The publicly funded research project BeHyPSy aims at a lightweight, air-cooled fuel cell system for aviation. It targets unmanned aerial vehicles (UAV) and aircraft with a take-off weight between 25 and 2,000 kilograms. The Centre for Fuel Cell Technology (ZBT) coordinates the project. Graebener is involved as a subcontractor.
Air cooling saves weight and space
Fuel cell systems in the higher power range have so far generally relied on liquid cooling. This method is reliable but comparatively heavy. However, every gram counts in drones and light aircraft. BeHyPSy therefore relies on air cooling. This is intended to significantly reduce weight and space. However, the requirements for air management increase as a result – a central development focus of the consortium. According to ZBT, the goal is "the development, integration, and testing of an innovative propulsion system" that can be scaled to be used in other aviation applications.
Another feature of the system is a multi-phase electric motor powered by a multi-stack fuel cell system. This architecture is intended to increase the reliability and availability of the overall system.
Graebener manufactures bipolar plates from titanium foil
In the project, Graebener is responsible for manufacturing the bipolar plates for the air-cooled fuel cell stacks. The plates are made from thin titanium foils. The process chain includes forming by hydroforming, laser cutting, laser welding, and straightening of the welded plates. In addition, Graebener supports the development process with engineering services. In collaboration with ZBT, the company analyses the feasibility limits of the design and checks whether a process-secure series production is possible.
