On-Site Robotic Assembly and Disassembly for Alkaline Electrolyzer Units
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Solution Overview
Problem
The assembly and disassembly of alkaline electrolyzer units in hydrogen producing plants are time-consuming, require heavy lifting equipment, and pose hazardous environments for personnel, leading to inefficient use of space and high production costs.
Innovation Solution
An industrial robot system with a controller and robots is used to assemble and disassemble alkaline electrolyzer units on-site, utilizing manipulators and tools to arrange electrodes, membranes, and other components, reducing the need for manual labor and heavy equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly and disassembly methods are used, then personnel can perform the tasks with basic tools, but the process is time-consuming and requires heavy lifting equipment
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated robot system comprising a mobile platform, manipulator, and sensor system. The robot autonomously performs assembly and disassembly tasks, eliminating the need for heavy lifting equipment and significantly reducing assembly time while maintaining ease of manufacture through standardized interfaces
Solution Approach 2:
The robot system is designed to autonomously perform assembly operations without continuous human intervention. The system includes self-navigation capabilities, automatic component recognition through sensors, and automated manipulation, enabling the system to service itself during operations and reducing overall manufacturing time
2Reliability
If electrolyzer units are assembled off-site and transported, then assembly can be performed in controlled conditions, but transportation requires bulky facilities and heavy equipment
Solution Approach 1:
The patent segments the electrolyzer system into modular units that can be independently assembled and positioned. The robot system assembles units in-situ at predetermined locations, eliminating the need to transport complete assembled units. Only individual components or sub-assemblies need to be moved, dramatically reducing transportation weight and facility requirements
Solution Approach 2:
The invention transitions from horizontal transportation of assembled units to vertical stacking and in-situ assembly. By assembling units at their final destination and utilizing vertical space for stacking, the system eliminates the need for bulky horizontal transportation facilities while maintaining assembly quality through controlled robotic operations
3Ease of repair
If personnel perform disassembly in operating plants, then maintenance can be conducted, but the environment is dangerous and hazardous
Solution Approach 1:
The patent replaces human personnel with an automated robot system for disassembly operations in hazardous environments. The robot includes sensors for detecting gas leaks and environmental conditions, manipulators for safe component removal, and can operate in confined spaces, enabling maintenance without exposing personnel to dangerous conditions while maintaining ease of repair
Solution Approach 2:
The robot system acts as an intermediary between maintenance personnel and the hazardous environment. It performs dangerous disassembly tasks remotely, with operators controlling the robot from safe locations. The robot includes environmental monitoring and safety systems that mediate between the hazardous operating conditions and human operators
4Device complexity
If traditional assembly methods are used, then simple equipment can be employed, but space utilization is inefficient
Solution Approach 1:
The robot system is designed as a multi-functional platform that can perform multiple operations: navigation to different locations, assembly of various electrolyzer components, disassembly for maintenance, and environmental monitoring. This universal system replaces multiple specialized pieces of equipment, reducing overall device complexity while optimizing space utilization through vertical stacking and compact in-situ assembly
Solution Approach 2:
The invention utilizes vertical space for stacking electrolyzer units and positioning the robot system, transitioning from horizontal space utilization to three-dimensional space optimization. This allows efficient use of installation area while maintaining simple equipment requirements through the compact, multi-functional robot design
Data Source
AI summary
A method for assembling and/or disassembling alkaline electrolyzer units of a hydrogen producing plant. The method includes: providing an industrial robot system including a controller having robot functionality, and a plurality of robots; transporting the plurality of robots to a plurality of electrolyzer unit sites, assembling the alkaline electrolyzer units at the electrolyzer unit sites by the plurality of robots executing assembly instructions included in the controller, and/or disassembling at least one of the alkaline electrolyzer units at an electrolyzer unit site by at least one of the plurality of robots executing disassembly instructions included in the controller.