Robotic End-of-Line Testing for Hydrogen Pressure Vessels Using a Strain-Based SHM System

Abstract

High safety factors lead to increased material input and costs for Composite Overwrapped Pressure Vessels (COPV) in hydrogen mobility. Reducing safety factors in the form of material can improve profitability, but reliability must be maintained. Currently, there is no automated end-of-line testing that can help quickly and reliably check the structural integrity and enhance testing scalability for COPVs. Our novel approach to COPV quality assurance uses robotically applied test loads to inspect the structural condition of each COPV. It captures the structural response using a strain-based SHM system. The design of the sensor layout for this application faces two central challenges: selecting an efficient combination of measuring points, damage indicators, and appropriate test loads and ensuring the system is functional as an onboard SHM system. In the context of this conference contribution, we explain the mentioned quality assurance approach in more detail. Additionally, the first results in the design of the sensor layout, which measures the structural state of COPV in robotic testing and onboard operation, are presented.