At the Fraunhofer Institute for Machine Tool and Molding Technology IWU, researchers are developing advanced technologies for manufacturing fuel cell engines to facilitate rapid, cost-effective mass production. To this end, IWU researchers initially focused directly on the heart of these engines and are studying methods for making bipolar plates from thin metal foils. At the Hannover Messe, Fraunhofer IWU will showcase these and other promising fuel cell engine research activities with Silberhummel Racing.
When it comes to powering electric engines, fuel cells are an ideal way to supplement batteries to increase driving range. However, manufacturing fuel cells is still a costly process, so there are still very few models using this drive technology in the German market. Now Fraunhofer IWU researchers are working on a more cost-effective solution: “We use a holistic approach to study all the components in a fuel cell engine. The first thing to do is to provide hydrogen, which affects the choice of materials. It is directly involved in fuel cell power generation and extends to the fuel cell itself and the temperature regulation of the entire vehicle.” Chemnitz Fraunhofer IWU project manager Sören Scheffler explained.
In the first step, the researchers focused on the heart of any fuel cell engine: the “fuel cell stack.” This is where energy is generated in many stacked batteries composed of bipolar plates and electrolyte membranes.
Scheffler said: “We are investigating how to replace traditional graphite bipolar plates with thin metal foils. This will enable stacks to be mass-produced quickly and economically and significantly increase productivity.” The researchers are also committed to quality assurance. Check every component in the stack directly during the manufacturing process. This is to ensure that only fully inspected parts can enter the stack.
At the same time, Fraunhofer IWU aims to improve the chimney’s ability to adapt to the environment and driving conditions. Scheffler explained: “Our hypothesis is that with the help of AI, dynamically adjusting environmental variables can save hydrogen. Whether it is using the engine at high or low temperatures, or using the engine on the plain or in a high temperature environment, it will Different. Currently, the stack works within a predetermined fixed operating range, which does not allow such environment-dependent optimization.”
Experts from the Fraunhofer Laboratory will present their research methods at the Silberhummel exhibition at the Hannover Messe from April 20th to 24th, 2020. Silberhummel is based on a race car designed by Auto Union in the 1940s. The developers of Fraunhofer IWU have now used new manufacturing methods to reconstruct the vehicle and create modern technology demonstrators. Their goal is to equip Silberhummel with an electric engine based on advanced fuel cell technology. This technology has been digitally projected at the Hannover Messe.
The Silberhummel body itself is also an example of innovative manufacturing solutions and molding processes further developed by Fraunhofer IWU. However, the focus here is low-cost manufacturing in small batches. Silberhummel’s body panels are not formed by large stamping machines, which involve complex operations of cast steel tools. Instead, a female mold made of wood that is easy to process is used. A machine tool designed for this purpose uses a special mandrel to press the body panel little by little on the wooden mold. Experts call this method “incremental shaping”. “Compared with the traditional method, whether it is the fender, the hood, or the side of the tram, this method can produce the required parts faster. For example, the conventional manufacturing of tools used to make body parts It may take several months. We need less than a week from the manufacture of the wooden mold to the testing of the finished panel,” Scheffler said.
Post time: Sep-24-2020