Assembly Automation
for SUSTAINABLE
Energy Solutions
Assembly lines and test equipment for electrolysers
In the emerging technology-based energy world, and with increasing economic and geopolitical competition, the rapid expansion of electrolysis capacity and required plant production will become a key factor in a nation's future economic performance.
Electrolysers are at the heart of the emerging green hydrogen world. However, the challenges associated with scaling up production are often underestimated.
Hydrogen production is in the center of the energy roadmaps in many regions of the world. The mobility sector is depending on the availability of green hydrogen and therefore electrolyzer technologies are playing a vital role at XENON.
With a clear commitment to fuel cell technologies we have expanded our expertise and solution portfolio into that area.
XENON is committed to proactively shaping the energy transition. As a leading automation specialist, we design and develop automation equipment for the series production of electrolysis systems.
To meet this goal, we rely on an extensive process know-how and a broad technology portfolio and cover the entire value chain: from component manufacturing to stack and system assembly.
Functions & Stack Components
HOW IT WORKS
Electrolysis is a redox reaction forced by the use of (green) electrical energy. The electricity is converted into chemical energy.
2 H2O → 2 H2 + O2
Only water, electricity and heat are produced as reaction products, no pollutants such as particles or nitrogen oxides. In the opposite direction (electrolysis), hydrogen can be produced from electricity and water.
A single electrolyser can only produce a small amount of hydrogen, so many of them are connected together in a stack. If more power is required, the number of cells or stacks is also increased accordingly.
Contributing our expertise of more than 30 years in fast-cycle assembly lines and changeable production systems to the new business area and helping to solve one of the most important problems of our time is a rewarding challenge.
Dr. Hartmut Freitag
Senior Vice President, XENON Dresden
Model: TU Chemnitz - Open Source Stack
XENON Automation Solutions for PEM & SOEC Electrolysers
PEM
Proton-Exchange-Membran electrolysis
PEM or also called polymer electrolyte membrane electrolysis uses a thin membrane made of thermoplastic (ionomer) as electrolyte. Anode and cathode are separated by this gas-tight membrane, only positive hydrogen ions can pass through the membrane. Due to ion migration, this process of electrolysis belongs to the acidic processes. This makes the use of precious metals necessary for the catalysts in order to avoid corrosion.
Advantages
The good load change behaviour. It can react quickly to fluctuations in the energy supplied and can be operated at partial load without any problems. The efficiency of PEM electrolysis is currently around 63%, which is slightly lower than that of alkaline electrolysis. Since the technology is still relatively new, the investment costs are considerably higher than for alkaline electrolysis. The power range of the plants reaches values of up to 6 megawatts.
SOE
Solid Oxide electrolysis
Solid Oxide Electrolysis uses a solid ceramic material as the electrolyte, which separates the two half cells. The water is fed to the reaction chambers in the form of steam. This type of electrolysis is currently in transition from research to industrial application.
Advantages
This technology belongs to the high-temperature electrolysis, is operated at temperatures of 600-900 °C and can achieve a very high efficiency of over 80%. The investment costs are about the same as for PEM electrolysis. Recently, the largest SOE electrolyser in the world with a power of 250 kW was commissioned by our strategic partner Sunfire.
Assembly and test automation for the entire value chain
COMPONENT PRODUCTION
Automation PROCESSES
- Feeding and separating of the bipolar plate (BPP) and the membrane electrode assembly (MEA)
- Forming or injection molding of the BPP
STACK-ASSEMBLY
Automation PROCESSES
- Feeding, positioning and stacking of the cells
- Apply gasket
- Compress and tensioning of the stack
- Assembling media connections
- Testing for leaks
- EOL test
SYSTEM ASSEMBLY
Automation PROCESSES
- Feeding and assembly of peripheral components
- System test
"We have to set the course so that Germany becomes the No. 1 in the world in hydrogen technologies"
Peter Altmaier, Federal Minister for Economic Affairs and Energy
Our key technologies for fuel cells and electrolyzers
Feeding
Linear-Transfer-System, Band Transfer System, SCARA Robots, 6-axis robots
Stacking
SCARA robots, 6-axis robots, Multi-axis gantry systems, High-speed pick and place systems
Testing
Vision control (AOI), Quality control, Leak tests, Flow-rate tests, Electrical tests, End-of-line tests, Force and distance measurement
Screwing
Plastic and metalic components
We are a member of the Innovation Cluster HZwo e.V.
In the saxon innovation cluster Hzwo, companies and research institutes from Saxony are working together in the field of fuel cells and green hydrogen.
New products and manufacturing processes are designed and developed in joint projects. The entire value chain is addressed, from material selection and series production to the practical application of the stacks.
Reference Projects
Fully automated assembly of a fuel cell stack
Customer product
Fuel cell stack
Automation requirements
- Handling of extremely thin material / flexible components
- High precision in positioning the stack / individual layers
- Mechanical centering of thin-walled fuel cells without rupture
- Automated clamping/tensioning of the stack in the carrier
- 100% quality and traceability
Would you like to learn more about our solutions
for fuel cells and electrolyzers?
Just give us a call.
+49 351 40209-100
