Who this is for: Quality Engineers at electrolyser stack manufacturing facilities.
PROBLEM: Electrolyser manufacturers face a costly tradeoff in end-of-line QC. Miss a defect, and you risk field failures that endanger warranties and multi-million dollar commercial relationships. Catch every defect, and you're absorbing the infrastructure cost of full-power testing on every stack.
ROOT CAUSE: Many defect categories require electrical excitation to surface. Full-power testing remains the industry default for electrical QC. Full-power tests demand dedicated hydrogen handling infrastructure, high electrical load capacity, and significant time per stack. The result: manufacturers ship with incomplete electrical QC, or pay a steep price to avoid it.
SOLUTION: The Pulsenics Pulse Probe, which can run stack QC at OCV.
About stack defects and quality escapes
“Quality escapes” are when a defective product leaves a factory despite passing standard QC protocols. Today, most electrolyser stack quality escapes are not detected until the customer runs a full power SAT on-site. Whatever defects are detected must then be repaired on-site or the stack is returned under warranty. These mitigations are expensive, time-consuming, and a huge headache for all involved.
In fact, a stack-level quality escape can cost the OEM more than the sale price of the stack itself!
Typical stack defects that escape through QC protocols include:
- Electrode assembly faults
- Electrolyte or membrane contamination
- Missing components
- Contact resistance issues
- Cell-to-cell uniformity faults
These defects escape stack QC because they normally require full-power testing protocols, which many stack OEMs find prohibitive. The Pulsenics Pulse Probe catches these defects at OCV, which is a much more affordable (and faster) solution.
The Pulsenics Pulse Probe series tests electrochemical assets, such as batteries or hydrogen stacks, non-invasively. The Pulse Probe scans across dozens of frequencies to produce high-quality impedance data. These insights allow quality engineers to detect problems at their facility while the stack is dormant, preventing quality escapes.
The Pulse Probe Difference
POWER
The Pulsenics Pulse Probe series is a step-change innovation in the history of EIS diagnostics. It’s the world’s most powerful EIS.
- High-voltage, high-current capability for industrial scale diagnostics
- EIS under load for 5MW+ assets
- Test as low as 0.01 Hz with total confidence
- Scale your testing protocols to industrial volume
CONVENIENCE
Test for stack defects at your own facility without expensive infrastructure upgrades.
- On-site testing at OCV or low-power
- Rapid quality control, measured in minutes
SCALABILITY
Pulse Probes can monitor an unprecedented number of assets through our modular, scalable, high-power architecture.
- Monitor hundreds of cells simultaneously
- See your data in real-time and leverage our proprietary ML models to flag defects without burdensome energy consumption
- Advanced analytics and automated analysis speed your workflows
INSIGHT
Pulse Probes detect the problems that typically escape quality control.
- Test for electrode assembly faults, electrolyte or membrane contamination, missing components, contact resistance issues and cell-to-cell uniformity faults
- Industry-leading machine learning and predictive capabilities
- Customizable pass/fail criteria, unique to every customer
Protect your warranties
Do not risk the costs of replacing a full stack. Pulsenics Pulse Probes help you avoid multi-million dollar quality control incidents, along with all the reputational risk. Contact a Pulsenics consultant today.
