moehwald Bosch Group

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1 moehwald Bosch Group Division Testing Technology for Fuel Cells Moehwald GmbH Michelinstraße 21 Postfach Homburg, Germany Tel.: +49 (0) / Fax: +49 (0) /

2 Test benches for Fuel Cell Systems Fuel Cells Components Drive Systems Traction Batteries moehwald Lizenz 2

3 Competence of two companies one product Cooperation between Moehwald and MS2 in July, 2008 The longstanding collaboration between Moehwald, the world's leading manufacturer of testing systems for injector systems, and MS2, a company experienced in design and operation of fuel cell and fuel cell system testing systems, was put into contractual form in July. The goal of this cooperation is a customer-oriented alliance to improve operations on the global market using shared strategies, and to be able to meet the challenges of fuel cell technology. 3

4 moehwald Bosch Group Know-how 30 years in the test bench business Over 1000 test benches worldwide For development and production Worldwide sales and service Know-how Test rigs for Fuel Cell Systems Fuel Cells Fuel Cell Components > Test benches moehwald Lizenz Customer-orientated partnership to meet the challanges of fuel cell test technology Development and production test benches for Fuel Cell Systems Fuel Cells H 2 -Loop Air Supply Cooling Systems Tank Systems Drive Systems Traction Batteries Infrastructure Laboratory Test Area Container 4

5 Test bench for Fuel Cell Stacks - Example For test and further development of fuel cell stacks test benches with a range of 100W to 5kW power, for automotive fuel cell systems rigs up to 120kW are offered. More power for special applications available on request. In addition to our standard test benches with predefined power classes, we also offer systems with flexible design adaptation to your requirements for mass flow, dynamics, and load. Quelle ZSW 5

6 Test bench for Fuel Cell Stacks - Block Diagram The test rig provides at least gas circuits for anode and cathode gases, the exhaust unit, the cooling circuit and the electronic load. Optionally, additional gas circuits for mixing noxious gases can be made available. Continuous operation of a fuel cell stack can be enabled with the automation system with a time dependent load condition. The available sensors and the overlaid control technology allow the load dependent setting of mass flow, temperature, humidity and fuel gas pressure and the cooling medium temperature. Additional necessary installations (not included in the test bench), such as H 2 supply system Waste water discharge / Exhaust gas discharge Cooling water supply can be offered optionally close to the requirements of our customer. 6

7 Test bench for Fuel Cells - Features Depending on the type of fuel cell, our test systems have the following features: Fully automated, unattended operation of the test system using a control system Test runs with free specification of cycles and parameters Start up and shutdown procedures Accurate sensors which enable high precision measurement acquisition Storage of measurement data and preparation according to your specifications Large temperature ranges for media supply (e.g. coolant from -40 C to 130 C, with thermal oil circuit up to 200 C) Low-temperature cooling of fuel cells down to - 40 C for cold start testing Coolant: De-Ionized water or DI-water/ethylene glycol mixture or thermal oils High dynamics in media supply High-precision pressure regulation, pulse-free gas flow High-precision temperature regulation Highly dynamic, precisely configurable humidification using direct steam dosing Different fuel cell operating modes on one test bench (e.g. dead-end, recycling) 7

8 Test bench for Fuel Cell Stacks - Views Fully Know How in fuel cell technology Customer specific test equipment for fuel cells and fuel cell systems for hydrocarbon reformation for CNG components (e.g. injectors) leakage test systems Many years of experience in the construction of gas test stands On-site calibration service for gas flow meters and gas flow regulators, some with pure gas 8

9 Test bench for Fuel Cell Stacks - Process Technology Test benches for fuel cells can be optionally extended with: Humidity measurement Online gas analysis for exhaust and recycling (H 2, CO, CO 2, N 2, O 2 concentrations) Impedance spectroscopy Cyclovoltimetry Gas addition to anode and cathode (different gas types / flow ranges) Power regenerating for large power Zero-volt option for electrical load DMFC configuration (up to 5 kw fuel cell power) Interface for HIL simulation with MATLAB / SIMULINK 9

10 Test bench for Fuel Cell Stacks - Components Hood Electronic Load Flow Controller Pressure Valves Gas Conditioning Cooling System 10

11 Test bench for Fuel Cells - Safety Concept Mature safety and alarm processing concept with 3-level alarm processing and alarm notification via software Safety-relevant alarms redundancy through hardware wiring in EMERGENCY STOP circuit Inert flooding with nitrogen on EMERGENCY STOP Location of fuel cells in transparent, ventilated housing Gas warning sensors and flow monitors in suction Risk analysis with SafeExpert software 11

12 The Fuel Cell in System with Peripherals Development and production test benches for: Fuel Cell Systems H 2 -Loop / Air Supply / Cooling Systems Tank Systems Drive Systems Traction Batteries 12

13 Fuel Cell Types and Applications Type: Applications PEM FC: Proton Exchange Membrane Fuel Cell (Polymer Electrolyte Membrane - Fuel Cell) Low temperature cell. Operates at approx C, external cooling required. The cell type for use in the automotive application. At present, prototypes from e.g. Ballard / Hydrogenics with a power of up to 150kW. Fuel gases are hydrogen and air. Disadvantage: fuel gases must be humidified. HT PEM: High Temperature PEM High temperature PEM fuel cell, running with temperatures to 150 C. DMFC: Direct Methanol Fuel Cell Low temperature cell, is operated directly by methanol without an additional reformer. Lowest power density. For mobile / transportable applications, power area only up to approx. 500W. Fuels, methanol + water, CO 2 formed. SOFC : Solid Oxide Fuel Cell High temperature cell 900 C. For stationary applications, power thermal coupling. Operation with natural gas!! Disadvantage, complex start up procedure, complex isolation. Application is home heating up to block heating power plants. Power is saved to the grid, warmth is used for heating. 13

14 Test benches moehwald Lizenz Moehwald GmbH Michelinstraße 21 Postfach Homburg, Germany Tel.: +49 (0) / Fax: +49 (0) / MS2 Engineering und Anlagenbau GmbH Tanenbergstraße 115/ Kirchheim / Teck, Germany Tel.: +49 (0) 7021 / Fax: +49 (0) 7021 /

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