How it is Made: The Lead Acid Battery – Part X Assembly

In this article we will try to understand the procedure for the lead-acid battery assembly and equipment needed for this.

Lead Acid Battery Assembly Procedure

Technicians will first connect the plates, either in their amorphous state or in their physically formed state. Next, they will carefully place them into specially designed closed containers. Additionally, this step is particularly crucial in the lead-acid battery assembly process, as it ensures the proper arrangement of components. Ultimately, this preparation is essential for shaping the finished battery, making it ready for further processing and final use.

Joining the Plates

Technicians begin by operating a specialized machine that carefully produces insulated envelopes. Into these envelopes, they systematically insert one type of plate. After that, they proceed to combine the plates, whether enclosed in envelopes or not, to form well-structured groups. Next, they meticulously weld the positive and negative plates of each group together. Following this, they securely connect these welded plates to the opposite type from the adjacent group. As a result, this arrangement forms a continuous series of alternating positive and negative plates. Technicians then diligently repeat this process six times across six different cells. Consequently, this structured approach ensures the achievement of the standard voltage required for a car battery, which is 12 volts. Overall, this process plays a crucial role in the precise and efficient assembly of lead-acid batteries.

The Battery Assembly

In a dedicated and independent department known as “battery assembly,” several advanced machines play a crucial role in facilitating this series of operations. Additionally, these specialized machines work together seamlessly to ensure precision and efficiency throughout the assembly process.

Enveloping Machine

The Enveloping Machine efficiently prepares insulated envelopes and carefully assembles insulated positive and negative plate groups.

This machine plays a crucial role in the lead-acid battery assembly process, ensuring accuracy and consistency in the arrangement of battery components.

Automatic Casting Machine for the Lug Connection(Cast-On Strap Machine – COS)

The Cast-On Strap Machine (COS) plays a crucial role in the lead-acid battery assembly process, as it ensures the precise alignment of both positive and negative plate sets. This precise positioning is essential for maintaining consistency and efficiency during the battery’s production.

Once the plat Once the plates are properly aligned, the machine welds the electrodes of each set, creating a strong and reliable connection. Additionally, the COS machine produces a specific appendix, known as a strap, for each set. This strap serves as the link that connects the plates of one set to the corresponding set of opposite signs in the next group, allowing for a seamless electrical flow.

Furthermore, achieving accurate lug connections is a critical aspect of the assembly process, as any misalignment or weak connections can compromise the battery’s overall performance and durability. By utilizing the COS machine, manufacturers can enhance the efficiency, reliability, and quality of lead-acid batteries, ensuring optimal functionality in their final application.

The following machines then handle the task of finishing the battery:

Machine for verifying the insulation between the plates

To verify the insulation between the plates, the machine sets a voltage between the positive and negative electrodes of each group (2000–3000 V) and checks the amount of current that can pass between the plates. A suitable limit to the current passage will detect the presence of electrical contacts between the plates. This verification step is a key part of ensuring a reliable lead acid battery assembly.

Electronic arc welding machine

Electronic arc welding machine: It operates on the appendices of each set by connecting each group with the next one, creating a six-cell series. The precision of this welding process is crucial for the lead acid battery assembly.

Cover welding machine

A specialized device, often equipped with an automatic cover loader, securely seals the battery casing with a specific cover during the lead-acid battery assembly process, ensuring efficiency and precision.

To achieve a strong and reliable seal, the machine operates using a mold maintained at a carefully controlled temperature.

If the mold is uncoated, the temperature ranges between 350–380°C, whereas a Teflon-coated mold requires a lower range of 210–240°C.

During the welding process, the machine melts both the upper edge of the monobloc and the lower edge of the cover. Once melted, these two components are aligned and firmly pressed together, ensuring a secure and durable bond.

Effective cover welding is essential for the overall integrity of the battery, as it prevents leaks and maintains the structural strength of the casing. By implementing this precise process, manufacturers can ensure the successful completion of the lead-acid battery assembly while enhancing the battery’s longevity and performance.

Machine for melting the terminal poles

The terminal pole melting machine plays a vital role in the lead-acid battery assembly process by effectively joining various battery components together.

It achieves this by carefully melting the terminal poles of a group, which are essential elements of the battery’s internal circuit. After melting, the machine seamlessly connects these poles to the cover bush, a crucial component that helps seal the battery and maintain its structural integrity.

Once technicians position the battery correctly, the machine automatically initiates the process. It utilizes specially designed cooled molds to carefully shape the materials while maintaining precision. Additionally, advanced torches regulate flames, ensuring accurate melting of the two battery terminals. The machine then systematically connects the terminal groups to the bushes, securely inserting them into the battery cover.

As the final step, technicians thoroughly inspect the previous phases, including the welding of the groups, covers, and terminal poles. This meticulous process guarantees the correct completion of the lead-acid battery assembly, ensuring both functionality and durability.

Pneumatic testing machine

Pneumatic testing machine: Using special sealing nozzles, it presses each battery cell. This helps find any losses caused by drops in pressure. Such losses would indicate that one of the previous operations had failed. This testing step is vital to verify the integrity of the lead acid battery assembly.

Additionally, this marks the end of the dry-charged batteries’ production cycle.

Various operations may follow depending on the destination market (labelling, packaging, and palletizing).

Technicians will carry out the forming phase for the wet-charged batteries.

Source

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