The main objective of the RODEO project is to propose a lightweight robotized orbital drilling equipment, and associated operating conditions and tools, to enable the drilling of tightly spaced small diameter holes in aluminium with the control of induced residual stresses. This will be accomplished by: - modelling the phenomena involved in orbital drilling that impact residual stresses - developing a combined drilling and burnishing tool and associated operating conditions to attain required residual stresses - pursuing the development of a high-speed orbital drilling unit (existing in the consortium) capable to drive the tool in the prescribed conditions - integrating the developed orbital drilling unit on a lightweight industrial robot - defining the operating conditions of the lightweight robot to be used to ensure the drilling operation To reach this objective, numerical simulation tools (already developed in the consortium) will be used to pursue the study and determine the mechanisms modifying the properties of the material during orbital drilling, and the impact on fatigue life (including the influence of a fastener). As a result, solutions to increase residual stresses in aluminium holes will be suggested in terms of cutting conditions, tool geometry and holemaking strategy (including burnishing). From this, an innovative orbital drilling tool, combining cutting and burnishing active parts will be developed and associated operating conditions will be proposed. To drive this tool along the expected trajectory with the required speeds, the development of a high-speed orbital drilling unit (provided by PRECISE) will be pursued. This will require the adaptation of the equipment to allow burnishing, and the integration of monitoring devices for cutting forces, spindle speed, feed speeds measurements. The orbital drilling unit will be handled by a lightweight industrial robot that will permit to drill holes without the need of a drill jig, allowing the drilli

The project’s proposition and charter is to advance (MRL4 > MRL6) the critical steps of the PEM fuel cell assembly processes and associated in-line QC & end-of-line test / handover strategies and to demonstrate a route to automated volume process production capability within an automotive best practice context e.g. cycle time optimization and line-balancing, cost reduction and embedded / digitized quality control. The project will include characterization and digital codification of physical attributes of key materials (e.g. GDLs) to establish yield impacting digital cause and effects relationships within the value chain, from raw material supply / conversion / assembly through to in-service data analytics, aligning with evolving Industry 4.0 standards for data gathering / security, and line up-time, productivity monitoring. The expected outcome will be a blueprint for beyond current state automotive PEM fuel cell manufacturing capability in Europe. The project will exploit existing EU fuel cell and manufacturing competences and skill sets to enhance EU employment opportunities and competitiveness while supporting CO2 reduction and emissions reduction targets across the transport low emission vehicle sector with increased security of fuel supply (by utilizing locally produced Hydrogen).

Water electrolysis supplied by renewable energy is the foremost technology for producing “green” hydrogen for fuel cell vehicles. The ability to follow rapidly an intermittent load makes this an ideal solution for grid balancing. To achieve large-scale application of PEM electrolysers, a significant reduction of capital costs is required together with a large increase of production rate and output pressure of hydrogen, while assuring high efficiency and safe operation. To address these challenges, a step-change in PEM electrolysis technology is necessary. The NEPTUNE project develops a set of breakthrough solutions at materials, stack and system levels to increase hydrogen pressure to 100 bar and current density to 4 A cm-2 for the base load, while keeping the nominal energy consumption <50 kWh/kg H2. The rise in stack temperature at high current density will be managed by using Aquivion® polymers for both membrane and ion exchange resin. Aquivion® is characterised by enhanced conductivity, high glass transition temperature and increased crystallinity. Dramatic improvements in the stack efficiency will be realised using novel thin reinforced membranes, able to withstand high differential pressures. An efficient recombination catalyst will solve any gas crossover safety issues. Newly developed electro-catalysts with increased surface area will promote high reaction rates. The novel solutions will be validated by demonstrating a robust and rapid-response electrolyser of 48 kW nominal capacity with a production rate of 23 kg H2/day. The aim is to bring the new technology to TRL5 and prove the potential to surpass the 2023 KPIs of the MAWP 2017. The proposed solutions contribute significantly to reducing the electrolyser CAPEX and OPEX costs. The project will deliver a techno-economic analysis and an exploitation plan to bring the innovations to market. The consortium comprises an electrolyser manufacturer, suppliers of membranes, catalysts and MEAs and an end-user.