Saturday, December 18, 2010

【 Weak current College 】 typical lead-acid battery technology process overview 】

Lead-acid battery mainly by the battery Bay, battery cover, positive and negative plates, dilute sulfuric acid electrolyte, shelves and accessories. Process are summarized as follows:
Lead manufacturing: 1 # electrolytic lead lead with special equipment for machine made by oxidation filter meets the requirements of the lead.
Grid casting: will lead-antimony alloys, lead-calcium alloy or other alloy lead usually use gravity casting foundry way into compliance with requirements of different types of plate gate.
Plate manufacturing: lead and dilute sulfuric acid and additive blend to smudge the grid surface to dry curing is born plates.
Plate into: positive and negative plates in DC's role and the adoption of dilute sulfuric acid redox reactions lead oxide production and further cleaning, drying, is available for battery positive and negative plates used in the Assembly.
Assembling the battery: put the number of different models of different slices of the plates according to different demands assembled into a variety of different types of batteries.
Note: units for process conditions to select distinct processes.

Introduction to grid casting
Grid is the carrier of the active substance is used in any collector. General open battery grid general use lead-antimony alloys casting, maintenance-free battery grids to general use low antimony alloy or lead-calcium alloy casting, sealing valve regulated lead-acid battery grid general use lead-calcium alloy casting.
Step one: according to battery type determines the alloys of lead model in the lead melting furnace heating, meet the technological requirements will lead into the liquid metal casting
After cooling the mold, formwork Mikawa stack.
Step 2: after finishing the grid after a certain time to turn to the next procedure.
The main grid: the grid control parameters; quality; grid grids full thickness; grid geometry size, etc.;

Introduction to lead manufacturing
Leadmanufacturing with Shimadzu and Barton method, the result will be 1 # electrolytic lead processing to meet the requirements of the battery production process lead. Lead in lead oxide is the main ingredient and the metallic lead, lead by quality and manufactured quality has very close relations. In my many lead with Shimadzu method production, while in Europe and the use of lead production by Barton.
Shimadzu method production lead process are summarized as follows:
Step one: set laboratory qualified electrolytic lead after casting or other methods for processing into a certain size or lead shot put;
Step 2: be shot or lead segments into the lead tank, shot or lead paragraph after oxidation produces lead oxide;
Step three: will lead into the specified container or storage toner cartridge, after 2-3 days after passing the prescription, laboratory.
Lead major control parameters: oxidation degree; apparent density; absorption; particle size, etc.;

Plate manufacturing introduction
Plate is a core part of the battery, its quality has a direct impact on battery for various performance metrics. Coloured cream-style plates production process are summarized as follows:
Step one: set laboratory qualified lead, dilute sulfuric acid, additives for special equipment and made into paste;
The second step: lead paste used coating machine or manual tiantu to grid;
Step three: will make the plates after tiantu curing, drying, i.e. get hygiene plates.
Health plate main control parameters: lead paste formula; depending on the amount of acid; cast plaster; lead thickness; free; moisture content, etc.

Assembling process description
Battery Assembly for automotive batteries and sealed valve regulated lead acid batteries have a greater difference, sealed valve regulated lead acid battery requires tight Assembly generally used AGM battery separators, PE, PVC for general use or rubber spacers. The Assembly process are summarized as follows:
Step one: set laboratory qualified plates according to technological requirements mount soldering tools;
Step 2: cast welding or manual welding of very groups into a cleaned battery slot;
Step three: automotive batteries subject to wear wall welding and heat seal once, and sealed valve regulated lead acid batteries to use ABS battery bay with special adhesive bonding.
Battery Assembly main control parameters: bus welding quality and materials; sealing performance, positive, negative, etc.

Chemical process description
Plate formation and batteries into the battery manufacture of two different methods, depending on the circumstances. Plate formed generally relatively easy control costly and need specialized control environmental pollution. Battery into quality control difficult, generally on the production of health plate quality requirements are higher, but the cost is relatively low. Sealed valve regulated lead-acid batteries as follows:
Step one: set laboratory qualified health plate according to technological requirement into the battery slot sealing;
Step 2: Add a certain concentration of dilute sulfuric acid required quantity grouted with battery;
Step 3: after placing the size by pressing control-DC, generalized into required discharge after checking with the group preparing the factory after the library.
Battery into the main control parameters: tank acid; tanks acid density; tanks acid temperature; charge capacity and time, etc.

Use and maintenance
Lead-acid battery to its manufacturing process is simple, raw material sources rich, affordable in secondary chemical power plays an irreplaceable role, in particular the emergence of VRLA batteries makes the traditional battery, have a great vitality. Battery life and manufacturing are closely related, and use the methods also have a great influence on the correct use of the using methods to extend the battery life benefits. For traditional open-type battery everyday to thefollowing note:
① electrolyte quantity, density, and charging level, attention, especially with its closely related charging system special interest, if the amount is large then the charging battery water loss, easily plates of the active substance falls off the bottom of a short circuit caused the battery internal temperature high and shorten the life, if the charge in smaller then easily battery of lack of electricity, the battery in long-term lack of electricity, it can lead to irreversible Kraft plates, its performance is charging voltage rise faster, complete a very short time, when the voltage drops rapidly discharge.
② the purity of the electrolyte, generally use battery liquid electrolyte or supplementary special-site, is strictly prohibited to use ordinary tap water and sulphuric acid.
③Daily use surface clean exhaust flow.
④ placed without first when fully charged, at the same time three months to carry out a supplementary charge.
For sealing valve regulated lead-acid batteries for daily to the following note:
① Note charging voltage range floating charge voltage control when used generally in 2.15 ± 0.1V/single, recyclable voltage General 2.35 ± 0.1V/single-frame, if instructions are required to follow instructions.
② the use of ambient temperature, generally not more than 30 degrees. Larger temperature changes should enhance voltage adjustment.
③ for different manufacturers of products is not mixed with the same manufacturer's product is a mixture of old and new.
④ sealed valve regulated lead acid battery it is best not to supplement their own open lid and replace the electrolytes.

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