Mikrosam has delivered a multi-spindle high-performance filament winding machine to HydroExceed, part of H2APEX – Germany for producing new generation hydrogen vessels. Equipped with advanced support systems, auxiliary units, and various automated features, it’s optimized for maximum efficiency.  This solution is tailored for HydroExceed’s current and upcoming projects, ensuring a seamless transition from small-scale to high-volume serial production.

The development, production, and marketing of individual system solutions for the use of renewable energy are the cornerstones of the corporate group H2APEX. HydroExceed as part of the group relies on networks of cooperating companies and research institutions that provide the necessary technologies for a sustainable infrastructure in the new markets in the energy storage segment to advance through continuous growth in know-how. New approaches are constantly being taken to optimize the efficiency and optimal use of renewable energy in customized hydrogen storage applications. The combination of extensive experience and close contact with customers, especially in the maritime sector and transport in general, coupled with the systematic search for innovations, creates new insights into energy storage and its technical implementation. In the field of expertise of developing and manufacturing compressed gas storage units made of carbon fiber composite material, HydroExceed strives to provide the market with the most efficient and safest solutions for storing and transporting hydrogen. The automated and technologically complete production line is ready to be expanded to a series production of up to 50,000 CO2-neutrally produced storage units per year at the Rostock-Laage site.

The procedural nature of this production requires a high level of vertical integration and thus the development and qualification of a diversified workforce. At HydroExceed a highly skilled pool of experts with experience in composite construction and the maritime industry operates state-of-the-art production and testing facilities at the Rostock-Laage site. To address the diversified tasks and challenges in the area of hydrogen topics in a more targeted manner and to enable further growth, HydroExceed combines efforts in the area of compressed gas storage and the simulation of energy systems with the associated research and development.

Mikrosam’s high-performance filament winding machine

About the filament winding machine, Mikrosam’s patented automatic cut-and-restart system (CRS) introduces advanced functionality by automating the start and stop of the winding process, reducing operator intervention. Additionally, the equipment has a fast-exchange second resin bath with automated and programmable resin pick-up and a second fiber creel for speeding up the fiber splicing. Together these features reduce the downtime of filament winding, improve efficiency during cleaning, and reduce operator burden.

The resin baths are equipped with programmable doctor blades for precise resin pick-up settings, allowing each fiber tape, routed to different spindles, to have individual and programmable resin pick-up adjustments, which is crucial for ensuring consistent and optimal process quality.

Mikrosam’s equipment also includes a liner pick-up station, a robot handling system, continuous and stationary curing ovens, an in-house developed Premium Quality Control System (QCS), and a Real-Time Industrial Network Communication from the Top-Level Control System (TCON) that allows the customer to control and monitor the entire process from a single location. This complete setup is seamlessly integrated with the WindingExpert programming software with lifetime licenses!

“Customers prefer Mikrosam not only for our expertise in advanced composites but also for dedicated focus on meeting their market needs. With our track record of delivering innovative automated filament winding systems, Mikrosam has become a trusted leader in winding automation. Our clients seek to enhance machine productivity without compromising on the return on investment (ROI), retain flexibility of their CapEx with selective upgrades of the equipment, which our company consistently delivers on those expectations,” explained Vele Samak, Vice President at Mikrosam.

„Mikrosam’s collaboration with HydroExceed marks a significant milestone in the evolution of hydrogen pressure vessel technology, promising higher efficiency, quality, and versatility in meeting the demands of the future. We are pleased by Mikrosam’s professionalism and innovative drive, providing us complete support. Stay tuned for more exciting developments in our ongoing projects!” – says Dr. Peter Sponholz, CEO at HydroExceed

Automated Handling Systems by Mikrosam

As the demand for the transport of compressed hydrogen grows, so do the demands on the equipment handling the production. In some cases, individual composite pressure vessels can exceed 450 and 500kg in typical dimensions, while sizes of composite pressure vessels of 2 tons and more are not uncommon. Robotic handling systems are typically a lower-cost entry into handling the smaller-sized pressure vessels in automated production. As the need for higher capacity in handling and larger pressure vessels increases, Mikrosam introduced an innovative gantry-based multi-axis handling system for composite hydrogen pressure vessels. This is a completely new solution from the conventional robotic systems. Gantry handling is crucial in multi-spindle winding, especially for handling more pressure vessels with each pressure vessel exceeding 400kg, or pressure vessels exceeding 1500 liters, where robotic handling cannot be used. Vele Samak, explains, “This latest technology represents a significant advancement in our pursuit of excellence in hydrogen pressure vessel manufacturing.”

During JEC World, Paris from March 5-7, 2024, Mikrosam and HydroExceed will display one of the produced pressure vessels.