I. Industry Background: Hydrogen Energy Industry Boom — Automated Production Lines Become Essential for Mass Production
Driven by the dual-carbon strategy, hydrogen fuel cell stacks (hydrogen utilization) and PEM electrolyzers (green hydrogen production) are expanding rapidly and simultaneously. In the transportation sector, heavy-duty trucks and buses equipped with fuel cells are being deployed at scale; industrial green hydrogen and photovoltaic hydrogen production projects continue to launch. From 2026 to 2030, the electrolyzer market is projected to grow at a compound annual growth rate exceeding 120%, while fuel cell stack production capacity demand continues to double.
Whether for vehicular fuel cell stacks or hydrogen-production PEM electrolyzers, the machining precision and stacking consistency of core components — bipolar plates and membrane electrode assemblies (MEA) — directly determine product lifespan and energy efficiency. Traditional manual assembly suffers from low yield rates and limited production capacity, making fully process-integrated intelligent automated production lines the standard configuration for leading hydrogen energy enterprises and new energy groups when establishing manufacturing facilities.
Shenzhen Second Intelligent Equipment Co., Ltd. has been deeply engaged in precision fluid dispensing since 2005 and fully entered the hydrogen fuel cell equipment sector in 2014. Through over a decade of R&D accumulation, the company has grown into an automated production line solution provider covering the entire process chain for both hydrogen fuel cell stacks and PEM electrolyzers. As a national-level “Little Giant” specialized and sophisticated enterprise, Second Intelligent leverages its self-developed dispensing control system, vision inspection algorithms, and MES digital platform as its technological foundation, providing global Tier 1 customers with turnkey solutions ranging from single machines to complete production lines, from incoming material inspection to finished product delivery.
II. Hydrogen Fuel Cell Stack Production Equipment Overview
A hydrogen fuel cell stack is a device that directly converts the chemical energy of hydrogen fuel into electrical energy, also known as an electrochemical generator.
The electrochemical reaction process is as follows: hydrogen undergoes oxidation at the anode (negative electrode), releasing protons (H+) and electrons (e-); protons cross the proton exchange membrane to reach the cathode, while electrons travel through the external circuit to perform work before reaching the cathode; at the cathode (positive electrode), protons, electrons, and supplied oxygen (or air) undergo a reduction reaction to produce water. This process directly converts hydrogen energy into electrical energy, with the only byproducts being pure water and heat, achieving true zero-carbon emissions and zero pollution.
The stack consists of multiple unit cells stacked in series. Bipolar plates and membrane electrodes are alternately stacked, with sealing components inserted between units, then compressed by front and rear end plates and fastened with tie rods to form the hydrogen fuel cell stack.
Bipolar plates: Available in metal, graphite, and composite material types, responsible for directing hydrogen/air flow, conducting current, and dissipating heat.
Membrane electrode assembly (MEA): The “heart” of the electrochemical reaction, composed of a proton exchange membrane (PEM), anode and cathode platinum catalyst layers, and gas diffusion layers (GDL), directly determining the stack’s power density and service life. The industry mainstream adopts multi-layer packaging structures such as 3CCM (membrane + catalyst layer), 5CCM (with frame/sub-gasket), and 7CCM (with GDL) to suit different packaging processes and power requirements.
Auxiliary structures: Insulation plates, current collector plates, end plates, locking straps/tie rods, etc., used to secure the stack structure and provide balanced compression force.
(I) Bipolar Plate Packaging and Inspection Equipment Series (Compatible with Metal/Graphite/Composite Plates)
Bipolar plates are the core sealing components of the stack. Gas tightness and adhesive line precision determine the stack’s leak indicators. Second Intelligent’s self-developed front-end vision inspection + integrated dispensing, lamination, and curing production line replaces multiple single-machine redundant processes:
● SEC-H500-3D adhesive strip/metal plate flow channel 3D vision inspection machine: Adopts a single-machine workbench in-situ inspection architecture, integrating high-precision four-axis modules, profilometer scanner, universal positioning platform, portable operating system, and information management system as full core units. It can perform adhesive break detection, adhesive profile inspection, adhesive strip width/height detection, flow channel depth and width multi-dimensional size inspection. Non-contact inspection prevents secondary workpiece damage. Maximum inspection product size 500x300mm, maximum inspection speed 50mm/sec, repeatability accuracy up to +/-0.01mm. Supports barcode scanner, dedicated fixtures, 2D positioning system and other optional accessories; compatible with MES and CIM system data interconnection; supports automatic process data saving and one-click backup. Suitable for fuel cell bipolar plate sealing adhesive strip and flow channel profile single-machine offline high-precision inspection scenarios.
● Universal/dual Y-axis dispensing and lamination integrated line: Two configurations — single-station prototyping and dual-station high-speed mass production — integrating CCD vision and laser height measurement to complete double-sided seal dispensing, adhesive strip lamination, high-temperature curing, and online gas tightness testing, suitable for annual output of millions of plates.
● Bipolar plate fully automated packaging line SEC-H500-BP: Modular and freely combinable, integrating loading, vision positioning, dispensing, adhesive strip lamination, high-temperature curing, adhesive width/height inspection, gas tightness testing, and unloading — full process. Pressure range 0-3000kg, curing temperature adjustable from room temperature to 200 degrees C, suitable for annual output of millions of plates.
(II) Membrane Electrode Assembly Packaging and Inspection Production Line
MEA is the core of fuel cell energy conversion, containing proton exchange membrane, carbon paper, and frame. Second Intelligent covers the full set of process equipment including cutting, hot pressing, dispensing, and gas tightness testing:
SEC-H500-ML membrane electrode production line: Adopts modular freely combinable architecture, integrating roll cutting, vision positioning, five-in-one lamination, five-in-one pressing, seven-in-one packaging, cutting, defect inspection, gas tightness testing, and information management — full process. Compatible with both sheet and roll feeding modes, supports 3CCM, frame, GDL and other raw material cutting and waste recycling. Five-in-one pressing rated 20T, seven-in-one rated <=5T, temperature control range room temperature to 150 degrees C adjustable, MEA assembly precision <=+/-0.2mm, suitable for fuel cell MEA large-volume automated production, meeting mid-to-large hydrogen energy factory MEA mass manufacturing needs.
SEC-V5030-SDFC membrane electrode defect inspection production line: Modular and flexibly configurable, integrating high-precision line scan camera, marble inspection platform, high-precision linear motor, vision processing system, and high-precision vacuum stage as full core units. It can perform fuel cell membrane electrode defect identification and 2D dimensional inspection. Optical grating ruler triggers image acquisition, Z-direction inspection accuracy up to 0.01mm, scanning speed 120-300mm/s, maximum inspection product size 500x300mm. Supports FFU filter unit, fully automatic/semi-automatic loading and unloading, barcode reading and other optional accessories. Features massive data storage and process information traceability, suitable for MEA large-volume online quality inspection scenarios.
High-precision imported flowmeter
(IV) Fuel Cell Stack Fully Automated Stacking and Assembly Line (Core Flagship Production Line)
Stack stacking precision directly affects lifespan. Second Intelligent offers both laboratory semi-automatic and industrial fully automated solutions, configurable as needed:
● Semi-automatic rotary stacking machine: 0-90 degree flip fixture, suitable for R&D pilot and small-batch trial production.
● Laser strap welding machine: Integrated bending and welding, replacing traditional bolt locking, simplifying stack structure.
● Six-axis robot fully automated stacking line: Industry-leading mass production equipment. Robot automatically picks plates/MEA, binocular vision layered alignment, servo segmented compression, steel band laser welding and bundling, multi-channel gas tightness testing, laser marking — fully unmanned operation. Single production line annual output of 5,000 units of 150kW heavy-duty truck stacks.
● Fuel cell engine system assembly line SEC-H500-SAL:Designed for complete hydrogen fuel cell engine assemblies. Uses AGV intelligent logistics flow, integrates 360 degree flip fixture, intelligent torque tightening, whole-machine gas tightness testing, insulation, and CAN bus I/O inspection. Paired with WMS intelligent warehousing and KBK crane, achieves integrated intelligent assembly of stack, air compressor, hydrogen cylinder, and cooling system. Digital dashboard monitors capacity and defect rate in real time.
III. Second Intelligent PEM Electrolyzer Complete Hydrogen Production Automated Production Line (Green Hydrogen Core Equipment)
An electrolyzer is a reversible reverse device of a fuel cell. When direct current is applied, it decomposes pure water to produce 99.999% high-purity hydrogen, adaptable to photovoltaic and wind power fluctuating green electricity. It is the only mainstream route for large-scale green hydrogen production.
The core stacking unit is similar to fuel cells, but materials and pressure resistance standards are significantly upgraded:
● Titanium alloy bipolar plates: Acid-resistant and high-pressure resistant, replacing graphite/ordinary metal plates, with extremely high requirements for coating and high-pressure sealing.
● Electrolyzer-specific MEA: Anode uses iridium precious metal catalyst, paired with titanium felt porous transport layer.
● Heavy-duty stacking structure: Thousand-ton-level pressure retention, long-term load-bearing operation, eliminating hydrogen gas leak safety hazards.
As photovoltaic and wind power hydrogen production projects are implemented, PEM electrolyzer demand is surging. Leveraging fuel cell process accumulation, Second Intelligent has launched equipment fully adaptable to titanium bipolar plates, electrolyzer MEA, and high-power electrolyzer stacking presses, covering 100MW to 500MW electrolyzer factory complete line delivery. China’s first fully automated ton-level PEM electrolyzer production line has been put into batch production.
(I) Electrolyzer Plate Pre-Processing & Packaging Equipment (Titanium Metal Plate Specific)
Electrolyzers operate in acidic, high-pressure environments. Titanium plate sealing and coating inspection requirements far exceed those of fuel cells. Second Intelligent has specifically upgraded large-stroke, high-pressure-resistant equipment:
● Large-stroke electrolyzer dispensing machine SEC-H800S: XY stroke 1000x800mm, linear motor driven, laser height measurement accuracy +/-0.02mm, suitable for oversized titanium plates. Supports primer and seal dual-line dispensing, optional plasma cleaning front-end unit, uniform adhesive lines without breaks, suitable for high-power electrolyzer plate mass production.
● Electrolyzer adhesive strip lamination machine SEC-H800-TP: Maximum lamination pressure 5000kg, suitable for thick titanium plate seal lamination, lamination repeatability +/-0.02mm, can connect to fully automatic roller conveyor production line.
● PVD coating thickness detector SEC-H800S-GP: XRF spectroscopy detection, precisely measures titanium plate precious metal coating thickness and element ratio. 25s single-point inspection, automatically determines whether coating meets standards, essential inspection equipment for electrolyzer plate incoming quality.
● Electrolyzer plate gas tightness inspection machine SEC-H800-AT: Maximum test pressure 1MPa, supports helium high-precision leak detection, flow resolution 0.1mL/min, can detect single plate, half-stack serial leaks, and external leaks, suitable for high-pressure hydrogen production working condition inspection standards.
(II) PEM Electrolyzer Membrane Electrode MEA Production Line
Electrolyzer MEA uses titanium felt and proton exchange membrane. The process differs from fuel cells. Second Intelligent’s five-in-one production line is specifically optimized for high-pressure hot pressing process:
SEC-H800S-5ML Five-in-One Electrolyzer MEA Complete Line: Adopts modular freely combinable architecture, integrating cutting system, vision positioning system, lamination system, pressing system, defect inspection system, unloading system, and information management system — full process units. Can achieve PEM electrolyzer frame + 3CCM + frame five-in-one packaging, completing material cutting, vision positioning pre-lamination, cold/hot pressing forming, bubble and alignment accuracy defect inspection, unloading stacking and interlayer laying. Post-pressing product dimensional accuracy <=+/-0.3mm, rated pressure 100T, temperature control range room temperature to 150 degrees C adjustable, suitable for maximum 800x600mm products. Supports coding, barcode scanning, gas tightness testing, 5CCM flow channel hole and profile cutting and other optional modules. Compatible with MES system data communication, achieving pressing position, pressure, capacity and other process data transmission and automatic saving, supports one-click backup, suitable for PEM electrolyzer MEA large-scale automated mass production.
(III) High-Power Electrolyzer Servo-Hydraulic Stacking Press (Core Equipment)
PEM electrolyzer stacking requires thousand-ton-level stable pressure. Second Intelligent’s SEC-H800S-ZD series servo-hydraulic press fills the domestic high-end gap: Rated pressure available in 1000KN/2000KN/3000KN three specifications, hydraulic closed-loop control, pressure control accuracy 0.5% FS; maximum adaptable 1000x800mm plates, stack height up to 1200mm, supports manual loading stacking and automatic pressure retention. Integrates online high-pressure gas tightness testing, supports nitrogen and helium multi-medium leak detection, synchronously records stacking pressure and pressure retention time data, suitable for large-scale green hydrogen factory mass production.
SEC-H800-ZDL Stack Semi-Automatic Stacking Production Line: Features high scalability and compatibility, integrating high-precision six-axis robot, CCD vision system, custom fixture platform, servo-hydraulic system, fixture turnover system, and information management system as full core units. Can achieve stacking assembly, press stacking, and online gas tightness testing for both electrolyzers and fuel cell stacks. Supports dual control logic of pressure mode and position mode. Robot completes automatic stacking, while synchronously performing manual bolt locking, press stacking gas tightness testing, and finished product unloading. Stacking accuracy +/-0.2mm, rated output force covers 1000KN/2000KN/3000KN. Uses differential pressure method for gas tightness testing, with leak detection accuracy up to +/-0.1% FS. Supports overhead crane optional accessories, features historical data storage and parameter traceability, suitable for fuel cell and PEM electrolyzer stack semi-automatic assembly mass production scenarios.
IV. Second Intelligent Hydrogen Energy Equipment Core Technology Advantages (Industry Differentiated Competitiveness)
● Full Supply Chain One-Stop Delivery
One of the few domestic enterprises simultaneously covering both fuel cell and PEM electrolyzer dual-track equipment. From plate dispensing, MEA packaging, vision inspection, stack/electrolyzer stacking to system assembly — single machines, modular production lines, and complete factory turnkey solutions all customizable. Customers need no multi-supplier coordination, reducing project management costs.
● Self-Developed Precision Fluid Control Core Patents
Self-developed piezoelectric jet valves and screw valves — two core dispensing valve bodies — with dozens of invention patents. Minimum dispensing volume 0.001ml, adhesive line width and height error controllable to +/-0.01mm, solving industry pain points of hydrogen energy plate seal adhesive overflow and breakage, adaptable to graphite, metal, and titanium all-material plates.
● 2D/3D Vision Integrated Inspection Solution
Self-developed vision algorithms covering five inspection dimensions: dimensions, appearance, adhesive lines, coatings, and impedance. Inspection accuracy leads peers. Equipment features native MES integration, with production data uploaded in real time and full lifecycle traceability, meeting new energy factory digitalization and intelligent factory standards.
● Robot Flexible Stacking Technology
Four/six-axis industrial robots paired with binocular vision, compatible with 300~1000mm full-size plates and MEA. Quick changeover without major fixture modifications. Servo segmented compression technology, smooth and controllable stacking pressure, preventing membrane and plate extrusion damage, significantly improving stack/electrolyzer yield rates.
● Global Delivery and Service System
Passed CE and ISO9001 international certification. Overseas distributors cover Malaysia, Vietnam, South Korea, India, Russia, and more. Domestic dual production bases in Huai’an, Jiangsu and Shenzhen, with 24-hour technical hotline. Provides full-process services including process sampling, production line planning, on-site commissioning, and after-sales maintenance. Cumulatively completed process sampling validation of 30,000+ hydrogen energy components for 80+ enterprises.
● Multi-Scenario Customization Capability
Covers laboratory small single machines, pilot semi-automatic lines, and ten-thousand-ton-scale green hydrogen factory fully automated complete lines. Adaptable to commercial vehicle fuel cells, stationary power generation stacks, air-cooled small stacks, high-power PEM electrolyzers, and flow battery multi-category flexible production.
V. Summary: Choose Second Intelligent for One-Stop Hydrogen Energy Mass Production Automation Needs
In the wave of fuel cell commercialization and green hydrogen scaling, automated production lines are the core lever for enterprises to reduce costs, improve quality, and expand capacity. Second Intelligent, with over a decade of hydrogen energy equipment R&D accumulation, has bridged the entire process equipment chain for both hydrogen-production PEM electrolyzers and hydrogen-utilization fuel cells, covering everything from single-machine process equipment to digitalized complete factory solutions. Relying on three core self-developed technologies-precision fluid control, vision inspection, and robot stacking-Second Intelligent provides hydrogen energy enterprises with high-yield, high-flexibility, digitalized intelligent production equipment, helping accelerate the global hydrogen energy industry’s large-scale implementation.
