Battery Cell Electrolyte Filling With On-Demand Mixing Control
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Solution Overview
Problem
Existing filling devices for battery cells are inflexible and require pre-production and storage of electrolyte solutions, leading to quality degradation and inefficiencies, especially in lead-acid battery manufacturing.
Innovation Solution
A fully automatic filling device with a mixing unit, metering unit, and control/regulating unit that produces electrolyte solution on demand, allowing for flexible composition and adjustment of component concentrations, and includes features like vibration and pressure units to enhance electrolyte penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electrolyte solution is pre-produced and stored in batch processes, then production planning is simplified, but quality of electrolyte solution decreases with increasing storage time and flexibility is reduced
Solution Approach 1:
The system performs preliminary preparation of electrolyte components (sulfuric acid and water) in storage tanks, but the actual mixing occurs immediately before dosing. This allows components to be pre-positioned without pre-mixing the final electrolyte solution, maintaining quality while simplifying planning.
Solution Approach 2:
The patent implements a continuous process where electrolyte solution is mixed and dosed without interruption or storage. The mixing unit continuously produces electrolyte solution that is immediately dosed into battery cells, eliminating the batch production-storage-batch filling cycle and preventing quality degradation over time.
2Productivity
If electrolyte solution is stored in large quantities, then filling operations can be buffered, but complex storage and transport systems are required
Solution Approach 1:
The patent extracts the storage function from the electrolyte solution itself and applies it only to the individual components (sulfuric acid and water). This eliminates the need for complex storage and transport infrastructure for the final electrolyte solution, as only simple component storage is required.
Solution Approach 2:
The mixing unit and dosing unit are merged into a single integrated system. The mixing unit is positioned directly upstream of the dosing unit, allowing electrolyte solution to be mixed and dosed in immediate succession without separate storage and transport steps, thereby simplifying the overall system.
3Ease of manufacture
If batch production of electrolyte solution is used, then production is simplified, but errors cannot be corrected and inferior solution must be discarded
Solution Approach 1:
The system transitions from static batch production to dynamic continuous production with real-time control. The control/regulation unit continuously monitors and adjusts the mixing process, allowing immediate correction of any deviations or errors. This dynamic approach enables quality assurance while maintaining production simplicity.
Solution Approach 2:
The control/regulation unit implements feedback control by continuously monitoring the mixing process and adjusting parameters as needed. This allows real-time detection and correction of errors in electrolyte solution production, preventing the creation of inferior solution and eliminating waste.
4Adaptability or versatility
If different electrolyte solutions with different compositions are required for different battery cell types, then customization is possible, but intensive planning and multiple pre-produced batches are needed
Solution Approach 1:
The control/regulation unit enables dynamic adjustment of electrolyte composition parameters (such as acid density and concentration ratios) without requiring separate batch productions. The mixing unit can continuously adapt the electrolyte solution composition to match different battery cell requirements, eliminating planning delays.
Solution Approach 2:
The system changes the parameters of the electrolyte solution (concentration, density, composition ratios) on-demand based on the specific battery cell type being filled. The control/regulation unit adjusts mixing parameters in real-time, allowing rapid customization without the time loss associated with producing and storing multiple different batches.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables a coherent, continuous filling process with improved flexibility and quality control, reducing storage needs and allowing for real-time adjustment of acid density, thereby enhancing the efficiency and quality of lead-acid battery cell filling.
Implementation Method 1
a mixing unit, in particular a mixing cylinder, for producing electrolyte solution from a plurality of components
Implementation Method 2
a dosing unit for introducing the electrolyte solution into the battery cell, the dosing unit being fluidly connected to the mixing unit
Implementation Method 3
sensors and actuators connected to the mixing unit and/or the dosing unit for data transmission purposes
Data Source
Figure 1
AI summary
The invention relates to a fully automatic filling device for filling battery cells, in particular lead-acid accumulator cells, with electrolyte solution, in particular a sulfuric acid-containing electrolyte solution, comprising a mixing unit, in particular a mixing cylinder, for producing electrolyte solution from several components at temperatures of at least -25 °C, a metering unit for introducing the electrolyte solution into the battery cell, wherein the metering unit is fluidly connected to the mixing unit and is downstream of the electrolyte solution in the flow direction, and comprising a control unit for fully automated control and regulation of at least the mixing unit and metering unit, comprising a digital data processing device, a digital data storage device, and sensors and actuators connected to the mixing unit and/or metering unit for data transmission.