Electrode Head Forming Apparatus with Vertical Transfer and Wax Dipping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional lead-acid battery manufacturing processes are inefficient due to high material consumption, electrolyte stratification, active substance loss, long production times, environmental pollution, low energy-to-weight ratio, short cycle life, and lengthy charging times, particularly in vertically arranged batteries.
Innovation Solution
An apparatus automatically transforms horizontal electrode plate groups to vertical orientation for quick and efficient formation of electrode heads using transfer units and wax dipping processes, enabling simultaneous formation of electrode heads on both ends of the plate group.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operation is used to form electrode heads, then flexibility and simplicity are maintained, but productivity is low and time consumption is high
Solution Approach 1:
The apparatus divides the electrode head formation process into distinct segments: a first forming unit for creating the first electrode head, and a second forming unit for creating the second electrode head. Each unit operates independently on opposite ends of the electrode plate group, allowing parallel processing and significantly improving productivity while keeping each individual unit relatively simple in structure.
2Reliability
If electrode plates are vertically arranged to improve electrolyte distribution, then concentration polarization is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention inverts the conventional vertical arrangement of electrode plates by arranging them horizontally instead. This inversion eliminates concentration polarization caused by vertical stratification while simplifying the battery structure. The horizontal arrangement allows electrolyte to distribute more uniformly across the electrode plates without requiring complex vertical support structures.
3Strength
If lead ingots are used for grid construction to ensure structural strength, then grid strength is sufficient, but material consumption is high and environmental pollution occurs
Solution Approach 1:
The invention changes the physical state and form of lead material from solid lead ingots to lead paste. This parameter change allows the lead to be molded into grid structures with optimized material distribution, reducing overall material consumption while maintaining sufficient strength. The lead paste can be precisely applied where needed, eliminating waste associated with cutting and shaping solid ingots, and the process occurs at lower temperatures, reducing lead vapor emissions.
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
This approach reduces material consumption, enhances cycle life, decreases charging time, and improves energy-to-weight ratio by ensuring uniform active substance distribution and reduced internal resistance, while minimizing environmental impact and operational inefficiencies.
Implementation Method 1
the first electrode head is formed on one end of the electrode plate group, and the second electrode head is formed on the other end of the electrode plate group
Implementation Method 2
delivered it to the first area to dip the wax
Data Source
AI summary
An apparatus for forming electrode heads includes a first and second lost-wax areas; a first and second electrode head forming areas; and a first, second and third transfer units. The first transfer unit rotates an electrode plate group from a horizontal to a vertical orientation. The second transfer unit holds the electrode plate group oriented vertically, and delivers it to be dipped in wax in the first lost-wax area, and then delivers the wax dipped electrode plate group to the first electrode head forming area to form one electrode head on one end thereof. The third transfer unit rotates the electrode plate group with the first electrode head, and delivers it to be dipped in wax in the second lost-wax area, and then delivers the wax dipped electrode plate group with the first electrode head to the second electrode head forming area to form another electrode head on thereof.