An energy sector manufacturer required a fully automated production system to scale Solid Oxide Fuel Cell (SOFC) stack assembly from research and development into high-volume manufacturing. The existing in-house system lacked the throughput, precision, and integration needed to support production targets. The client needed a turnkey automation solution capable of assembling complete SOFC stacks within a 53-minute cycle time while maintaining dimensional tolerances of ±0.5 mm across multiple integrated processes including robotic stacking, spot welding, vision inspection, and laser marking, all within a compact 64″ x 64″ footprint.
The Details
Industry
Energy & Environment
CAPABILITIES APPLIED
The project presented interconnected technical, cost, and performance challenges requiring custom engineering across hardware, software, and system integration:
Cost Constraints with High Accuracy Requirements: Commercial battery monitoring systems included features not required for flow battery applications, adding unnecessary expense. The client needed a stripped-down, purpose-built solution that achieved high measurement accuracy while targeting a 90% reduction in unit manufacturing cost compared to off-the-shelf alternatives.
High Cell Count Voltage Measurement: Grid-scale flow batteries comprise hundreds of individual cells requiring continuous voltage monitoring. The system needed to accurately measure and aggregate data from large cell arrays while maintaining low per-cell monitoring costs and minimizing wiring complexity.
Precision Analog Design in High-Voltage Environments: Measuring individual cell voltages in high-voltage battery stacks presented signal integrity challenges. The system required low-noise analog circuits with robust high-voltage isolation to prevent measurement errors, electrical interference, and safety hazards.
Self-Calibration and Long-Term Accuracy: Over a 20-year operational lifespan, analog measurement circuits can drift, compromising accuracy. The monitoring system needed automatic self-calibration capabilities to maintain measurement precision without manual intervention or scheduled recalibration procedures.
Fault Detection and Safety Interlocks: The system needed to detect open connections, wire breaks, and abnormal voltage conditions in real time. Safety-critical fault detection required immediate shutdown interlock logic to prevent damage to battery stacks or control systems.
Scalability and Flexible System Architecture: Flow battery installations vary in size and configuration. The monitoring solution needed a modular, distributed architecture that could scale from small pilot systems to large grid-scale deployments without redesigning core components.
Integration with Plant Control Systems: The monitoring system needed seamless communication with higher-level control systems using standard industrial protocols while supporting remote firmware updates, data logging, and diagnostic access without disrupting operations.
Re:Build delivered a fully automated SOFC stack assembly system achieving 50-minute cycle times, exceeding the 53-minute target by 6% while maintaining ±0.5 mm dimensional tolerances.
The system features an EPSON SCARA robot positioned between two build stations for continuous operation. Safety light curtains enable operators to reload one station while the robot assembles at the other. A servo-driven slide and integrated vision system ensure precise part placement and automated alignment corrections throughout the build process.
Integrated spot-welding joins Nichrome wire to interconnect tabs without impacting cycle time. A Class 1 certified laser marking enclosure with barcode scanning provides part identification and traceability. The compact 64″ x 64″ system uses a welded steel tower for structural support and an 8020-aluminum frame for component mounting.
Two on-site validation visits during development provided operator training and gathered feedback for usability improvements before shipment. The system replaced the client’s legacy equipment, representing their largest automation investment and establishing a scalable platform for future SOFC production growth.
