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 !