Battery Acid Ring Profile Transformation Without Disassembly
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Solution Overview
Problem
Existing methods for forming acid rings on battery terminals require dedicated tooling systems that necessitate shutdown or disassembly to change characteristics, leading to undesired delays in production.
Innovation Solution
A battery part manufacturing system and method that allows for the transformation of acid ring profiles without disassembly, using a machine with a spindle assembly, motorized tools, and a system controller to adjust and modify the shape of sealing features on battery parts in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated tooling systems are used to form acid rings on battery terminals, then manufacturing precision is improved, but productivity deteriorates due to required shutdown and disassembly for changes
Solution Approach 1:
The patent applies the dynamics principle by making the tooling system adjustable and reconfigurable without disassembly. The forming tool includes adjustable components that can be repositioned along the battery terminal to create different acid ring profiles (single ring, double ring, triple ring configurations) while maintaining manufacturing precision. This dynamic adjustability eliminates production shutdowns and disassembly operations.
Solution Approach 2:
The patent implements parameter changes by allowing modification of forming tool parameters (position, configuration, geometry) to produce different acid ring characteristics. The system can change the number, position, and shape of acid rings by adjusting tool parameters rather than replacing entire tooling systems, thereby maintaining precision while improving productivity.
2Manufacturing precision
If dedicated tooling systems are used for specific acid ring characteristics, then manufacturing precision is improved, but device complexity increases due to multiple tooling systems
Solution Approach 1:
The patent applies universality by designing a single forming tool that can perform multiple functions to create different acid ring configurations. The tool can produce single ring, double ring, and triple ring patterns, as well as various ring shapes and positions, by adjusting its configuration rather than requiring separate dedicated tools for each acid ring type.
Solution Approach 2:
The patent implements segmentation by dividing the forming tool into adjustable modular components that can be independently positioned and configured. This allows the tool to be segmented into different active zones along the battery terminal to create multiple acid rings with different characteristics using a single unified system.
Data Source
AI summary
Systems and methods for producing battery parts, such as battery parts, are described herein. In one embodiment, a battery part machine is configured transform a profile of one or more acid rings on a battery part from a first cross-section to a second cross-section. The machine can include a rotatable spindle configured to receive the battery part, and a first tool and a second tool configured to engage the battery part. The orientation of the first tool and the second tool can be configured to engage the battery part at adjustable to polish, crimp, flare or otherwise transform the profile of the acid rings thereon to produce a finished battery part. An operator can input operating parameters to a machine controller to adjust the finished profile of the acid rings produced by the machine without requiring disassembly thereof.