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Customer application 14 July 2025

Support for the Hydrogen Economy

Automated test systems optimize hydrogen electrolysis stacks

Automated test systems optimize hydrogen electrolysis stacks Hot on the heels of the fourth industrial revolution – the digital revolution – the German economy is already undergoing another transformation. Its objectives include consistent use of renewable energy, thorough electrification of production and mobility and the creation of a new hydrogen economy. The good news is that both the expertise and the innovative products this transformation will require already exist. One example: an automated test system for optimizing electrolyzers.

In this article, you will learn:

Why the economic importance of green hydrogen production has increased
How end-to-end, open-system automation enables optimization of hydrogen electrolysis stacks
Why the flexible WAGO I/O System 750 is the perfect basis for a wide variety of applications in the hydrogen economy

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Innovation through Cooperation

A Collaboration between Bürkle and WAGO

Green Hydrogen on the Rise

All the forecasts agree: As we transition to a more sustainable economy, the demand for green hydrogen will increase significantly. Studies show that, in Germany alone, completely substituting hydrogen for the coal/coke used in steel production would increase the demand for hydrogen by 2.4 megatons per year – an enormous amount.

The European Union has also recognized that steps need to be taken quickly to make such a huge hydrogen economy a reality. Billions of euros in public subsidies are now available to stimulate the development and expansion of the hydrogen industry. Economists expect this funding to attract almost nine billion euros of additional private investment,

so it’s no surprise this has created a hydrogen production mania. The number of companies that store or transport the gas or offer solutions for its distribution of is growing.

End-to-End Automation of Complex Systems

In anticipation of the enormous production quantities expected and the gigantic size of the market, companies are now working to tweak the intricacies of electrolysis stacks. Every manufacturer wants to increase its systems’ quality and yield while also making them as cost-effective as possible. However, in a complex system with hundreds of parameters, how can you evaluate the impact of one single, seemingly insignificant, change?

Jörg Bürkle is especially familiar with calculating the performance of electrolyzers. His young company, Bürkle Anlagenbau GmbH from Stuttgart, already produces measurement and test stands in small series. They use a large number of sensors to record all the relevant performance indicators of an electrolysis cell and identify interactions among various parameters.

Two factors have been especially important in their success to date: the expertise gained from more than ten years of research at the German Aerospace Center (DLR), and reliable components for end-to-end automation of the test systems.

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Download the complete customer application report here – and discover the many possibilities our solutions offer.

Components from WAGO

Details of the WAGO Products Installed in the Project

Controllers

Availability for machines and systems: Thanks to top performance, low power consumption, multiple interfaces, compact dimensions and a high degree of safety, our programmable logic controllers (PLCs) offer cost-effective automation solutions for numerous applications.

The Benefits for You:

Programmable via CODESYS per IEC 61131-1
Scalable computing power
Use in extreme environments
Ideal for combination with the WAGO I/O System 750 Learn more

I/O Systems

For the best automation, both inside and outside the control cabinet: the flexible IP20 and IP67 remote I/O systems for all applications and environments.

The Benefits for You:

Fieldbus-independence – support for all common fieldbus protocols and ETHERNET standards
A wide variety of I/O modules available for nearly every application
National and international approvals for worldwide use
An extensive range of accessories for marking and connection technology
CAGE CLAMP® connection technology for vibration-proof, fast, maintenance-free connections of the IP20 I/O systems Learn more

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