Ballard Engineering Services
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Transcript of Ballard Engineering Services
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Commercial Confidential
Technology Solutions
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Commercial ConfidentialCommercial Confidential
Ballard Power Systems
• Ballard is the global leader in clean energy proton exchange membrane (“PEM”) fuel cell products and services … design, manufacturing & deployment
o Telecom Backup Power 2,700+ systems … 11MW’s of power
o Material Handling 6,000 stacks … 100M hours of runtime
o Technology Solutions C$60‐100M contract with Volkswagen
o IP Licensing power module assembly for buses in China
• 400 employees
o HQ in Vancouver, Canada
o Product Engineering in Vancouver, Bend, Oregon & Denmark
o Manufacturing in Vancouver & Mexico
Ballard HQ facility –Vancouver, B.C., Canada
Key Customers
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Commercial ConfidentialCommercial Confidential
Corporate Transformation
2007
2009
2015
The future builds on commercial and development stage markets and Engineering services for a wider range of industries and partners, including automotive
Considerable fuel cell R & D effort focused on automotive requirements
• Extensive development of PEM fuel cell intellectual property (IP)
• Leading fundamental ‘know‐how’ acquired in key areas: fuel cell stack operation; system integration; as well as fuel processing
Clean energy fuel cell products enabling optimized power products for a range of commercial applications
• Shift of strategic focus to fuel cell products for commercial applications
• Corporate cost base re‐set
• Telecom Backup Power
• Material Handling
Development Stage Products
Power Products
Technology Solutions
• Engineering Services
• IP Licensing
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Commercial ConfidentialCommercial Confidential
Ballard Competitive Advantage
• Sustainable leadership position in technology & product development
• Long history with automotive industry
o 4 major automotive development programs
o Supplier to more than 10 small automotive fleets
• Significant R&D work over past 15 years
o $1B+ investment in development
• Extensive patents portfolio and license rights to patents owned by Daimler, Ford & IdaTech
• Strategic partnership with UTC enables joint exploration of IP licensing & Technology Solutions opportunities
o UTC maintains ongoing commitment to fuel cells through the alliance and
receives a portion of licensing revenue
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Business Overview
• Meet the power needs of customers through delivery of high value, clean energy products that reduce customer costs and risks
Power Products
• Help customers solve difficult technical and business challenges in their fuel cell and electrolyzer programs
Technology Solutions
• Telecom Backup Power• Material Handling• Bus• Distributed Generation
• Automotive• Non‐automotive
o Aerospaceo Militaryo Railway
Mandate Markets
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Fuel Cell Stacks
• 500W‐2kW• Up to 8k hrs
• 2‐8kW• Up to 30k hrs
• 4‐20kW• Up to 12k hrs
• 100kW• > 10k hrs
Fuel Cell Modules
Complete Fuel Cell Systems
Ballard Fuel Cell Product Portfolio
• 75‐150kW• Up to 20k hours
• Multi‐MW power
• 2kW & 5kW • Direct hydrogen
• Indoor (rack‐mountable) & outdoor use
• 2.5kW & 5kW • Methanol fuelled• Outdoor use
• 100 kW• Up to 20k hours
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Commercial ConfidentialCommercial Confidential
Ballard Fuel Cell Products in the Field
Thousands of installed telecom systems
+50 fuel cell buses operating
Thousands of fork lift trucks operating
+300 fuel cell cars operating
Smarter Solutions for a Clean Energy Future Ballard Confidential Information 7
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Commercial ConfidentialCommercial Confidential
Experienced Automotive Fuel Cell Supplier
• Ballard has supplied >500 fuel cell products and 1,000s of engineering hours providing Technology Solutions to 8 of the top automotive companies
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Commercial Confidential
Technology Solutions
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Scope of Technology Solutions
Customized Engineering Services solutions offered for all stages of development:
Reference Systems
Applications Engineering
Predictive Simulation &
Modeling
Fuel Cell Testing Services and Test Stations
Product Development
Failure Diagnosis and
Analysis
Prototype Manufacturing
EARLY TECHNOLOGY EXPLORATION MATURE PROGRAMS
Licensing & Technology
Transfer
ADVANCED DEVELOPMENT
• High‐value Engineering Services for accelerating fuel cell development programs
o Pathway for aligning fuel cell product development with Ballard’s technologies
o Problem solving through leveraging Ballard’s broad technical expertise
o Avenue for exploring Ballard’s extensive patent portfolio for licensing
• Driving long‐term product opportunities
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Early Technology Exploration
Reference SystemsEngineering and Integration
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Engineering Reference Systems
• Reference systems accelerate system integration and developmento Includes fuel cell engine with key BOP components
o Suitable for hybridization with capacitor and/or battery
Humidification
Coolant Flow and Temperature Control
Hydrogen Recirculation
Air Supply
ControlsStack
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System Engineering and Integration
• Support systems development, stack integration and operating assessments o Supported OEMs to develop over 50 different FC products
• Guidance for product selection and system design through remote and on‐site support
• Evaluating tradeoffs at stack/system‐level• Troubleshooting during design process• Material and component selection & sourcing• Codes, standards & certification
• Evaluating tradeoffs at stack/system‐level• Troubleshooting during design process• Material and component selection & sourcing• Codes, standards & certification
Applications, service and systems engineers with expertise in:
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Commercial ConfidentialCommercial Confidential
Advanced Development
Product DevelopmentFuel Cell Testing Services
Test Stations
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Product Development
Bi‐polar plate design
CCM Development
Fluid & Thermal Models
• Product design & research of components, fuel cell stacks and complete systems
• Ability to combine membrane, catalyst and ionomers from various supplierso Work with existing supply chain to bring the right materials
together from multiple suppliers
• Stack and system modeling & design• Component design & prototyping services• Membrane electrode assembly (MEA) design & manufacturing• Catalyst coated membrane (CCM) design & manufacturing• Single electrode design & manufacturing• Design for manufacturing
• Stack and system modeling & design• Component design & prototyping services• Membrane electrode assembly (MEA) design & manufacturing• Catalyst coated membrane (CCM) design & manufacturing• Single electrode design & manufacturing• Design for manufacturing
Services for fuel cell product development
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Fuel Cell Stack Development
• > 10 application‐specific stack designs
• Stack development experience for a range of applications:o Several watts to multi‐MW
o Stationary and Motive applications
o Pure hydrogen and reformate fuel stacks
• Testing and design experience from existing platforms• Models for design optimizations – performance, fluid,
thermal, structural, durability• Ex‐situ testing techniques for characterization• Integrate prototype or product‐ready components• Design for manufacturing
• Testing and design experience from existing platforms• Models for design optimizations – performance, fluid,
thermal, structural, durability• Ex‐situ testing techniques for characterization• Integrate prototype or product‐ready components• Design for manufacturing
Delivering custom stack solutions
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Control System Development
• Experience with controls developmento System products have integrated controls
• Off‐the‐shelf embedded controller
• Custom board design
o Software development completed internally
• Test station controls and data acquisition are done in‐house
o LabView‐based control software
• Interface to other systems and controllers, including CAN‐bus, serial
• Process tuning & optimization• Control algorithm specification and implementation• Stationary and motive applications
• Interface to other systems and controllers, including CAN‐bus, serial
• Process tuning & optimization• Control algorithm specification and implementation• Stationary and motive applications
Systems and controls engineers have expertise in:
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Commercial ConfidentialCommercial Confidential
Fuel Cell Testing
• State‐of‐the‐art fuel cell testing facilityo Collect 400,000+ hours annually
o 24/7 operation, simulate real duty cycles
o Test station capacity < 100 W to 333 kW
• 60+ automated test stations and specialized test tools
o Environmental: 10 temperature and humidity chambers
o Stack diagnostics: Current mapping, reference electrodes, water management, freeze protocols, SEM
o Accelerated stress tests (AST): Membrane durability, cell reversal tolerance, voltage cycling, start‐up/shutdown, ice tolerance
Current Map
Test Facility• Component‐, stack‐ and system‐level testing• Standard and accelerated testing methods• Custom diagnostic tests
• Component‐, stack‐ and system‐level testing• Standard and accelerated testing methods• Custom diagnostic tests
Develop and execute custom testing programs
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Test Stations and Customer Facilities
• Expertise in facilities and test equipment design and supply
o Clean rooms, test labs, production facilities
o Standard and custom testing equipment
• Equipment and services are supplied to customers such as VW, AFCC, Daimler
Ballard Test Stand with Cold Chamber
Ballard Clean Room
Clean Room Humidity Control
• Test stations from multiple watts to megawatts• Automated testing features – dynamic drive cycling,
custom performance/durability test protocols
• Test stations from multiple watts to megawatts• Automated testing features – dynamic drive cycling,
custom performance/durability test protocols
Custom test stations
• Hydrogen infrastructure and safety• Lab and test facility layout and design• Fuel cell system assembly and plant layout
• Hydrogen infrastructure and safety• Lab and test facility layout and design• Fuel cell system assembly and plant layout
Facility consultation services
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Mature Programs
Prototype ManufacturingLicensing
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State‐of‐the‐Art Manufacturing
• High volume manufacturing and prototyping equipmento Robotics, liquid injection molding and roll‐to‐roll processingo Proven yields in excess of 99%o SPC run charts Full traceability on raw materials
• For key customers Ballard offers custom development, including:o Framed, sealed or unframed MEAso CCM (various configurations and applications)o Reference electrodeso Engineering support and failure analysis for integration
• Develop custom components to customer specifications or provide off‐the‐shelf componentso Leverage Ballard or customer component technologyo Collaborate on component development and bring advanced technology to the tableo Ability to combine various membrane, catalyst and ionomers
Framed MEA & plateCatalyst Layer Coating
Stack Assembly
MEA Assembly
•Membrane coating•Catalyst ink mixing & composition to meet specifications•MEA framing and liquid injection sealing•Plate sealing
•Membrane coating•Catalyst ink mixing & composition to meet specifications•MEA framing and liquid injection sealing•Plate sealing
Internal fabrication of custom components
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590
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132160
196
95 106
175
Fuel CellSystem
FuelReforming
Balance ofPlant
Fuel CellStack
Plates Electrodes MEA &Sealing
Catalyst &Membrane
Patent Portfolio & Know‐How
Key technology advancements• Unique system control strategies for
start/stop and voltage clipping
• Continuous innovations related to flow field plate with flow guide
• Component technologies enabling low RH, low catalyst loaded MEAs
• Advanced sealing designs for extended lifetime operation
• ‘Freeze’ technology, enabling rapid start‐up at low temperature
• Unique water management, eliminates need for humidifiers and enables 5,000+ operational hours
• Ballard’s IP portfolio consists of ~200 patents/applications with access to ~1,500 patents/applicationso System, stack, and component‐level designo Membrane, electrode, catalyst and materialso System and stack operation and control
Trade secrets and know‐how are centered on predictive design methods, accelerated test methods, CCM and MEA manufacturing processes
SYSTEM STACK COMPONENTS & MATERIALS
Ballard Patents and Accessible Patent Portfolio
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Summary
• Ballard has a long history of leadership in fuel cell stack development and supply
• Technology Solutions offers a cooperative model to partners for accelerating fuel cell development programs and builds the foundation for long term partnerships
• Component prototyping and high volume production leverage existing manufacturing infrastructure
• Our technology development activities position us well to work with partners to jointly develop products for all applications