Introduction to the production process and equipment of traditional alkaline electrolyzers

The hottest link in the hydrogen energy industry chain is hydrogen production. As of 2016, there were less than 10 water electrolysis hydrogen production equipment (electrolyzer) companies in the country. Nearly 200 companies are producing electrolyzers, which is the best interpretation of this enthusiasm . Of course, this data is still increasing. First, there are still many companies in the industry that have not surfaced; second, new and different technical routes are gradually emerging. In short, the popularity of electrolyzers is even greater than that of fuel cells back then.

Although there are several ways to produce hydrogen by electrolysis of water, the most popular and concentrated one at present is the alkaline electrolyzers system. Putting aside the product performance and applicable scenarios, the traditional alkaline electrolyzers of water to produce hydrogen is probably the most accessible technical route for all new forces. 

 

In the past and even in the current situation, the production of electrolyzers is a purely handmade process, with very limited equipment. Of course, as the demand for electrolytic cells gradually increases, various manufacturers have begun to gradually increase equipment, including auxiliary equipment, semi-automatic equipment, etc. Some companies have even tried fully automatic equipment, although there are still some obstacles. 

Some equipment is commonly used in the processing of alkaline electrolytic cells. The processing process of traditional electrolytic cells mainly includes basic process processes such as welding, cutting, assembly, and locking, so the processing equipment of the entire electrolytic cell is mainly cutting, welding , and assembly, as shown in the following figure:

Alkaline electrolytic cell processing and main equipment of alkaline electrolyzers

The following is an introduction to the main equipment:

 

1. Diaphragm cutting machine

Equipment function :

This equipment realizes semi-automatic cutting of electrolytic cell diaphragms (PPS cloth).  

Equipment parameters 

1. Repeatable positioning accuracy: ±0.02mm; 
2. Cutting speed: 10~15m/min
3. Cutting accuracy: ±1.5mm> 

Equipment advantages 

1. This equipment is suitable for cutting sheet materials by manually loading the material and spreading the cloth, starting the equipment to automatically cut the cloth, and finally unloading the material manually.
2. The equipment is simple and stable to operate, and the cutting efficiency is high; 
3. The cutting head seals the edges of the cutting part while cutting. Makes the diaphragm trimmed smoother. 
4. The equipment is compatible with cutting circular-shaped fabrics within a certain diameter range.

2. Automatic cutting machine for screen/electrode screen

Equipment function :

This equipment realizes automatic cutting of electrolytic cell electrode mesh and mesh plates. 

Equipment parameters 

1. Repeated positioning accuracy: ±0.02mm 
2. Maximum cutting speed: 20m/min
3. Dimensional cutting accuracy: ±0.1mm.

Equipment advantages 

1. This equipment adopts upper and lower double worktables, and realizes rapid loading and unloading through a uniquely designed automatic climbing exchange method, reducing the waiting time for material change and improving design and processing efficiency.
2. The equipment is equipped with a pressing plate mechanism, which can move the electrode mesh /The mesh plate is pressed flat before cutting, which improves the cutting accuracy of the circular outer diameter of the electrode mesh. 
3. Compatible with various CAD software, providing integrated services from software design, and printing to cutting.

 

3. Pole frame runner groove cutting machine

 

Equipment function: 

This equipment realizes automatic cutting of pole frame flow channels.  

Equipment parameters 

1. Repeated positioning accuracy: ±0.02mm 
2. Maximum cutting speed: 20m/min
3. Dimensional cutting accuracy: ±0.1mm. 

Equipment advantages 

1. This equipment adopts upper and lower double worktables and realizes fast loading and unloading through a uniquely designed automatic climbing exchange method, reducing the waiting time for material change and improving design and processing efficiency
2. The equipment is equipped with tooling fixtures that can frame the poles. Flatten and fix before cutting, which improves the cutting accuracy of the pole frame flow channel groove. 
3. Compatible with various CAD software, providing integrated services from software design, and printing to cutting.

 

4. gasket automatic cutting machine

 

Equipment function: 

This equipment realizes the automatic cutting of electrolytic cell pole frame gaskets. 

Equipment parameters 

1. Repeat positioning accuracy: ±0.02mm
2. Gasket cutting speed: 1.5m/min 
3. Gasket size cutting accuracy: ±0.1mm. 

Equipment advantages 

1. The edge of the gasket cut by this equipment is Smooth and burr-free
2. A variety of hole patterns can be cut at one time, with high compatibility
3. The cutting head has a self-correcting function, which reduces the operator’s assembly time.

 

5. Frame and plate/mesh plate automatic welding machine

 

Equipment function:

This equipment realizes spot welding of electrolytic cell plate frame and plate/mesh plate.

Equipment parameters 

1. Repeated positioning accuracy: ±0.02mm 
2. Welding speed: 2m/min
3. Welding accuracy: ±0.1mm. 

Equipment advantages 

1. The equipment uses a rotating double-loading platform to achieve fast loading and unloading, reducing changeover Reduce material waiting time and improve work efficiency 
2. The intelligent welding system of the fully automatic welding robot can identify the location and specifications of the weld through the weld tracking sensor, and place just the right amount of welding material to fill the weld, making the weld beautiful and strong.

 

6. Frame and plate/mesh plate automatic welding line (two types: single-sided welding and double-sided welding)

 

Equipment function: 

This equipment realizes automatic welding of electrolytic cell pole frames and plates. 

Equipment parameters 

1. Repeat positioning accuracy: ±0.02mm
2. Welding speed: 2m/min
3. Welding accuracy: ±0.1mm. 

Equipment advantages 

1. The equipment adopts a cache loading and unloading mechanism, a handling robot, and an alternating feeding platform. It does not stop the machine from loading, unloading, and welding, reducing the waiting time for material change and improving work efficiency
2. The intelligent welding system of the fully automatic welding robot can identify the location and specifications of the welding seam through the welding seam tracking sensor, and then place the welding Good welding materials fill the weld, and the weld will be beautiful and strong.

 

Automatic pole frame and plate welding line (double-sided welding)

Equipment function:

This equipment realizes automatic welding of the front and back sides of the electrolytic cell pole frame and plates.

Equipment parameters 

1. Repeatable positioning accuracy: ±0.02mm
2. Welding speed: 2m/min
3. Welding accuracy: ±0.1mm. 

Equipment advantages 

1. The equipment uses a handling robot and a cache loading and unloading mechanism to achieve non-stop loading and unloading and welding, reducing the waiting time for material change and improving work efficiency 
2. The intelligent welding system of the fully automatic welding robot can identify the location and specifications of the welding seam through the welding seam tracking sensor, and decentralize the welding seam just now Good welding materials fill the weld, and the weld will be beautiful and strong.

 

7. Hydraulic lifting platform (three models)

Equipment functions 

This equipment realizes the lifting and lowering of the manual working platform and the assembly of electrolyzers. 

Equipment parameters 

1. Platform load: 2000kg
2. Maximum lifting height: 7000mm
3. Minimum height of lifting base: 50~100mm
4. Lifting speed: 2-4m/min low speed adjustable 
5. Base tooling load-bearing: > 60T

Equipment advantages 

1. The lifting platform can be stopped and raised immediately, and manual operation is convenient
2. The equipment power system is equipped with an overload self-locking function. If the equipment’s self-locking function is automatically activated if the cargo is overweight, the equipment will stop and not rise to ensure accidents caused by excessive overloading of the equipment
3. The base tooling and the overall structure are stressed Reasonable, rigid, stable, and reliable, and strictly guarantee the safety of electrolytic cell assembly.

 

Hydraulic lifting platform (intelligent material retrieval model) 

Equipment function 

This equipment realizes the lifting and lowering of the manual working platform, intelligent and convenient material retrieval, and assembly of electrolytic cells. 

Equipment parameters 

1. Manned platform load: 2000kg
2. Material platform load: 3000kg
3. Maximum lifting height: 7000mm
4. Minimum height of lifting base: 50-100mm
5. Lifting speed: 2-4m/min low speed Adjustable
6. Base tooling load-bearing: >60T

Equipment advantages 

1. The lifting platform can be stopped and raised immediately, and manual operation is convenient
2. The power system of the equipment is equipped with an overload self-locking function. If the self-locking function of the equipment is automatically activated if the cargo is overweight, the equipment will stop and not rise to ensure that the equipment is excessively overloaded. Accidents caused
3. The base tooling and the overall structure have reasonable stress, strong rigidity, stability, and reliability, and strictly ensure the safety of electrolytic cell assembly. 
4. The manned platform is equipped with a movable translation crane and a scissor-type material lifting Lowering the platform makes it easy to pick up and place materials
5. It can reduce human labor intensity and improve manual operation safety

 

8. Hydraulic bolt tensioner

 

Equipment function:

This equipment realizes the stretching of the electrolytic cell screw. 

Equipment parameters 

1. Maximum working pressure of the tensioner: 1500 bar
2. Maximum load of the tensioner: 2500KN
3. Maximum output pressure of the hydraulic pump: 2000 bar
4. Using a first-line brand controller and human-machine interface, stable performance
5. You only need to input the tensile force, one-button operation can realize signal remote control, which is convenient and fast
6. Automatic pressure compensation function eliminates pressure loss from mechanical deformation and makes stretching more accurate
7. The operation record data can be queried
8. 8. The hydraulic stretching stroke has a mechanical anti-fool limit to prevent misoperation
9. The automatic pressure relief function is safe and reliable
10. The end pressure plate is controlled through a closed-loop feedback system and a hydraulic bolt tensioner. The pressing flatness is ensured, and the end pressing plate assembly is carried out digitally. 

 

9. Pole frame flipping table

 

Equipment function: 

This equipment realizes the 180° automatic flipping action of the pole frame and pole plate. 

Equipment parameters 

1. Use a servo motor and reducer to drive the fixture back and forth to turning
2. Turning speed: adjustable
3. Rotation radius: 1100mm
4. Repeatable positioning accuracy: ±0.1mm
5. Rated load: ≤ 300KG
6. Flip angle: ±180°
7. Applicable product size range: This can be customized according to the size of the pole frame. 

Equipment advantages 

1. Use servo motor reducer for speed regulation, with high precision and large starting torque
2. Combined box-type base, high rigidity, and strong bearing capacity
3. Advanced license technology, good straightness, and parallelism of each axis hole minimize the studio momentum caused by insufficient manufacturing and accuracy.

 

10. Plate laser welding machine (two models)

 

Equipment function:

This equipment realizes the welding action of the pole plate and pole frame. 

 Equipment parameters 

1. Turntable rated load: >2000KG
2. Applicable product size range: can be customized according to pole frame size
3. Use ≥2000W continuous laser welding; 4. Rotation speed 0~10m/min (variable frequency speed regulation, Uniform rotation speed, no jitter). 

Equipment advantages

1. When welding, the jig presses the electrode plate for welding, which can ensure the position accuracy of the welding electrode plate.

 

Pole frame and plate welding machine machine 

Equipment function

This equipment realizes the welding of pole frame and pole plate. 

Equipment parameters 

1. Rated load of turntable: >150KG
2. Applicable product size range: can be customized according to the size of the pole frame
3. Use laser continuous welding
4. Rotation speed 0-10m/min (frequency control, uniform speed, no jitter)
5. Welding efficiency <10min/pcs (this is the pure equipment welding time, not considering the actual manual operation efficiency). 

Equipment advantages 

1. Rotary table welding station and automatic plate gland to ensure position accuracy and stability during plate welding
2. Three stations to realize equipment welding, manual loading and unloading, and welding flipping simultaneously, which can reduce the need for equipment Welding and manual waiting time, thereby improving the overall welding efficiency of the equipment
3. Use a cantilever crane with an auxiliary spreader and a pole frame turning table.

 

11. Nickel wire mesh laser welding machine

 

Equipment function: 

This equipment realizes the welding action of nickel wire mesh and pole frame. 

Equipment parameters 

1. Turntable rated load: >2000KG
2. Applicable product size range: can be customized according to pole frame size
3. Use ≥2000W continuous laser welding
4. Rotation speed 0~10m/min (variable frequency speed regulation, Uniform rotation speed, no jitter). 

Equipment advantages 

1. When welding, the fixture presses the nickel wire mesh for welding, which can ensure the position accuracy of the welded nickel wire mesh.

 

12. Linear body

 

Equipment function:

 The complete line of plate welding realizes the welding action of the plate and the frame.

Equipment configuration 

1. Mainly includes: temporary pole plate installation tooling, pole frame temporary installation tooling, manual pre-spot welding station, spot welding positioning tool, spot welding temporary installation tool, pole plate laser welding machine, pole frame flipping platform, grinding and degaussing Calibration platform, leveling and positioning tooling, post-weld temporary tooling, pole frame auxiliary spreader, pole plate auxiliary spreader, KBK cantilever crane, safety fence. 

Equipment advantages 

1. The use of KBK flexible aerial cranes and auxiliary spreaders can improve material transfer and transportation
2. Integrating the welding process of the electrode plate and the electrode frame into a linear method can improve the overall production efficiency.

 

Nickel mesh welding complete line 

Equipment functions

The nickel mesh welding complete line realizes the welding action of nickel mesh and pole frame. 

Equipment configuration 

1. Mainly includes: support network temporary installation tool, pole frame temporary installation tool, support network resistance spot welding station, nickel wire mesh temporary installation tool, nickel wire mesh laser welding machine, pole frame flipping platform, manual inspection platform, Inspection and positioning tooling, post-weld temporary tooling, pole frame auxiliary spreader, nickel wire mesh auxiliary spreader, KBK cantilever crane, safety fence. 

Equipment advantages 

1. The use of KBK flexible aerial cranes and auxiliary spreaders can improve material transfer and transportation
2. Integrating the welding process of the electrode plate and the electrode frame into a linear method can improve the overall production efficiency.

Having introduced so much equipment used in the electrolyzer processing process above, it is also necessary to briefly introduce the current market supply situation. Although the electrolyzer is not a new industry, in the past, there was almost no semi-automatic or automatic equipment used , and many processing scenarios were still purely manual in workshops, so before that, there was almost no complete equipment supply chain like fuel cells. 

Now with the hot hydrogen production link, some equipment manufacturers are also waiting for opportunities to enter this link. The difference is that most equipment manufacturers have not yet fully mastered the production process of electrolyzers, so there are not many manufacturers that can quickly and completely provide professional equipment in a targeted manner. 

Working principle and structure of PEM electrolyzer