Reciprocating Block Lead Delivery Apparatus for Battery Strap Casting
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Solution Overview
Problem
In the manufacturing of batteries, particularly lead acid batteries, there is a challenge in ensuring consistent lead delivery to mould cavities while minimizing cooling and maintaining unimpeded access for battery plates, as excess lead can impact cost and weight due to factors like mould features and the need for quick cooling to reduce cycle time.
Innovation Solution
An apparatus with a housing, lead reservoir, and a reciprocating block mechanism that delivers a predetermined volume of lead with minimal heat loss, featuring a runway, bleed opening, and a chute system to ensure accurate and consistent lead delivery with reduced turbulence and dross formation, using a graphite coating for sealing and inert gas to prevent oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lead is delivered through a reservoir with weirs to fill mould cavities, then the mould can be filled with lead, but excess lead is generated impacting cost and weight
Solution Approach 1:
The lead delivery system is segmented into discrete portions using individual blocks, each with a cavity of predetermined volume. Each block delivers exactly one portion of lead to the mould, eliminating the excess lead problem associated with continuous reservoir delivery and weirs.
Solution Approach 2:
The lead portions are pre-measured and stored in the blocks before delivery. The cavities are filled with the exact required volume of lead in advance, ensuring precise dosage control and preventing both excess and deficient lead delivery to the mould.
2Reliability
If lead is kept hot to ensure good connection between lugs and casting, then connection quality improves, but cycle time increases due to slower cooling
Solution Approach 1:
The lead is segmented into small, individual portions delivered by separate blocks. This allows each portion to be optimally heated for connection quality while the overall system can cool more efficiently between deliveries, reducing the impact on cycle time.
Solution Approach 2:
While one block is being cooled after lead delivery, another block can be heated and prepared for the next delivery. This continuous preparation and delivery cycle maintains connection quality requirements while minimizing idle time and reducing overall cycle time.
3Manufacturing precision
If a reciprocating block mechanism is used to deliver precise lead volume, then lead delivery precision improves, but device complexity increases
Solution Approach 1:
The complex precision delivery problem is segmented into simple, identical blocks with fixed-volume cavities. Each block is a simple reciprocating element that moves between a reservoir and mould, delivering precise lead volume through its predetermined cavity size rather than complex metering mechanisms.
Solution Approach 2:
The precision of lead delivery is achieved by changing the physical parameter of the block cavity volume rather than using complex control systems. The cavity is designed with specific dimensions to hold exactly the required lead volume, and precision is maintained through mechanical consistency rather than electronic control.
4Productivity
If lead flows quickly to minimize cycle time, then productivity improves, but heat loss increases reducing lead temperature
Solution Approach 1:
The lead delivery is segmented into discrete blocks that can be individually heated and insulated. This allows rapid cooling of previously delivered lead portions while newly delivered portions maintain their temperature through the insulated block mechanism, enabling faster cycle times without sacrificing lead temperature.
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 solution enables precise and consistent lead delivery with minimal heat loss and reduced dross formation, ensuring accurate casting of battery straps while maintaining the required connection between battery plates, thus optimizing production efficiency and reducing the final product's weight and cost.
Implementation Method 1
The facing surfaces of the block and the reservoir may form a seal therebetween. The facing surfaces of the block and the runway may form a seal therebetween. At least one of the, or each, pair of facing surfaces may be provided with a graphite coating.
Implementation Method 2
The housing may define a bleed opening, which may be aligned in the second position for allowing the ingress of gas into the upper part of the cavity in the second position. Thus, advantageously the bleed opening assists with smooth delivery of the volume of lead when the block is in the second position.
Implementation Method 3
using a graphite coating for sealing and inert gas to prevent oxidation
Implementation Method 4
a housing defining a lead reservoir having a lead outlet defined in its base and in communication with the reservoir
Data Source
AI summary
An apparatus for delivering a predetermined volume of lead to a mould includes a housing defining a lead reservoir having a lead outlet defined in its base and in communication with the reservoir. A runway is provided beneath the base, spaced from the base and generally parallel thereto. A block is provided slidably mounted between the base and the runway and defining a through cavity having the predetermined volume for receiving lead from the outlet in a first position and for releasing the lead in a second position. A mechanism is provided for reciprocating the block between the first and second positions. A cast on strap machine is also disclosed. A lead delivery apparatus comprising a delivery chute is also disclosed.