Low-cost industrial UPS lead-acid battery production process

Abstract

The invention discloses a low-cost industrial UPS (uninterrupted power supply) lead-acid battery production process, which comprises the following steps: S1, battery design: a positive plate has one more structure than a negative plate (N is the number of single-cell negative plates, and the number of the positive plates is N + 1), and the structure forms a layout that the negative plates are wrapped by the positive plates; s2, raw material preparation: preparing raw materials for producing a positive plate and a negative plate and an AGM separator; s3, pole plate manufacturing: producing a positive pole plate and a negative pole plate through raw materials and a pole plate production process; s4, assembling the battery; s5, performing a formation process; and S6, performance and quality detection. Through innovative design and optimized production process, on the premise of not influencing the discharge performance of the battery, the material cost is effectively reduced, the market competitiveness of the product is improved, and the production process has the advantages of simplicity and convenience in operation, low cost, stable performance and the like, is suitable for large-scale industrial production, and has a wide application prospect.

Description

Technical Field

[0001] The invention belongs to the technical field of UPS lead-acid batteries, and in particular relates to a low-cost production process of industrial UPS lead-acid batteries. Background Art

[0002] Lead-acid batteries have a history of over 160 years. Compared to other types of batteries, such as nickel-metal hydride, nickel-cadmium, and lithium batteries, lead-acid batteries not only offer lower costs and higher recycling rates, but also offer comprehensive advantages such as mature technology, no memory effect, high cell voltage, stable discharge, and high safety. In terms of both safety and cost, lead-acid batteries are the preferred backup power source for UPS equipment. Currently, the vast majority of UPS systems on the market use lead-acid batteries. In industrial UPS power systems, lead-acid batteries serve as a critical backup power source, and their performance and cost directly impact the reliability and economics of the entire system. Currently, the main factors determining battery capacity include the amount of active material on the positive and negative plates, as well as the amount of sulfuric acid content.

[0003] Industrial uninterruptible power supplies (UPS) play a vital role in ensuring the continuity and stability of industrial production. Lead-acid batteries, a common energy storage device in industrial UPS systems, have a direct impact on the application and promotion of the entire UPS system due to their performance and cost.

[0004] The main factors that determine battery capacity include the amount of active material on the positive plate, the amount of active material on the negative plate, and the sulfuric acid content. In traditional industrial UPS battery designs, to ensure the utilization rate of the positive plate, a design method is usually adopted in which each single cell of the electrode group structure has one more negative plate than the positive plate. There are also equal-sheet structures for positive and negative plates. However, these designs lead to a significant increase in material costs due to the large number of plates, and the utilization rate of the positive plate is relatively low due to its thickness. The excessive number of plates not only increases the use of raw materials such as lead and separators, but also makes the battery assembly process more complicated, further increasing production costs. In addition, with the increasing demand for UPS systems due to industrial development, reducing the cost of lead-acid batteries has become an urgent problem that the industry needs to solve. Summary of the Invention

[0005] The purpose of the present invention is to provide a low-cost industrial UPS lead-acid battery production process. Through innovative design and optimized production process, the material cost is effectively reduced and the market competitiveness of the product is improved without affecting the battery discharge performance. The production process has the advantages of simple operation, low cost and stable performance. It is suitable for large-scale industrial production and has broad application prospects, so as to solve the problems in the prior art raised in the above background technology.

[0006] To achieve the above object, the present invention adopts the following technical solutions:

[0007] A low-cost industrial UPS lead-acid battery production process comprises the following steps:

[0008] S1. Battery design: The positive plate has one more piece than the negative plate (N is the number of negative plates per cell, and the number of positive plates is N+1). This structure forms a layout where the positive plate wraps the negative plate.

[0009] S2. Raw material preparation: prepare the raw materials for producing positive and negative plates and AGM separators;

[0010] S3. Plate manufacturing: Produce positive and negative plates through raw materials and plate production processes;

[0011] S4. Battery assembly: Arrange the positive and negative plates according to the battery design and weld them to form electrode groups. Insert separators into the electrode groups and install them into battery slots for packaging.

[0012] S5, formation process: the battery product is formed by charging and the discharge performance test is performed;

[0013] S6. Performance and quality testing: Conduct cycle life testing and safety performance testing on battery products.

[0014] Preferably, in S1, the battery cell adopts a structure in which one more positive plate than negative plate is used (N is the number of negative plates in a cell, and the number of positive plates is N+1). This structure forms a layout in which the positive plate wraps the negative plate, which can minimize the number of plates, thereby reducing the use of raw materials such as lead. The mass of the active material of the positive plate is controlled at 10-12g / Ah. By precisely controlling the mass of the active material of the positive plate, it can not only ensure that the battery has sufficient discharge capacity, but also avoid excessive use of active materials and reduce costs.

[0015] Preferably, in S1, the total amount of active material in a single cell of the negative electrode plate is 72-78% of the total amount of active material in a single cell of the positive electrode plate. A reasonable ratio of positive and negative electrode active materials helps to improve the charge and discharge efficiency and cycle life of the battery while reducing the waste of negative electrode active materials.

[0016] Preferably, in S2, the raw materials include lead powder, sulfuric acid, deionized water and additives, wherein the lead powder is manufactured using a Barton-type lead powder machine, wherein the lead ingot is melted at a high temperature, and the lead liquid is atomized into lead powder by a high-speed rotating disc, and the oxidation degree of the lead powder is controlled to be between 70-80%, and the particle size distribution is within an appropriate range to ensure the performance of the active substance.

[0017] Preferably, the step S3 specifically includes the following steps:

[0018] a. Paste Mixing: Add lead powder, sulfuric acid, deionized water, and additives in a specific proportion to a paste mixer and mix. Additives such as short fibers and humic acid can improve the structure and performance of the active material. Maintain the paste temperature between 50-60°C and stir for 30-40 minutes to ensure thorough mixing and form a lead paste with good plasticity.

[0019] b. Plate coating: Use a plate coating machine to evenly coat the lead paste on the grid. The grid is made of a specially designed alloy material with good conductivity and corrosion resistance. The coating thickness is controlled to ensure that the quality of the active material of the positive plate meets the design requirements. After coating, the plate is preliminarily dried at room temperature and then sent to the curing room for curing.

[0020] c. Curing: The curing process is a key step in plate manufacturing. It enables the lead compounds in the lead paste to undergo a chemical reaction to form a stable crystal structure. The plates are placed in a curing chamber, the temperature is controlled at 50-70°C, the relative humidity is between 90-95%, and the curing time is 24-36 hours to obtain positive and negative plates.

[0021] Preferably, in said S4, the thickness of a single AGM separator is ≥ 70% of the thickness of a single positive plate. The appropriate separator thickness can effectively prevent the positive and negative plates from short-circuiting, while ensuring ion conduction inside the battery and improving battery performance. The positive plates are all U-shaped coated with AGM separators. This coating method can further enhance the protective effect of the separator on the positive plate, reduce the shedding of active substances, and extend the battery life.

[0022] Preferably, the step S4 specifically includes the following steps:

[0023] A. Pole group welding: Arrange the manufactured positive and negative plates according to the designed structure and weld them with lead-tin alloy to form pole groups. During the welding process, the welding temperature should be controlled at 350℃-400℃ and the welding time should be 2s-3s to ensure a firm weld and low resistance.

[0024] B. Install the separator: Install the AGM separator on the positive plate in a U-shaped wrapping manner, and then place the electrode group into the battery slot. Note that the separator must be installed tightly to prevent short circuits between the positive and negative plates.

[0025] C. Battery compartment sealing: Inject an appropriate amount of sulfuric acid electrolyte into the battery compartment, and then use sealant to seal the battery compartment to prevent electrolyte leakage.

[0026] Preferably, in S5, the battery is formed by a segmented charging method. First, a small current is used for pre-charging to fully activate the active materials in the electrode plates. Then, the charging current is gradually increased, and the charging time and charging amount are controlled to ensure that the positive and negative electrode active materials reach the designed conversion degree. After charging is completed, the battery is discharged to check the discharge capacity and performance of the battery. During the discharge process, the discharge current and discharge time are controlled to avoid over-discharge.

[0027] Preferably, in S6, a charge and discharge cycle life test is performed on the battery product to simulate the aging process of the battery in actual use, evaluate the battery's service life, and detect the battery's safety performance such as short circuit protection, overcharge protection, and over-discharge protection to ensure safe and reliable use of the battery.

[0028] Technical effects and advantages of the present invention:

[0029] Compared with the existing technology, the low-cost industrial UPS lead-acid battery production process proposed in this invention effectively reduces material costs and improves the market competitiveness of the product without affecting the battery discharge performance through innovative design and optimized production process. This production process has the advantages of simple operation, low cost, and stable performance. It is suitable for large-scale industrial production and has broad application prospects. It has the following advantages:

[0030] 1. Cost reduction: By adopting a structure in which one more positive plate is used than a negative plate, the number of plates is reduced, and the use of raw materials such as lead is reduced, thereby significantly reducing material costs. Precise control of the mass and ratio of positive and negative active materials avoids waste of active materials and further reduces costs.

[0031] 2. Performance improvement: The reasonable ratio of positive and negative active materials and separator design improves the battery's charge and discharge efficiency and cycle life, ensuring the battery's discharge performance; the U-shaped coated AGM separator enhances the protection of the positive plate, reduces the shedding of active materials, and extends the battery's service life.

[0032] 3. Process optimization: The use of advanced plate manufacturing technology and formation technology ensures the quality and performance stability of the battery and improves production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 Flowchart of the present invention. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. The specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0035] The present invention provides Figure 1 A low-cost industrial UPS lead-acid battery production process is shown, comprising the following steps:

[0036] S1. Battery design: The positive plate has one more piece than the negative plate (N is the number of negative plates per cell, and the number of positive plates is N+1). This structure forms a layout where the positive plate wraps the negative plate.

[0037] S2. Raw material preparation: prepare the raw materials for producing positive and negative plates and AGM separators;

[0038] S3. Plate manufacturing: Produce positive and negative plates through raw materials and plate production processes;

[0039] S4. Battery assembly: Arrange the positive and negative plates according to the battery design and weld them to form electrode groups. Insert separators into the electrode groups and install them into battery slots for packaging.

[0040] S5, formation process: the battery product is formed by charging and the discharge performance test is performed;

[0041] S6. Performance and quality testing: Conduct cycle life testing and safety performance testing on battery products.

[0042] In S1, the battery cell adopts a structure in which one more positive plate than negative plate is used (N is the number of negative plates in a cell, and the number of positive plates is N+1). This structure forms a layout in which the positive plates are wrapped around the negative plates, which can minimize the number of plates and thus reduce the use of raw materials such as lead. The mass of the active material in the positive plate is controlled at 10-12g / Ah. By precisely controlling the mass of the active material in the positive plate, it can not only ensure that the battery has sufficient discharge capacity, but also avoid excessive use of active materials and reduce costs.

[0043] In S1, the total amount of active material in a single cell of the negative plate is 72-78% of the total amount of active material in a single cell of the positive plate. A reasonable ratio of positive and negative active materials helps to improve the charge and discharge efficiency and cycle life of the battery, while reducing the waste of negative active materials.

[0044] In S2, the raw materials include lead powder, sulfuric acid, deionized water and additives. The lead powder is manufactured using a Barton-type lead powder machine. After the lead ingot is melted at a high temperature, the lead liquid is atomized into lead powder by a high-speed rotating disc. The oxidation degree of the lead powder is controlled between 70-80%, and the particle size distribution is within an appropriate range to ensure the performance of the active substance.

[0045] Specifically, the following steps are included:

[0046] 1. Select lead ingots with a purity of more than 99.9% as raw materials, put the lead ingots into the furnace of the Barton lead powder machine, heat it to 450-500℃ to melt it, start the high-speed rotating disc to atomize the lead liquid into lead powder;

[0047] 2. By adjusting the rotation speed and air volume of the disc, the oxidation degree of the lead powder is controlled between 70-80% and the particle size distribution is between 1-10μm;

[0048] 3. Carry out sampling inspection on the manufactured lead powder to ensure that its oxidation degree and particle size meet the requirements.

[0049] In S3, the following steps are specifically included:

[0050] a. Paste Mixing: Add lead powder, sulfuric acid, deionized water, and additives in a specific proportion to a paste mixer and mix. Additives such as short fibers and humic acid can improve the structure and performance of the active material. Maintain the paste temperature between 50-60°C and stir for 30-40 minutes to ensure thorough mixing and form a lead paste with good plasticity.

[0051] Among them, when mixing the ointment:

[0052] a.1. Prepare the paste materials according to the following formula: 1000kg lead powder, sulfuric acid (density 1.4g / cm 3 ) 150-180kg, deionized water 120-150kg, short fiber 2-3kg, humic acid 5-8kg;

[0053] a.2. Add the lead powder to the paste mixing machine, start the agitator, and stir at low speed for 5-10 minutes to evenly disperse the lead powder;

[0054] a.3. Slowly add sulfuric acid and deionized water while gradually increasing the stirring speed and controlling the paste temperature between 50-60°C;

[0055] a.4. Add short fibers and humic acid and continue stirring for 30-40 minutes to fully mix the materials and form a lead paste with good plasticity;

[0056] a.5. Test the lead paste to ensure that its density, viscosity and water content meet the requirements.

[0057] b. Plate coating: Use a plate coating machine to evenly coat the lead paste on the grid. The grid is made of a specially designed alloy material with good conductivity and corrosion resistance. The coating thickness is controlled to ensure that the quality of the active material of the positive plate meets the design requirements. After coating, the plate is preliminarily dried at room temperature and then sent to the curing room for curing.

[0058] Among them, the following steps are included when coating the board:

[0059] b1. Use specially designed grid alloy materials, whose components include lead, calcium, tin and other elements, with good conductivity and corrosion resistance;

[0060] b2. Install the grid on the coating machine and adjust the parameters of the coating machine to evenly coat the lead paste on the grid. Control the coating thickness of the positive plate and ensure that the active material mass of the positive plate is between 10-12g / Ah.

[0061] b3. After coating, place the plate at room temperature for 1-2 hours for preliminary drying, and then send it to the curing room for curing.

[0062] c. Curing: The curing process is a key step in plate manufacturing. It enables the lead compounds in the lead paste to undergo a chemical reaction to form a stable crystal structure. The plates are placed in a curing chamber, the temperature is controlled at 50-70°C, the relative humidity is between 90-95%, and the curing time is 24-36 hours to obtain positive and negative plates.

[0063] Wherein, the following steps are included during curing:

[0064] c1. Place the plate in the curing chamber and control the temperature at 50-70°C and the relative humidity at 90-95%;

[0065] c2. The curing time is 24-36 hours. During the curing process, the temperature and humidity of the plate should be monitored regularly to ensure stable curing conditions.

[0066] c3. After curing is completed, the plates are inspected for appearance and tested for performance, and qualified plates enter the next process.

[0067] In S4, the thickness of a single AGM separator is ≥ 70% of the thickness of a single positive plate. The appropriate separator thickness can effectively prevent the positive and negative plates from short-circuiting, while ensuring ion conduction inside the battery and improving battery performance. The positive plates are all U-shaped coated with AGM separators. This coating method can further enhance the protective effect of the separator on the positive plate, reduce the shedding of active substances, and extend the battery life.

[0068] S4 specifically includes the following steps:

[0069] A. Pole group welding: Arrange the manufactured positive and negative plates according to the designed structure and weld them with lead-tin alloy to form pole groups. During the welding process, the welding temperature should be controlled at 350℃-400℃ and the welding time should be 2s-3s to ensure a firm weld and low resistance.

[0070] Among them, the electrode group welding includes the following steps:

[0071] A1. Arrange the manufactured positive and negative plates according to the designed structure, so that there is one more positive plate than negative plate, forming a layout where the positive plate wraps the negative plate;

[0072] A2. Use lead-tin alloy for welding, the welding temperature is controlled between 350-400℃, and the welding time is 2-3 seconds;

[0073] A3. After welding is completed, check the welding quality of the electrode group to ensure that the welding is firm and the resistance is less than the specified value.

[0074] B. Install the separator: Install the AGM separator on the positive plate in a U-shaped wrapping manner, and then place the electrode group into the battery slot. Note that the separator must be installed tightly to prevent short circuits between the positive and negative plates.

[0075] The installation of the partition includes the following steps:

[0076] B1. Select AGM separator with a single piece thickness ≥ 70% of the thickness of a single positive plate.

[0077] B2. Install the AGM separator on the positive plate in a U-shaped wrapping manner. Note that the separator must be installed tightly to prevent short circuit between the positive and negative plates.

[0078] B3. After installation, check the installation quality of the partition to ensure that the partition is not damaged or wrinkled.

[0079] C. Battery compartment sealing: Inject an appropriate amount of sulfuric acid electrolyte into the battery compartment, and then use sealant to seal the battery compartment to prevent electrolyte leakage.

[0080] The battery container sealing process includes the following steps:

[0081] C1. Place the electrode group into the battery slot and adjust the position of the electrode group so that it is centered;

[0082] C2. Inject an appropriate amount of sulfuric acid electrolyte into the battery tank. The density of the electrolyte is 1.28-1.30g / cm 3 ;

[0083] C3. Use sealant to seal the battery compartment. Apply the sealant evenly to ensure a good seal and prevent electrolyte leakage.

[0084] In S5, the battery is formed using a segmented charging method. First, a low current is used for pre-charging to fully activate the active materials in the plates. Then, the charging current is gradually increased, and the charging time and charge amount are controlled to ensure that the positive and negative active materials reach the designed conversion level. After charging is completed, the battery is discharged to check the discharge capacity and performance of the battery. During the discharge process, the discharge current and discharge time must be controlled to avoid over-discharge.

[0085] Among them, in the chemical process, the battery is formed by a segmented charging method, which specifically includes:

[0086] In the first stage, pre-charging is performed with a current of 0.1C for 5-6 hours to fully activate the active substances in the plates;

[0087] In the second stage, the charging is carried out at a current of 0.2C for 8-10 hours, and the charging voltage is controlled not to exceed the specified value;

[0088] In the third stage, supplementary charging is performed at a current of 0.05C until the battery is fully charged.

[0089] During the charging process, the battery voltage, current and temperature are monitored regularly to ensure a safe and stable charging process.

[0090] Among them, in the chemical process, after charging is completed, the battery is discharged at a current of 0.2C for 5-6 hours until the battery voltage drops to the specified value, and the battery's discharge capacity and discharge time are recorded to check whether the battery's discharge performance meets the requirements.

[0091] In S6, the battery products are subjected to charge and discharge cycle life tests to simulate the aging process of the battery in actual use, evaluate the battery service life, and detect the battery's short circuit protection, overcharge protection, over-discharge protection and other safety performance to ensure safe and reliable battery use.

[0092] Among them, the batteries after formation are subjected to comprehensive quality inspection, including appearance inspection, voltage test, capacity test, internal resistance test, etc. The appearance inspection mainly checks whether there are defects such as scratches, cracks, electrolyte leakage, etc. on the battery surface; the voltage test uses a voltmeter to measure the open circuit voltage of the battery to ensure that the voltage is within the specified range; the capacity test adopts the constant current discharge method to measure the actual discharge capacity of the battery to ensure that the capacity meets the design requirements; the internal resistance test uses an internal resistance tester to measure the internal resistance of the battery, and the internal resistance should meet the specified value.

[0093] To verify the effectiveness of the present invention's low-cost lead-acid battery production process for industrial UPSs, a comparative experiment was conducted. Two groups were used: one using the present invention's production process (the experimental group) and the other using a conventional production process (the control group). Both groups had a design capacity of 100 Ah and were tested under the same conditions.

[0094] Cost comparison table:

[0095]

[0096] From the cost comparison data, it can be seen that the number of plates in the experimental group was reduced by 4, the amount of lead used was reduced by 3kg, and the amount of separator used was reduced by 0.3m 2 , the total cost was reduced by 500 yuan, a decrease of 20%.

[0097] Performance comparison table:

[0098]

[0099] In terms of performance, the experimental group's initial discharge capacity reached 98Ah, higher than the control group's 95Ah; after 100 cycles, the capacity retention rate was 90%, higher than the control group's 85%; and the internal resistance was 15mΩ, lower than the control group's 18mΩ. This shows that the experimental group's batteries outperformed the control group in terms of discharge capacity, cycle life, and internal resistance.

[0100] Comprehensive experiments lead to the conclusion:

[0101] 1. The main reason for the cost reduction is that the structure with one more positive plate than negative plate is adopted, which reduces the number of plates and thus reduces the use of raw materials such as lead and separators. At the same time, the precise control of the mass and ratio of positive and negative active materials avoids the waste of active materials and further reduces costs.

[0102] 2. The reason for the performance improvement is the reasonable ratio of positive and negative active materials and separator design, which improves the battery's charge and discharge efficiency and cycle life. The U-shaped coated AGM separator enhances the protection of the positive plate, reduces the shedding of active materials, and extends the battery's service life.

[0103] The present invention provides a low-cost industrial UPS lead-acid battery production process. By optimizing the battery's structural design and production parameters, this process significantly reduces material costs without compromising battery discharge performance. Experimental data demonstrates that the present production process has good feasibility and practicality, and can bring significant economic and social benefits to the production and application of industrial UPS lead-acid batteries. The present production process has broad prospects for promotion and application in future industrial UPS lead-acid battery production.

[0104] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A low-cost industrial UPS lead-acid battery production process, characterized in that: The following steps are involved: S1. Battery design: The positive plate has one more piece than the negative plate (N is the number of negative plates per cell, and the number of positive plates is N+1). This structure forms a layout where the positive plate wraps the negative plate. S2. Raw material preparation: prepare the raw materials for producing positive and negative plates and AGM separators; S3. Plate manufacturing: Produce positive and negative plates through raw materials and plate production processes; S4. Battery assembly: Arrange the positive and negative plates according to the battery design and weld them to form electrode groups. Insert separators into the electrode groups and install them into battery slots for packaging. S5, formation process: the battery product is formed by charging and the discharge performance test is performed; S6. Performance and quality testing: Conduct cycle life testing and safety performance testing on battery products.

2. A low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In S1, a single cell of the battery adopts a structure in which one more positive plate is used than one negative plate (N is the number of negative plates in a single cell, and the number of positive plates is N+1). This structure forms a layout in which the positive plates are wrapped around the negative plates, which can minimize the number of plates and thus reduce the use of raw materials such as lead. The mass of the active material in the positive plate is controlled at 10-12 g / Ah. By precisely controlling the mass of the active material in the positive plate, it can not only ensure that the battery has sufficient discharge capacity, but also avoid excessive use of active materials and reduce costs.

3. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In S1, the total amount of active material in a single cell of the negative plate is 72-78% of the total amount of active material in a single cell of the positive plate. A reasonable ratio of positive and negative active materials helps to improve the charge and discharge efficiency and cycle life of the battery while reducing the waste of negative active materials.

4. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In S2, the raw materials include lead powder, sulfuric acid, deionized water, and additives. The lead powder is manufactured using a Barton-type lead powder machine. A lead ingot is melted at a high temperature, and then a high-speed rotating disc atomizes the lead liquid into lead powder. The oxidation degree of the lead powder is controlled between 70% and 80%, and the particle size distribution is within an appropriate range to ensure the performance of the active substance.

5. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: The S3 specifically includes the following steps: a. Paste Mixing: Add lead powder, sulfuric acid, deionized water, and additives in a specific proportion to a paste mixer and mix. Additives such as short fibers and humic acid can improve the structure and performance of the active material. Maintain the paste temperature between 50-60°C and stir for 30-40 minutes to ensure thorough mixing and form a lead paste with good plasticity. b. Plate coating: Use a plate coating machine to evenly coat the lead paste on the grid. The grid is made of a specially designed alloy material with good conductivity and corrosion resistance. The coating thickness is controlled to ensure that the quality of the active material of the positive plate meets the design requirements. After coating, the plate is preliminarily dried at room temperature and then sent to the curing room for curing. c. Curing: The curing process is a key step in plate manufacturing. It enables the lead compounds in the lead paste to undergo a chemical reaction to form a stable crystal structure. The plates are placed in a curing chamber, the temperature is controlled at 50-70°C, the relative humidity is between 90-95%, and the curing time is 24-36 hours to obtain positive and negative plates.

6. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In the above-mentioned S4, the thickness of a single AGM separator is ≥ 70% of the thickness of a single positive plate. The appropriate separator thickness can effectively prevent the positive and negative plates from short-circuiting, while ensuring the ion conduction inside the battery and improving the battery performance. The positive plates are all U-shaped coated with AGM separators. This coating method can further enhance the protective effect of the separator on the positive plate, reduce the shedding of active materials, and extend the battery life.

7. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: The S4 specifically includes the following steps: A. Pole group welding: Arrange the manufactured positive and negative plates according to the designed structure and weld them with lead-tin alloy to form pole groups. During the welding process, the welding temperature should be controlled at 350℃-400℃ and the welding time should be 2s-3s to ensure a firm weld and low resistance. B. Install the separator: Install the AGM separator on the positive plate in a U-shaped wrapping manner, and then place the electrode group into the battery slot. Note that the separator must be installed tightly to prevent short circuits between the positive and negative plates. C. Battery compartment sealing: Inject an appropriate amount of sulfuric acid electrolyte into the battery compartment, and then use sealant to seal the battery compartment to prevent electrolyte leakage.

8. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In S5, the battery is formed using a segmented charging method. First, a low current is used for pre-charging to fully activate the active materials in the plates. Then, the charging current is gradually increased, and the charging time and charge amount are controlled to ensure that the positive and negative active materials reach the designed conversion level. After charging is completed, the battery is discharged to check the discharge capacity and performance of the battery. During the discharge process, the discharge current and discharge time are controlled to avoid over-discharge.

9. The low-cost industrial UPS lead-acid battery production process according to claim 1, characterized in that: In the above-mentioned S6, the battery product is subjected to a charge and discharge cycle life test to simulate the aging process of the battery in actual use, evaluate the battery service life, and detect the battery's short circuit protection, overcharge protection, over-discharge protection and other safety performance to ensure safe and reliable use of the battery.

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