BALLARD POWER SYSTEMS
ENGINEERING SERVICES CAPABILITIES
JANUARY 2014
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You can benefit from Ballard’s
expertise and know-how, gained
over 25 years of proton exchange
membrane fuel cell product
development experience.
Ballard’s Engineering Services provide a high-value way to accelerate your
PEM fuel cell development efforts. Leverage Ballard’s competencies in fuel
cell design optimization at every stage of the development process, from
“Phase 0” to commercial launch, to address your most pressing fuel cell
product challenges.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
COMPREHENSIVE ENGINEERING SERVICES
Fuel cell product developers can capitalize on Ballard’s high level of competency in a range of specialized
fuel cell activities, with the Ballard team providing tools and technologies for development, optimization,
integration and validation of fuel cell components, stacks and systems.
Flexible fully-tailored programs, ranging from short term analysis to extensive, multi-year product
development projects, provide our customers with exactly the tools required to meet internal targets.
A range of Engineering Services (ES) programs are currently underway supporting clients’ efforts in
a number of market areas. Global automakers are accessing Ballard’s expertise in the design and
manufacture of fuel cells to power next generation vehicles. ES projects are also enabling products for
a number of other emerging markets, including aerospace, railway, residential and military applications.
Ballard’s fuel cell science, engineering and manufacturing skill sets are unsurpassed in the marketplace.
Projects are focused across a range of specialized fuel cell activities.
Read on to learn more about each of these offerings…
STAGES OF DEVELOPMENT
TECHNOLOGY EXPLORATION
Reference
Systems
Applications
Engineering
Predictive
Simulation
& Modeling
ADVANCED DEVELOPMENT
Fuel Cell
Testing
Services
and Test
Stations
Product
Development
Failure
Diagnosis
and
Analysis
Manufacturing
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
ENGINEERING REFERENCE SYSTEMS
Ballard has developed Engineering Reference Systems to help customers get a quick start with system
design and system integration activities. These brass board prototype systems are built around Ballard’s
air-cooled and liquid-cooled fuel cell stack technologies, and are designed to give customers a starting
point for their own system design.
Engineering Reference Systems provide a baseline for technology evaluation, and can act as a test
platform for ongoing system development, as a customer leverages the system design to begin
customization to meet specific application requirements.
The systems include a Ballard fuel cell stack, balance of plant components, and controls. Humidification,
coolant temperature and flow control, cathode air supply and hydrogen recirculation are included within
the system, and are all coordinated by a pre-programmed central controller. These components are
assembled and packaged into a frame for ease of use and are arranged to be easily accessible.
Along with an operational system, the customer receives significant design information, including an
integration manual and operation guide, a P&ID, drawings, and a detailed BOM with manufacturer
information. Ballard also provides information and access to the control software, allowing customers
to modify the control code as they make changes to the system.
Reference systems significantly reduce engineering cycle times by starting with a baseline system that is
already operational and can be easily modified. Ballard currently offers two standard reference systems,
or can design and build custom systems to meet specific customer requirements.
PRODUCT SPECIFICATIONS
Fuel cell stack
FC velocity 9SSL
™
FC gen 1020ACS
™
Cooling
Liquid
Air
Output voltage
60–110 VDC
42–55 VDC (48 VDC Nominal)
Output current
0–300 A
0–70 A
Rated net power
15kW
2.8kW
Dimensions
1065mm x 660mm x 360mm
610mm x 480mm x 800mm
Mass
153kg
105kg
Hydrogen consumption
150 slpm at rated power
40 slpm at rated power
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
APPLICATIONS ENGINEERING
Ballard’s Applications Engineering team offers a unique knowledge of proton exchange membrane fuel
cells to support customers in their system design and integration activities. The team has helped
customers successfully integrate fuel cell stacks into thousands of telecom backup systems, forklift
trucks and other applications operating around the world. We have also supported the integration of
180 fuel cell buses, and numerous demonstration fuel cell cars.
Early in the sales cycle, Applications Engineers provide guidance to customers in determining the best
Ballard product to meet specific requirements. After purchase, Applications Engineers support customers
through their system design and integration process, offering expertise in the following areas:
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and system level
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interfaces and interactions
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problems during the design process
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compatibility
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and assisting with certification
Ballard’s team strives to provide world-class
technical support and guidance to ensure
satisfaction with our products. Relying on many
combined years of fuel cell experience, our
Applications Engineering team is available to
ensure customer success through the entire
integration process.
Engineering Services clients leverage a high level of competency
at Ballard, across a wide range of specialized fuel cell activities.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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Ballard has developed a sophisticated in-house modeling capability that
can be put to work as an input to the fuel cell product design cycle. The
models allow for a much larger range of scenarios to be investigated than
possible through in-situ tests, and avoid the need to build and test design
iterations, significantly reducing development time. In addition, modeling
facilitates better understanding of localized effects that cannot be
measured in the context of a full fuel cell stack or system.
The use of simulation tools and modeling is core to Ballard fuel cell stack
design and system integration activities. Key areas of focus include:
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Stack-level models define the high-level stack design and the stack-tosystem interface requirements to ensure intended functionality.
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Fuel cell performance models are typically used to optimize cell
components and geometries, but also offer simulations in various
operating scenarios for systems development.
Simulation tools and modeling.
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3D finite element analysis (FEA) models are used extensively during the stack design stage to identify
potential failure modes that can affect both the performance and durability of the stack.
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CFD models are used to understand the complex fluid flow mechanisms of the fuel cell stack and
provide designers with valuable insights into the behavior of the fluid domains.
Data from testing and in-field operation is fed back to Ballard’s simulation models to provide validation
and ensure confidence in the modeled results. Through this repetitive feedback, Ballard’s models are
refined, and the accuracy and effective range of the models are constantly improved.
CASE STUDY: AEROSPACE
SITUATION
SOLUTION
RESULT
A leading aircraft manufacturer required an in-depth understanding of the
performance of fuel cells across a wide range of aerospace functions, where
reliable performance and safety are of the utmost concern.
Ballard conducted a comprehensive testing program on our FCvelocity™-9SSL fuel
cell stack, utilizing specific and specialized operating conditions outside Ballard’s
standard operating protocol.
Ballard delivered the test results, along with a mathematical model for future
simulations, to the aircraft manufacturer within three months. This allowed the
company to successfully pass its technology readiness gate.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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Ballard’s state-of-the-art test lab sets the industry
standard for proton exchange membrane fuel cell
development and testing. Access to our world-class test
capability and infrastructure translates into lower
investment costs for our customers, allowing for the
evaluation of a variety of design options in a short amount
of time. Tests can be carried out on Ballard products, or
test articles provided by the customer.
TEST STATIONS
Ballard builds many of our own
test stations, and we have an
internal team dedicated to
building and customizing test
stations for installation and
operation at customer sites.
Ballard’s test lab contains more than 60 automated test
stations and ten environmental chambers, generating
400,000+ hours of test data annually. Testing capabilities
range from components, single cell, and small stack
testing, to 180kW test stations for fuel cell module
testing. Test stands are capable of simulating duty cycles
and pushing the operational boundaries for a range of
product applications, through tests including dynamic
durability, freeze start, ambient start and system
representative testing.
Custom advanced diagnostic tests for systems, stacks and
components have also been developed. A broad range of
tests are available, including:
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Results are benchmarked against published protocols or evaluated using Ballard’s own internal testing
protocols developed over many years of testing experience. Failure analysis is completed on tested
components, with raw data and evaluation reports made available to the customer to support future
design work.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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As the leader in proton exchange membrane fuel cell products, Ballard’s ES group can streamline your
product development efforts to help you deliver solutions quickly and efficiently. Assisting customers at
every stage of the fuel cell product development process, Ballard offers unparalleled engineering expertise
and solutions that work across a broad range of applications. Our world-class design services, test
equipment and manufacturing processes accelerate your time to market.
Product Development services at Ballard cover a diverse number of activities ranging from the design
and manufacture of individual fuel cell components to full stack and system development programs. Our
experience with many different catalysts and ink formulations has created in-depth knowledge essential
for designing custom electrodes, while our history in developing stack products for a wide variety of
applications has granted expertise in executing development programs. Customers can choose to work
with Ballard’s existing technologies, from membrane electrode assemblies built to your specifications to
stacks configured for your applications, or we can collaborate on the development of a unique concept
design. Our design capability and efficiency is enhanced by using proprietary models and unique testing
protocols to evaluate and verify designs, shortening the entire product design cycle.
During the initial design phases, our knowledgeable engineers partner with your engineering team to
provide innovative solutions that best meet your application requirements. As the product moves to
production, Ballard can provide manufacturing solutions and access to our international supply
chain network.
Ballard has the people, products, facilities and technical expertise to serve a broad and diverse customer
base, from small design firms to large, global manufacturers. From concept until delivery of the final
product to your end customer, Ballard can help you make informed decisions and streamline your
product development processes.
CASE STUDY: VOLKSWAGEN AG
SITUATION
Volkswagen approached Ballard for expertise and resources in support of
advancing the automaker’s fuel cell automotive research program.
SOLUTION
In March 2013, the companies signed a 4-year Engineering Services contract
(with two 1-year optional extensions) to support the current fleet of Volkswagen
HyMotion demonstration cars, as well as design and manufacture next
generation fuel cell technology. Ballard engineers are supporting critical areas of
fuel cell product design – including the membrane electrode assembly, plate
and stack components – along with testing and system integration work.
RESULT
A collaborative working relationship has quickly developed between the Ballard
and Volkswagen teams, permitting rapid progress in support of key program
deliverables.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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The same robust engineering design principals and analysis tools used by Ballard to identify and resolve
failures in our fuel cell stack and system development activities are available to our ES customers.
Ballard’s technical expertise allows for a very structured approach to assess the performance of fuel
cell stack products.
Through the use of problem solving processes, simulation models, diagnostic tools, and accelerated
stress tests, significant information can be provided to:
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These processes focus on the most important aspects of the design to prevent failures and at a basic
level involve organizing requirements, reviewing past component failures, brainstorming new failures
and assessing what actions can be taken to prevent these failures. With significant experience in
developing fuel cell product specifications, Ballard maintains an extensive list of documented failure
modes through the use of Failure Modes and Effects Analysis (FMEA) methods and fault trees. These
tools have guided the development of many modeling and experimentation techniques, and are
aligned with Ballard’s ability to conduct high value experiments to ensure that the engineering effort
be focused on solving the correct problems efficiently.
Our approach is based on Ford Motor
Company’s well-established design process
and focuses on early concept risk assessments,
parameter-diagrams (p-diagram), FMEA
methods and design verification against the
FMEA. In addition, Ballard has refined this
approach and added various design tools for
robustness, improved reliability measures and
design verification techniques, including:
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identification
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Ballard’s world class fuel cell testing lab offers
integrated data collection and reporting.
Failure analysis results can be provided as raw
data, or can be delivered as a full report with
detailed analysis.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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Delivering thousands of fuel cell products to the marketplace has
helped Ballard develop an extensive range of manufacturing
technology and experience. At 110,000 square feet, Ballard’s
facility in Burnaby, Canada is widely considered to be the world’s
largest manufacturing facility in the proton exchange membrane
fuel cell industry.
Ballard has performed contract manufacturing on behalf of
Daimler AG, Ford Motor Company and the Automotive Fuel Cell
Cooperation, delivering to the automotive industry’s exceptionally
high standards. Ballard can leverage from its existing designs for
catalyst coated films, catalyst coated membranes, membrane
electrode assemblies, bipolar plates and fuel cell stacks or
customize parts according to customer specifications.
Quality management systems support
advanced automated manufacturing
techniques.
Ballard maintains a quality management system that integrates
environment, health, safety and quality considerations. We have
been registered to ISO/TS16949 since 2004, and complies with ISO14001 (environment), and OHSAS
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achieve systematic improvements in cost, quality, and throughput. Manufacturing systems trace the
materials used in the making of our products from supplier to customer.
Whether you require Ballard to deliver low quantities of a fuel cell component prototype or mass
produce fuel cell stacks, Ballard has the scale to reduce costs and speed your time to market.
Fuel cell stacks are
assembled at Ballard’s
manufacturing
facility.
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PUTTING FUEL CELLS TO WORK
ENGINEERING SERVICES
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Ballard is a recognized leader in proton exchange
membrane (PEM) fuel cells. From our headquarters in
Burnaby, Canada, we handle the entire engineering cycle
for fuel cells. Our stacks are fully designed in-house,
including catalyst layer and bipolar plate design.
With a long history of fuel cell research and development,
Ballard has a strong intellectual property portfolio covering
all aspects of design, materials, processes and operating
strategies. In addition to the 200 patents and applications
that Ballard owns, we also license the rights to over 1,000
other patents and applications owned by companies we
have worked with in the past. Aside from registered
patents, Ballard has a wealth of fundamental
understanding covering all aspects of stack operation,
testing protocols, system integration, component
design and fuel processing.
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Our history of automotive technology development has
provided a means for significant improvement in a
number of areas of fuel cell performance. During
automotive development, Ballard has achieved reduced
cost, enhanced reliability, and improved manufacturability.
The know-how gained in automotive projects can be
seen in the fuel cell stack and system products that
Ballard sells commercially today. The quality standards put
in place for automotive customers have become a part of
Ballard culture, and are applied across all products and
processes. Through engagement with Ballard’s
Engineering Services, this wealth of knowledge is
made available to customers.
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CONTACT
INFORMATION
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