Lead-acid battery manufacturing process and main equipment

1, the manufacture of the plate

Including: lead powder manufacturing, grid casting, plate manufacturing, plate formation and so on.

(1) Lead powder manufacturing equipment, granulator or cutting machine, lead powder machine and transport storage system;

(2) Slag casting equipment, lead casting machine and various molds for grid casting equipment;

(3) Electrode manufacturing equipment and paste machine, smear machine, surface drying, curing and drying system, etc.;

(4) Electrode charging and discharging machine for plate forming equipment;

(5) Water cooling and environmental protection equipment.

2, assembly of battery equipment

Automobile battery, motorcycle battery, electric vehicle battery, large, medium and small valve-controlled sealed battery assembly line, battery testing equipment (various battery performance testing).

(1) Overview of the process of a typical lead-acid battery

Lead-acid batteries are mainly composed of battery cells, battery covers, positive and negative plates, dilute sulfuric acid electrolytes, separators and accessories.

(2) Process manufacturing is briefly described as follows

Lead powder manufacturing: The lead powder powder of 1# electrolytic lead is processed by oxidation to produce lead powder that meets the requirements.

Grid casting: Lead-bismuth alloys, lead-calcium alloys or other alloys are usually cast by gravity casting into different types of slabs that meet the requirements.

Plate manufacturing: After mixing with lead powder and dilute sulfuric acid and additives, it is applied to the surface of the grid and then dried and solidified.

The formation of the plate: the positive and negative plates are produced by the redox reaction of the dilute sulfuric acid under the action of direct current, and then washed and dried to be used for the positive and negative plates used in battery assembly.

Assembling the battery: Different types of different plates are assembled into different types of batteries according to different needs.

3. Introduction to grid casting

The grid is the carrier of the active material and is also a conductive current collector. Ordinary open battery grids are generally cast with lead-bismuth alloy, maintenance-free battery grids are generally cast with low-bismuth alloy or lead-calcium alloy, and sealed valve-regulated lead-acid battery grids are generally cast with lead-calcium alloy.

**Step: According to the battery type, the alloy lead type is put into the lead furnace for heating and melting. After the process requirements are met, the lead liquid is cast into the metal mold, and after cooling, the mold is trimmed and placed.

The second step: after the trimming of the grid, after a certain period of time, it can be transferred to the next process. Main control parameters of the grid: grid quality; grid thickness; grid integrity; grid geometry;

4. Introduction to lead powder manufacturing

The lead powder is manufactured by the Shimadzu method and the Barton method. The result is that the 1# electrolytic lead is processed into lead powder that meets the requirements of the battery production process. The main components of lead powder are lead oxide and metal lead. The quality of lead powder is closely related to the quality of the manufactured. In China, the Shimadzu method is used to produce lead powder, while in Europe and the United States, the Barton method is used to produce lead powder.

The process of producing lead powder by Shimadzu is briefly described as follows:

**Step: Process the qualified electrolytic lead into a certain size of shot or lead by casting or other methods;

Step 2: Put the shot or lead into the lead powder machine, and the shot or lead segment is oxidized to form lead oxide;

The third step: put the lead powder into the designated container or the powder storage bin, after 2-3 days aging, the test can be used after passing the test.

Main control parameters of lead powder: oxidation degree; apparent density; water absorption; particle size; 5, introduction of plate manufacturing

The plate is the core part of the battery, and its quality directly affects various performance indicators of the battery. The production process of the pasted plate is as follows:

**Step: Test the qualified lead powder, dilute sulfuric acid, special equipment for additives and make lead paste;

The second step: the lead paste is applied to the grid by a smear machine or by hand;

The third step: curing and drying the filled plate to obtain a raw plate.

Main control parameters of the raw plate: lead paste formula; apparent density; acid content; paste amount; thickness; free lead content; moisture content.

5, assembly process introduction

Battery assembly has a big difference between automotive batteries and valve-regulated sealed lead-acid batteries. Valve-controlled sealed lead-acid batteries require tight assembly, generally using AGM separators. Car batteries generally use PE, PVC or rubber separators. The assembly process is briefly described as follows:

**Step: Load the qualified plate into the welding tool according to the process requirements;

Step 2: Cast or hand soldered pole groups are placed in a clean battery compartment;

The third step: the car battery needs to pass through the wall welding and heat sealing. For valve-regulated sealed lead-acid batteries, if ABS battery cells are used, they must be bonded with special adhesives.

Main control parameters of battery assembly: bus bar welding quality and material; sealing performance, positive and negative polarity.

6. Introduction to chemical conversion process

Plate formation and battery formation are two different methods of battery manufacturing, which can be selected according to specific conditions. The formation of plates is generally relatively easy to control and the cost is high and environmental pollution needs to be specifically managed. Battery quality control is difficult, and the quality of the produced raw plates is generally higher, but the cost is relatively lower.

The valve-controlled sealed lead-acid battery is briefly described as follows:

**Step: Put the qualified test plates into the battery slot seal according to the process requirements;

The second step: pouring a certain concentration of dilute sulfuric acid into the battery according to the specified amount;

The third step: after the placement, the direct current is passed according to the size of the specification. After the generalization, the discharge inspection is required to be placed in the warehouse.

The main control parameters of the battery are: acid amount, acid density, acid temperature, charge amount and charging time.

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