Modular, High-Volume Fuel Cell Leak-Test Suite And Process - Energy

D.O.E. Program ReviewModular, High-Volume Fuel Cell Leak-Test Suite andProcessIan Kaye, Ru Chen, Matt MendezUltraCell CorporationPeter Rieke, Dale KingPacific Northwest National LaboratoryGordon SpleteCincinnati Test SystemsMay 20, 2009Project ID # mf 03 kayeThis presentation does not contain any proprietary,confidential, or otherwise restricted information

Introduction to UltraCell Founded 2002 Mission– To provide compact and portable grid-independent power to the global market Core Technology– Reformed Methanol Fuel Cells (RMFC)– Originally invented at the U. S. Department of Energy's Lawrence Livermore NationalLaboratory (LLNL). Locations– Livermore, CA (HQ), Vandalia, Ohio (Manufacturing) Existing product line– XX25 fuel cell– XX55 fuel cell– Various fuel tanks and accessories

Implementation of this project’s goals will beimplemented in our current/future product line XX25: currently producedin low volume at our Daytonplant. XX55: Currentlylimited availability.Will be produced inDaytonThe technology developed under this projectwill be installed in our plant and go right intoour existing product like for reduced costs andfaster production rates

Why is this project important? There is an acute, demonstrated andmission critical weight problem withcurrent battery technologies that canbe addressed by our technology 20W mission for 72-hrs benchmarkshows great potential for the XX25architecture Getting more units, faster and withgreater reliability to the field is criticalXX25 Energy density 360 Whr/Kg72 hr mission wt. 4.0 Kg (8.8 lb)BA-5590 (Primary Lithium)Group II Lead AcidEnergy density 36 Whr/Kg72 hr mission wt. 40 Kg (88 lb)Energy density 221 Whr/Kg72 hr mission wt. 6.5 Kg (14.3 lb)BA-2590 (Li-Ion)Energy density 130 Whr/Kg72 hr mission wt. 12.2 Kg (27.1 lb)

OverviewBarriersTimeline F: Low levels of Quality Controland inflexible processesStart: 09/01/2008End: 08/31/201120% completeBudget Total project funding–– DOE 2,411,888Contractor 2,281,603Funding for FY09– 1,661,881Partners UltraCell – Project leadPNNL – Fuel cell stack properties,method selection, quality metricsCTS – Leak-test suite design,fabrication, and installation5

Objectives - Relevance A fuel cell is an excellent leak-sensor: we plan to use the manufactured partas part of the sensor network Project Objectives––––– Design a modular, high-volume fuel cell leak-test suite capable of testing in excess of100,000 fuel cell stack per year (i.e., 50 fuel cell stacks per hour).Perform leak tests inline during assembly and break-in stepsDemonstrate fuel cell stack yield rate to 95%.Reduce labor content to 6 min.Reduce fuel cell stack manufacturing cost by 80%.Project Phases––Phase I: focus on analysis of manufacturing process, stack failure modes, leak-testmethods; prototype design and fabrication; leak test suite design.Phase II: pilot production line modification; leak-test suit fabrication, integration, andverification; limited production test run.6

Milestones - Relevance7

ApproachFeatures Modular structure High throughput Inline leak test Automation Diagnostics Add software/hardwaremods to existing “testboxes”8

Approach1. Crossover Current test4. Voltage Decay2. Flexo-Tiltometer5. Pressure/Vacuum Decay3. Current Interrupt6. Fuel Cell Sensor for Coolant Leak9

Approach Milestones (FY09)– 11/08 Manufacturing process analysis– 07/09 Demonstrate leak check accuracy– 07/09 Go/No-Go: Flexo-Tiltometer accuracy– 11/09 Complete design review package– 02/10 Achieve 5 pph capacity on prototype leak test suite– 02/10 Go/No-Go: 50 pph throughput Progress– Analyzed fuel cell stack manufacturing processprocedure, throughput time, labor time, yield, failure modes– Investigated leak-test methods– Investigated fuel cell stack components– Created specification for leak-test suite lab prototype– Started design leak-test suite lab prototype10

Technical AccomplishmentsCrossover Current Test Fuel cell with crossover shows higher current Sensitivity depends on Nitrogen flow on cathode side11

Technical AccomplishmentsCurrent InterruptVoltage Decay Fuel cell with crossover showslower OCV and fast decay Fuel cell with crossover shows lower voltageand OCV12

Technical AccomplishmentsStack Dynamic Mechanical AnalysisObjective: Understand how DMA techniques can be used to probe pressuredistributions, aid in stack assembly protocols, decrease break-in times and identifycauses of leaks.The “Flexo-Tiltometer” Final static assembly pressureshould assure– Seal integrity– Good electrical contact– Correct compression of allcomponents Static Stress Scans of stack probesonly most compressible component. Difficult to determine what finalassembly pressure should be.13

Technical AccomplishmentsCreep & RecoveryGasket A Slow reversible and irreversibledimensional changes. GDLs have both irreversible andprogressive “crush” and a reversibleelastic compression. Gasket A shows an initial irreversiblecompression followed by reversible butslow elastic compression and recovery.Gas Diffusion Layers When should stack be “Bolted”?14

Technical AccomplishmentsDynamic Temperature ScansGasket B Low temperature relaxation at 30 CProbably due to flattening of wrinkles Features at 140 C correlate withglass transition temperature for thismaterial. Dynamic pressure oscillations duringassembly can help reveal forcedistributions during stack assembly.15

Collaborations PNNLCTSDOEHydrogen Program UltraCellINVOTECMoundTechnical Ohio Department ofDevelopment, 3rdFrontier Fuel Cell Program UltraCell CorporationProject lead.Leading producer of fuel cellsystems for remote or mobiledevices.Pacific Northwest NationalLaboratoryStack properties, methodselection, quality metricsCincinnati Test SystemsLeak-test suite design,fabrication, and installationInvotec Engineering, Inc.Design, fabrication, andinstallation of fuel cell stackrobotic manufacturing systemMound Technical Solutions,Inc.Design and fabrication of fuelcell performance test fixtureand automated test data16analysis

Future Work FY09Design and fabricateleak-test suite labprototype with 5 pphcapacityTest lab prototypeGenerate stack qualitymetricsDesign leak-test suitewith 50 pph capacityFY10 Fabricate leak-test suite Modify pilot productionline to accommodateleak test suite Integrate leak-test suite17

Summary Objectives– Design a modular, high-volume fuel cell leak-test suitecapable of testing in excess of 100,000 fuel cell stack per year(i.e., 50 fuel cell stacks per hour).– Perform leak tests inline during assembly and break-in steps Progress– Analyzed fuel cell stack manufacturing process– Investigated leak-test methods– Investigated fuel cell stack components– Created specification for leak-test suite lab prototype– Started design leak-test suite lab prototype Future Work– Design and fabricate leak-test suite lab prototype with 5 pphcapacity– Test lab prototype and generate stack quality metrics– Design and fabricate leak-test suite with 50 pph capacity18

Pressure/Vacuum Decay. 6. Fuel Cell Sensor for Coolant Leak. . procedure, throughput time, labor time, yield, failure modes . - Design and fabricate leak-test suite with 50 pph capacity. Summary. Title: Modular, High-Volume Fuel Cell Leak-Test Suite and Process Author: