of hydrogen production systems. A reformer-based system designed using the DFMA approach is expected to significantly reduce the capital cost by minimizing the overall part count, simplifying the design, and optimizing the assembly process. Praxair, in cooperation with the U.S. Department of Energy (DOE), is developing a small SMR-based system using this approach. This paper presents an overview of the impact of this approach on the system design as well as the overall cost for small on-site hydrogen production. The paper also provides an analysis of hydrogen fueling station criteria and an overview of issues related to on-board hydrogen vehicle storage.

scholarly journals Towards Autonomous Robotic Assembly: Using Combined Visual and Tactile Sensing for Adaptive Task Execution

2021 ◽  
Vol 101 (3) ◽  
Author(s):  
Korbinian Nottensteiner ◽  
Arne Sachtler ◽  
Alin Albu-Schäffer
Keyword(s):  
Autonomous Robots ◽  
Vision System ◽  
Dynamic Environments ◽  
Bayesian Framework ◽  
Experimental Results ◽  
Robotic Assembly ◽  
Tactile Sensing ◽  
Task Execution ◽  
Industrial Assembly ◽  
Assembly Tasks

AbstractRobotic assembly tasks are typically implemented in static settings in which parts are kept at fixed locations by making use of part holders. Very few works deal with the problem of moving parts in industrial assembly applications. However, having autonomous robots that are able to execute assembly tasks in dynamic environments could lead to more flexible facilities with reduced implementation efforts for individual products. In this paper, we present a general approach towards autonomous robotic assembly that combines visual and intrinsic tactile sensing to continuously track parts within a single Bayesian framework. Based on this, it is possible to implement object-centric assembly skills that are guided by the estimated poses of the parts, including cases where occlusions block the vision system. In particular, we investigate the application of this approach for peg-in-hole assembly. A tilt-and-align strategy is implemented using a Cartesian impedance controller, and combined with an adaptive path executor. Experimental results with multiple part combinations are provided and analyzed in detail.

Manufacturing Processes of Solid Oxide Fuel Cell Components

2007 ◽  
Vol 336-338 ◽  
pp. 498-501
Author(s):  
Xian Feng Jiang ◽  
Min Fang Han ◽  
Su Ping Peng
Keyword(s):  
Fuel Cell ◽  
Solid Oxide Fuel Cell ◽  
Screen Printing ◽  
Sol Gel ◽  
Tape Casting ◽  
Solid Oxide ◽  
Oxide Fuel ◽  
Cell Components ◽  
One Step ◽  
Made In

The all processes for manufacturing materials parts of solid oxide fuel cell (SOFC) are discussed in the paper. The films are made in one step by the ways of APS, VPS, EVD, which are usually used to produce the electrolyte and interconnect. The films are thin and good gas-resistance, but with relatively high cost. All parts of SOFC are made by the following ways, such as sol-gel, tape casting, tape calendaring and screen printing, which are suitable for manufacturing samples in industry with the cheapest process by co-sintered together ways.

Avoiding Compressor Surge During Emergency Shutdown Hybrid Turbine Systems

2013 ◽  
Vol 135 (10) ◽  
Author(s):  
Paolo Pezzini ◽  
David Tucker ◽  
Alberto Traverso
Keyword(s):  
Fuel Cell ◽  
System Analysis ◽  
Risk Mitigation ◽  
Dynamic Effect ◽  
Transient Behavior ◽  
Open Loop ◽  
Department Of Energy ◽  
Mitigation Strategies ◽  
Emergency Shutdown ◽  
Compressor Surge

A new emergency shutdown procedure for a direct-fired fuel cell turbine hybrid power system was evaluated using a hardware-based simulation of an integrated gasifier/fuel cell/turbine hybrid cycle (IGFC), implemented through the Hybrid Performance (Hyper) project at the National Energy Technology Laboratory, U.S. Department of Energy (NETL). The Hyper facility is designed to explore dynamic operation of hybrid systems and quantitatively characterize such transient behavior. It is possible to model, test, and evaluate the effects of different parameters on the design and operation of a gasifier/fuel cell/gas turbine hybrid system and provide a means of quantifying risk mitigation strategies. An open-loop system analysis regarding the dynamic effect of bleed air, cold air bypass, and load bank is presented in order to evaluate the combination of these three main actuators during emergency shutdown. In the previous Hybrid control system architecture, catastrophic compressor failures were observed when the fuel and load bank were cut off during emergency shutdown strategy. Improvements were achieved using a nonlinear fuel valve ramp down when the load bank was not operating. Experiments in load bank operation show compressor surge and stall after emergency shutdown activation. The difficulties in finding an optimal compressor and cathode mass flow for mitigation of surge and stall using these actuators are illustrated.

Preparation of Polymer Composite Bipolar Plate with Different Multi-Filler for Polymer Electrolyte Membrane Fuel Cell (PEMFC)

2014 ◽  
Vol 699 ◽  
pp. 689-694 ◽  
Author(s):  
Mohd Zulkefli Selamat ◽  
Mohd Shakir Ahmad ◽  
Mohd Ahadlin Mohd Daud ◽  
Musthafa Mohd Tahir ◽  
Safaruddin Gazali Herawan
Keyword(s):  
Electrical Conductivity ◽  
Fuel Cell ◽  
Polymer Electrolyte ◽  
Alternative Energy ◽  
Polymer Electrolyte Membrane ◽  
Energy System ◽  
Bipolar Plate ◽  
Filler Loading ◽  
Shore Hardness ◽  
Electrolyte Membrane

Polymer Electrolyte Membrane Fuel Cell (PEMFC) is an alternative energy system that has been verified with great potential for high power density, durability and cost effectiveness. Since the bipolar plate is the key component in PEMFC, the component must operate with multifunction and have a balance of properties, essentially well in both electrical and mechanical properties. At present, many different materials have been tested to be applied for bipolar plate in order to fulfill the balance in each property. In this work, the different material is tested and observed. Polypropylene (PP) is used as a binder material, Graphite (Gr) is used as a main filler and Carbon Black (CB), Iron (Fe) and Nickel (Ni) as the second filler. This composite is produced through compression molding and the effect of different filler material loading on the properties such as electrical conductivity, flexural strength, bulk density and shore hardness are observed. The result showed the increasing of electrical conductivity as the increased the CB and Fe loading. But for Ni, the result showed the decreasing of electrical conductivity as the loading of Ni has been increased. The targeted value also achieved for some certain degree of filler loading.

Evaluation of Cathode Air Flow Transients in a SOFC/GT Hybrid System Using Hardware in the Loop Simulation

2014 ◽  
Author(s):  
Nana Zhou ◽  
Chen Yang ◽  
David Tucker
Keyword(s):  
Fuel Cell ◽  
Gas Turbine ◽  
Hybrid System ◽  
Mass Flow ◽  
Cell System ◽  
Department Of Energy ◽  
Dynamic Responses ◽  
Partial Recovery ◽  
Fuel Cell System ◽  
Air Mass

Thermal management in the fuel cell component of a direct fired solid oxide fuel cell gas turbine (SOFC/GT) hybrid power system, especially during an imposed load transient, can be improved by effective management and control of the cathode air mass flow. The response of gas turbine hardware system and the fuel cell stack to the cathode air mass flow transient was evaluated using a hardware-based simulation facility designed and built by the U.S. Department of Energy, National Energy Technology Laboratory (NETL). The disturbances of the cathode air mass flow were accomplished by diverting air around the fuel cell system through the manipulation of a hot-air bypass valve in open loop experiments. The dynamic responses of the SOFC/GT hybrid system were studied in this paper. The evaluation included distributed temperatures, current densities, heat generation and losses along the fuel cell over the course of the transient along with localized temperature gradients. The reduction of cathode air mass flow resulted in a sharp decrease and partial recovery of the thermal effluent from the fuel cell system in the first 10 seconds. In contrast, the turbine rotational speed did not exhibit a similar trend. The collection of distributed fuel cell and turbine trends obtained will be used in the development of controls to mitigate failure and extend life during operational transients.

Sign in / Sign up

Export Citation Format

Share Document