Acid filling machine and acid filling and weighing method

Abstract

The acid filling machine comprises a rack, an acid storage device, an acid liquid quantifying device, and a weighing device. A first workbench, a second workbench, a third workbench, and an acid adding platform for placing lead storage batteries are sequentially arranged from top to bottom at the front of the rack. The acid storage device is installed at the rear of the rack. The acid liquid quantifying device is installed between the first workbench and the second workbench. The weighing device is installed on the side of the rack. The weighing device comprises a man-machine touch screen, a PLC controller, a first weight sensor, and a second weight sensor. The man-machine touch screen is installed on the PLC controller. The first weight sensor and the second weight sensor are electrically connected to the PLC controller. The first weight sensor and the second weight sensor are respectively installed at the entrance side and the exit side of the rack. The weighing device can detect whether the acid in the quantifying cup is sufficient and whether the acid in the quantifying cup is completely filled into the lead storage battery.

Description

Technical Field

[0001] This invention relates to the field of lead-acid battery acid filling technology, and in particular to an acid filling machine and a method for weighing lead-acid batteries during acid filling. Background Technology

[0002] Lead-acid batteries require an acid filling process during production. However, existing lead-acid battery acid filling equipment and processes do not include an acid filling weighing structure or a weighing process.

[0003] Existing acid filling equipment or processes mainly involve using a magnetic pump to draw acid from the acid tank of the equipment through a pipeline to a measuring cup above the equipment. Then, negative pressure is used to draw the acid from the measuring cup into the lead-acid battery in a short time, thus completing the acid filling process. However, it is impossible to determine whether the required amount of acid has been added to the battery, which often leads to problems such as too much or too little acid being added, resulting in serious quality issues.

[0004] Currently, when filling batteries with acid, the amount of acid to be filled is measured using a measuring cup in the acid filling equipment. However, the acid in the measuring cup is pumped in by a pump that operates on a timer. The pump starts drawing acid from the acid tank of the acid filling equipment into the measuring cup, and the timer begins as soon as the pump starts. Once the time is up, the pump will automatically stop, regardless of whether the measuring cup is full. When there are problems such as improper operation, incorrect parameter settings, insufficient acid in the acid tank, leakage from the acid pump, leakage in the pipeline, or pump malfunction, the amount of acid pumped into the measuring cup will be insufficient. However, the current acid filling equipment cannot recognize this and will continue to execute the current process. This results in insufficient acid being added to the battery, leading to defective battery products and serious quality problems. Moreover, these products will still flow to the next stage of processing, causing a waste of manpower and material resources. Summary of the Invention

[0005] In view of this, in order to solve the technical problems existing in the prior art, the present invention provides an acid filling machine and acid filling weighing method that can accurately check whether the amount of acid added to the battery is within the process standard, can immediately sound an alarm when an abnormal acid amount occurs, remind employees that the acid filling of the battery is abnormal, employees can immediately handle the abnormality, and can completely prevent defective products from flowing to the next process.

[0006] The present invention solves the above-mentioned technical problems through the following technical solutions:

[0007] On one hand, the present invention provides an acid filling machine, including an acid filling machine for filling and weighing lead-acid batteries. The acid filling machine includes a frame, an acid storage device, an acid metering device, and a weighing device. A first workbench, a second workbench, a third workbench, and an acid filling platform for placing lead-acid batteries are arranged sequentially from top to bottom in front of the frame. The acid storage device is installed at the rear of the frame. The acid metering device is installed between the first workbench and the second workbench. The weighing device is installed on the side of the frame.

[0008] The weighing device includes a human-machine interface touch screen, a PLC controller, a first weight sensor, and a second weight sensor. The human-machine interface touch screen is mounted on the PLC controller. The first and second weight sensors are both electrically connected to the PLC controller. The first and second weight sensors are respectively installed on the entrance and exit sides of the frame. The PLC controller is fixed on the entrance side of the frame and located above the first weight sensor. The PLC controller is electrically connected to an indicator light and an alarm light.

[0009] The acid storage device includes an acid source pipe, an acid storage tank, and an acid delivery pipe. The acid source pipe is connected to the acid storage tank. One end of the acid delivery pipe is connected to the acid storage tank, and the other end of the acid delivery pipe is connected to an acid metering device. An acid pump is installed on the acid delivery pipe. The acid in the acid storage tank is pumped into the acid delivery pipe by the acid pump and then delivered to the acid metering device. The acid pump is electrically connected to a PLC controller. A start valve is installed on the acid source pipe, and the start valve is electrically connected to the PLC controller.

[0010] The acid metering device includes several metering cups and several transition cylinders of the same number as the metering cups. Each metering cup is equipped with an acid inlet pipe and an acid return pipe that pass through the first workbench. The acid inlet pipe and the acid return pipe of each metering cup are connected to the acid delivery pipe. Each transition cylinder is fixed at the upper end of the third workbench. The top of each transition cylinder is connected to an acid delivery branch pipe. Each transition cylinder is connected to the corresponding metering cup above it through the acid delivery branch pipe. The bottom of each transition cylinder is connected to an acid filling pipe.

[0011] An acid-adding device is provided below the transition cylinder. The acid-adding device is installed at the lower end of the third workbench and above the acid-adding platform.

[0012] As a further improvement to the above technical solution, the acid filling machine includes a negative pressure circulation device, which is installed at the rear of the frame. The negative pressure circulation device includes two negative pressure storage tanks and two negative pressure source pipes. The two negative pressure source pipes are connected to the two negative pressure storage tanks. The negative pressure storage tanks are electrically connected to a PLC controller. A negative pressure conveying pipe is also connected between the two negative pressure storage tanks. The two negative pressure storage tanks are connected to an acid metering device through the negative pressure conveying pipe. Switching valves are installed on the two negative pressure source pipes.

[0013] As a further improvement to the above technical solution, the lower end of each acid inlet pipe and the lower end of each acid return pipe extend into their corresponding metering cup, and the upper end of each acid inlet pipe and the upper end of each acid return pipe are connected to the acid delivery pipeline. Each acid inlet pipe is equipped with an acid injection valve controlled by a PLC controller, and each acid return pipe is equipped with an acid return valve controlled by a PLC controller.

[0014] As a further improvement to the above technical solution, a vacuum tube is also sealed to the top of each transition cylinder. The vacuum tube is connected to the negative pressure storage tank of the negative pressure circulation device, and a vacuum control valve controlled by a PLC controller is installed on each vacuum tube.

[0015] As a further improvement to the above technical solution, the acid filling machine includes an acid filling limiting device, which is installed at the rear of the machine frame. The acid filling limiting device includes an acid filling limiting frame, an acid filling lifting motor, and an acid filling support plate. The acid filling support plate is installed at the top of the acid filling limiting frame, and the acid filling lifting motor is installed below the acid filling limiting frame. The acid filling limiting frame is equipped with an acid filling lifting screw, and the output shaft of the acid filling lifting motor is connected to the acid filling lifting screw. The acid inlet pipe and acid return pipe in each metering cup are both passed through the acid filling support plate at the top of the acid filling limiting frame. The acid filling lifting motor outputs power to the acid filling lifting screw. The acid filling lifting motor is electrically connected to a human-machine interface touch screen and a PLC controller. The human-machine interface touch screen is used to input the stroke of the acid filling lifting motor to control the upward and downward movement of the acid filling limiting frame. The PLC controller controls the acid filling lifting motor to drive the acid filling limiting frame to rise and fall.

[0016] As a further improvement to the above technical solution, the acid adding device includes a lifting structure and an acid filling head of the same number as the metering cup. The lifting structure is installed at the lower end of the third platform, and the acid filling head is installed at the bottom of the lifting structure. Each acid filling head is connected to an acid filling pipe corresponding to the transition cylinder.

[0017] As a further improvement to the above technical solution, the lifting structure includes a lifting adjustment screw, a lifting cylinder, and a lifting fixing frame. The lifting adjustment screw is connected to the lifting cylinder, the lifting cylinder is installed at the upper end of the lifting fixing frame, and the acid filling head is fixed at the lower end of the lifting fixing frame.

[0018] As a further improvement to the above technical solution, an induction structure is also installed inside the acid storage tank. The induction structure is electrically connected to the PLC controller. The induction structure includes a high liquid level sensor and a low liquid level sensor. The high liquid level sensor is installed at the top of the acid storage tank, and the low liquid level sensor is installed at the bottom of the acid storage tank.

[0019] On the other hand, the present invention also provides an acid filling and weighing method, including an acid filling and weighing method for adding acid to a lead-acid battery using an acid filling machine, the acid filling and weighing method comprising the following steps:

[0020] Step S1) Set the standard acid filling amount M0 for the lead-acid battery in the PLC controller;

[0021] Step S2) Before the acid-adding device fills the lead-acid battery with acid, the lead-acid battery is automatically weighed by the first weight sensor at the rack inlet. The first weight sensor sends the weight M1 data of the lead-acid battery obtained after weighing to the PLC controller.

[0022] Step S3) After the acid-adding device has filled the lead-acid battery with acid, the lead-acid battery is placed on the second weight sensor at the outlet of the rack for automatic weighing. The second weight sensor sends the weight M2 of the lead-acid battery after filling with acid to the PLC controller.

[0023] Step S4) By reading the weight M1 of the lead-acid battery before acid filling and the weight M2 of the lead-acid battery after acid filling, the PLC controller will automatically calculate the actual amount of acid filled into the lead-acid battery as M2-M1.

[0024] Step S5) The PLC controller compares the calculated actual acid filling amount M2-M1 with the standard acid filling amount M0 and displays the comparison result on the human-machine touch screen. If the actual acid filling amount M2-M1 is consistent with the standard acid filling amount M0, it is judged as qualified and the indicator light will light up. If the actual acid filling amount M2-M1 is inconsistent with the standard acid filling amount M0, it is judged as unqualified and the alarm light will immediately sound an alarm. The human-machine touch screen will also display the current acid amount filled into the lead-acid battery to determine whether the acid amount filled into the lead-acid battery is too much or too little. The staff will then adjust the acid filling amount of the acid filling machine or check whether the acid filling machine is malfunctioning.

[0025] Step S6) Repeat steps S1-S5 above until the actual amount of acid injected is consistent with the standard amount of acid injected M0.

[0026] Compared with the prior art, the technical solution of the present invention has at least the following beneficial effects:

[0027] (1) The acid filling machine of the present invention includes a frame, an acid storage device, an acid metering device, and a weighing device. A first workbench, a second workbench, a third workbench, and an acid filling platform for placing lead-acid batteries are sequentially arranged from top to bottom at the front of the frame. The acid storage device is installed at the rear of the frame, the acid metering device is installed between the first and second workbench, and the weighing device is installed on the side of the frame. The weighing device includes a human-machine interface touchscreen, a PLC controller, a first weight sensor, and a second weight sensor. The human-machine interface touchscreen is mounted on the PLC controller. Both the first and second weight sensors are electrically connected to the PLC controller. The first and second weight sensors are respectively installed at the inlet and outlet sides of the frame. This invention, by setting up a weighing device, allows for the automatic weighing of the lead-acid battery before the acid-adding device fills the battery with acid. A first weight sensor at the rack inlet automatically weighs the battery, sending the weight data M1 to the PLC controller. After the acid-adding device has filled the battery with acid, the battery is placed at the rack outlet and automatically weighed again by a second weight sensor. The second weight sensor sends the weight data M2 (the weight of the battery after acid filling) to the PLC controller. The PLC controller reads the battery weights M1 and M2 before and after acid filling and automatically calculates the actual amount of acid added (M2-M1). The PLC controller then compares the calculated actual amount of acid added (M2-M1) with the standard amount (M0). The weighing device of this invention can accurately check whether the amount of acid added to the lead-acid battery is within the process standard. When an abnormal acid level is detected, an alarm will sound immediately to alert employees that there is an issue with the acid filling process. Employees can then immediately address the problem, completely preventing defective products from flowing to the next process and ensuring the production quality of the lead-acid batteries. The weighing device of this invention can detect whether there is enough acid in the metering cup each time, and whether all the acid in the metering cup has been poured into the lead-acid battery, thus providing accurate assurance for the measurement of the amount of acid added to the lead-acid battery.

[0028] (2) The acid storage device of the present invention includes an acid source pipe, an acid storage tank, and an acid delivery pipe. The acid source pipe is connected to the acid storage tank, one end of the acid delivery pipe is connected to the acid storage tank, and the other end of the acid delivery pipe is connected to an acid metering device. An acid pump is installed on the acid delivery pipe. The acid in the acid storage tank is pumped into the acid delivery pipe by the acid pump and then delivered to the acid metering device by the acid delivery pipe. The acid pump is electrically connected to a PLC controller. A start valve is installed on the acid source pipe and is electrically connected to the PLC controller. The acid metering device includes several metering cups and several transition cylinders of the same number as the metering cups. Each metering cup is provided with an acid inlet pipe and an acid return pipe passing through the first workbench. The acid inlet pipe and the acid return pipe of each metering cup are connected to the acid delivery pipe. Each transition cylinder is fixed to the upper end of the third workbench. The top of each transition cylinder is connected to an acid supply branch pipe, and each transition cylinder is connected to its corresponding metering cup above it via the acid supply branch pipe. The bottom of each transition cylinder is connected to an acid filling pipe, and an acid adding device is located below each transition cylinder. The lower ends of each acid inlet pipe and each acid return pipe extend into their corresponding metering cups, and the upper ends of each acid inlet pipe and each acid return pipe are connected to the acid supply pipeline. Each acid inlet pipe is equipped with an acid injection valve controlled by a PLC controller, and each acid return pipe is equipped with an acid return valve controlled by a PLC controller. The lower end of each acid inlet pipe extends into its corresponding metering cup, and the upper end of each acid inlet pipe is connected to the acid supply pipeline, utilizing the acid supply pipeline for acid supply. This invention uses a PLC controller to control the acid injection valve and the acid return valve, facilitating control of the acid addition amount, improving the accuracy of the acid volume in each metering cup, and reducing errors.

[0029] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, the following detailed description is provided in conjunction with preferred embodiments and accompanying drawings. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the acid filling machine of the present invention. Figure 1 ;

[0031] Figure 2 This is a schematic diagram of the structure of the acid filling machine of the present invention. Figure 2 ;

[0032] Figure 3 This is a schematic diagram of the structure of the acid filling machine of the present invention. Figure 3 ;

[0033] Figure 4 This is a detailed enlarged schematic diagram of the acid filling limiting device in the acid filling machine of the present invention;

[0034] Figure 5 This is a schematic diagram showing the relationship between the acid metering device and the acid addition device of the present invention;

[0035] Figure 6 This is a detailed enlarged schematic diagram of the acid metering device and the acid addition device of the present invention;

[0036] Figure 7 This is a detailed enlarged schematic diagram of the acid addition device of the present invention;

[0037] Figure 8 This is a rear view of the acid filling machine of the present invention;

[0038] Figure 9 This is the electrical wiring diagram of the PLC controller and the human-machine interface screen of the present invention;

[0039] Figure 10 This is the electrical wiring diagram of the PLC controller, the first weight sensor, and the second weight sensor of the present invention.

[0040] In the diagram: Frame 1, First workbench 11, Second workbench 12, Third workbench 13, Acid adding platform 14, Transparent glass door 15, Inlet side 16, Outlet side 17, Acid storage device 2, Acid source pipe 21, Acid storage tank 22, Sensing structure 221, High level sensor 2211, Low level sensor 2212, Acid delivery pipe 23, Acid pump 24, Start valve 25, Acid metering device 3, Metering cup 31, Acid inlet pipe 311, Acid return pipe 312, Acid injection valve 313, Acid return valve 314, Transition cylinder 32, Acid delivery branch pipe 321, Acid filling pipe 322, Vacuum pipe 323, Vacuum control valve 3 24. Weighing device 4. Human-machine interface touch screen 41. PLC controller 42. Indicator light 421. Alarm light 422. First weight sensor 43. Second weight sensor 44. Switching power supply 45. 485 module 46. Acid filling device 5. Lifting structure 51. Lifting adjustment screw 511. Lifting cylinder 512. Lifting fixing frame 513. Acid filling head 52. Negative pressure circulation device 6. Negative pressure storage tank 61. Two negative pressure source pipelines 62. Switching valve 63. Negative pressure conveying pipeline 64. Acid filling limit device 7. Acid filling limit frame 71. Acid filling lifting motor 72. Acid filling support plate 73. Acid filling lifting screw 74. Detailed Implementation

[0041] The present invention will now be described in detail with reference to the accompanying drawings, which form part of this specification. The principles of the invention are illustrated by means of embodiments, and other aspects, features, and advantages of the invention will become apparent from this detailed description. In the accompanying drawings, the same or similar parts in different figures are indicated by the same reference numerals.

[0042] like Figure 1-8As shown, Embodiment 1 of the present invention provides an acid filling machine, including an acid filling and weighing machine for lead-acid batteries. The acid filling machine includes a frame 1, an acid storage device 2, an acid metering device 3, and a weighing device 4. From top to bottom, a first workbench 11, a second workbench 12, a third workbench 13, and an acid filling platform 14 for placing lead-acid batteries are arranged in sequence in front of the frame 1. The acid storage device 2 is installed at the rear of the frame 1. The acid metering device 3 is installed between the first workbench 11 and the second workbench 12. A transparent glass door is also installed between the first workbench 11 and the second workbench 12. The weighing device 4 is installed on the side of the frame 1. The weighing device 4 includes a human-machine interface 41, a PLC controller 42, a first weight sensor 43, and a second weight sensor 44. The human-machine interface 41 is mounted on the PLC controller 42. The first weight sensor 43 and the second weight sensor 44 are both electrically connected to the PLC controller 42. The first weight sensor 43 and the second weight sensor 44 are respectively mounted on the inlet side 16 and the outlet side 17 of the frame 1. The inlet side 16 of the frame 1 is the inlet before the lead-acid battery is filled with acid, and the outlet side 17 of the frame 1 is the outlet after the lead-acid battery is filled with acid. In this invention, the PLC controller 42 is fixed on the inlet side 16 of the frame 1 and located above the first weight sensor 43. The PLC controller 42 is electrically connected to an indicator light 421 and an alarm light 422. The acid storage device 2 includes an acid source pipe 21, an acid storage tank 22, and an acid delivery pipe 23. The acid source pipe 21 is connected to the acid storage tank 22. One end of the acid delivery pipe 23 is connected to the acid storage tank 22, and the other end of the acid delivery pipe 23 is connected to the acid metering device 3. An acid pump 24 is installed on the acid delivery pipe 23 and is electrically connected to a PLC controller 42. An start valve 25 is installed on the acid source pipe 21 and is electrically connected to the PLC controller 42. The acid metering device 3 includes several metering cups 31 and several transition cylinders 32 in equal numbers to the metering cups 31. Each metering cup 31 is provided with an acid inlet pipe 311 and an acid return pipe 312 passing through the first workbench 11. The acid inlet pipe 311 and the acid return pipe 312 of each metering cup 31 are connected to the acid delivery pipe 23. Each transition cylinder 32 is fixed to the upper end of the third workbench 13. The top of each transition cylinder 32 is connected to an acid delivery branch pipe 321. Each transition cylinder 32 is connected to the corresponding metering cup 31 above it through the acid delivery branch pipe 321. The bottom of each transition cylinder 32 is connected to an acid filling pipe 322. An acid adding device 5 is provided below the transition cylinder 32. The acid adding device 5 is installed at the lower end of the third workbench 13 and is located above the acid adding platform 14.In this invention, the standard acid filling amount for lead-acid batteries is set in the PLC controller 42. By starting the PLC controller 42, the start valve 25 is opened, and the acid is transported from the acid source pipe 21 to the acid storage tank 22. The acid in the acid storage tank 22 is pumped into the acid delivery pipe 23 by the acid pump 24 and then transported to the metering cup 31 of the acid metering device 3 for measurement. Excess acid in the metering cup 31 can be returned to the acid delivery pipe 23 through the acid return pipe 312.

[0043] In a specific implementation of this invention, the acid-adding device 5 includes a lifting structure 51 and an acid-filling head 52 in the same number as the metering cup 31. The lifting structure 51 is installed at the lower end of the third platform, and the acid-filling head 52 is installed at the bottom of the lifting structure 51. Each acid-filling head 52 is connected to an acid-filling pipe 322 corresponding to the transition cylinder 32. The lifting structure 51 includes a lifting adjusting screw 511, a lifting cylinder 512, and a lifting fixing frame 513. The lifting adjusting screw 511 is connected to the lifting cylinder 512. The lifting cylinder 512 is installed at the upper end of the lifting fixing frame 513, and the acid-filling head 52 is fixed at the lower end of the lifting fixing frame 513. By manually turning the lifting adjusting screw 511, the piston rod of the lifting cylinder 512 is adjusted to move up and down, thereby driving the lifting cylinder 512 to move the lifting fixing frame 513 up and down, and thus driving the acid-filling head 52 to move up and down.

[0044] The acid filling machine of the present invention includes a negative pressure circulation device 6, which is installed at the rear of the frame 1. The negative pressure circulation device 6 includes two negative pressure storage tanks 61 and two negative pressure source pipes 62. The two negative pressure source pipes 62 are connected to the two negative pressure storage tanks 61. The negative pressure storage tanks 61 are electrically connected to the PLC controller 42. Switching valves 63 are installed on the two negative pressure source pipes 62. A negative pressure conveying pipe 64 is also connected between the two negative pressure storage tanks 61. The two negative pressure storage tanks 61 are connected to the acid metering device 3 through the negative pressure conveying pipe 64.

[0045] In a specific implementation of this invention, the lower end of each acid inlet pipe 311 and the lower end of each acid return pipe 312 extend into their corresponding metering cup 31. The upper end of each acid inlet pipe 311 and the upper end of each acid return pipe 312 are connected to the acid delivery pipe 23. Each acid inlet pipe 311 is equipped with an acid injection valve 313 controlled by a PLC controller 42, and each acid return pipe 312 is equipped with an acid return valve 314 controlled by a PLC controller 42. The top of each transition cylinder 32 is also sealed with a vacuum tube 323. The vacuum tube 323 is connected to the negative pressure storage tank 61 through the negative pressure delivery pipe 64 so that the negative pressure storage tank 61 is connected to the acid metering device 3 through the negative pressure delivery pipe 64. Each vacuum tube 323 is equipped with a vacuum control valve 324 controlled by a PLC controller 42.

[0046] The acid filling machine of the present invention includes an acid filling limiting device 7, which is installed at the rear of the frame 1. The acid filling limiting device 7 includes an acid filling limiting frame 71, an acid filling lifting motor 72, and an acid filling support plate 73. The acid filling support plate 73 is installed at the top of the acid filling limiting frame 71, and the acid filling lifting motor 72 is installed below the acid filling limiting frame 71. The acid filling limiting frame 71 is equipped with an acid filling lifting screw 74. The output shaft of the acid filling lifting motor 72 is connected to the acid filling lifting screw 74. The acid inlet pipe 311 and the acid return pipe 312 in each metering cup 31 pass through the acid filling support plate 73 at the top of the acid filling limiting frame 71. The power output of motor 72 is supplied to the acid filling lifting screw 74 to adjust the lifting and lowering of the acid filling limit frame 71. The lifting and lowering of the acid filling limit frame 71 drives the lifting and lowering of the acid filling support plate 73, thereby adjusting the position of the acid inlet pipe 311 in the metering cup 31. The acid filling lifting motor 72 is electrically connected to the human-machine interface touch screen 41 and the PLC controller 42. The stroke of the acid filling limit frame 71 that needs to be controlled by the acid filling lifting motor 72 is input through the human-machine interface touch screen 41. The PLC controller 42 controls the stroke of the acid filling lifting motor 72 to drive the acid filling limit frame 71 to rise and fall, so that the amount of acid to be added to the lead-acid battery can be input through the human-machine interface touch screen 41.

[0047] In a specific implementation of this invention, a sensing structure 221 is installed inside the acid storage tank 22. The sensing structure 221 is electrically connected to the PLC controller 42. The sensing structure 221 includes a high-level sensor 2211 and a low-level sensor 2212. The high-level sensor 2211 is installed at the top of the acid storage tank 22, and the low-level sensor 2212 is installed at the bottom. The high-level sensor 2211 is located at about seven-tenths of the height of the acid storage tank 22, and the low-level sensor 2212 is located at about three-tenths of the height. The high-level sensor 2211 prevents acid overflow, while the low-level sensor 2212 replenishes the acid storage tank 22 with acid in a timely manner. This invention also includes an insulation layer on the outer layer of the acid storage tank 22. This insulation layer can be made of insulation materials such as polyurethane foam, polystyrene board, glass wool, or rock wool. Through the sensing structure 221 on the acid storage tank 22, this invention can detect the acid level inside the acid storage tank 22. The acid storage tank 22 is configured as a small acid storage tank. The reason for configuring a small acid storage tank 22 is to transport the acid from the acid source pipe 21 to the small acid storage tank 22. This can reduce the temperature fluctuation of the acid. Because the acid is cold, if it is transported through a pipe, the pipe needs to be long, the transmission time will be long, and the temperature fluctuation of the acid will be large. By sending the acid to the small acid storage tank 22 first, the usage time is short, which can reduce the temperature fluctuation of the acid. In addition, the acid storage tank 22 of this invention is also equipped with a heat insulation layer, which can better reduce the temperature fluctuation of the acid and prevent the acid temperature from changing too much.

[0048] In other embodiments, the present invention may also provide a cover over the acid storage tank 22.

[0049] Embodiment 2 of the present invention provides an acid filling and weighing method, including an acid filling and weighing method for adding acid to a lead-acid battery using an acid filling machine, the acid filling and weighing method comprising the following steps:

[0050] Step S1) Set the standard acid filling amount M0 of the lead-acid battery in the PLC controller 42;

[0051] Step S2) Before the acid adding device 5 fills the lead-acid battery with acid, the lead-acid battery is automatically weighed by the first weight sensor 43 at the inlet side 16 of the frame 1. The first weight sensor 43 sends the weight M1 data of the lead-acid battery obtained after weighing to the PLC controller 42.

[0052] Step S3) After the acid adding device 5 has finished adding acid to the lead-acid battery, the lead-acid battery is placed on the second weight sensor 44 at the outlet side 17 of the frame 1 for automatic weighing. The second weight sensor 44 sends the weight M2 of the lead-acid battery after weighing to the PLC controller 42.

[0053] Step S4) By reading the weight M1 of the lead-acid battery before acid filling and the weight M2 of the lead-acid battery after acid filling, the PLC controller 42 will automatically calculate the actual amount of acid filled into the lead-acid battery as M2-M1.

[0054] Step S5) The PLC controller 42 compares the calculated actual acid filling amount M2-M1 with the standard acid filling amount M0 and displays the comparison result on the human-machine touch screen 41. If the actual acid filling amount M2-M1 is consistent with the standard acid filling amount M0, it is judged as qualified and the indicator light 421 will light up. If the actual acid filling amount M2-M1 is inconsistent with the standard acid filling amount M0, it is judged as unqualified and the alarm light 422 will immediately sound an alarm. The human-machine touch screen 41 will also display the current acid amount filled into the lead-acid battery to determine whether the acid amount filled into the lead-acid battery is too much or too little. The staff will then adjust the acid filling amount of the acid filling machine or check whether the acid filling machine is malfunctioning.

[0055] Step S6) Repeat steps S1-S5 above until the actual amount of acid injected is consistent with the standard amount of acid injected M0.

[0056] The working process of the acid filling machine of this invention is as follows:

[0057] First, based on the standard amount of acid required in the lead-acid battery production process, the standard acid filling amount data of the lead-acid battery is stored in the PLC controller 42 through the human-machine touch screen 41, and the amount of acid measured by the measuring cup 31 is set in the PLC controller 42.

[0058] Next, before adding acid, the lead-acid battery is placed on the first weight sensor 43 at the entrance side 16 of the rack 1 for automatic weighing and the weighed data is sent to the PLC controller 42. Then the lead-acid battery is placed on the acid adding platform 14 of the rack 1.

[0059] Then, the lifting adjustment screw 511 is turned to adjust the piston rod of the lifting cylinder 512 to move up and down. The lifting cylinder 512 drives the lifting fixing frame 513 to move up and down, thereby driving the acid filling head 52 to move up and down. The acid filling head 52 is inserted into the acid filling port of the lead-acid battery. The PLC controller 42 controls the vacuum control valve 324 of the transition cylinder 32 to open, and the transition cylinder 32 is evacuated. The transition cylinder 32 and the acid filling head 52 are connected through the acid filling pipe 322, thereby realizing the vacuuming of the inside of the lead-acid battery, so that the inside of the lead-acid battery is in a negative pressure state. Then, the negative pressure source pipe 62 is switched by the switching valve 63.

[0060] Next, the PLC controller 42 is started, and the PLC controller 42 controls the start valve 25 to open, so that the acid is transported from the acid source pipe 21 to the acid storage tank 22. When the acid in the storage tank 22 reaches the high liquid level sensor 2211 of the sensing structure 221, the PLC controller 42 controls the start valve 25 to close, controls the acid pump 24 and the acid injection valve 313 to open. At the same time, the PLC controller 42 controls the acid filling lifting motor 72 to drive the acid filling limit frame 71 to rise and fall. The PLC controller 42 controls the acid pump 24 to pump the acid in the storage tank 22 into the acid delivery pipe 23 and transport it to each acid inlet pipe 311 of the acid metering device 3. Each acid inlet pipe 311 delivers the amount of acid set by the PLC controller 42 to each metering cup 31 of the acid metering device 3.

[0061] Then, the acid in each metering cup 31 is transported to each transition cylinder 32 through the acid delivery branch pipe 321. The acid in each transition cylinder 32 is transported to the acid filling head 52 through the acid filling pipe 322. The acid is then poured into the lead-acid battery's acid filling port by the acid filling head 52.

[0062] Finally, the lead-acid battery filled with acid is placed on the second weight sensor 44 at the outlet side 17 of the rack 1. The second weight sensor 44 automatically weighs the lead-acid battery filled with acid and sends the weighing data to the PLC controller 42.

[0063] like Figure 9 As shown, Embodiment 3 of the present invention provides an electrical wiring diagram of PLC controller 42 and human-machine touch screen 41, wherein PLC controller 42 is electrically connected to NES-100-24 switching power supply 45 and human-machine touch screen 41.

[0064] like Figure 10As shown, Embodiment 4 of the present invention provides an electrical wiring diagram of the PLC controller 42 and the first weight sensor 43 and the second weight sensor 44. The PLC controller 42 is electrically connected to a reset / clear button SB1 via the X0 terminal of its internal IO input port. A manual / automatic button SE1 is electrically connected to the X1 terminal of the PLC controller 42. A front-load button SB2 is electrically connected to the X2 terminal of the PLC controller 42. A 485 module 46 is internally connected to the PLC controller 42, and the 485 module 46 is electrically connected to the first weight sensor 43 and the second weight sensor 44. The data obtained by the first weight sensor 43 and the second weight sensor 44 after weighing can be transmitted through the IO input terminal of the PLC controller 42, and then simulated by the 485 module 46 and transmitted to the PLC controller 42. The PLC controller 42 performs program transmission and comparison based on the received data, and outputs the data through the IO output terminals Y0, Y1, Y2, Y3, Y4, Y5, Y6, Y7, and Y10 of the PLC controller 42.

[0065] Compared with the prior art, the technical solution disclosed in the above embodiments has the following beneficial effects:

[0066] In the above embodiments, by setting up a weighing device 4, the present invention can automatically weigh the lead-acid battery by using a first weight sensor 43 at the inlet side 16 of the rack 1 before the acid-adding device 5 adds acid to the lead-acid battery. The first weight sensor 43 sends the weight M1 data of the lead-acid battery obtained after weighing to the PLC controller 42. After the acid-adding device 5 adds acid to the lead-acid battery, the lead-acid battery is placed at the outlet side 17 of the rack 1 for automatic weighing by a second weight sensor 44. The second weight sensor 44 sends the weight M2 data of the lead-acid battery after adding acid to the PLC controller 42. The PLC controller 42 reads the weight M1 of the lead-acid battery before adding acid and the weight M2 of the lead-acid battery after adding acid and automatically calculates the actual amount of acid added to the lead-acid battery as M2-M1. The PLC controller 42 compares the calculated actual amount of acid added M2-M1 with the standard amount of acid added M0. The weighing device 4 of this invention can accurately check whether the amount of acid added to the lead-acid battery is within the process standard. When an abnormal acid amount is detected, an alarm sound can be immediately issued to alert employees that there is an error in the acid filling of the lead-acid battery. Employees can immediately handle the abnormality, completely preventing defective products from flowing to the next process and ensuring the production quality of lead-acid batteries. The weighing device 4 of this invention can detect whether the acid in the metering cup 31 is sufficient each time, and whether all the acid in the metering cup 31 has been poured into the lead-acid battery, thus providing accurate assurance for the measurement of the amount of acid added to the lead-acid battery.

[0067] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. An acid filling machine, characterized in that: The machine includes an acid filling machine for weighing lead-acid batteries. The acid filling machine includes a frame, an acid storage device, an acid metering device, and a weighing device. From top to bottom, a first workbench, a second workbench, a third workbench, and an acid filling platform for placing lead-acid batteries are arranged in sequence at the front of the frame. The acid storage device is installed at the rear of the frame. The acid metering device is installed between the first and second workbench. The weighing device is installed on the side of the frame. The weighing device includes a human-machine interface touch screen, a PLC controller, a first weight sensor, and a second weight sensor. The human-machine interface touch screen is mounted on the PLC controller. The first and second weight sensors are both electrically connected to the PLC controller. The first and second weight sensors are respectively installed on the entrance and exit sides of the frame. The PLC controller is fixed on the entrance side of the frame and located above the first weight sensor. The PLC controller is electrically connected to an indicator light and an alarm light. The acid storage device includes an acid source pipe, an acid storage tank, and an acid delivery pipe. The acid source pipe is connected to the acid storage tank. One end of the acid delivery pipe is connected to the acid storage tank, and the other end of the acid delivery pipe is connected to an acid metering device. An acid pump is installed on the acid delivery pipe. The acid in the acid storage tank is pumped into the acid delivery pipe by the acid pump and then delivered to the acid metering device. The acid pump is electrically connected to a PLC controller. A start valve is installed on the acid source pipe, and the start valve is electrically connected to the PLC controller. The acid metering device includes several metering cups and several transition cylinders of the same number as the metering cups. Each metering cup is equipped with an acid inlet pipe and an acid return pipe that pass through the first workbench. The acid inlet pipe and the acid return pipe of each metering cup are connected to the acid delivery pipe. Each transition cylinder is fixed at the upper end of the third workbench. The top of each transition cylinder is connected to an acid delivery branch pipe. Each transition cylinder is connected to the corresponding metering cup above it through the acid delivery branch pipe. The bottom of each transition cylinder is connected to an acid filling pipe. An acid-adding device is provided below the transition cylinder. The acid-adding device is installed at the lower end of the third workbench and above the acid-adding platform.

2. The acid filling machine according to claim 1, characterized in that: The acid filling machine includes a negative pressure circulation device installed at the rear of the frame. The negative pressure circulation device includes two negative pressure storage tanks and two negative pressure source pipes. The two negative pressure source pipes are connected to the two negative pressure storage tanks. The negative pressure storage tanks are electrically connected to a PLC controller. A negative pressure delivery pipe is also connected between the two negative pressure storage tanks. The two negative pressure storage tanks are connected to an acid metering device through the negative pressure delivery pipe. Switching valves are installed on the two negative pressure source pipes.

3. The acid filling machine according to claim 1, characterized in that: The lower end of each acid inlet pipe and the lower end of each acid return pipe extend into their corresponding metering cup. The upper end of each acid inlet pipe and the upper end of each acid return pipe are connected to the acid delivery pipeline. Each acid inlet pipe is equipped with an acid injection valve controlled by a PLC controller, and each acid return pipe is equipped with an acid return valve controlled by a PLC controller.

4. The acid filling machine according to claim 1, characterized in that: Each transition cylinder is also sealed at the top with a vacuum tube, which is connected to the negative pressure storage tank of the negative pressure circulation device. Each vacuum tube is equipped with a vacuum control valve controlled by a PLC controller.

5. The acid filling machine according to claim 1, characterized in that: The acid filling machine includes an acid filling limiting device, which is installed at the rear of the machine frame. The acid filling limiting device includes an acid filling limiting frame, an acid filling lifting motor, and an acid filling support plate. The acid filling support plate is installed at the top of the acid filling limiting frame, and the acid filling lifting motor is installed below the acid filling limiting frame. The acid filling limiting frame is equipped with an acid filling lifting screw, and the output shaft of the acid filling lifting motor is connected to the acid filling lifting screw. The acid inlet pipe and acid return pipe in each metering cup pass through the acid filling support plate at the top of the acid filling limiting frame. The acid filling lifting motor outputs power to the acid filling lifting screw. The acid filling lifting motor is electrically connected to a human-machine interface touch screen and a PLC controller. The human-machine interface touch screen is used to input the stroke of the acid filling lifting motor to control the upward and downward movement of the acid filling limiting frame. The PLC controller controls the acid filling lifting motor to drive the acid filling limiting frame to rise and fall.

6. The acid filling machine according to claim 1, characterized in that: The acid filling device includes a lifting structure and an acid filling head of the same number as the metering cup. The lifting structure is installed at the lower end of the third platform, and the acid filling head is installed at the bottom of the lifting structure. Each acid filling head is connected to an acid filling pipe corresponding to the transition cylinder.

7. The acid filling machine according to claim 6, characterized in that: The lifting structure includes a lifting adjustment screw, a lifting cylinder, and a lifting fixing frame. The lifting adjustment screw is connected to the lifting cylinder, the lifting cylinder is installed at the upper end of the lifting fixing frame, and the acid filling head is fixed at the lower end of the lifting fixing frame.

8. The acid filling machine according to claim 1, characterized in that: The acid storage tank is also equipped with a sensing structure, which is electrically connected to the PLC controller. The sensing structure includes a high liquid level sensor and a low liquid level sensor. The high liquid level sensor is installed at the top of the acid storage tank, and the low liquid level sensor is installed at the bottom of the acid storage tank.

9. A method for weighing lead-acid batteries after adding acid, comprising a method for weighing lead-acid batteries using an acid filling machine as described in any one of claims 1-8, characterized in that: The acid filling and weighing method includes the following steps: Step S1) Set the standard acid filling amount M0 for the lead-acid battery in the PLC controller; Step S2) Before the acid-adding device fills the lead-acid battery with acid, the lead-acid battery is automatically weighed by the first weight sensor at the rack inlet. The first weight sensor sends the weight M1 data of the lead-acid battery obtained after weighing to the PLC controller. Step S3) After the acid-adding device has filled the lead-acid battery with acid, the lead-acid battery is placed on the second weight sensor at the outlet of the rack for automatic weighing. The second weight sensor sends the weight M2 of the lead-acid battery after filling with acid to the PLC controller. Step S4) By reading the weight M1 of the lead-acid battery before acid filling and the weight M2 of the lead-acid battery after acid filling, the PLC controller will automatically calculate the actual amount of acid filled into the lead-acid battery as M2-M1. Step S5) The PLC controller compares the calculated actual acid filling amount M2-M1 with the standard acid filling amount M0 and displays the comparison result on the human-machine touch screen. If the actual acid filling amount M2-M1 is consistent with the standard acid filling amount M0, it is judged as qualified and the indicator light will light up. If the actual acid filling amount M2-M1 is inconsistent with the standard acid filling amount M0, it is judged as unqualified and the alarm light will immediately sound an alarm. The human-machine touch screen will also display the current acid amount filled into the lead-acid battery. The staff will then adjust the acid filling amount of the acid filling machine or check whether the acid filling machine is malfunctioning. Step S6) Repeat steps S1-S5 above until the actual amount of acid injected is consistent with the standard amount of acid injected M0.

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