Fuel Cell Testing Case Study Highlights
Challenge
- The existing fuel cell testing system was becoming obsolete, with many parts outdated and no longer serviceable.
- The manufacturer needed to quickly scale from sample production to low volume manufacturing while meeting stringent quality and safety standards.
- The manufacturer had to address potential safety hazards for operators.
Solution
- Replaced old parts with modern components such as new valves, flow meters, and temperature sensors.
- Designed and implemented custom connectors for secure and leak-free connections.
- Implemented advanced safety features, including a safety circuit, to shut down the system in case of emergencies.
Results
- The ATS team installed the upgraded system, conducting factory acceptance testing (FAT) and site acceptance testing (SAT) to ensure its reliability.
- The manufacturer’s personnel received comprehensive training to operate and maintain the new system.
- The successful, timely implementation of the new system prompted the manufacturer to order additional lines.
Company
Battery Energy Storage Systems (BESS) Manufacturer
Industry
Fuel Cell & Energy Storage
Region
Asia
Customer
A major battery energy storage systems (BESS) manufacturer based in South Korea, specializing in producing fuel cell engines. These products are designed to replace diesel generators for various applications such as hospitals, grocery stores, farms, and other facilities.
Challenge
Overcoming Obsolescence and Scaling Challenges in Fuel Cell Testing Systems
The BESS manufacturer faced a major challenge with its existing fuel cell testing system. The primary issue was the instrumentation’s obsolescence. Since many parts could no longer be serviced, this created a big risk. If critical parts broke down, the customer would face prolonged downtime and the potential inability to repair the system, which could severely impact production. Additionally, manufacturing leaders needed to scale from sample production to low volume manufacturing. The upgraded system also had to meet stringent quality and safety standards to protect operators.
The BESS manufacturer chose ATS Industrial Automation as its automation partner for several reasons, including the global company’s reputation for scalable, high-quality builds and attention to detail. With extensive experience in mechanical and electrical instrumentation, ATS experts were well-equipped to handle the complexities of upgrading the fuel cell testing system. The automation partner’s ability to provide durable solutions that met North American standards ensured the upgraded system would be robust and efficient as the manufacturer transitioned from sample production to low volume output.
Solution
A Comprehensive Solution for an Upgraded Fuel Cell Testing System
ATS Industrial Automation provided a custom approach to upgrade the customer’s fuel cell testing system. This included replacing obsolete parts with modern components, such as new valves, pressure transducers, flow meters, and temperature sensors. Additionally, ATS upgraded the system’s materials to stainless steel, helping prevent corrosion and elevate the equipment’s durability. This update helped enhance the testing system’s reliability and efficiency, allowing it to handle increased throughput while meeting quality and safety standards.
While developing the solution, ATS had to validate the accuracy of the fuel test machine and upgraded instruments. These efforts were accomplished through durability test machines, which could run the fuel cell at a certain temperature and duration to monitor power output. The team conducted these tests over several days to simulate specific conditions, such as a blackout scenario. The ATS team also added advanced safety features, such as a safety circuit, to shut down the system in the event of an emergency.
Another standout of the testing solution was the fuel cell’s custom connectors. These ensured a secure and leak-free connection, helping prevent wear and tear on the connection points while driving the system’s longevity.
Results
Achieving High Standards and Scalability in Fuel Cell Testing
The BESS manufacturer was highly satisfied with the outcomes of the new fuel cell testing system. The attention to detail and commitment to quality standards demonstrated by ATS played a crucial role in delivering a robust and scalable solution that met North American standards.
Once the ATS team installed the upgraded system, they conducted factory acceptance testing and site acceptance testing to ensure the system performed optimally. ATS also provided comprehensive training to key personnel, enabling them to successfully operate and maintain the new system even after the project ended. This successful implementation prompted the manufacturer to order two additional test machines, further demonstrating their satisfaction with the ATS team’s ability to efficiently scale production while keeping operators safe and maintaining quality standards.
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