Assembly station and method for use thereof

Abstract

The present invention relates to an assembly station (100) for carrying out assembly operations on a product (P) under a conditioned assembly atmosphere (MA), having: a robot device (10), a housing (20) and a conditioning unit (30) which is connected to an assembly chamber (22). According to the invention, the assembly station (100) comprises a sensor module (40R) on the robot device (10) having at least one sensor (48, 49), the sensing region (E) of which is oriented to measure a contamination-related parameter on a surface of one of the components (K) of the product (P).

Description

[0001] PP34263WO / bg September 15, 2025 AVL List GmbH

[0002] Assembly station and method for its use

[0003] The present invention relates to an assembly station for carrying out assembly operations on a product under a conditioned assembly atmosphere, a manufacturing system for manufacturing fuel cell stacks with the assembly station, and a method for using the assembly station for assembling components of a fuel cell stack under a conditioned assembly atmosphere.

[0004] Products requiring component assembly are typically manufactured in a production hall, with different machines or robots performing various manufacturing steps at different stations along a production line. This is currently also the standard practice for fuel cell technology, battery cell technology, and other related technologies.

[0005] Furthermore, it is known from semiconductor technology or medical technology that such a production line is housed in a cleanroom in order to protect manufacturing steps that are critical with regard to low levels of contamination from these, or at least to provide a controlled load of contaminants, such as a limited fine dust rate under defined conditions.

[0006] In fuel cell technology, among other areas, it has been shown that even small impurities on fuel cells mounted in a fuel cell stack can impair the performance of the fuel cell stack from the beginning of its life cycle.

[0007] A production line for manufacturing fuel cells or fuel cell stacks passes through numerous stations for component supply, physical pressure testing of the assembled fuel cell stack, electrical testing using power measurement, and similar procedures. A comprehensive production line for fuel cell stacks, including all its stations, is therefore quite large and occupies a correspondingly significant amount of space. Providing a sufficiently large cleanroom is therefore very costly for PP34263WO / bg 15.09.2025 AVL List GmbH

[0008] Providing cleanroom technology is associated with high maintenance costs for energy and upkeep.

[0009] Accordingly, there is a need for solutions that enable an improvement in the manufacturing quality of fuel cell stacks at lower costs by preventing impurities and ensuring a defined performance of a fuel cell stack or the quality of any other product.

[0010] One object of the invention is to at least partially overcome the disadvantages of the prior art. A further object of the invention is to provide at least an alternative, preferably more cost-effective, technique for creating a clean manufacturing environment for product production. A further, application-related object of the invention is to achieve an improvement in quality or a reduction in quality variations in fuel cell stack production at reduced costs.

[0011] The foregoing problems are solved by an assembly station having the features of claim 1. Further features and details of the invention will become apparent from the dependent claims, the description and the drawings.

[0012] Features and details described in connection with the assembly station according to the invention naturally also apply in connection with the manufacturing system and the method for using the assembly station, and vice versa, so that with regard to the disclosure of the individual aspects of the invention, mutual reference is always made or can be made.

[0013] The assembly station is used to perform assembly operations on a product under a conditioned assembly atmosphere. For this purpose, the assembly station comprises a robot device with at least one handling tool for handling product components; a housing to provide an assembly space surrounding the robot device, wherein the housing separates the assembly atmosphere in the assembly space from an ambient atmosphere outside the assembly station; a conditioning unit, which is fluidly connected to the assembly space via at least one flow inlet arranged on or in the housing, comprising: a flow generator for supplying a gas flow into the assembly atmosphere and at least one filter element for filtering out solid particles in the gas flow passing through the conditioning unit.

[0014] According to the invention, the assembly station further comprises a sensor module that is arranged on the robot device, with at least one sensor whose detection range is directed to measure a contamination-related parameter on a surface of the handled component of the product.

[0015] A robotic device according to the invention includes, in particular, a general automated system and / or, more specifically, a so-called pick-and-place device.

[0016] The invention thus provides for the first time a focus of cleanroom technology on only one section of a production line or assembly line, supported by special sensor technology, wherein such a section equipped with cleanroom technology is provided for a single production machine for assembly, such as in particular for a robot, and is separated from a surrounding atmosphere.

[0017] In other words, a cleanroom-conditioned assembly atmosphere is created only in a specific sub-environment for certain assembly processes, particularly those involving the robotic assembly of components. The sensor technology employed for this purpose, combined with the significantly reduced volume of the space, achieves increased detection density in the sub-environment of critical assembly processes and allows for the inspection of components immediately before they are assembled into the product. Furthermore, the sensor technology provides improved control of contamination in the immediate vicinity of the assembly processes.

[0018] The invention offers the significant advantage that, compared to a conventional cleanroom, the substantial reduction in volume to, for example, a single cabin allows for a much smaller cleanroom technology, resulting in considerably lower operating costs within the overall production budget. The same applies to the maintenance of the cleanroom technology. PP34263WO / bg 15.09.2025 AVL List GmbH

[0019] Furthermore, the invention offers the advantage that air purification focused on critical assembly processes is not only more energy-efficient, but also enables a more targeted supply of a purified airflow with a more precise reaction capability and correspondingly precise adjustment to measured values ​​of the sensor technology, a higher quality of the conditioning conditions and the defined control thereof in the sub-environment of the critical assembly processes.

[0020] Furthermore, the sensor technology, which in particular provides a sensor module on the robot device with a detection area of ​​a preferably optical sensor directed towards components in storage or components located in the handling tool, enables an additional check for contamination on the surface of the component to be assembled. Thus, regardless of the conditions of the assembly atmosphere, a further inspection of the component surfaces can be carried out before assembly.

[0021] Another advantage of the invention is that the assembly station can be used not only for fuel cell technology, within which the invention was made, but also for other types of products, such as products from medical technology or battery technology.

[0022] Furthermore, the invention offers the advantage of improved quality control with regard to external influences during critical assembly processes, whereby this improved quality control is achieved through a possible minimum of plant technology and energy expenditure in a manufacturing process.

[0023] According to the definition in this disclosure, the term “controlling” includes both steering and regulating parameters, possibly in response to other parameters.

[0024] Furthermore, according to the definition in this disclosure, the term "fuel cell" also includes other types of electrochemical cells, such as an electrolysis cell. Accordingly, the invention can also be applied to a stack of electrolysis cells.

[0025] According to an advantageous aspect of the invention, the sensor module arranged on the robot device can comprise an optical sensor, in particular a camera, for measuring potential contamination on a surface of a component of the product during handling of the component. In particular, using an optical sensor with optics similar to the objective lens of a microscope, the optical sensor visually detects solid particles, such as dust particles, hair, and the like, at sufficiently high resolution and optical magnification based on the contour of the solid particles on a surface of the component. In this way, the optical sensor can scan the surface of the next component to be handled before it is assembled by the handling tool.Thus, at a time when subsequent contamination by particles in the ambient atmosphere is unlikely, a possible initial, or at least final, inspection can be carried out immediately before assembly. This ensures that no visually detectable contaminants are trapped on the surfaces of or between adjacent components of a product immediately before assembly.

[0026] According to an advantageous aspect of the invention, the sensor module arranged on the robot device can include a force sensor for measuring the weight of or the fixing force for a component of the product during handling of the component. Thus, using precision weighing technology, deviations from standard values ​​regarding the mass of the component can be checked during handling, which may be increased, for example, by humidity and the corresponding fine droplet formation on a surface.

[0027] According to an advantageous aspect of the invention, at least one sensor module comprising at least two different sensors can be arranged in the assembly space or conditioning unit, consisting of: a particle sensor, a flow sensor, a pressure sensor, a temperature sensor, a humidity sensor, a light sensor, and / or a gas sensor. By providing preferably all of the aforementioned sensors, a highly comprehensive quality check of a gas flow in the assembly atmosphere is ensured, after which highly sensitive control of the conditioning can be carried out in response to these measured values.

[0028] According to an advantageous aspect of the invention, each sensor module can comprise a microcomputer with a data storage unit for collecting and processing data on the measured values ​​from the sensors and a transmitter for transmitting the measured value data to an external data processing device. Consequently, the measured values ​​acquired from the assembly atmosphere or at the components can be evaluated and, in connection with conditions such as threshold values, fed into a control and regulation system for cleanroom technology, in particular the conditioning unit for controlling an operating parameter of the flow generator or for handling a filter element. Furthermore, the acquired measured values ​​can be stored, evaluated, and, in particular, monitored externally from the assembly station.

[0029] It is further advantageous if each sensor module has a monitoring interface to monitor and / or measure sensor degradation. Here, the degradation of the sensor modules and / or an individual sensor over time is advantageously measured. It can also be advantageous to provide a common monitoring interface for two or more sensor modules.

[0030] According to an advantageous aspect of the invention, the microcomputer of the sensor modules can each comprise a forecasting module which is configured to output a forecast for a maintenance interval of one of the sensors, of the at least one filter element or of the handling tool of the robot device, based on the data on the measured values ​​of the sensors and a machine-trained algorithm using predetermined data sets.

[0031] According to an advantageous aspect of the invention, the housing can have at least one resealable opening for feeding the product components into the assembly area and / or for removing the product or a sub-product from the assembly area. Accordingly, it is possible to open the assembly area only when components or products are being transferred into or out of the assembly area. In a version of the housing with two such resealable openings, the assembly station according to the invention can also be integrated into a continuous manufacturing process, such as an assembly line or similar system, so that the assembly station is loaded with components from one side and an assembled product or sub-product leaves the assembly station through another resealable opening on the opposite side of the housing. PP34263WO / bg 15.09.2025 AVL List GmbH

[0032] According to an advantageous aspect of the invention, the resealable housing opening can be covered by a flexible surface element suspended at an upper end, preferably by a plurality of flexible louvers. This provides a technical solution for a housing opening that is as simple as possible in design and closes automatically.

[0033] According to an advantageous aspect of the invention, a detection area of ​​one of the sensor modules can be aligned with a region of the resealable housing opening. This arrangement and alignment of sensors enables the detection of contaminants introduced by the components fed into the assembly device, preferably immediately after they enter the assembly atmosphere of the housing. If such sensor alignment and arrangement detects contaminants, such as dust stirred up during the transfer process into the housing, control measures can be taken at an early stage, particularly before the same component is assembled, to improve the quality of the assembly atmosphere or to interrupt the assembly of the same component beforehand.

[0034] According to an advantageous aspect of the invention, an assembly position can be defined in the assembly space, at which the product or its sub-product is positioned for assembly; wherein a detection range of one of the sensors is directed towards a region of the assembly position. This arrangement and orientation of sensors enables a metrological focus on a local section of the assembly atmosphere in the immediate vicinity of the product or sub-product. Thus, it is also possible to verify whether movements and contacts during the assembly processes themselves cause contamination of the product or sub-product, such as abrasion, fine dust disturbances, or the like, and whether these contaminations are within a predetermined tolerance.

[0035] According to an advantageous aspect of the invention, a detection area of ​​one of the sensor modules can be directed towards a region of the flow inlet, and a detection area of ​​one of the sensor modules can be directed towards a region of the flow outlet. This arrangement and orientation of the sensors of the sensor modules makes it possible to acquire numerous parameters relating to the conditioned gas flow through the conditioning unit, as well as its effectiveness, in real time. For example, by measuring particle concentrations in the gas flow before and after the conditioning unit, it can be determined whether sufficient conditioning, such as dust removal or dehumidification, is taking place.Such a comparative measurement before and after the conditioning unit enables the control of operating parameters of the conditioning unit, such as flow generator power to increase a volume flow or comparative values ​​for a prediction or determination of a filter condition.

[0036] According to an advantageous aspect of the invention, the conditioning unit can include a chemical purification stage configured to remove carbon from carbon dioxide contained in the assembly atmosphere. In this way, further physical contaminants, such as gas species, present in the assembly atmosphere that could lead to impurities or reactions on the surface of components can be detected.

[0037] According to an advantageous aspect of the invention, the assembly station can have an input device and a display device, preferably integrated in a touch-sensitive screen for displaying data on measured values ​​or forecasts and for entering operating parameters or settings, at least for monitoring the conditioning unit. This allows a user to visually verify or continuously monitor measured parameters, enabling the user to make changes to operating parameters of the conditioning unit or other parts of the assembly station, or at least to be informed about their operating states.

[0038] According to an advantageous aspect of the invention, a manufacturing system for producing fuel cell stacks is provided, comprising the following: a production line with several production stations for carrying out different production steps and the assembly station according to the invention for carrying out assembly operations on a fuel cell stack under a conditioned assembly atmosphere. Such a production system can, for example, have a conveyor belt or a similar conveying device, wherein the assembly station according to the invention is positioned at one beginning of the conveying device or as an intermediate station between conveying devices on the production line. It is essential according to the invention that only a housing PP34263WO / bg 15.09.2025 AVL List GmbH's separated environment of the assembly station is supplied by an assembly environment conditioned using cleanroom technology, while the other production stations on the production line are exposed to an ambient atmosphere.

[0039] According to an advantageous aspect of the invention, the assembly station can be used for assembling components of a fuel cell stack under a conditioned assembly atmosphere. This represents a preferred application, as the product quality of fuel cell stacks benefits from the advantages of the inventive technical solution. However, the assembly station according to the invention can also be used for products from other technical fields, such as battery technology or medical technology.

[0040] Further advantages, features, and details of the invention will become apparent from the following description, in which an exemplary embodiment is described in detail with reference to the drawing. The drawing schematically shows:

[0041] Fig. 1 shows a block diagram of the assembly station according to one embodiment of the invention;

[0042] Fig. 2 shows a block diagram of a sensor module, a plurality of which are arranged in the housing of the assembly station, according to an embodiment of the invention;

[0043] Fig. 3 shows a block diagram of the sensor module arranged on the robot device according to one embodiment of the invention; and

[0044] Fig. 4 shows a block diagram of a production line of the manufacturing system, which includes various production stations and the assembly station according to the invention.

[0045] Figure 1 shows a schematic representation of assembly station 100. Assembly station 100 forms a module or station within a production line 220 of a production system 200 shown in Fig. 4, which includes further production stations 210.

[0046] The assembly station 100 has a housing 20 that surrounds an assembly chamber 22, whereby an assembly atmosphere MA within the assembly chamber 22 PP34263WO / bg 15.09.2025 AVL List GmbH is separated by the housing 20 from an ambient atmosphere UA. The housing 20 also has a resealable housing opening 21 through which components K can be inserted into the housing 20 or a product P, preferably a fuel cell stack BS or a semi-finished sub-product thereof, can be removed from the housing 20.

[0047] In an embodiment not shown further, two such resealable housing openings 21 can also be arranged, for example on opposite sides of the housing 20, so that the housing 20 can be integrated as an intermediate assembly station along a conveyor line.

[0048] In the illustrated embodiment, the resealable housing opening 21 comprises a curtain of vertically suspended louvers, i.e., adjacent strips of flexible surface elements which automatically reseal the housing opening 21 due to gravity. A robotic device 10 with a handling tool 11 is arranged within the assembly space 22. The robotic device 10 has several joints and actuators, enabling it to move controllably along multiple axes. The handling tool 11 is preferably designed as a gripping tool or a vacuum tool for the releasable fixing and movement of components from one location or position to another within a product assembly.For this purpose, an assembly position MP is defined within the assembly space 22, at which the robot device 10 assembles or mounts components to form a product or sub-product.

[0049] In the application described here, the components relate in particular to fuel cell components, such as membrane electrolyte assemblies (MEAs) and bipolar plates, which are assembled into a fuel cell stack in an assembly operation of the robot device 10. These assembly operations all take place within the assembly atmosphere MA, which is located inside the housing 20.

[0050] The modular assembly station 100 also includes a conditioning unit 30, which is provided for conditioning a gas stream GS. In the illustrated embodiment, the assembly atmosphere MA is supplied by the gas stream GS pretreated by the conditioning unit 30. That is, the conditioned PP34263WO / bg 15.09.2025 AVL List GmbH

[0051] Gas stream GS enters the assembly chamber 22 via a flow inlet 31 arranged on the housing 20 and mixes with the assembly atmosphere MA contained therein. A gas stream GS of a corresponding quantity or volume flow rate flows from the assembly atmosphere MA out of the housing 20 into an ambient atmosphere UA via a flow outlet 33, which is also arranged on the housing 20 and enables pressure equalization.

[0052] In an alternative embodiment, not shown, a closed circuit of a gas flow GS and the conditioning unit 30 can also be provided within the assembly space 22. In this case, the conditioning unit 30, the flow inlet 31, and the flow outlet 33 are arranged, for example, within the housing 20, resulting in recirculated air operation.

[0053] In the illustrated embodiment, the conditioning unit 30 draws in a gas stream GS from the ambient atmosphere UA, which, after treatment via a pipe and a diffuser, is discharged into the assembly space 22 at the flow inlet 31, preferably at the top of the housing 20. For this purpose, the conditioning unit 30 includes a flow generator 32, which, for example, comprises a blower consisting of one or more fans, i.e., impellers. The conditioning unit also includes at least one or more cleaning stages. In the present embodiment, at least one mechanical cleaning stage is provided with a pre-filter element 34 and a fine filter element 35, which filter out solid particles, such as fine dust, from the drawn-in gas stream GS.Alternatively, an additional chemical purification stage (not shown) can be provided in the conditioning unit 30, which can bind atoms or molecules from certain gas species by means of a catalyst in a known manner, such as carbon deposition from carbon dioxide gas.

[0054] Furthermore, assembly station 100 comprises a plurality of sensor modules 40, 40R. These sensor modules 40 perform measurements of various contamination-related parameters in the assembly atmosphere MA at different positions within the assembly space 22. For this purpose, each sensor module 40, 40R has a detection range E, within the orientation of which measurements are taken in the assembly atmosphere MA. One of the sensor modules 40 is located near the resealable housing opening 21, and its PP34263WO / bg 15.09.2025 AVL List GmbH

[0055] The detection area E is aligned with a passage cross-section of the resealable housing opening 21. This sensor module 40 can measure contaminants introduced into the assembly atmosphere MA during the transfer of components or products into or out of the housing 20.

[0056] Another sensor module 40 is located near the assembly position MP, with its reception area E directed towards the product P to be assembled or towards a space occupied by a fully assembled product P. This sensor module 40 measures the assembly atmosphere MA locally in a specific area for contaminants, thus detecting, for example, the stirring up of fine dust or abrasion from components or the gripping tool, and the like, in the immediate vicinity.

[0057] Furthermore, a sensor module 40 is arranged near the flow inlet 31 and another sensor module 40 is arranged near the flow outlet 33, with their respective detection ranges E directed at a flow cross-section through the flow inlet 31 and the flow outlet 33. Consequently, the quality of the assembly atmosphere MA is measured in the area of ​​the gas stream GS that enters the working chamber 22 after conditioning by the conditioning unit 30 and mixes with the assembly atmosphere MA, as well as in a gas stream GS that leaves the assembly chamber 22 due to pressure equalization through the flow outlet 33. This allows, on the one hand, the measurement of the quality and contamination of the conditioned gas stream GS at its entry into the assembly atmosphere MA, where contamination should be lowest due to the conditioning.In addition, the quality and contamination of the assembly atmosphere MA is measured at an outlet of a gas stream GS from the assembly atmosphere MA, where contamination should be expected to be higher than at a measurement at a position of the aforementioned sensor module 40.

[0058] A further sensor module 40R is arranged on the robot device 10. Unlike the other sensor modules 40, this sensor module 40R has two additional sensors, as explained in connection with Figure 3 below. This applies in particular to an optical sensor 49, which is designed as a camera with macro optics. A detection range E of this sensor module 40R, that is, in particular, a focus of the camera and the optical PP34263WO / bg 15.09.2025 AVL List GmbH

[0059] Sensors 49 are aligned towards the handling tool 11 and a fixing area of ​​the handling tool 11. Thus, an optical measurement in the form of an area scan is performed on a surface of a component that is fixed in the handling tool, or optionally on a component that is stored in the assembly space 22 and is not yet mounted, or on a component K that is already mounted on the product P or fuel cell stack BS, whereby contaminants such as solid particles can be optically detected based on their contour on a smooth surface of the component.

[0060] Furthermore, the sensor module 40R on the robot device 10 features a force sensor 48 as a special characteristic. This force sensor is mechanically connected to a component of the robot device 10, electrically connected to an actuator of the robot device 10, or via a signal connection to a controller of the robot device 10. Thus, the force sensor 48 optionally measures the weight force of a component K to be handled. Deviations from a standard weight allow metrological conclusions to be drawn about contamination or damage to the component K prior to its assembly. In an alternative embodiment, the force sensor 48 measures the force required to grip the component K on a handling tool 11 designed as a gripping tool. Such a measurement allows conclusions to be drawn about wear on structured gripping surfaces of the handling tool 11.Furthermore, the sensor module 40R, like the other sensor modules 40, has additional types of sensors, which are discussed in connection with Figure 2 below. These sensors enable further measurement of the quality and contamination of the assembly atmosphere MA within the immediate operating area of ​​the assembly processes, within the movement range of the robot device 10. This allows for the immediate measurement of contaminants directly related to the movements of the assembly processes, such as the stirring up of fine dust, abrasion, and the like.

[0061] Finally, the assembly station 100 has a touchscreen 52 which is directly or indirectly connected to the sensor modules 40, 40R via an intermediary computer. The touchscreen 52 is also directly or indirectly connected to the conditioning unit 30 via an intermediary computer. The touchscreen 52 preferably displays a time-based sequence of contamination-related measured values, which are acquired by all sensor modules 40 or by individual sensor modules 40, 40R. Furthermore, the touchscreen 52 provides input means that allow a user to control or at least manually intervene in the operation of the conditioning unit 30.

[0062] Figure 2 shows a schematic diagram of a sensor module 40, as arranged in multiples within the mounting space 22. The sensor module 40 comprises a particle sensor 41, a flow sensor 42, a pressure sensor 43, a temperature sensor 44, a humidity sensor 45, a light sensor 46, a gas sensor 47, a microcomputer 50, and a transmitter 51.

[0063] The particle sensor 41 measures solid particles, such as fine dust, hair, and the like, in the air or in the assembly atmosphere MA. The flow sensor 42 detects a flow velocity or a volumetric flow rate or mass flow rate in connection with the conditioned gas flow GS passing through the conditioning unit 30. The pressure sensor 43 measures an atmospheric pressure within the assembly atmosphere MA, which prevails in the assembly space 22 of the housing 20. The temperature sensor 44 measures a temperature of the assembly atmosphere MA. The humidity sensor 45 measures a relative humidity in the assembly atmosphere MA. The light sensor 46 measures a brightness in the assembly space 22, which is used, among other things, for calibrating optical measurements, such as the particle sensor 41.The gas sensor 47 measures a proportion of a gas species, such as carbon oxides or nitrogen oxides, in the air gas mixture of the assembly atmosphere MA.

[0064] The microcomputer 50 is a small, energy-efficient computer, such as a Raspberry Pi, which collects and processes the data from the incoming measurement signals from sensors 41 to 49. A software-based predictive module, containing a machine learning-supported algorithm, is implemented within the microcomputer 50 of the signal module 40. Based on the measured values ​​and the trained algorithm, the predictive module generates forecasts regarding the operation or maintenance of assembly station 100. For example, the predictive module uses a calculated relationship between the measured values ​​of particle sensor 41 PP34263WO / bg 15.09.2025 AVL List GmbH and a cumulative operating time to generate a forecast for the required replacement of one of the filter elements 34, 35.In another embodiment, the predictive module, based on measured values ​​from the force sensor 48 in conjunction with the handling tool 11 designed as a gripping tool, outputs a prediction of the wear of structured gripping surfaces. The transmitter 51 establishes a wireless radio standard with a computer, which is integrated, for example, into the touch-sensitive screen 52 or into an external data processing device. The transmitter 51 is data-connected to the microcomputer 50 in order to send the data stored or processed in the microcomputer 50 relating to the measured values ​​to the touch-sensitive screen 52 or the external data processing device, thus making it available for display or further processing.

[0065] The arrangement of sensors 41 to 47 within the structure of the sensor module 40 is selected such that all sensors 41 to 47 are measured within a common detection area E of the sensor module 40. The orientation of the detection area E of the sensor module 40 is specifically determined for each of the sensor modules 40 within the mounting space 22 of the mounting device 100, as previously described in connection with Figure 1.

[0066] Figure 3 shows a schematic diagram of the sensor module 40R, which is arranged on the robot device 10. The structure and the various sensors 41 to 47, as well as the microcomputer 50 and the transmitter 51, correspond to the structure of the sensor module 40 shown in Figure 2. In addition, the sensor module 40R on the robot device 10 also has the force sensor 48 and the optical sensor 49, in particular a camera. As described above, the force sensor 48 is connected to mechanical components or actuators or to a controller of the robot device 10 in order to perform measurements that allow conclusions to be drawn about the applied force for lifting a mass of a component K or for fixing the component K in a handling tool 11 designed as a gripper.The optical sensor 49 is equipped with macro optics similar to a microscope, enabling visual scanning of the surface of a component K along a direction of movement of the robot device 10. The optical measuring range of the optical sensor 49, as well as all individual measuring ranges of the other sensors 41 to 47 (PP34263WO / bg 15.09.2025 AVL List GmbH), lies within the detection range E of the sensor module 40R, which is specifically directed towards an area of ​​operation of the handling tool 11 or towards a fixing area within which a component K can be fixed to the handling tool 11.

[0067] Figure 4 shows a manufacturing system 200, a modular component of which is the previously described assembly station 100. In the present embodiment, the manufacturing system 200 is designed for the production of fuel cell stacks BS. For this purpose, the manufacturing system 200 has a production line 220, which includes conveying devices, such as conveyor belts (indicated by arrows). The conveying devices are arranged between production stations 210 to supply sub-products at various stages of production to the respective subsequent production steps. The production steps at the production stations 210 are carried out in an ambient atmosphere UA of the site, such as a factory hall. The assembly station 100 is inserted at the beginning of, or within, a chain of production stations 210 on the production line 220.As previously described in connection with Figure 1, the assembly station 100 has an assembly atmosphere MA separated by the housing 20, which is supplied with purified and dust-free air by means of the previously described conditioning unit 30 using cleanroom technology. Accordingly, a production line 220 is created in which, within the entire production system 200, only critical assembly operations are carried out within a controlled, conditioned sub-environment, i.e., in the purified assembly atmosphere MA, among a multitude of production steps.

[0068] The preceding descriptions of the embodiments describe the present invention solely by way of example. PP34263WO / bg 15.09.2025 AVL List GmbH

[0069] Reference symbol list

[0070] 10 robot device

[0071] 11 Handling tools

[0072] 20 cases

[0073] 21 resealable housing openings

[0074] 22 Assembly room

[0075] 30 conditioning units

[0076] 31 Flow inlet

[0077] 32 flow generators

[0078] 33 Flow outlet

[0079] 34 pre-filters

[0080] 35 fine filters

[0081] 40 Sensor module

[0082] 40R sensor module on robot device

[0083] 41 Particle sensor

[0084] 42 Flow sensor

[0085] 43 Pressure sensor

[0086] 44 Temperature sensor

[0087] 45 humidity sensor

[0088] 46 Light sensor

[0089] 47 Gas sensor

[0090] 48 Force sensor

[0091] 49 optical sensor (camera)

[0092] 50 microcomputers

[0093] 51 channels

[0094] 52-inch touchscreen

[0095] BS fuel cell stack

[0096] E Detection range of a sensor module

[0097] K Component of the product / fuel cell stack

[0098] MA assembly atmosphere

[0099] P Product

[0100] MP mounting position

[0101] UA ambient atmosphere

Claims

PP34263WO / bg September 15, 2025 AVL List GmbH Patent claims 1. Assembly station (100) for performing assembly operations on a product (P) under a conditioned assembly atmosphere (MA), comprising: a robot device (10) with at least one handling tool (11) for handling components (K) of the product (P); a housing (20) for providing an assembly space (22) surrounding the robot device (10), wherein the housing (20) separates the assembly atmosphere (MA) in the assembly space (22) from an ambient atmosphere (UA) outside the assembly station (100); a conditioning unit (30) which is fluidly connected to the assembly space (22) via at least one flow inlet (31) arranged on or in the housing (20), comprising: a flow generator (32) for supplying a gas stream (GS) into the assembly atmosphere (MA), and at least one filter element (34, 35) for filtering out solid particles in the gas stream (GS) passing through the conditioning unit (30);and characterized in that a sensor module (40R) is arranged on the robot device (10), with at least one sensor (48, 49) whose detection range (E) is directed to measure a contamination-related parameter on a surface of one of the components (K) of the product (P).

2. Assembly station (100) according to claim 1, wherein the sensor module (40R) arranged on the robot device (10) comprises: an optical sensor (49), in particular a camera, for measuring a potential contamination on a surface of a component (K) of the product (P) during handling of the component (K). PP34263WO / bg September 15, 2025 AVL List GmbH 3. Assembly station (100) according to claim 1 or 2, wherein the sensor module (40R) arranged on the robot device (10) comprises: a force sensor (48) for measuring a weight of or a fixing force for a component (K) of the product (P) during the handling of the components (K).

4. Assembly station (100) according to one of the preceding claims, wherein at least one sensor module (40) is arranged in the assembly space (22) or the conditioning unit (30), comprising at least two different sensors (41, 42, 43, 44, 45, 46, 47) consisting of: a particle sensor (41), a flow sensor (42), a pressure sensor (43), a temperature sensor (44), a humidity sensor (45), a light sensor (46), and / or a gas sensor (47).

5. Assembly station (100) according to one of the preceding claims, wherein each of the sensor modules (40, 40R) comprises: a microcomputer (50) with a data storage unit for collecting and processing data on the measured values ​​from the sensors, and a transmitter (51) for transmitting the data on the measured values ​​to an external data processing device.

6. Assembly station (100) according to claim 6, wherein the microcomputer (50) of the sensor modules (40, 40R) each comprises a prediction module configured to make a prediction about a maintenance interval of one of the sensors (41, 42, 43, 44, 45, 46, 47, 48, 49), of the at least one filter element (34, 35) or of the handling tool (11) of the robot device PP34263WO / bg 15.09.2025 AVL List GmbH to be issued, based on the data on the measured values ​​of the sensors (41 , 42, 43, 44, 45, 46, 47, 48, 49) and a machine-trained algorithm using predetermined data sets.

7. Assembly station (100) according to one of the preceding claims, wherein the housing (20) has at least one resealable housing opening (21) for feeding the components (K) of the product (P) into the assembly space (22) and / or for removing the product (P) or part thereof from the assembly space (22).

8. Assembly station (100) according to claim 7, wherein the resealable housing opening (21) is covered by a flexible surface element suspended at an upper end, preferably by a plurality of flexible lamellae.

9. Assembly station (100) according to claim 7 or 8, wherein a detection area (E) of a sensor module (40) is directed towards an area of ​​the resealable housing opening (21 ).

10. Assembly station (100) according to one of the preceding claims, wherein an assembly position (MP) is defined in the assembly space (22) at which the product (P) or its sub-product is positioned for assembly; wherein a detection area (E) of a sensor module (40) is directed towards an area of ​​the assembly position (MP).

11. Assembly station (100) according to one of the preceding claims, wherein a detection area (E) of a sensor module (40) is directed towards an area of ​​the flow inlet (31) and a detection area (E) of a sensor module (40) is directed towards an area of ​​the flow outlet (33).

12. Assembly station (100) according to one of the preceding claims, wherein the conditioning unit (30) comprises a chemical purification stage configured to remove carbon C from carbon dioxide CO2 contained in the assembly atmosphere. PP34263WO / bg September 15, 2025 AVL List GmbH 13. Assembly station (100) according to one of the preceding claims, comprising an input device and a display device, preferably integrated in a touch-sensitive screen (52) for displaying data on the measured values ​​or forecasts and for inputting operating parameters or settings, at least for controlling the conditioning unit (30).

14. Manufacturing system (200) for manufacturing fuel cell stacks (BS), comprising: a manufacturing line (220) with several manufacturing stations (210) for carrying out different manufacturing steps, and the assembly station (100) for carrying out assembly operations on a fuel cell stack (BS) under a conditioned assembly atmosphere (MA) according to one of claims 1 to 13.

15. Use of the assembly station (100) according to any one of claims 1 to 13 for assembling components (K) of a fuel cell stack (BS) under a conditioned assembly atmosphere (MA).

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