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 connect the plates either in their amorphous state or physically formed state. Then, they will put them into special closed containers. This creates a product ready for shaping the finished battery.
Joining the Plates
Technicians start by using a machine that makes insulated envelopes. Into these envelopes, they insert one type of plate. Technicians then combine the plates, whether they are in envelopes or not, to form groups. They weld the positive and negative plates of each group together. Then, they join these plates to the opposite type from the next group. This forms a series of positive and negative plates. Technicians repeat this process six times in six different cells. This gives them the standard voltage for a car battery. The standard voltage is 12 volts.
The Battery Assembly
In an independent department known as “battery assembly,” the following machines assist in this series of operations:
Enveloping Machine
Enveloping Machine is used to prepare insulated envelopes and insulated positive and negative plate groups.
Automatic Casting Machine for the Lug Connection(Cast-On Strap Machine – COS)
The Cast-On Strap Machine (COS) is essential for precisely aligning the (positive and negative) plate sets in relation to each other and for welding the electrodes of each set. The machine will produce a specific appendix (called a strap) for each set to connect the plates of one set to the set of opposite signs of the next group.
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.
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.
Cover welding machine
Cover welding: a device that seals the battery casing with a specific cover. It is usually equipped with an automatic cover loader. The machine, using a mold at a controlled temperature (350–380 °C or 210–240 °C if the mold is coated with Teflon) melts the upper edge of the monobloc and the lower edge of the cover, ensuring that they seal upon matching and pressing.
Machine for melting the terminal poles
The terminal pole melting machine joins parts of a battery together. It does this by melting the terminal poles of a group. These poles are part of the battery’s internal circuit. The machine then connects them to the cover bush, which is a part that helps seal the battery.
Once you place the battery in position, the machine starts working. It uses cooled molds to shape the materials. It also uses special torches to control flames. These torches melt the two terminals of the battery. The machine connects the terminal groups with bushes. These bushes are inserted in the battery cover. The final step is to check the previous phases (welding of the groups, covers, and terminal poles).
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 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.
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