Engineering design and development

Axane's engineering services for fuel cell design

Our engineers are experts in the design of stacks and fuel cell systems for a variety of application areas. This unique know-how attracts companies including one of the world leaders in fuel cells for forklift trucks to partner with our teams in developing a new range of fuel cells for the European market.

Looking for performance? Improved lifetime? To solve reliability and safety issues? Optimise production costs?

Our design office helps you define technical specifications, drawing on expertise in the choice of technology.

Your project benefits from state-of-the-art testing facilities at our Sassenage test centre.

You benefit from the safety guarantees and access to hydrogen in large quantities that only a group such as Air Liquide can provide.

Looking for a service provider to test your products? To acquire test benches?

Our teams take charge of testing products you have developed at our Sassenage test centre.

We can design and manufacture test benches adapted to tests required for your products.

Stages of project development in partnership

Co-construction of technical specifications

Our engineers analyse your needs, a fundamental step for your project. Knowing how to identify the fundamental characteristics is crucial to guarantee the efficiency and profitability of your product. What are your priorities? Fuel Cell lifetime, compactness, performance, reliability, production cost?

At each stage our design office provides the advice you need to make the best decisions, which we then incorporate together in your specifications.

Customised product design (stack, system, bench)

Throughout this process, our experts subject your products to several tests that evaluate their performance, reliability and suitability in accordance with your specifications. 

Our project management method – Cycle V – results in a high-performance product based on quality design.

Preliminary design

To define the system architecture, we study the structure of the fuel cell system, draw up the functional architecture diagrams and measure potential risks.

Detailed design

At this stage, our experts design the detailed drawings of the stacks and fuel cell systems. This work includes the specification of all materials and components of the assembly, as well as the tools and software required for its implementation.

We validate the technical hypotheses and perform the necessary calculations for the brief, with certain elements prototyped. For example, sub-component testing allows us to validate hypotheses and identify potential problems, with the aim of reducing the level of risk and uncertainty. In this way, our experts can ensure that production complies with specifications and decide to proceed with the assembly of your system or stack.

Prototyping

Prototyping is to validate whether your fuel cell system confirms with specifications such as:

• Electrical performance
• Mechanical characteristics
• Reliability
• Lifetime
• Manufacturing cost.

The prototype is subjected to multiple tests at our dedicated site in Sassenage. Our teams can then manufacture pre-series for testing of your products in real-life situations.

Transfer of skills

Our collaboration can conclude with a transfer of skills to your teams, allowing you to operate the manufacturing of your hydrogen fuel cell system in full autonomy.

Fuel cell: how does it work?



For 1 to 120 kW cells, Axane uses PEM (proton exchange membrane) technology. Through an electrochemical reaction, the cell produces electricity and heat while only emitting water.

The fuel cell consists of several cells, each containing a membrane electrode assembly (MEA), which is the active heart of electricity generation. The MEA consists of two electrodes, the anode (negative) and cathode (positive), on either side of the PEM membrane.

At the anode, H₂ hydrogen molecules are transformed into H+ ions (protons) and electrons. The H⁺ ions are directed to the cathode through the PEM membrane. At the cathode, they react with oxygen and electrons to form water. The production of electrons and their consumption generate the expected electrical current and power.

The electrochemical reactions at the electrodes are:

at the anode 2 H₂ → 4 H⁺ + 4 e^-
at the cathode O₂ + 4 H⁺ + 4 e^- → 2 H₂O

The resulting overall electrochemical reaction is:

O₂ + 2 H₂ → 2 H₂O

Stacks: carbon and metal 

Why choose one technology over another for the development of your fuel cell? The field of application, as well as the environmental constraints, may be determining factors in your choice.

Carbon technology Applications: Transport - heavy vehicles (truck, bus, train) & stationary applications Power density  2 kW.L-1 and 1.4 kW.kg-1	Metal technology Application: Automotive Power density  4 kW.L-1 and 2 kW.kg-1
CARBON : CUSTOMER BENEFITS Average power density Long service life Low development cost Low production cost for small and medium production runs	METAL : CUSTOMER BENEFITS Very high power density Compact and lightweight stack (high power density) Low production cost for very large series
CARBON : ADVANTAGES OF AXANE'S SOLUTIONS Bipolar plates for optimised compactness Formed in place seals for increased reliability and reduced assembly cost New MEAs & improved flow fieldsfor exceptional electrical performance: 1.2W/cm2 from 1 barg New clamping device for better compactness	METAL : ADVANTAGES OF AXANE'S SOLUTIONS Thin metal bipolar plates for optimised compactness Formed in place seals for increased reliability and reduced assembly cost Compatible with high pressure: up to 2.5 barg Composite clamping plates to optimise the stack weight  Complies with requirements of the automotive industry

Fuel cell systems

Our teams have designed and developed hundreds of systems for 20 years. Choosing AXANE for the design and development of your fuel cell system is the guarantee of benefiting from the expertise of a leader in its field.

Systems & stacks developed by Axane

Products - metal technology

Stack M240 Name: Stack M240 Project: Axane designed this commercial stack for a Chinese car manufacturer Description: Liquid cooled metal stack for automobiles Dimensions: 450 x 110 x 210 mm  Weight: 20 kg Power: 40 kW @ 145 cells (can be mounted with 360 cells for 100 kW) 240 cm² active/cell 4 kW/L and 2 kW/kg Cell pitch 1.18 mm Download the Stack M240 product sheet

Products - carbon technology

Stack C260 Name: Stack C260 Project: Axane developed this stack for bus and freight transport (trucks, trains, ships). Description: Liquid-cooled compact carbon stacks for heavy vehicles (trucks, buses, trains, boats) Dimensions: 230 x 200 x 965 mm @ 100 kW Weight: 26.9 to 58.8 kg (30 to 300 cells) Power: 40 kW @ 145 cells 260 cm² active/cell 2 kW/L and 1.4 kW/kg 2.1mm cell pitch Download the Stack C260 product sheet

Stack HPS Name: Stack HPS Project: Axane developed this commercial stack for application on forklift trucks. The Stack HPS has been integrated with the third-party GenDrive™ systems. Description: Liquid-cooled carbon stacks for forklift trucks and stationary generators Dimensions: 261 x 208 x 340 mm 260 cm² active/cell 14 kW @ 60 cells Thousands of copies produced and operated daily

Stack G1 Name: Stack G1 Project: Axane developed commercial stacks for permanent stationary applications. The Stack G1 has been integrated into the GaEL 2 kW standalone system and into the HyES 5 kW stationary system. Description: Liquid-cooled carbon stack for stationary and portable applications 76 cm² active/cell 3 kW @ 60 cells

Systèmes

HyES generator Name: HyES-G1 Description: High-efficiency stationary electric generator for permanent power supply of isolated sites. Dimensions: 280 x 112 x 105 cm Weight: 580 kg Power: 5kW - 48 VDC or 230 VAC Download the HyES generator product sheet
GaEL generator Name: GaEL  Description: Compact electric generator. The components of the GaEL can be assembled without their casing, such as in a vehicle. Dimensions: 940 x 450 x 385 mm Power: 2 kW - 48 VDC Temperature resistance (-10°C to + 45°C) Download the GaEL generator product sheet