Vorbereitende Technologieentwicklung -Perspektive der ... · (e.g. 50 g single shock in vertical...

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

14.12.2016 NIP-Vollversammlung, ElringKlinger, J. Kraft 2

Outlook

In 2025 30 % of the ElringKlinger sales will berelated to electric drive trains/vehicles


Approach

Developing solutions for efficient powertrains

� new products e.g. innovative lightweight technology

� future products e.g. fc components/stacks/modules, battery components/modules


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

14.12.2016 6

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


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


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


� 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


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


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


� 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


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


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


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


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


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


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

[email protected]

www.elringklinger.com


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