Battery Grid Pasting Machine Automated Paste Control
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Solution Overview
Problem
Existing lead-acid battery manufacturing processes lack precision and consistency in applying electrochemically active paste material to battery grids, leading to inefficiencies and increased costs, particularly in producing sealed batteries like AGM and VRLA batteries.
Innovation Solution
A battery grid pasting system that includes a machine with a hopper, conveying apparatus, and sensing stations, controlled by a controller to automatically adjust the amount of paste applied based on sensed properties such as thickness, weight, and moisture content of the grids, ensuring accurate and consistent paste application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustments are used to change the amount of paste applied, then the machine is easier to operate, but the manufacturing precision of paste application deteriorates
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect grid properties and automatically adjusts paste application parameters, eliminating the need for operator intervention while maintaining high precision
Solution Approach 2:
The system incorporates feedback loops where sensors continuously monitor grid characteristics and provide real-time data to the controller, which then adjusts paste application parameters dynamically to maintain consistent quality without manual intervention
2Manufacturing precision
If automated control is implemented to adjust paste application, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The controller serves multiple functions including receiving sensor data, processing grid property information, adjusting paste application parameters, and coordinating with the conveying apparatus, thereby consolidating control functions into a single device and reducing overall system complexity
Solution Approach 2:
The system merges the controller, sensors, and paste application mechanism into an integrated automated system that operates as a unified whole, reducing the number of separate components and simplifying system architecture while maintaining precision
3Manufacturing precision
If precise paste application is achieved through automated control, then the manufacturing precision improves, but the loss of substance increases due to additional sensing and control components
Solution Approach 1:
The system applies paste slightly in excess of the minimum required amount and then uses automated control to precisely manage the application, ensuring that while a small amount of excess paste is used, overall material waste is minimized through consistent, controlled application that prevents defects and rework
Data Source
AI summary
A battery grid pasting system includes a battery grid pasting machine, a sensing station, and a controller. The battery grid pasting machine includes a conveying apparatus confronting a hopper's dispensing end across a space, and includes a motor actuatable to cause variance of the space and hence variance of the amount of battery paste received on carried battery grids through the space. The sensing station senses a value of a property of a pasted battery grid. And the controller receives the sensed value of the property and controls actuation of the motor based in part or more on the received value.