Laboratory for hydrogen and fuel cell applications

Hydrogen and fuel cells

Test bench - metal hydride chiller
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Test benches for fuel cell systems and stacks enable fuel cells to be analysed and evaluated under real conditions. Parameters such as performance, efficiency and durability are tested here to ensure suitability for use in various applications.

Areas of application and unique characteristics:

  • Characterisation of fuel cells or batteries using state-of-the-art methods
  • Single cell, cell groups and system measurements possible
  • Different operating conditions can be realised
  • Can be flexibly extended to meet special test requirements

Power

 

Stacks

Tests up to approx. 80 kW possible

Fuel cell systems

up to 30 kW

Air supply

up to 60 kW

Combination Kaeser compressor + domestic supply

H2 supply for approx. 60 kW

Supply from H2 bundle station

Kaeser compressor characteristics

 

Operating pressure

7.5 bar

Max. delivery quantity

1.859 m³/min (= 40 g/s)

Voltage

up to 400 V (0.2 %, 0.01 %)

Current

0-400 A (0.2 %, 0.01 %)

Blower characteristics

 

Operating pressure

1.2 bar

Max. delivery quantity

2,500 l/min

Measuring equipment - dynamics and measuring accuracy

 

100 measuring channels

21 bit, 0.01 %, potential separation 650/750 V

5 Coriolis flow sensors

Liquid 0.1 %, gases 0.5 % for water, hydrogen and air

8 Differential pressure sensors

in the range from 0.01 to 4 bar (0.065 %)

Single cell voltage measurement

for 240 (600) cells (0.1 %, time < 1 ms/cell, isol. 1 kV)

Pressure sensors

0 - 6 bar, 0.5 %

Temperature sensors

Class A, 0.15°C

4 sensors for relative humidity

0 - 100 % rH, 0.5+1.5 % from measured value, up to 100 °C)

Conductivity

0.001 - 200 μs/cm, 0.5 %

Other

Highly dynamic media supply (fast hydraulic valves, 0 - 100 % - 1 s)

Fuel cell test bench

Laboratory for hydrogen and fuel cell applications
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Power

 

Fuel cell systems

up to 30 kW

Air supply

currently for approx. 30 kW

 

CompAir compressor or blower

H2 supply

currently for approx. 60 kW

Supply from H2 bundle station

CompAir compressor characteristics

 

Operating pressure

7.5 bar

Max. delivery quantity

13.98 m³/min

Blower characteristics

 

Operating pressure

1.2 bar

Max. delivery quantity

2,500 l/min

Voltage

up to 650 V (0.2 %, 0.01 %)

Current

0 - 400 A (0.2 %, 0.01 %)

Measuring equipment - dynamics and measuring accuracy

 

100 measuring channels

21 bit, 0.01 %, potential separation 650/750 V

5 Coriolis flow sensors

Liquid 0.1 %, gases 0.5 % for water, hydrogen and air

8 Differential pressure sensors

in the range from 0.01 to 4 bar (0.065 %)

Single cell voltage measurement

for 240 (600) cells (0.1 %, time <1 ms/cell, isol. 1 kV)

Impedance spectroscopy (single cells and systems up to 100 V and 400 A)

10 µHz- 2 MHz, ±5 V-±15 V, AC amplitude 0 - 6 V or 0 - 2 A

Pressure sensors

0 – 6 bar, 0.5 %

Temperature sensors

Class A, 0.15 °C

4 sensors for relative humidity

0 – 100 % rH, 0.5+1.5 % from measured value, up to 100 °C

Conductivity

0.001 - 200 μs/cm, 0.5 %

Other

 
 

Highly dynamic media supply (fast hydraulic valves, 0 - 100 % - 1 s)

 

Cyclovoltammetry

 

U-I characteristic curves

Stacktesting and Health-Monitoring

Fuel cell health monitoring
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Power

 

Stacks

12 kW

Air supply

currently for approx. 30 kW

 

CompAir compressor

H2-Supply

for approx. 60 kW

Supply from H2-bundle station

Coolant supply

20–90 °C, 60 l/min

CompAir compressor characteristics

 

Operating pressure

7.5 bar

Max. delivery quantity

13.98 m³ /min

Characteristics of the air conditioning system

 

Operating pressure

4 bar

Max. delivery quantity

2.333 m³ /min

Temperature range

5–90 °C

Humidity

20–85 %

Voltage

bis 400 V (0.2 %, 0.01%)

Current

0–650 A (0.2 %, 0.01 %)

Measuring equipment - dynamics and measuring accuracy

 

100 measuring channels

21 bit, 0.01 %, potential separation 650/750 V

5 Coriolis flow sensors

Liquid 0.1 %, gases 0.5 % for water, hydrogen and air

8 differential pressure sensors

in the range from 0.01 to 4 bar (0.065 %)

Single cell voltage measurement

for 240 (600) cells (0.1 %, time <1 ms/cell, isol. 1 kV)

Impedance spectroscopy (single cells and systems up to 100 V and 400 A)

10 µHz- 2 MHz, ±5 V-±15 V, AC amplitude 0 - 6 V or 0 - 2 A

Pressure sensors

0 - 6 bar, 0.5 %

Temperature sensors

Class A, 0.15 °C

4 sensors for relative humidity

0 - 100 % rH, 0.5+1.5 % from measured value, up to 100 °C

Conductivity

0.001 – 200 μs/cm, 0.5 %

Other

 
 

Highly dynamic media supply (fast hydraulic valves, 0 - 100 % - 1 s)

 

Cyclovoltammetry

 

U-I characteristic curves

Impedance spectroscopy 

For analysing batteries, rechargeable batteries, super caps, fuel cells and thermoelectric modules.

  

Brand

Zahner

Frequency range

10 µHz to 12 MHz

Resolution

32 bit DC and 24 bit AC

AC Ampl.

0 - 6 V for EIS

Impedance range

0 - 10 MOhm

Internal potentiostat

12 V, 1 A, 12 W 

Electrical load

1000 W, 200 A expandable to 600 A with external load, ± 4 V expandable to ± 100 V

Power Multiplexer

17 channels

4 quadrant power potentiostat

±40 A, ±20 V

Electrochemical measurement methods

Electrochemical impedance spectroscopy, current-voltage curves, linear sweep voltammetry, cyclic voltammetry, battery cyclisation, AC-DC-AC test procedures

Contact

Dr.-Ing. Michael Schier

Head of Research Area
German Aerospace Center (DLR)
Institute of Vehicle Concepts
Vehicles Energy Concepts
Pfaffenwaldring 38-40, 70569 Stuttgart