CATS is a NYSTAR-Designated Center for Advanced Technology

Fuel Cell Stack Assembly Robotic Workcell

Stephen Derby

Associate Professor

MANE Department

Rensselaer Polytechnic Institute

This is the work of many people

Ray Puffer Steve RockChristina Laskowski Casey GoodwinCarey Klemm Bob LawlerJakob Georgek Dave JengrasJudd Rattner Steve Derbyand others

RPI 2005 RIA Award Winner

The Center for Advanced Technologies and Systems (CATS), formally known as the Flexible Manufacturing Center (FMC) requested:

• 2 6 DOF Robot• 1 SCARA Robot• Robotic breakaway wrist devicesAnd• KUKA Robotics• Robotic AccessoriesLoaned these products through RIA award

3 Robots and Breakaway Wrist Devices

Thanks !!!

What Did RPI Want To Do?

Assemble Fuel Cell stacks !

• Many stacks still assembled by hand• Automation needed to lower assembly time and

cost• RPI looked to form consortium of interested

companies using RIA award• RPI did hold consortium organizing meeting Oct

2006

Fuel Cell Stack

Stack Assembly Material Handling

• Automation is needed to handle (load/unload, transport, manipulate, align, assemble) stack components– Bipolar plates, end plates– Cell seals– Electrodes– MEA’s

• Electrodes and MEA’s are not rigid

Flexible Material Handling

RPI team has had many projects in past 25 years with material handling of flexible objects

• Fabrics• Hydrated contact lenses• Springs• Surgical robotics• Fuel Cell Electrodes & Membranes

Flexible Material Handling - FabricRPI team created a robotic workcell to press men’s dress

trousers (during manufacture) for Defense Logistics Agency (DLA)

• First tried to duplicate humans• Sense wrinkles then smooth out• Finally gripped with 4 grippers - easier

Flexible Material Handling - Springs

RPI team created automation to handle springs for• Kodak one time use camera assembly• Texas Instruments sensor assembly• Standard Gage (Brown & Sharpe) dial indicator

assembly

Flexible Material Handling - Membranes

RPI team developed robotic end effector to handle fuel cell membrane

Flexible Material Handling - Membranes

• Vacuum alone not sufficient• Spatula used to break surface tension

Prototype End Effector

Fuel Cell Stack Components

Bipolar Plate Gasket MEA

How a Fuel Cell Works

3 Robot Timing Diagram

Multiple Carts Looping Through Workstations

Lab Prototype

Fuel Cell Stack Assembled

Use Holes In Each Component For Alignment

Vision System for Accurate Pickup

Cart Lowers Fixture – Some Issues

More Issues

Components Not Similar To CAD

Robot Gripper For Bipolar Plates

Bipolar Plate Feeder

First End Effector For Flex Parts

Second End Effector - Defects

Gripper Works Well – But…

Third End Effector Under Development

Fixtures For Flex Component Pickup Needed

Larger Stacks Use 2 Robots With Breakaway Wrists

SCARA Robot Tested and Integrated Soon

Clean Room Likely Needed In Future

Work To Date Just A Starting Point

RPI team needs financial and intellectual support from

• Fuel Cell Industry• Robotic Industry• Government Labs and Agencies• Otherin order to succeed.

Work To Date Just A Starting Point

There is much work to be done !