DIGIMAN has met all its key objectives including:
• Delivery of a blueprint design for a fully automated, build-to-print ready, production line capable of producing over 50 thousand stacks per annum.
• Validation of the build-to-print readiness of the blueprint design to the mandatory MRL6 – the EU’s definition of pre-production readiness – and one stage prior to pilot production.
• Development of a digital cause and effects model and tool constructs which was used to analyse the data which verified MRL6 attainment of the full auto stack assembly processes via the PoP demonstrator
• Validation of the cell assembly cycle time KPI of less than 5 seconds, meaning that the uplift to full automation from IE’s incumbent semi-automation has achieved a five-fold improvement.
• Validation via in–situ small and large stack test activities that the MRL advancement from WP3, WP4 and WP5, that any changes in cell architecture, materials characterisation and assembly / test processes have not been detrimental to the AC64’s performance, meeting KPI of 0.7 A/cm2 @ 0.7V BoL (Beginning of Life):
The KPIs for fully automated stack assembly and test were generated. Work was performed on the methods to reduce the duration of handover tests and conditioning cycles. Candidate automated handling systems to suit each stack transfer approach have been identified.
Non-destructive thermal diffusivity scanning methods were found to be highly sensitive to heterogeneities in GDLs materials. The digital quality control of GDLs has progressed with roll good optimization and digitalization for the digital mapping of ocular defects (via camera-based inspection) operational within FPM’s production line and structural scanning of structural heterogeneities (via thermal scan) qualified to MRL6. A case study was performed that resulted in the requirements necessary for a line-side converting step capable of singulating pre-screened GDL to deliver ready-to-use GDL sheets.
To correlate defects and performance, GDL samples with and without defects were generated, properties such as thickness, permeability, resistivity, and thermal diffusivity were measured, and in situ tested within stack. Results indicate a particular sensitivity of AC64 performance to the heterogeneities which impair in-plane permeability.
Based on IE’s operational experience, key technical requirements for the automation uplift were established for the Blueprint design and have been validated via the PoP Demonstrator.
Data links/harvesting capability has been established and fully validated. For data from nonautomated processes IE has developed a web-based application which allows the manual data input (by bespoke configured tablets) and is currently being trailed by said expert staff.
