Post on 29-Aug-2019
Vorbereitende Technologieentwicklung - Perspektive der Zulieferer
NIP-Vollversammlung | Berlin | 14.12.2016
Jürgen Kraft| Leiter PEMBZ-Entwicklung, ElringKlingerAG
Chances - Challenges
Challenge: high volume production100.000 FCEV – 100.000 systems – 100.000 stacks
� 40.000.000 cells
� ∼100.000.000 components/assembly steps
e.g. 10 assembly lines (stack assembly):
2 s per assembly step (sequential processes)
� Product technology (components, stack)
� Processes, quality
� Production processes components and assembly cell/stack
� Bottlenecks e.g.
- end of line test bipolar plate (tightness)
- end of line step stack (break in)
� Industrialisation, development product technology - production technology
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Outlook
In 2025 30 % of the ElringKlinger sales will berelated to electric drive trains/vehicles
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Approach
Developing solutions for efficient powertrains
� new products e.g. innovative lightweight technology
� future products e.g. fc components/stacks/modules, battery components/modules
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Door module carrier*
Organo sheets
� Technology: reinforced thermoplastics with injected plastic devices
� Launching order of door module carriers by Brose:− Received in H1 2016
− Volume: more than EUR 100 million until 2024
− SOP 2017 in Hungary, 2018 in China and Mexico
Hydroform-hybrid technology
� Commonly developed with German premium OEM, license agreement in 2015
� Launching order with a volume of more than EUR 120 million until 2020,
produced in China and Canada since 2015
� Large-scale order for next generation of vehicles from US market
− Received in H2 2016
− Representing a triple-digit million Euro volume over five years
− New location in close proximity to customer, SOP in mid-2017Cross-car beam
* © Brose
Overview ElringKlinger
Key figures, Activities
ElringKlinger at a glance
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Key figures as of December 31, 2015 (py)
Group7,912 (7,255)
+ 9.1%
Germany3,445 (3,342)
Employees worldwide
Family W. H.
Lechler and
estate of Klaus Lechler
52.0%
Institutional
investors
38.4%
Private
investors
9.6%
Shareholder structure
Group sales by segment
Total group sales: € 1,507 Mio (2005: € 475 Mio, CAGR: 12,3 %)
NIP-Vollversammlung, ElringKlinger, J. Kraft
ElringKlinger Divisions
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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 Competences
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Industrial
production,
Process-
Know-how,
Technology-/
product Know-how,
simulation (fuel cell,stamping, FEM),
tooling, process optimisation, …
fc simulation electrochemistry, CFD, …
PEMFC-Technology at ElringKlinger
Products
- from component to module
PEMFC Products
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� Sheet metal bipolar plates
� Elastomer sealings
(optional on bipolar plate assembly)
� Injection-molded plastic components
o End plate
o Media supply unit
� PEM fuel cell stacks and modules
Metallic bipolar plates
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Product
� Multi layer sheet metal assembly
� Coated layers – coated assembly
� Stack sealing optional on assembly
Processes
� Progressive die set stamping and cutting
o 40 pcs/min
� Joining by laser welding (laser scanner system)
o High accuracy welding < 3 s per bipolar plate
� Active area welding
o Welding < 3 s per plate
serial status proven (process, volume, …),volume > 10 Mio. bipolar plates p.a.
PEMFC Stack NM 5
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Stack based on metallic bipolar plates
� Produced by high volume processes
Lifetime test ongoing, currently > 8100 hrs
Freeze start capability proven
Power density pressurized
(2,5 bara, 360 A @ UC=0,6 V):
� 7,5 kW/l (active area),
� 6,6 kW/l (CCM size),
� 4,1 kW/l (cell stack w/o end plates)
i.e. stack NM5- 200 cells
� 44 kW @ 2,5 bara
� 27 kW @ 1,2 bara
� L /W/H (mm): 244/162/382
(stack with end plates)
PEMFC Stack NM 5
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� Homogeneous cell voltage
distribution over the whole
load range and at different
operating conditions
Cell voltage distribution for various stack sizes
96-cell stack
200-cell stack
240-cell stack
� … due to component homogeneity and stack concept (flow distribution, endplate,…)
PEMFC Stack NM 5 - Outlook
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Stack NM 5, new cell configuration
Power density at pressurized operation
(2,5 bara, 380 A @ UCell=0,6 V):
• > 8,3 kW/l (active area)
• > 7,3 kW/l (CCM area)
• > 4,6 kW/l (cell block)
• > 3,5 kW/l (400 cell stack incl. endplates)
� Performance in dry operation above EU/DOE-target
1 W/cm² @ 1,5 A/cm² (with commercial MEA-Technology,
see EU-MAWP and current call FCH-01.1_2015)
PEMFC Stack NG 3
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Application Material Handling, low pressure operationCathode: λ < 1.7, 85 % r.H. , 150 mbarg
Anode: dry, with recirculation, 300 mbarg
U/I Characteristics: 180 A @ 600 mV
Prated(24 Z/72 Z): 2.3 kWel/6.9 kWel (press. up to 10 kWel)
Cooling: Glysantin
Operating temperature: > 0 to 73°C/ 83°C (Tcoolant in/out)
Storage temperature: -25 … 70°C
TÜV-Certification according to IEC 62282-2,
Vibration/shock testing accord. to DIN EN 60068-2-27/-64
(e.g. 50 g single shock in vertical and horizontal direction)
Successfull field test at different sites
� Stack technology proven in field operation
� No stack failure in more than three years
FC Modules, Media Supply Units
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Integration on module level
� Qualified internally and at customers
� Production processes established (injection
molding, joining technologies)
Module functions:
Sensors� Pressure, temperature
Actuators� valves, anode and cathode
� Pressure release valve, anode inlet
Passive components� Droplet separator
� Bypass ducts
� Reduced system complexity� Thermal Integration, optimisation water management� Low cost high performance components
PEMFC-Production at ElringKlinger
Cell- and Stack-Assembly
Cell-/Stack Assembly
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Step-by-step approach:
Development of manufacturing technology has to be in line with growing volume
� Scalable production concept
� Parallelization
� Throughput optimization� Simplified 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
Automation - Realisation
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Flexible manufacturing cell (mc):
� Fixed concept for basic setup and process linking� Two cells, for cell and stack assembly
� Covers stack designs NM 5, NG 3, NM 12
� 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
Targets:
� Development of process, automation concept
and plant-/machine technology
� Validation/revision of component design
� Guidelines for design optimisation (manufacturability)
� Approaching the requirement for high volume production
cell assembly
stack assembly
ElringKlinger, Product- and Production Technology
Necessary link to provide products and development partnership
Product – Production Technology
Stack:
• Product
• Test carrier (development plattform)
• Link application
• Link components and component technology
Production
• Processes
• Automation
• Supply chain
• Machine & plant technology
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Necessary to
develop and
proof production
concepts and
technology
Manufacturability
Vielen Dank für Ihre Aufmerksamkeit!
Dr. Jürgen Kraft
Leiter PEMBZ-Entwicklung
ElringKlinger AG
Max Eyth-Straße 2 | D-72581 Dettingen/Erms
Tel. +49 7123 724 9920
Fax: +49 7123 724 85 9920
juergen.kraft@elringklinger.com
www.elringklinger.com
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development supported by: