Lead acid battery detailed production process

Take the valve-regulated sealed lead-acid battery (VRLA) manufacturing process:

The production process is as follows:

Alloy Configuration---->Grid Manufacturing---->Mechanical Coating---->Crystal Curing and Drying---->Pole Plate Formation---->Pink Plate Drying---->Pole Plate segmentation brush---->Baoji group---->Polar group welding---->Pole group into the shell---->Battery short circuit test---->Pole group butt welding series- --->Capping---->High Temperature Curing---->Terminal Welding---->Terminal Seal---->High Temperature Curing---->Battery Hermeticity Testing---->Quantification Add Acid---->Charging---->Ultrasonic Cover Sheet Seal---->Battery Internal Resistance Test---->Battery Acid Sealing Test---->Battery OCV Detection----> Battery internal reliability test---->Production date imprint---->Battery trademark silk screen---->Package---->Incoming---->OQC detection---->Out of stock

With the rapid development of electric vehicles and automobiles, the power supply on the vehicle has also developed rapidly, but there are many problems in the production of batteries, resulting in a very uneven quality of the battery products in the market. The design life is not reached, which has a lot to do with the unique production process of the battery in production. The structure of the battery is composed of a casing, an upper cover, a pole plate, a partition plate, a bus bar, a pole column, a bridge protection plate, and a terminal.

Plate weighing

1. First, weigh the plates inside each battery and the plates. The capacity of each cluster should be equal. Otherwise, the group with small capacity will be fully charged in advance due to small capacity. Then the battery pack with large capacity is not fully charged, the terminal voltage of the battery is low, and the total voltage is not full. Charging, causing a group with a small capacity to form an overcharge, if the battery is discharged, the group with a small capacity will have no power in advance, the other battery terminals have a higher voltage, and the total voltage of the battery has no electric power to terminate the protection. The voltage and discharge continue, however, causing the battery to over discharge.

Overcharge and overdischarge of the battery and untimely charging will affect the service life of the battery. However, the battery capacity of the battery is further reduced, and the battery capacity is further reduced. The battery is overcharged and overdischarged. Decrease quickly and scrap.

2. Processing of the front plate before weighing

Before the plate is weighed, it is necessary to clear the excess front of the board, the burr, and the excess active material when the paste is applied. If it is not clean, it will cause short circuit of the battery plate, that is, the battery will self-discharge. Use the plate brush to clean the excess impurities on the plate for easy soldering to prevent soldering and false soldering. To make the plates have irregularities, remove the powder seriously, and have holes in the plates, select them.

3. How to weigh the plates

When the pole plate is weighed and matched, it is necessary to first weigh out a part of the plates and discharge them on the workbench according to the weight, and compare the weights. Then weigh the plates on the scales and weigh them on the scale. The weight of the plate is placed with the plate placed on the table according to the weight of the plate, thus eliminating some trouble. (The difference in weight between each group of positive or negative plates is as small as possible. The error of 10~14AH should not exceed 1g per group, and the error of 17~20AH should not exceed 2g per group.

Package partition

1. The weighed plates are weighted according to the regulations. After the group is assembled, the plates are coated. The separators are made of microporous rubber and glass fiber. Pay attention to the cleaning of the separators when packing. In the middle of the board, if the poles are aligned, they are placed in the pole box.

2. The two-piece positive plate is only used to hold the positive plate together with a thin separator plate. Do not include the negative plate, so as to avoid the short circuit caused by the defect of the single-piece separator. The single-piece package board is only used for packaging the positive electrode plate with the separator, and the negative electrode plate is placed inside the package plate box, which is convenient and simple.

Lead parts selection and processing

1. Lead parts have lead electrodes and poles, which are cast with special molds. Generally, at about 450 °C, the temperature is too high, lead oxidation is severe, and lead parts are severely cracked due to shrinkage. It is not allowed to use iron to beat the mold. Lead pieces should be made to ensure that there are no thorns around them, and if necessary, trim them.

1. Welding of clusters, welding is to weld the positive and negative electrodes together to form a cluster, and oxygen-acetylene is used as a tool for connecting the poles and the bus bars.

2. Place the packaged plate in the cluster box, insert the plate in the cluster box into the comb plate, insert the negative pole first and insert the positive pole, so that the tab is fully inserted into the comb. If there is not enough, manually arrange it, then put the strip between the positive and negative ears, the bridge column and the pole.

3. Turn on the acetylene and oxygen of the torch and ignite it to the appropriate size. The welding torch and the electrode are moved to the position of the ear, and then the lead strip and the tab are melted, and after the bus bar is basically welded, the pole and the bus bar are welded together. If there are impurities such as lead ash in the welding, the false welding and the virtual welding will be found. The welding of the pole and the bus bar is a key process in the production process, and the welding is firm, no welding, no false welding. . At this time, it is necessary to remove impurities while welding, and finally fill the bus bar.

4. After welding the bus bar, the test is free of defects and then enters the grooving process. Generally, the cluster with terminals is installed first, and then installed in other clusters. The positive and negative poles are arranged in +-, +-, +-, +-, +-, +- series, do not install the wrong polarity.

When the plate is grooved, it must be installed at the bottom, and then it is normal to check if the bridge column is used. If the displacement is handled manually, whether the upper cover of the test cover can be covered or not is completed.

5. How to check the pole group, first we use the multimeter to measure whether the battery is short-circuited. If the measured voltage is zero or close to zero, the battery is short-circuited. Check the cluster to find the short-circuit position for repair. Check that the multimeter is connected to the positive and negative terminals without a short circuit. The voltage displayed does not show a negative number. If it is, verify that the polarity is reversed and then reload it into the battery compartment.

6. The pole group welding is a key item when the plate is tested and there is no fault to enter the bridge welding. The bridge is clamped by a bridge and welded to the bridge by oxygen welding. When welding, the flame should be ensured not to burn to the battery casing, to ensure that there is no false welding, virtual welding, the poles are separated from the cluster, and the cover can be smoothly closed. The battery cover is sealed, and the epoxy resin glue and the curing agent are used in a ratio of 2:1. The glue should be used in time to avoid solidification for a long time. The solidification of the gel has a great relationship with the temperature the higher the temperature, the faster the solidification, so use it as soon as possible. There is also a heating device for the cover.

7. After the battery cover is completed, pole welding should be carried out to check whether the extracted pole is in the middle of the lead. If not, correct it. The pole mold is placed over the drawn pole and then the pole is melted with oxygen. There is also a kind of welding, the terminal is placed on the pole of the lead, the position is to be positive, the solder wire is melted with a soldering iron, and the terminal and the pole are welded together. Pay attention to the false welding and false welding when welding.

Electrolyte configuration

The lead battery electrolyte is made of pure water and concentrated sulfuric acid.

1.280±0.005g/cm3 ((25°C).

2. The container for preparing the electrolyte must be glazed ceramic, glass cylinder, plastic tank or lead-lined wooden tank which is resistant to acid and temperature. When preparing, the staff must wear protective equipment;

Wash the utensils before preparation and wash with pure water;

When preparing the electrolyte, the pure water to be used should be placed in the container first, then the concentrated sulfuric acid should be slowly injected into the pure water, and stirring is continued. It is strictly prohibited to inject water into the sulfuric acid to avoid splashing and burning.

The conversion formula is d25=dt+0.0007(t-25)

D25: 25 ° C electrolyte concentration dt: electrolyte concentration at temperature t

0.0007: Temperature coefficient t: measured electrolyte concentration

1. The composition of the electrolyte is mainly distilled water and sulfuric acid. When the configuration is made, the container must be acid-resistant and clean.

2. Staff should be safe and wear acid-resistant gloves and clothes when working. In the event of sulfuric acid splashing on the skin during operation, the skin should be washed repeatedly with water. When disposing, pour distilled water into a clean container, then slowly introduce concentrated sulfuric acid, and stir with an acid-resistant tool. If the temperature is too high, stop adding acid to prevent excessive temperature acidity from spilling. At a temperature of 25 °C, it can be adjusted to 1.1:28. It is strictly forbidden to pour water into the acid during configuration.

3. According to the battery capacity of the acid to be added, the capacity of the battery shell, the acid density, the distribution loss in charge and discharge, etc., the acid amount can be calculated, because the acid is no longer pumped out after charging and discharging.

Injection of electrolyte

Unscrew the vent plug, be sure to penetrate the venting hole on the plug, seal the gasket and seal paper, and remove it after acid filling;

The electrolyte temperature must be cooled below 30 ° C and filled into the battery;

The prepared electrolyte is injected into each cell, and the liquid surface of the molded case battery is flush with the outer casing mark "max", and the liquid level of the rubber groove battery should be 10-15 mm higher than the partition plate;

Tighten the vent plug to prevent acid leakage.

The page contains the contents of the machine translation.