The fuel cell boom – and Schmaltz is taking advantage

Handling of bipolar plates (BPP) (Image: J. Schmalz GmbH)

Surface gripper FLGR with high volume flow for full-surface gripping of sensitive workpieces such as membrane-electrode assemblies (MEA) and bipolar plates (BPP) (Image: J. Schmalz GmbH)

Gripper for gentle handling of gas diffusion layers (GDL) (Image: J. Schmalz GmbH)

Handling of highly structured workpieces with breakthroughs (Image: J. Schmalz GmbH)

Flawless handling of films and membranes (CCM) (Image: J. Schmalz GmbH)

Fuel cells are a serious solution for emission-free mobility. While they were long absent from the public eye, they are now establishing themselves as a viable path for zero-emission strategies. Accordingly, the development of hardware and automated manufacturing is highly dynamic. Here, Schmalz intervenes and adapts its handling systems to the constantly changing requirements – new process steps, surfaces, and materials.

Since 2001, there has been unrest among combustion engines. At the IAA early in the 21st century, more and more automakers directed attention to their "blue" vision of future mobility: vehicles with fuel cell drive. German automakers also sent test fleets onto the roads – quiet, clean, and easy to handle, just like gasoline or diesel vehicles, with some safety precautions in place. Then, the fuel cell faded from public attention. After years of promoting battery electric mobility as energy storage, hydrogen users are now back in the spotlight. In a study, the VDE defined the "Drive Portfolio of the Future" in April 2021 as a demand-oriented mix: batteries for passenger cars, batteries or fuel cells for trucks, and e-fuels for existing vehicles, motorsport, and classic cars. The Association of Electrical Engineering, Electronics, and Information Technology surveyed politicians and business leaders. The fact is: fuel cells are establishing themselves and are an opportunity for emission-free driving and the economy in Germany. For efficient production, automated gripping systems are also needed to handle the different components and assemblies gently and safely.

"Fuel cells are currently a highly dynamic topic. Especially in Germany and Europe, as well as in some Asian countries, funding programs are bringing new players to the market, and the big names are further establishing themselves," says Matthias Müller, Head of International Sales and International Industry and Key Account Management at J. Schmalz GmbH. The challenge for him and his team is to stay on top of all projects and meet the high level of innovation. "We can do this easily – thanks to our industry management. This is our pivot point, uncovering relevant contacts and professionally supporting customers. Behind the success is very close cooperation with our sales organizations. With highly innovative solutions and a strong development department, we can keep pace with market dynamics," Müller explains. Accordingly, the Black Forest company is well-connected: Schmalz has been working with automakers for decades and participates in national research projects. The goal: economical series production of fuel cells. "Automation is crucial here, and that's where we come into play," Müller adds. Schmalz is well-equipped with its comprehensive gripper portfolio for this role. Nevertheless, there is plenty to do in the development department in Glatten. "The industry's dynamism is reflected in the requirements for our designers and developers: they must constantly adapt the gripping systems to changing production steps, workpieces, materials, and new surface structures."

Deep dive into the heart of the fuel cell

To understand what Matthias Müller means, it helps to look inside a fuel cell, whose structure essentially resembles a battery: an electrolyte layer separates anode and cathode and ensures ion transport. This membrane-electrode assembly (MEA) is the heart of every fuel cell. On the outside, there is a gas diffusion layer on each side, which is backed by bipolar plates.

The systems accessing the MEAs during manufacturing must be especially gentle on the sensitive surfaces and ideally handle all components. Therefore, Schmalz combines multiple vacuum circuits and gripping technologies to sequentially pick up the catalyst-coated membrane, gas diffusion layer, and sealing frame. A high volume flow and wear- and energy-efficient pneumatic vacuum generation through the SCPM compact ejectors prevent particle residues on the workpieces. "This allows our system to be used even in cleanrooms," explains Müller. The full-surface gripping principle of the sheet gripper, which combines large-area contact with a low vacuum level and high volume flow, protects the thin films from deformation. As in battery production, the vacuum expert must constantly ensure safe electrostatic discharge – using ESD-compliant contact surfaces.

From BPP to stack

Bipolar plates (BPP) made of metal or graphite materials frame the MEAs. Their task: to direct hydrogen to the anode and oxygen to the cathode, as well as to remove reaction water and dissipate thermal and electrical energy. The design of their surfaces influences the efficiency of the subsequent fuel cell. Research and development are accordingly highly dynamic. "Our development must keep pace with this tempo and adapt our grippers to changing formats and structures," Müller emphasizes.

In principle, Schmalz uses sheet grippers for the safe handling of structured flow fields. Additional integrated suction grippers increase the permissible shear force – so the BPP remains in place despite high acceleration. The plastic of the suction plates and the HT1 material of the suction grippers protect the coated surfaces from damage and chemical residues. Convex or concave BPP halves are securely sucked by the hover vacuum, which also pulls them evenly with high holding forces. Integrated sensors also clearly identify the components. These are also important during stacking, i.e., assembling the MEAs, gas diffusion layers, and bipolar plates.

According to the various components, the entire range of special grippers from Schmalz can be found in this production step: sheet grippers FLGR, flow field grippers SCG, hover vacuum SBS, and conventional vacuum suction grippers. Their different technologies – whether full-surface or contactless gripping – keep the surface pressure low and surfaces free of contamination. At the same time, they keep pace with the dynamics of the production process.

"The requirements for fuel cell production are similar to battery manufacturing – as we handle comparable materials. They are thin, coated, and thus extremely sensitive. And we keep pace with the development dynamics – both in research projects and in series production," summarizes Matthias Müller. After speaking with the head of international industry management, it is clear: whether it's the "blue" vision of automakers or the "green" plan of policymakers – Schmalz blue will continue to shine through in the automated production of fuel cells.