What equipment is needed to build a lead-acid battery production factory?

Lead-acid batteries are common for various applications, such as automotive, motorcycle, industrial, traction, and stationary power. They consist of positive and negative plates, separators, terminals, electrolyte, and casing. To produce lead-acid batteries, a factory needs to have different types of equipment for different stages of the production process.

Equipment for making plates

Equipment for making plates is designed to produce positive and negative plates for lead-acid batteries. The plates are made of lead or lead alloy grids coated with active materials, such as lead oxide and lead sulfate. The equipment for making plates includes:

• Grid casting machines: These machines are used to cast molten lead or lead alloy into grids of various shapes and sizes. The grids are then cooled and trimmed to the desired dimensions.

• Pasting machines: These machines are used to apply active materials onto the grids using a pasting machine. The pasting machine consists of a hopper, a mixer, a conveyor belt, and a pasting roller.

• Curing chambers: These chambers are used to cure the pasted plates at controlled temperature and humidity conditions. The curing process allows the active materials to bond with the grids and form a solid structure.

• Formation tanks: These tanks are used to form the plates by immersing them in sulfuric acid solution and applying an electric current. The formation process converts the active materials into their final electrochemical state.

Equipment for assembling cells or modules

Equipment for assembling cells or modules is used to assemble plates, separators, terminals, and other components into battery cells or modules. The equipment for assembling cells or modules includes:

• Enveloping and stacking machines: These machines are used to wrap the plates with separators and stack them into groups according to the desired polarity and capacity. The separators prevent short circuits between the plates and allow the electrolyte to flow through.

• Cos casting machines: These machines are used to cast molten lead or lead alloy onto the plate lugs to form intercell connectors (cos). The cos connect the cells in series or parallel to form a battery module.

• Heat sealing machines: These machines are used to seal the battery modules with plastic cases using heat and pressure. The cases protect the modules from external damage and leakage.

Equipment for forming cells or modules

Equipment for forming cells or modules is used to charge and discharge battery cells or modules to activate them and form their capacity. The equipment for forming cells or modules includes:

• Formation chargers: These devices are used to charge the cells or modules with a constant current or voltage until they reach their full state of charge. The charging process initiates chemical reactions within the cells or modules that generate electricity.

• Formation dischargers: These devices are used to discharge the cells or modules with a constant current or voltage until they reach their end of discharge. The discharging process reverses the chemical reactions within the cells or modules that consume electricity.

• Formation testers: These devices are used to test the performance and quality of the cells or modules after formation. The testers measure parameters such as voltage, current, capacity, internal resistance, and temperature.

Conclusion

To build a lead-acid battery production factory, a factory needs to have equipment for making plates, equipment for assembling cells or modules, and equipment for forming cells or modules. These equipment can help produce high-quality lead-acid batteries for various applications. However, these equipment also require proper maintenance and operation to ensure safety and efficiency.