Lead-Acid Electrode Plate Positioning With Automated Bridge Pressing
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Solution Overview
Problem
The conventional assembly process of lead-acid batteries is labor-intensive and time-consuming due to the manual placement and positioning of cell electrode plate groups, which requires manual pressing of lead bridges.
Innovation Solution
A positioning apparatus with a support structure, hoisting unit, clamping unit, and micro adjustment unit that automates the pressing and positioning of cell electrode plate groups using actuators and sensors to facilitate precise placement and fastening in battery compartments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual placement and pressing of cell electrode plate groups is used, then the positioning can be completed with simple equipment, but the assembly process becomes labor-intensive and time-consuming
Solution Approach 1:
The positioning apparatus is designed to automatically perform positioning and pressing operations without requiring manual intervention. The system uses its own integrated components (actuators, pressing blocks, positioning blocks) to complete the assembly task independently, eliminating the need for external tools and manual labor while maintaining operational simplicity
Solution Approach 2:
The positioning apparatus integrates multiple functions into a single device: it provides both positioning (through positioning blocks) and pressing (through pressing blocks with actuators) capabilities. This multi-functional design eliminates the need for separate manual operations and tools, thereby improving productivity without proportionally increasing device complexity
2Loss of time
If manual pressing of lead bridges is performed, then the equipment requirement is minimal, but the assembly time and labor cost increase
Solution Approach 1:
The manual mechanical pressing operation is replaced with an automated actuating mechanism. The actuators (pneumatic or hydraulic) automatically control the pressing blocks to apply force to the lead bridges, eliminating the need for manual tool operation and significantly reducing assembly time while introducing only moderate device complexity through standardized actuator components
Solution Approach 2:
The positioning blocks are designed to pre-position the cell electrode plate groups before the pressing operation occurs. This preliminary positioning action ensures correct placement is achieved automatically as part of the integrated process, eliminating separate manual positioning steps and reducing overall assembly time without requiring complex multi-stage equipment
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
The apparatus significantly reduces labor and time required for assembly, enhancing efficiency by automating the pressing and positioning process of lead-acid batteries.
Implementation Method 1
the first actuator includes a first piston passing through the top plate and threadedly secured to the second hoisting plate so that the first piston is configured to move the second hoisting plate which in turn lifts or lowers the pressing blocks
Implementation Method 2
each of the second actuators include at least one second piston having an end secured to the pushing block so that the at least one second piston is configured to move one of the pushing blocks forward to approach one of the pressing blocks or rearward to leave one of the pressing blocks
Data Source
AI summary
A positioning apparatus includes a support structure including a top plate and legs extending downward from four corners of the top plate; a hoisting unit including a first hoisting plate, piston members, a second hoisting plate, two pressing blocks, and a first actuator; and a clamping unit including two opposite second actuators and two pushing blocks. The positioning apparatus is used for cell electrode plate groups of a lead-acid battery.