Piston Dosing Device for Lead-Acid Battery Pole Connectors
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Solution Overview
Problem
Existing methods for casting pole connectors onto lead-acid battery lugs are inefficient in precisely controlling the amount of liquid lead, often resulting in excess lead usage and inadequate adaptation to varying battery types and connector designs.
Innovation Solution
A method where the mold cavities are filled with a predefined amount of liquid lead from a dosing device, allowing for adjustable dosing based on the specific requirements of the battery type and connector design, by using a dosing device with a piston that can adjust the position to control the amount of lead transferred into the mold cavity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a sprue mold with overflow system is used to fill mold cavities with molten lead, then the mold cavities can be filled with lead, but the amount of lead cannot be precisely controlled resulting in excess lead usage
Solution Approach 1:
The dosing device prepares and measures the exact amount of liquid lead required for the mold cavity before the casting process begins. The piston is positioned to define a precise volume, and this pre-measured amount is then transferred to the mold cavity, eliminating the need for overflow systems and preventing excess lead usage from the outset.
Solution Approach 2:
The traditional sprue mold overflow system is replaced with a dosing device that uses a piston-cylinder mechanism to precisely meter and transfer a specific volume of liquid lead. This mechanical dosing system provides accurate control over the quantity of lead introduced into the mold cavity, replacing the imprecise gravity-based overflow method.
2Adaptability or versatility
If a fixed overflow system is used in the mold, then lead can be supplied to cavities, but the system cannot adapt to varying battery types and connector designs
Solution Approach 1:
The dosing device incorporates adjustable parameters including piston position, dosing volume, and transfer timing that can be dynamically modified to accommodate different battery types and connector designs. This dynamic adjustability allows the same basic system to serve multiple applications without requiring complex reconfiguration of the entire mold system.
Solution Approach 2:
The dosing device is designed as a universal component that can transfer precise amounts of liquid lead to various mold cavity configurations. By adjusting the dosing parameters and piston position, the same dosing device can adapt to different battery types, connector designs, and cavity geometries, eliminating the need for multiple specialized systems.
3Manufacturing precision
If the pump speed is increased to raise the fill level in the lead feed channel, then lead flows into cavities, but the control precision of the lead amount is insufficient
Solution Approach 1:
The pump-based lead transfer system is replaced with a dosing device using a piston-cylinder mechanism. The piston's position and stroke length directly define the volume of lead transferred, providing precise control over the lead amount. This mechanical dosing approach maintains productivity by enabling rapid, repeatable dosing cycles without relying on pump speed adjustments.
Solution Approach 2:
The dosing device is designed so that the piston's movement automatically defines and transfers the precise volume of lead required. The system self-regulates the lead amount based on the piston geometry and position, eliminating the need for external flow control mechanisms or complex feedback systems, thereby maintaining high productivity with improved precision.
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 ensures precise control over the amount of lead used, reducing waste and enabling the casting of pole connectors that accurately match the design of different battery types and connector requirements, improving the efficiency and adaptability of the casting process.
Implementation Method 1
a piston (2) which can be raised to transfer liquid lead into the mold cavity (13)
Implementation Method 2
the cooling device (18) cools and solidifies the liquid lead in the mold cavity (13)
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A metering unit (14) for molten lead is paired with the molding cavity (13) of a molding block (6). The metering unit (14) comprises a cylinder (1), to which molten lead is supplied via a blockable line (8), and a piston (2), which can be lifted in order to transfer molten lead into the molding cavity (13) in order to cast pole connectors onto battery plate lugs.