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The FCAS stacks 250 MEA layers per hour.   Each layer is picked from a dedicated bin, located and oriented with machine vision, and then placed onto the stack.  Guide features ensure that each layer is accurately placed to ensure alignment and minimize the potential for leaks.

Two feed bins are provided for each type of media.  The bins slide out for easy reloading during operation.  A lockout system allows the bins to be loaded while the machine continues to operate, ensuring continuous operation.



The fuel-cell assembly system combines robotic stacking with a stack press and leak tester, allowing for complete assembly and test of the fuel cell in one system.  The system is divided into two zones - an enclosed automated area, where the stack is built, and an open semi-automatic area where the stack is compressed, tested and secured. 


The system is designed such that each side can be used at the same time, allowing the robotic stacking and final assembly operations to occur in parallel.

  • Robotic Stacking

    • 250 MEA layers per hour​

    • Machine vision aligned

  • Stack Press

    • Load cell controlled​

    • 5000 lbf / 2250 kgf

  • Leak Testing

    • Under load​

    • Mass flow detectors

    • Leak to absolute and cross channel


No operator waiting needed while the machine works. The dual-sided rotary fixture  allows an operator to safely work on the finished stack while the robot is building the next stack. 


The integral press allows the stack to compressed and strapped without movement to a new fixture, preventing any slippage or errors.  A servo-controlled ball-screw compresses the stack, using a force sensor to measure and control the load.  



Leak testing is performed automatically before the stack is strapped.  Each channel is tested for leakage to the external environment, and leakage between channels.

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