A method for improving the heat seal quality of agm lead acid batteries

Abstract

A method for improving the heat sealing quality of AGM lead-acid storage battery, a pre-detection station of the storage battery is arranged, the deformation amount of the heat sealing part of the storage battery is detected one by one in the pre-detection station for the storage battery which has been installed with the pole group before entering the heat sealing process, the qualified storage battery is entered into the heat sealing process, the battery tank which does not pass the detection and has the heat sealing risk is removed, and the heat sealing is performed after manual correction. The method can ensure the matching of the heat sealing parts of the battery tank and the battery cover, avoid the heat sealing deviation, reduce the process quality loss, and improve the quality of the AGM lead-acid storage battery. The detection device is used for detecting the storage battery, the detection device has high automation degree, the detection result is accurate, the detection is time-saving and labor-saving, and the detection device can be used for different specifications of the storage battery.

Description

Technical Field

[0001] This invention relates to a method for manufacturing lead-acid batteries, and in particular to a method for improving the heat-sealing quality of AGM lead-acid batteries, belonging to the field of lead-acid battery technology. Background Technology

[0002] With the rapid development of new energy vehicles, the market share of AGM lead-acid batteries is increasing. Vehicle-mounted AGM lead-acid batteries typically use PP material for the battery casing. AGM lead-acid batteries are designed with a low electrolyte level, placing extremely high demands on the sealing of the battery casing. Currently, a significant portion of batteries returned to the market are due to heat-sealing leaks. The reasons for these leaks are analyzed as follows: During the heat-sealing process, the heat-sealing parts of the battery cover and the battery case are melted by a hot plate, and then bonded together by the heat-melted parts of the cover and battery case. The battery cover, being an injection-molded part, is not affected by external forces during the heat-sealing process, resulting in relatively accurate positioning. However, because the battery case already has the electrode group inserted before heat-sealing, the tight assembly of the electrode group exerts significant pressure on the battery case, causing deformation. This deformation, occurring at the heat-sealing area and being substantial, prevents the heat-sealing parts of the battery cover and battery case from properly aligning, leading to misalignment and ultimately, battery leakage. Summary of the Invention

[0003] This invention aims to solve the problems existing in the prior art and provides a method to improve the heat sealing quality of AGM lead-acid batteries. The method adds a heat sealing pre-inspection process to inspect each battery before heat sealing, and removes battery cells with excessive deformation at the heat sealing part, thereby effectively avoiding battery heat sealing leakage.

[0004] The problem described in this invention is solved by the following technical solution:

[0005] A method for improving the heat sealing quality of AGM lead-acid batteries involves setting up a pre-inspection station for batteries. Before entering the heat sealing process, batteries with installed electrode groups are inspected one by one at the pre-inspection station to check whether the deformation of the heat sealing part of the battery is qualified. Qualified batteries enter the heat sealing process, while battery cells that fail the inspection and have heat sealing risks are removed, manually corrected, and then heat sealed.

[0006] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries has the following testing standards for batteries at the pre-inspection station: For 1×6 structure batteries, two testing points are set, which are respectively located in the middle of the heat-sealed parts of the two small faces of the battery case, and the deformation of each testing point is no more than 2 mm; For 2×3 structure batteries, six testing points are set, which are respectively located in the middle of the heat-sealed parts of each individual cell on the large face of the battery case, and the deformation of each testing point is no more than 2 mm.

[0007] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries includes a battery pre-inspection station equipped with a conveying device and an inspection device. The battery to be inspected is transported to the inspection station by the conveying device and inspected by the inspection device. The inspection device is equipped with a bracket, and an inspection cylinder is installed on the top of the bracket. The piston rod of the inspection cylinder is fixedly connected to a connecting plate, and the connecting plate is fixedly connected to an inspection frame. The inspection frame is equipped with an inspection template, and inspection components are set on the inspection template corresponding to the inspection points of the battery.

[0008] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries includes a testing component comprising an outer sleeve, a displacement sensor, a spring, a connecting arm, and a mounting plate. The mounting plate is connected to the testing template via the connecting arm. The outer sleeve passes through the mounting plate and is threadedly connected to it. The spring is located inside the outer sleeve. The displacement sensor passes through the outer sleeve and the spring. The first end of the displacement sensor corresponds to the battery, and the second end of the displacement sensor is equipped with a nut.

[0009] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries includes a conveyor frame, a conveyor belt and a conveyor motor on the conveyor frame, a conveyor motor frame driving the conveyor belt to move, and a battery support plate on the conveyor belt.

[0010] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries also includes a testing device equipped with positioning cylinders. Two positioning cylinders are supported by support columns and symmetrically arranged on both sides of the conveyor frame. The piston rods of the positioning cylinders are connected to clamps.

[0011] The above-mentioned method for improving the heat sealing quality of AGM lead-acid batteries includes a photoelectric switch on the conveyor frame.

[0012] This invention addresses the problem of heat-sealing leakage in AGM lead-acid batteries by adding a pre-inspection station for the battery cells. Before heat sealing, each battery cell with its electrode group already installed is inspected at this station to accurately determine if the deformation is within acceptable limits. Batteries that pass inspection proceed to the heat sealing process, while those with significant deformation posing a heat-sealing risk are discarded and manually corrected before heat sealing. This method ensures a proper fit between the battery cell and the battery cover at the heat-sealing point, preventing misalignment during heat sealing, reducing process quality loss, and improving the overall quality of AGM lead-acid batteries. The invention utilizes a highly automated testing device for battery inspection. This device provides accurate results, saves time and labor, and can be used for batteries of various specifications. Attached Figure Description

[0013] The invention will now be further described with reference to the accompanying drawings.

[0014] Figure 1 This is a schematic diagram of the battery pre-testing station;

[0015] Figure 2 yes Figure 1 View from direction A;

[0016] Figure 3 yes Figure 1 A magnified view of a portion of point B in the middle;

[0017] Figure 4 This is a schematic diagram showing the distribution of detection points in a 2×3 battery structure;

[0018] Figure 5 This is a schematic diagram of the distribution of test points in a 1×6 battery structure.

[0019] The following are the labels in the diagram: 1. Bracket, 2. Detection cylinder, 3. Connecting plate, 4. Detection frame, 5. Detection template, 6. Conveyor frame, 7. Conveyor motor, 8. Conveyor belt, 9. Battery support plate, 10. Photoelectric switch, 11. Support column, 12. Positioning cylinder, 13. Clamping plate, 14. Battery under test, 15. Mounting plate, 16. Mounting arm, 17. Outer sleeve, 18. Spring, 19. Displacement sensor, 20. Detection point, 21. Outer sleeve nut. Detailed Implementation

[0020] This invention improves upon existing technologies to address the issue of heat-sealing quality in AGM lead-acid batteries. Before the heat-sealing process, each battery with assembled electrode groups is inspected individually to accurately determine if the battery case deformation meets requirements. Batteries that fail inspection or have significant deformation posing a heat-sealing risk are discarded, repaired, and corrected before heat-sealing. Batteries that pass inspection can directly proceed to the heat-sealing process. For locations prone to deformation after assembling electrode groups for two commonly used battery specifications, please refer to [link / reference needed]. Figure 4 , Figure 5 . Figure 4 The 2×3 structure battery shown has a deformation-prone position in the middle of the heat-sealed part of each cell on the large side of the battery case. This position is far from the support point and has the largest deformation. The easily deformable part will bulge outward under the action of the electrode group. Therefore, six detection points are set for the 2×3 structure battery, and the deformation of each detection point 20 is not greater than 2 mm. Figure 5 The 1×6 battery shown has a deformation-prone area at the midpoint between the two end cell heat-sealing sections on the small side of the battery case. Therefore, two detection points 20 are set for the 1×6 battery, with the deformation at each point not exceeding 2 mm. If any detection point of the tested battery fails to meet the requirements, it needs to be repaired and corrected, thus effectively ensuring the heat-sealing quality of the battery.

[0021] Battery deformation detection is performed at the newly added battery pre-inspection station. (See also...) Figures 1-3 The battery pre-inspection station is equipped with a conveyor and a testing device. Batteries awaiting pre-inspection are transported to the testing station by the conveyor and then tested by the testing device. (See also...) Figure 1 , Figure 2 The testing device includes a support frame 1, with a testing cylinder 2 mounted on the top of the support frame. The piston rod of the testing cylinder is fixedly connected to a connecting plate 3, and the connecting plate is bolted to a testing frame 4. The testing frame can be replaced to meet the testing requirements when testing batteries of different specifications. The testing frame is equipped with a testing template 5, on which testing components are set according to the inspection points of the heat-sealed parts of the battery being tested. Each set of testing components corresponds to one testing point. Figure 1 , Figure 2 The illustrated embodiment is for testing a 2×3 structure battery, with six testing components corresponding to six testing points. Each testing component includes an outer sleeve, a displacement sensor, a spring, a connecting arm, and a mounting plate. The mounting plate is fixedly connected to the connecting arm, and one side of the connecting arm passes through a pre-drilled hole on the testing template and is secured by a nut. Loosening the nut allows adjustment of the distance between the mounting plate and the battery being tested. The spring 18 is installed inside the outer sleeve, and the displacement sensor 19 passes through the outer sleeve and the spring. The first end of the displacement sensor (… Figure 3 The left end of the sensor corresponds to the battery being tested. The tail end of the displacement sensor is threaded, and a nut is screwed into the thread. The outer sleeve is threaded, passes through the mounting plate, and is threadedly connected to it. The outer sleeve is fixed to the mounting plate by the outer sleeve nut 21. Loosening the outer sleeve nut and rotating the outer sleeve allows for precise adjustment of the zero-position of the displacement sensor's head end according to the testing requirements. If the battery deforms and bulges excessively during the testing process, the displacement sensor is activated, and it sends a signal to the PLC. The head end of the displacement sensor is spherical.

[0022] See Figure 1 , Figure 2 The conveying device includes a conveyor frame 6, on which a conveyor belt 8 and a conveyor motor 7 are mounted. The conveyor motor drives the conveyor belt via a transmission mechanism frame. A battery tray 9 for placing the battery to be tested is mounted on the conveyor belt. The testing device also includes positioning cylinders 12. Two symmetrically arranged positioning cylinders are supported by support columns 11, and the positioning cylinders are located on both sides of the conveyor frame and at the bottom of the testing frame, respectively. The piston rods of the positioning cylinders are connected to clamping plates 13. When the piston rods extend, the two clamping plates hold and position the battery 14 to be tested. A photoelectric switch 10 is also mounted on the conveyor frame.

[0023] The working process of the conveying and testing devices is as follows: The testing frame is installed according to the battery specifications; the position of the displacement sensor is adjusted according to the battery deformation requirements; the battery to be tested, with its electrode group assembled, is placed on the battery tray of the conveyor belt; the conveyor motor is started, and the conveyor belt moves to transport the battery to be tested to the testing frame; the photoelectric switch detects that the battery to be tested has reached its position and transmits a signal to the PLC, which controls the conveyor motor to stop; the piston rod of the positioning cylinder extends to fix the battery to be tested; the piston rod of the testing cylinder moves downward, and the displacement sensor moves to the testing point. If the deformation of the battery in the testing slot meets the requirements, it will not touch the displacement sensor, the piston rod of the positioning cylinder retracts, the testing cylinder retracts, and the conveyor motor moves to remove the qualified battery from the testing device for the heat sealing process; if the deformation of the battery in the testing slot exceeds the standard, it will touch the displacement sensor, the PLC will alarm, and the unqualified battery will be manually removed for repair. In the above testing process, the coordinated actions of the conveyor motor, positioning cylinder, and testing cylinder are controlled by the PLC, and the photoelectric switch and displacement sensor are electrically connected to the PLC.

[0024] The method of this invention is used to test each battery in the assembled electrode group. The test method is fast and accurate, and batteries with heat sealing risks can be removed and repaired in time, which greatly improves the heat sealing quality of AGM lead-acid batteries.

Claims

1. A method of improving the heat seal quality of an AGM lead acid battery, characterized by: The pre-detection station is arranged to detect whether the deformation of the heat sealing part of the battery is qualified before the battery with the installed pole group enters the heat sealing process. The detection standard of the pre-detection station for the battery is as follows: two detection points are arranged for the 1x6 structure battery, and the detection points are arranged at the middle positions of the heat sealing parts of the two small faces of the battery tank, and the deformation of each detection point is not greater than 2 mm; six detection points are arranged for the 2x3 structure battery, and each detection point is arranged at the middle position of the heat sealing part of each single cell of the large face of the battery tank, and the deformation of each detection point is not greater than 2 mm. The pre-detection station for the battery is provided with a conveying device and a detection device, the battery to be detected is conveyed to the detection position by the conveying device, and the detection device is used for detection, the detection device is provided with a support, a detection cylinder is arranged at the top of the support, a connecting plate is fixedly connected to the piston rod of the detection cylinder, a detection frame is fixedly connected to the connecting plate, the detection frame is provided with a detection template, and detection assemblies are arranged on the detection template and correspond to the detection points of the battery. When detection is performed, the battery to be detected with the assembled pole group is placed on the battery supporting plate of the conveying belt. The conveying motor is started, the conveying belt moves to convey the battery to be detected to the detection frame, the photoelectric switch detects that the battery to be detected is in position, transmits a signal to the PLC, and the PLC controls the conveying motor to stop working; the piston rod of the positioning cylinder extends to fix the battery to be detected; the piston rod of the detection cylinder descends, the displacement sensor moves to the detection point, if the deformation of the battery in the battery tank to be detected meets the requirements, the displacement sensor will not be touched, the piston rod of the positioning cylinder is retracted, the detection cylinder is retracted, the conveying motor moves to move the qualified battery out of the detection device and into the heat sealing process; if the deformation of the battery in the battery tank to be detected exceeds the requirements, the displacement sensor is touched, the PLC alarms, and the unqualified battery is manually removed for repair; in the detection process, the coordinated actions of the conveying motor, the positioning cylinder and the detection cylinder are controlled by the PLC, and the photoelectric switch and the displacement sensor are connected with the PLC electric signal.

2. The method of improving heat seal quality of an AGM lead-acid battery of claim 1, wherein: The detection assembly comprises an outer sleeve, a displacement sensor, a spring, a connecting arm and a mounting plate, the mounting plate is connected to the detection template through the connecting arm, the outer sleeve is threadedly connected to the mounting plate, the spring is located in the outer sleeve, the displacement sensor passes through the outer sleeve and the spring, the front end of the displacement sensor corresponds to the battery, and the tail end of the displacement sensor is provided with a nut.

3. The method of improving heat seal quality of an AGM lead-acid battery of claim 1, wherein: The conveying device is provided with a conveying frame, the conveying belt and the conveying motor are arranged on the conveying frame, the conveying motor drives the conveying belt to move, and the battery supporting plate is arranged on the conveying belt.

4. The method of improving heat seal quality of an AGM lead-acid battery of claim 1, wherein: The detection device is also provided with positioning cylinders, the two positioning cylinders are supported by support columns and symmetrically arranged on the two sides of the conveying frame, and the piston rods of the positioning cylinders are connected to the clamping plates.

5. The method of improving heat seal quality of an AGM lead-acid battery of claim 1, wherein: The conveying frame is provided with a photoelectric switch.

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